Diesel Engine MTU4000R41 Workshop Manual

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com
MTU_ValueService
Technical Documentation
Diesel Engine
12 V 4000 R41
16 V 4000 R41
Workshop Manual
M020124/02E
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Printed in Germany
© 2009 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the
prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution,
translation, microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or
damage during operation.
Subject to alterations and amendments.
Table of Contents 01
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03
Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Instructions for Major Overhaul .................................................. 59
Diesel Engine 12V 4000 R41 / 16V 4000 R41 (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 949
Instructions for Major Overhaul .................................................. 959
Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1841
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M020124/02E 2009-02 © MTU

02 Table of Contents
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M020124/02E 2009-02 © MTU

General Information 03
General Information
1 Important Notes ............................................................... 05
1.1 Prerequisites for maintenance work and general assembly instructions ........... 05
1.2 Reman assemblies ....................................................... 07
2 General Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
2.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
2.2 Personnel and organizational requirements .................................. 10
2.3 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Auxiliary materials, fire prevention and environmental protection ................ 14
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2.5 Standards for warning notices in the publication .............................. 16
2.6 General information regarding the Tolerances and Wear Limits List . . . . . . . . . . . . . . . 17
2.7 Engine side and cylinder designations ...................................... 18
2.8 Tightening specifications for screws, nuts and bolts ........................... 19
2.9 Settings ................................................................ 36
2.10 Conversion tables ....................................................... 38
2.11 Repairing threaded bores with threaded inserts (Heli-Coil) ...................... 44
2.12 Abbreviations ........................................................... 46
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04 General Information
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Important Notes 05
1 Important Notes
1.1 Prerequisites for maintenance work and general

assembly instructions
This Workshop Manual is for technicians responsible for maintenance.
Contents: Extended component maintenance
Observe the following sequences:
• Disassemble engine.
• Assemble engine.
Prerequisites for maintenance work

For maintenance work performed by the customer, the following conditions must be fulfilled:
• All safety regulations are to be observed.
• Deployment of trained and qualified personnel.
• Suitable workshop equipment with general tools.
• Suitable test equipment.
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• Approved special tools.
General assembly instructions

For assembly work, use new sealing and securing elements.
Components that are exposed to contact with oil, fuel, coolant and combustion air must be clean. Components with
the requirement "particularly clean" (e.g. components carrying oil and fuel) should be cleaned in the appropriate
manner and checked for cleanness. Remove packaging of components immediately before assembly.
Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners.
• Remove oil or fuel coatings. The parts should be wiped with a dry cloth.
• Elastomer components such as engine mounts, damping elements, couplings and V-belts must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
Radial-lip shaft seals treated by the manufacturer with oil show, as a result, definite signs of swelling when delivered.
They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.
The surfaces of parts that slide against each other must be lubricated with SAE30 engine
oil when installed, unless otherwise specified.
O-rings and surfaces moving against them during installation (bores and shafts) must be coated with grease, unless
otherwise specified. When installing O-rings with counterrings in coolant pumps, always follow the installation
instructions. After installing O-rings in shaft grooves, pass a rounded marking tool under the O-ring in the direction
of the circumference if the O-ring diameter is sufficiently large. Make sure that the O-ring is not damaged.
Before assembling shaft seals:
• On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft
running surface with thin-film lubricant or SAE 30 engine oil.
• In support bores, in the case of a metal outer jacket, the outer surface must be coated with surface sealant,
unless otherwise specified in the drawing. For elastomer outer jackets or combined metal/elastomer
outer jackets, the outer surface must be coated with denatured ethanol.
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This symbol applies to radial-lip shaft seals and its significance depends on its position. The
arrow indicates the position of the sealing lip.
Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on the
flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be fitted
to the component and then (no more than 20 minutes later) the seal components screwed together.
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Before installing antifriction bearings, lubricate the bearing seats. Only remove the bearings from their
original packaging immediately before installation. Do not remove the corrosion inhibitor from the
bearings in the original packaging. Use petroleum spirit or acid-free kerosene to clean the antifriction
bearings. After cleaning, lubricate the bearings with engine oil SAE 30.
• During assembly, do not apply any (axial) force to rolling elements and do not hit the
bearing rings with a hammer (use assembly aids).
• Do not use a naked flame to heat bearing inner races.
• The temperature must be between 80 °C and 100 °C and never exceed 120 °C.
• Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
Do not oil dry bearings.
When assembling gears, the splines must be lubricated with SAE 30 engine oil.
All contact and mating faces of components (e.g. mating faces for centering devices, flange and sealing faces, joint
faces of press fittings) must be clean, polished or provided with the specified surface protection and free from surface
irregularities and damage. Corrosion inhibitor (e.g. oil, grease) must be removed from the contact and mating faces.
After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate
must be removed and the parts coated with SAE 30 engine oil.
Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
Line connections with cutting ring unions must be preassembled and tightened in a vice, after
the threads have been coated with thin-film lubricant.
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If components are marked by etching, after the etching is completed the solution must be removed by means
of neutralization agent. The affected parts must then be preserved with SAE 30 engine oil.
Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes) must be coated at the contact
and mating faces with assembly compound, unless otherwise specified.
The mounting faces of screws, nuts, washers and of parts to be tensioned must be clean and polished or
provided with the specified surface protection and free from surface irregularities and damage. Corrosion
inhibitors (e.g. oil, grease) must be removed. Thread and screw mating faces must be coated with
lubricant before installation in accordance with the tightening specifications.
Unless otherwise specified, use engine oil SAE 30 as a lubricant and assembly compound in hot-component areas.
For threaded connections without tightening specifications, the tightening procedure can be selected
as required, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end
wrench or box wrench is possible. When machine-tightening is carried out, look up tightening torque
of thread size and strength class in the general tightening specifications.
Threaded connections with tightening specifications:
• The threaded connections must be tightened manually with a click wrench or angle-of-rotation torque
wrench. The specified tightening torques must be set without considering the specified tolerance
at the click wrench. When using an angle-of-rotation torque wrench, the torque indicated must be
within the torque specification limit value. Proceed in a similar manner with torsionally protected
threaded connections. This information also applies to checking torques.
• If no tolerance is specified for a tightening torque, the tightening tolerance is + 10% of specified torque.
• Angle-of-rotation tightening:
The angles of further rotation specified in the tightening specifications must be attained and may be
exceeded within the specified tolerance. If no tightening tolerance is specified, the following tolerances
must be observed: +5° for additional angle of rotation less than or equal to 90° +10° for additional
angle of rotation greater than 90°. Before angle-of-rotation tightening, each screw head must be
colormarked so that after tightening it is possible to check that the angle of rotation is correct (exception:
colormarking is not necessary in the case of a selfmonitoring NC screwdriver).
• Elongated tightening:
Carry out tightening according to tightening specifications, taking tightening tolerance into account.
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Important Notes 07
1.2 Reman assemblies
Reman assemblies
The following assemblies are only available via the exchange procedure:
Series 2000 Series 4000
Injector Injector
HP fuel pump HP fuel pump
Crankshaft Crankshaft
Cylinder head Cylinder head
Conrod Conrod
Crankcase Crankcase
Intercooler Intercooler
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Piston Piston
Exhaust turbocharger Exhaust turbocharger
Coupling
Vibration damper
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General Conditions 09
2 General Conditions
2.1 General Instructions

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.
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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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2.2 Personnel and organizational requirements

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

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

During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections when
installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
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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.
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• 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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into shaft end until correct sealing is achieved.

During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
M020124/02E 2009-02 © MTU

Working on electrical/electronic assemblies

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

protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible fluids near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
noises indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors
(protective wadding, plugs or capsules).
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Environmental protection
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applicable, which
means work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling
hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.
Lead
• When working with lead or lead-containing pastes, avoid direct contact with the
skin and do not inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust!
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
Painting
• When painting in other than spray booths equipped with extractors, ensure good ventilation.
Make sure that adjacent work areas are not affected.
• No naked flames!
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• No smoking.
• Observe fire prevention regulations!
• It is absolutely necessary to wear masks providing protection against paint and solvent fumes.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing.
• Wear protective clothing, gloves, closed shoes and protective goggles!
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• Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air tanks and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Connecting devices and equipment must either be designed for this pressure or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
• Always wear protective goggles when blowing off tools or extracting chips!
• The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents
air-borne particles being reflected and thereby prevents injury to eyes.
• First shut off compressed air lines before compressed air equipment is disconnected from the
supply line or before equipment or tool is to be replaced!
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII
and B) out of containers, results in a risk of explosion!
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• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of explosion!
• Do not blow dirty clothing with compressed air when being worn on the body.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.
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2.5 Standards for warning notices in the publication

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

and Wear Limits List
The tolerances and wear limits are intended as a guide for the examination of engine components
as well as for engine inspection and repair.
Explanation of terms for dimensions of new components
Toleranced size Designed size followed by a fit symbol (e.g. 24 H6) or by

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

dimensional deviation
Deviation Permissible tolerance of toleranced/basic size.

Deviation determines the upper and lower limit of the
toleranced/basic size
Clearance Difference between bore and shaft diameter when bore

diameter is greater than shaft diameter
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Interference Difference between bore and shaft diameter when bore
diameter is smaller than shaft diameter
Explanation of terms for reconditioning of components
Wear limit The wear limits do not denote the max. permissible
wear for correct functioning of the component. They are
to show that the component will reach the next required
complete overhaul. The component must be replaced if
the wear limit is exceeded.
Reworking instructions If wear limits are exceeded or values are below

specification, the components concerned must be
reworked as per reworking instructions or replaced.
Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limits unless
specifically indicated. All dimensions are given in "mm" unless otherwise specified.
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2.7 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).
The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of engine components is also from the driving end, starting with No. 1.
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1 KGS = Free end 3 KS = Driving end
2 Right side 4 Left side
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M020124/02E 2009-02 © MTU

2.8 Tightening specifications for screws, nuts and bolts
Crankcase
Designation Torque specifications Lubricant
Stud for crankshaft bearing cap in crankcase 80 Nm Engine oil

(to blind hole base)
Stud (nominal length: 347.5 mm to 348.5 mm):
Stud elongation for crankshaft bearing cap ΔI = 1.15 mm +0.05 mm
Residual screw elongation ΔI = 0.9 mm +0.05 mm
Newly fitted studs must be elongated before initial tightening.

Lateral socket-head screws:
1 Starting, driving end: Left side, all 80 Nm

screws
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2 Starting, driving end: Right side, all 80 Nm
screws
3 Final tightening torque, left side 280 Nm +20 Nm
4 Final tightening torque, right side 280 Nm +20 Nm
Screws for oil pan made of extruded and cast aluminum.
Screw “A” 60 Nm +6 Nm
Screw “B” 27 Nm +3 Nm
Stress bolt “C” 27 Nm +3 Nm
Stress bolt “D” 27 Nm +3 Nm
Screw “E” 74 Nm +7 Nm
Screws for spherical-graphite cast iron oil pan
Screw “A” 42 Nm +4
Screw “B” 42 Nm +4
Screw “C” 74 Nm +7
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Crank drive
Screws for counterweight Engine oil

• Nominal length: 129.6 mm to 130 mm
• Max. length: 132 mm
1 Pretightening torque 320 Nm +30 Nm
2 Additional angle of rotation 120° + 10°
3 Checking torque 800 Nm +50 Nm
Screws for vibration damper flange 500 Nm +50 Nm
Screws for side plate, vibration damper 400 Nm Engine oil on thread only
Conrod screws Engine oil

• Nominal length: 102.6 mm to 103.2 mm
• Max. elongation: 104.5 mm
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Sequence:
a Short arm
b Long arm

Sequence:
a Short arm
b Long arm

Sequence:
a Short arm
b Long arm
Screws for seal carrier, free end 74 Nm +7 Nm
Graduated disc screws 21 Nm +2 Nm
Piston crown screws
• Nominal size, incl. allowance: 49 mm

±0.1 mm.
• Max. length for reassembly: 49.8 mm.
• Nominal size, incl. allowance: 50 mm ±

0.1 mm.
1 Tighten screws diagonally and evenly. 17 Nm Molykote G-N Plus
2 Release screws
3 Pretightening torque 10 Nm + 10 Nm
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Cylinder head
Sleeve for injector 60 Nm +6 Nm Engine oil
Plug screw 60 Nm +6 Nm
Tightening sequence of screws:1 to 6
1 Tighten 25 Nm
3 Additional angle of rotation 180° +10°
4 Checking torque 400 Nm
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A Exhaust side
B Inlet side
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Valve gear
Screw camshaft gear. 100 Nm + 10 Nm Engine oil
Screws for rocker shaft support 250 Nm +25 Nm

Max. shaft length: 180.8 mm
Version I: Locknut 24 A/F of valve bridge for 90 Nm +9 Nm

exhaust valve clearance adjusting screw
Version I: 24 A/F locknut of valve bridge for 90 Nm +9 Nm

inlet and valve clearance of adjusting screw
Version II: Locknut 19 A/F of valve bridge for 35 Nm +5 Nm

Version II: 19 A/F locknut of valve bridge for 35 Nm +5 Nm

Locknut on adjusting screw for valve bridge 35 Nm +5 Nm
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Screw for cylinder head cover 42 Nm
Fuel system – high pressure

Nut, high-pressure line to limiting valve 140 Nm +10 Nm Engine oil
Nut, high-pressure line to injector 120 Nm +12 Nm
High-pressure accumulator to crankcase 57 Nm +6 Nm
Thrust screw for high-pressure accumulator 550 Nm +50 Nm

seal
Screw for holddown clamp at injector 100 Nm + 10 Nm
Socket-head screws of 15 Nm +2 Nm
pressure relief valve
High-pressure lines from pump to 100 Nm + 10 Nm

high-pressure accumulator TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Exhaust turbocharger
Designation Torque Lubricant
specifications
Rear wall to bearing housing screws 28 Nm
Screws for turbine-side clamping segment 40 Nm Ultra-Therm MTU
Self-locking nut for clamping segment of compressor housing 15 Nm
Nut on turbine wheel
1 Pretightening torque (left-hand thread) 10 Nm
2 Angle of further rotation of shaft nut (M8) 100° –5°
Nut on stud of exhaust turbocharger 35 Nm +3 Nm Ultra Ultratherm
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Stud in exhaust manifold 17 Nm +2 Nm
Exhaust pipework
Screws, exhaust line to cylinder head M10 42 Nm +4 Nm Ultra-Therm MTU or Molykote

x 120 P37
Clamps on exhaust line 15 Nm +2 Nm
Charge air cooling

Screw of connecting housing cover 31 Nm +3 Nm Engine oil
Starting equipment
Nut M12, terminal 30 30 Nm +3 Nm Engine oil
Nut M12, terminal 30b 30 Nm +3 Nm
Nut M12, terminal 31 30 Nm +3 Nm
Nut M5, terminal 50 4 Nm + 10 Nm

TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Lube-oil system
Pressure reduction valve in equipment carrier 60 Nm +20 Nm Engine oil
Screw for oil pump 60 Nm +7 Nm
Nut for cooler insert 100 Nm + 10 Nm
Oil spray nozzle 21 Nm +2 Nm
Screw to secure cover of centrifugal oil filter, 6 Nm +1 Nm

8/12/16 V engines
Clamp to secure cover of centrifugal oil filter, 6 Nm +1 Nm

8/12/16 V engines
Battery-charging generator
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Radial and axial screws of coupling 42 Nm +4 Nm Engine oil
Screws, generator carrier to 100 Nm + 10 Nm

equipment carrier
Nut, coupling to generator 200 Nm +20 Nm
Screw, coupling, engine side 250 Nm +25 Nm
Screws, clamp for generator on 74 Nm +7 Nm

carrier
Screws, heat shield 21 Nm +2 Nm
Mounting / support
Screw (M10) for engine mounting 42 Nm +4 Nm Engine oil

bracket on crankcase
Screw (M20) for engine mounting 350 Nm +35 Nm

Nuts for damping element on engine 580 Nm +50 Nm

carrier
Screw (M12) for engine support on 74 Nm +7 Nm

crankcase
Screw (M20) for engine support on 180 Nm + 18 Nm

TIM ID: 0000003825 – 005
crankcase
M020124/02E 2009-02 © MTU

PTO systems, driving end and free end (coupling)

Geislinger coupling F56
4 Assembly screws 150 Nm +15 Nm
Screw M16 for coupling on flywheel Engine oil
2 Additional angle of rotation 60° to 65°
Screw M 16 (slotted) 180 Nm
Screw M 10 45 Nm Molykote 1000
Screw M 10 75 Nm Loctite 242
Dished washers Loctite 270
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Geislinger coupling F56 with bearing housing
Screws for bearing housing cover 100 Nm + 10 Nm Engine oil
Diaphragm coupling, driving end, for alternator
Diaphragm coupling securing 250 Nm +25 Nm pretightening Engine oil

screws 50 Nm
Securing screws for alternator 100 Nm + 10 Nm

housing on flywheel housing
Küsel coupling for universal shaft
Screw M 16 x 60 250 Nm +25 Nm Engine oil
Screw M 18 x 40 290 Nm
Screw M 20 x 50 500 Nm +50 Nm
Screw M 22 x 55 680 Nm + 68 Nm
Socket-head screw M 22 x 50 780 Nm

TIM ID: 0000003825 – 005
Vulkardan-L coupling for universal shaft
M020124/02E 2009-02 © MTU

Screw M 10 x 70 41 Nm +5 Nm
Centa couplings CF-A-30-S for hydropump
Screws, hydropump to pump carrier 74 Nm +7 Nm Engine oil

flange
Screws, pump carrier flange to 40 Nm +4 Nm

housing
Socket-head screws, coupling hub 74 Nm +7 Nm

to additional earth (taper clamp)
Socket-head screw, rubber element 200 Nm + 10 Nm Socket-head screws and plug-in
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to coupling hub pins of coupling are provided with
INBUS PLUS adhesive on the
Plug-in pin for rubber element 200 Nm + 10 Nm thread.
Monitoring, control and regulation devices

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

• Charge air
• Engine coolant
• Lube oil
• Fuel
• Intake air
• Charge air coolant
Pressure sensor for 20 Nm to 45 Nm

• Lube oil
• Charge air
Fuel pressure sensor after filter 20 Nm + ±3 Nm
Pressure sensor for fuel high 30 Nm + 10 Nm

pressure
Pressure sensor for crankcase 20 Nm to 45 Nm

pressure
Differential pressure monitor for lube 27 Nm

oil
TIM ID: 0000003825 – 005
Tightening specification for setscrew and stud connections as

per works standard MTN 5008
This works standard applies to setscrews subjected to little dynamic load as per MMN 384, DIN 912, EN
24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.
They do not apply to heat-proof screws in the hot component area.
M020124/02E 2009-02 © MTU

Tightening torques MA are for screws of strength class 8.8 (bright surface, phosphate coating or
galvanized) and 10.9 (bright surface or with phosphate coating).
The values in the table are based on a friction coefficient µtot = 0.125. Precondition: Thread and mating
faces of screws and nuts must be coated in engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values
is permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process - e.g. resulting from inaccurate readings and overtightening during assembly.
When tightening mechanically, the permitted assembly tolerance is +15 %.
Hand-tightened Machine-tightened
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
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M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175

TIM ID: 0000003825 – 005
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA = tightening torques
M020124/02E 2009-02 © MTU

Tightening torques for stress bolt connections as per works standard MTN 5007
This standard applies to stress pin bolts and stress bolts which are subjected to static and
dynamic load of strength class 10.9 and the associated nuts.
Shaft and transition dimensions as to MMN 209 standard and material and machining to MMN
389 standard (bright surface or with phosphate coating).
When tightening manually (defined tightening), an assembly tolerance of + 10% of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
The values in the tables are for manual tightening with torque wrench.
Thread without torsion protection MA(Nm) with torsion protection MA(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
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M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230

TIM ID: 0000003825 – 005
M30 1250 1575
*Protect shank against torsion when tightening.

M020124/02E 2009-02 © MTU

Tightening torques for plugs as per works standard MTN 5183-1

This standard applies to plugs as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN
3852, model A (sealed by sealing ring DIN 7603-Cu).
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TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Tightening torques MA are given for plugs made of steel (St) with surface protected by a phosphate coating
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and oiled or galvanized. Thread and mating faces beneath heads must be coated in engine oil prior to
assembly. When tightening manually (defined tightening), an assembly tolerance of +10% of the table values
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Tightening torques for plugs DIN 908, DIN 910 and DIN 7604A (with short screwed plug)
inserted in
Thread steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
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M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Tightening torques for plugs as per DIN 7604C (with long screwed plug)
inserted in
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
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Tightening torques for banjo screws as per works standard MTN 5183-2
This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603-Cu
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

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

Installed in steel/gray cast iron/Al alloy MA
Thread
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160

TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Tightening torques for banjo screws made of copperaluminum alloys

Thread
(Nm)
M10 x 1 15
M16 x 1.5 30
Tightening torques for male connector as per works standard MTN 5183-3
This standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852,
model A (Sealed by sealing ring DIN 7603-Cu)
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Tightening torques MA are given for male connectors made of steel (St) with surface protected
by a phosphate coating and oiled or galvanized.
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Installed in steel/gray cast iron MA

Thread
(Nm)
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
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M42 x 2 260
M48 x 2 320
Tightening torques for union nut on screwed plug ISO 6149-3
1 Union nut
2 Union body
3 O-ring
4 Linear ball bearing
TIM ID: 0000003825 – 005
Union nut: When installing the linear ball bearing, the union nut must be tightened firmly by hand (noticeable
force increase), and then a further quarter rotation (90°) beyond this point.
M020124/02E 2009-02 © MTU

2.9 Settings
Firing order for Series 4000 engines

8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1 – B2 – A5 – B4 – A3 – B1 – A6 – B5 – A2 – B3 – A4 – B6
16V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
Direction of rotation, viewed towards driving end

Component Direction of rotation
Crankshaft left
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Camshaft right
H.P. fuel pump left
Oil pump left
Engine coolant pump left
Charge air coolant pump left
Battery-charging generator left

(if fitted)
Hydrostatic pump (if available) left
Valve clearance, engine cold (20 °C)

Inlet 0.20 mm
Exhaust 0.50 mm
TIM ID: 0000000528 – 002
M020124/02E 2009-02 © MTU

Valve timing with valve clearance adjusted
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No. Valve position Crank angle
1 Inlet opens 42.6° before TDC
2 Inlet closes 66.6° after BDC
3 Exhaust opens 57.6° before TDC
4 Exhaust closes 30.4° after TDC
5 Overlap 73 °
6 Start of delivery Performance-map controlled
I Top dead center (TDC)
II Bottom dead center (BDC)
Cam and valve lift for camshaft adjustment

Inlet Exhaust
Cam lift at TDC 1.43 mm 1.43 mm
Valve lift at TDC (zero valve 1.80 mm to 2.30 mm 1.70 mm to 2.20 mm

clearance)
TIM ID: 0000000528 – 002
M020124/02E 2009-02 © MTU

2.10 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km

nm 1.852 = km
yd 3 = ft
yd 36 = in
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Unit B multiplied by factor = Unit A
mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile
Area
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.5889 = km2
Unit B multiplied by factor Unit A

mm2 0.00155 = in2
m2 10.7643 = ft2
m2 1.1960 = yd2
km2 0.3863 stat. mile2

TIM ID: 0000000413 – 005
M020124/02E 2009-02 © MTU

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

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

TIM ID: 0000000413 – 005
M020124/02E 2009-02 © MTU

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

g 0.03527 = oz
kg 2.205 = lb
t 0.9843 = ton
Force
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lb 0.4536 = kp
lb 4.4483 =N
kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 =N
Density
lb s2/ft4 515.4 = kg/m3
kg/m3 0.00194 = lb s2/ft4

TIM ID: 0000000413 – 005
M020124/02E 2009-02 © MTU

Torque
ft lb 1.3563 = Nm
Nm 0.7373 = ft lb
Pressure
lb/sq in (psi) 703.1 = kp/m2 (mm WS)
lb/sq in (psi) 0.06895 = bar
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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
bar 14.503 = lb/sq in
Mass moment, 2nd grade

ft lb s2 1.3563 = kg m2
kg m2 0.7373 = ft lb s2
TIM ID: 0000000413 – 005
M020124/02E 2009-02 © MTU

Energy
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
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Power
HP (horse power) 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 =W
HP 550 = ft lb/s
kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
TIM ID: 0000000413 – 005
M020124/02E 2009-02 © MTU

Temperature
Celsius Kelvin Fahrenheit Réaumur
x °C = x + 273.15 K = 9/5x + 32 °F = (4/5x) °R
xK = x − 273. 15 °C = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R
x°F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 = 4/9(x − 32) °R

K
x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F
Fuel consumption
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km
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km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)

TIM ID: 0000000413 – 005
M020124/02E 2009-02 © MTU

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

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

tool from bore (left).
2. Bore core hole with suitable twist drill - see table.
3. Cut thread with special tap.
4. Do not countersink hole!
5. Mount spindle (2) and snout (1) corresponding
with thread.
6. Groove on snout must be aligned with markings on
installation tool (arrows).
1 Snout
2 Spindle
TIM ID: 0000000499 – 002
M020124/02E 2009-02 © MTU

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

installation tool.
8. Driver journal of the thread insert must be in
groove (arrow).
1 Spindle
2 Thread insert
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9. Use spindle to turn thread insert through snout
until it is flush at front (arrow).
10. Mount installation tool on threaded hole and install

thread insert without applying pressure to spindle.
11. Insert thread insert 1/2 to 1 1/2 turns deeper than
the threaded hole surface.
12. Use screw shearer to remove driver journals up
to M 14. With threaded inserts over M14, use
pointed pliers to move driver journal up and
down and remove.
TIM ID: 0000000499 – 002
M020124/02E 2009-02 © MTU

2.12 Abbreviations
Abbrevia- Meaning Explanation

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

TIM ID: 0000000383 – 004
ISO International Organization for

Standardization
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
M020124/02E 2009-02 © MTU

Abbrevia- Meaning Explanation

tion
LCD Liquid Crystal Display, Liquid Crystal

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

Unit
OT Oberer Totpunkt Top dead center (TDC()
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
UPS Unit Pump System
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps
SPC Spare Parts Catalog
SS Safety System Alarm initiated by safety system
SSK Schnellschlussklappe(n) Emergency Air Shutoff Flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TC Tools Catalog
TIM ID: 0000000383 – 004
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom dead center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water Jet Waterjet drive
M020124/02E 2009-02 © MTU

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TIM ID: 0000000383 – 004
M020124/02E 2009-02 © MTU

Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) 49
Diesel Engine 12V 4000 R41 /

16V 4000 R41 (1)
Instructions for Major Overhaul .............................................. 59
3 Maintenance Schedule 12V 4000 R41 / 16V 4000 R41 ................................. 61
3.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1.2 Maintenance schedule matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1.3 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 Task Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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4.1 Engine – Checking condition before a major overhaul .......................... 67
4.2 Engine – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3 Engine – Disassembly .................................................... 70
4.4 Engine – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.5 Engine – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.6 Engine – Run-in procedure ................................................ 76
4.7 Initial engine operation ................................................... 79
5 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1 Crankcase and Externally Mounted Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1.2 Crankcase and attachments – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.1.3 Crankcase – Overview ............................................ 99
5.1.4 Crankcase – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1.5 Crankcase – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1.6 Crankcase – Checking upper and lower cylinder liner fit . . . . . . . . . . . . . . . . . . . 107
5.1.7 Crankcase – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.1.8 Crankcase – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.1.9 Crankcase – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.1.10 Cylinder liner – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.1.11 Cylinder liner – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.1.12 Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.1.13 Cylinder liner – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.1.14 Cylinder liner – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.1.15 Cylinder liner – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.1.16 Oil pan – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.1.17 Oil pan – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.1.18 Oil pan – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.1.19 Oil pan – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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50 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1)
5.1.20 Oil pan – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.1.21 Tightening sequence for oil pan made of nodular cast iron (GGG) . . . . . . . . . . . . 153
5.1.22 Engine lifting equipment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.1.23 Engine lifting equipment – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.1.24 Engine lifting equipment – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.1.25 Engine lifting equipment – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.1.26 Engine lifting equipment – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.1.27 End housing, driving end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.1.28 End housing, driving end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.1.29 End housing, driving end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.1.30 End housing, driving end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.1.31 End housing, driving end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.1.32 End housing KS – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.1.33 End housing, driving end – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.1.34 End housing, driving end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.1.35 Crankcase ventilation – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.1.36 Crankcase ventilation – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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5.1.37 Crankcase ventilation – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5.1.38 Crankcase ventilation – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.1.39 Oil separator – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.1.40 Oil separator – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.1.41 Oil separator – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.1.42 Crankcase ventilation – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.2 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.2.1 Gearcase, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.2.2 Gearcase, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.2.3 Gearcase, free end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
5.2.4 Equipment carrier free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.2.5 Gearcase, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.2.6 Gearcase, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.2.7 Gearcase, free end – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.2.8 Gearcase, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
5.2.9 Gear train, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.2.10 Gear train, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5.2.11 Gear train, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.2.12 Gear train, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.2.13 Gear train, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.2.14 Gear train, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5.2.15 Bearing bushing of idler gear – Removal and installation . . . . . . . . . . . . . . . . . . . 210
5.3 Crank Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
5.3.1 Running gear – Overview .......................................... 212
5.3.2 Crankshaft – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.3.3 Crankshaft – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.3.4 Crankshaft – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5.3.5 Crankshaft - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5.3.6 Crankshaft – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.3.7 Crankshaft – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5.3.8 Crankshaft - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.3.9 Crankshaft – Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
M020124/02E 2009-02 © MTU

5.3.10 Crankshaft bearing shells - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

5.3.11 Crankshaft bearing bore – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
5.3.12 Crankshaft – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5.3.13 PTO flange, driving end, flywheel – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5.3.14 PTO flange, driving end, flywheel – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
5.3.15 Radial-lip shaft seal, driving end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
5.3.16 Flywheel on PTO flange, driving end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 260
5.3.17 Flywheel on PTO flange, driving end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
5.3.18 Radial-lip shaft seal, driving end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.3.19 PTO flange, driving end, flywheel – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 263
5.3.20 Crankshaft PTO, Free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
5.3.21 Vibration damper on PTO, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 269
5.3.22 Vibration damper on PTO, free end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . 272
5.3.23 Vibration damper on PTO, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 273
5.3.24 Vibration damper on PTO, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
5.3.25 Vibration damper on PTO, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . 275
5.3.26 Vibration damper on PTO, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . 276
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5.3.27 Piston and conrod – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5.3.28 Piston and conrod – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
5.3.29 Piston and conrod – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
5.3.30 Piston – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
5.3.31 Piston – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
5.3.32 Piston – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
5.3.33 Conrod – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
5.3.34 Conrod – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
5.3.35 Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
5.3.36 Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
5.3.37 Conrod – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
5.3.38 Piston – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
5.3.39 Piston and conrod – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5.4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
5.4.1 Cylinder head and attachments – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
5.4.2 Valve-seat turning machine for cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
5.4.3 Cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
5.4.4 Cylinder head – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
5.4.5 Cylinder head – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
5.4.6 Cylinder head – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
5.4.7 Cylinder head – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
5.4.8 Cylinder head – Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
5.4.9 Cylinder head – Plug repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
5.4.10 Cylinder head – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
5.4.11 Cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
5.5 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
5.5.1 Valve gear – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
5.5.2 Camshaft overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
5.5.3 Camshaft – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
5.5.4 Camshaft – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
5.5.5 Camshaft running surfaces and swing followers – Visual inspection . . . . . . . . . . 373
5.5.6 Camshaft – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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5.5.7 Camshaft – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

5.5.8 Camshaft – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
5.5.9 Camshaft drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
5.5.10 Camshaft drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
5.5.11 Camshaft drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
5.5.12 Camshaft drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
5.5.13 Camshaft drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
5.5.14 Camshaft thrust bearing – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
5.5.15 Camshaft thrust bearing – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
5.5.16 Camshaft thrust bearing – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
5.5.17 Camshaft thrust bearing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
5.5.18 Valve drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
5.5.19 Valve drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
5.5.20 Valve drive - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5.5.21 Valve drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.5.22 Valve drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
5.5.23 Valve drive – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
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5.5.24 Valve drive – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
5.5.25 Valve drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
5.5.26 Cylinder head cover – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
5.5.27 Cylinder head cover – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
5.5.28 Cylinder head cover – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
5.5.29 Cylinder head cover – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
5.5.30 Cylinder head cover – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
5.6 High Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
5.6.1 HP fuel system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
5.6.2 HP pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
5.6.3 HP pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
5.6.4 High-pressure pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
5.6.5 High-pressure pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
5.6.6 HP pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
5.6.7 H.P. fuel pump – Control block replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
5.6.8 Injector – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
5.6.9 Injector – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
5.6.10 Fuel injector disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
5.6.11 Injector – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
5.6.12 Injector – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
5.6.13 Injector – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
5.6.14 High-pressure line – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
5.6.15 HP fuel line – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
5.6.16 HP fuel line – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
5.6.17 HP fuel line – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
5.6.18 H.P. fuel line – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
5.6.19 HP fuel line – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
5.6.20 HP fuel line – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
5.6.21 H.P. fuel system – Leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
5.7 Low Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
5.7.1 Fuel system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
5.7.2 Fuel delivery pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
M020124/02E 2009-02 © MTU

5.7.3 Fuel delivery pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467

5.7.4 Fuel delivery pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
5.7.5 Fuel delivery pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
5.7.6 Fuel delivery pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
5.7.7 Fuel delivery pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
5.7.12 Fuel pipework from fuel delivery pump to fuel filter – Overview . . . . . . . . . . . . . . 476
5.7.13 Fuel lines from fuel delivery pump to fuel filter – Removal . . . . . . . . . . . . . . . . . . 477
5.7.14 Fuel lines from pump to filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
5.7.15 Fuel lines from fuel delivery pump to fuel filter – Check . . . . . . . . . . . . . . . . . . . . 479
5.7.16 Fuel lines from fuel delivery pump to fuel filter – Installation . . . . . . . . . . . . . . . . . 480
5.7.17 Fuel duplex filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
5.7.18 Fuel duplex filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
5.7.19 Fuel duplex filter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
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5.7.20 Fuel filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
5.7.21 Fuel filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
5.7.22 Fuel duplex filter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
5.7.23 Fuel duplex filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
5.7.24 Fuel pipework from fuel filter to HP pump – Overview . . . . . . . . . . . . . . . . . . . . . 488
5.7.25 Fuel pipework from fuel filter to HP pump – Removal . . . . . . . . . . . . . . . . . . . . . 489
5.7.26 Fuel pipework from fuel filter to high-pressure pump – Cleaning . . . . . . . . . . . . . 490
5.7.27 Fuel pipework from fuel filter to high-pressure pump – Check . . . . . . . . . . . . . . . 491
5.7.28 Fuel pipework from fuel filter to HP pump – Installation . . . . . . . . . . . . . . . . . . . . 492
5.7.29 Leak-off fuel pipework – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
5.7.30 Leak-off fuel line – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
5.7.31 Leak-off fuel pipework – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
5.7.32 Leak-off fuel pipework – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
5.7.33 Leak-off fuel line – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
5.8 Exhaust Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
5.8.1 Exhaust turbochargers – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
5.8.2 Exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
5.8.3 Exhaust turbocharger – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
5.8.4 Exhaust turbocharger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
5.8.5 Exhaust turbocharger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
5.8.6 Exhaust turbocharger – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
5.8.7 Exhaust turbocharger – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
5.8.8 Exhaust turbocharger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
5.9 Charge-Air Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
5.9.1 Intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
5.9.2 Intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
5.9.3 Intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
5.9.4 Intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
5.9.5 Intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
5.10 Air Intake/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
5.10.1 Air intake / air supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
M020124/02E 2009-02 © MTU

5.10.2 Intake housing – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

5.10.3 Intake housing – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
5.10.4 Intake housing – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
5.10.5 Intake housing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
5.10.6 Intake housing – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
5.10.7 Intake air system to cylinders, left – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
5.10.8 Air supply system to cylinders, left-hand side – Removal . . . . . . . . . . . . . . . . . . . 534
5.10.9 Air supply system to cylinders, left – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
5.10.10 Air supply to cylinders, left side – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
5.10.11 Air supply system to cylinders, left-hand side – Installation . . . . . . . . . . . . . . . . . 537
5.10.12 Air supply system to cylinders, right – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 538
5.10.13 Air supply system to cylinders, right-hand side – Removal . . . . . . . . . . . . . . . . . . 539
5.10.14 Air supply system to cylinders, right – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 540
5.10.15 Air supply to cylinders, RHS – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
5.10.16 Air supply system to cylinders, right-hand side – Installation . . . . . . . . . . . . . . . . 542
5.10.17 Air pipework from turbocharger to intercooler – Overview . . . . . . . . . . . . . . . . . . 543
5.10.18 Air pipework from exhaust turbocharger to intercooler – Removal . . . . . . . . . . . . 547
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5.10.19 Air supply from turbocharger to intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . 548
5.10.20 Air ducts from turbocharger to intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . 549
5.10.21 Air pipework from turbocharger to intercooler – Installation . . . . . . . . . . . . . . . . . 550
5.11 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
5.11.1 Exhaust system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
5.11.2 Exhaust pipework after cylinder head – Overview . . . . . . . . . . . . . . . . . . . . . . . . 552
5.11.3 Exhaust pipework after cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 553
5.11.4 Exhaust pipework after cylinder head – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
5.11.5 Exhaust pipework after cylinder head – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
5.11.6 Exhaust pipework after cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . 557
5.11.7 Exhaust pipework after exhaust turbocharger – Overview . . . . . . . . . . . . . . . . . . 560
5.11.8 Exhaust pipework after exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . . 562
5.11.9 Exhaust pipework after turbocharger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 563
5.11.10 Exhaust pipework after exhaust turbocharger – Check . . . . . . . . . . . . . . . . . . . . 564
5.11.11 Exhaust pipework after exhaust turbocharger – Installation . . . . . . . . . . . . . . . . . 565
5.11.12 Exhaust pipework after engine – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
5.11.13 Exhaust pipework after engine – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
5.11.14 Exhaust pipework after engine – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
5.11.15 Exhaust pipework after engine – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
5.11.16 Exhaust pipework after engine – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
5.12 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
5.12.1 Electric starter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
5.12.2 Starter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
5.12.3 Starter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
5.12.4 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
5.12.5 Starter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
5.12.6 Starter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
5.12.7 Flame starting system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
5.12.8 Flame starting system – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
5.12.9 Flame starting system – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
5.12.10 Flame starting system – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
5.12.11 Flame starting system – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
M020124/02E 2009-02 © MTU

5.13 Lube Oil System, Lube Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585

5.13.1 Lube-oil pump with drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
5.13.2 Lube-oil pump with drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
5.13.3 Lube-oil pump with drive – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
5.13.4 Lube oil pump with drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
5.13.5 Lube-oil pump with drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
5.13.6 Lube oil pump with drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
5.13.7 Oil filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
5.13.8 Oil filter with oil filter housing – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
5.13.9 Oil filter housing – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
5.13.10 Oil filter housing – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
5.13.11 Oil filter housing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
5.13.12 Oil filter housing – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
5.13.13 Oil filter with oil filter housing – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
5.13.14 Centrifugal oil filter– Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
5.13.15 Centrifugal oil filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
5.13.16 Centrifugal oil filter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
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5.13.17 Centrifugal oil filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
5.13.18 Centrifugal oil filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
5.13.19 Centrifugal oil filter - Bearing clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
5.13.20 Centrifugal oil filter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
5.13.21 Centrifugal oil filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
5.13.22 Oil heat exchanger – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
5.13.23 Oil heat exchanger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
5.13.24 Oil heat exchanger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
5.13.25 Oil heat exchanger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
5.13.26 Oil heat exchanger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
5.13.27 Oil system in crankcase – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
5.13.28 Oil system in crankcase – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
5.13.29 Oil pipework in crankcase – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
5.13.30 Oil pipework in crankcase – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
5.13.31 Oil system in crankcase – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
5.13.32 Turbocharger oil supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
5.13.33 Turbocharger oil supply – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
5.13.34 Turbocharger oil supply – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
5.13.35 Turbocharger oil supply – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
5.13.36 Turbocharger oil supply – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
5.14 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
5.14.1 Coolant system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
5.14.2 Engine coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
5.14.3 Engine coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
5.14.4 Engine coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
5.14.5 Engine coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
5.14.6 Engine coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
5.14.7 Engine coolant pump – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656
5.14.8 Engine coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
5.14.9 Engine coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
5.14.10 Coolant pipework of engine coolant pump, intake side – Overview . . . . . . . . . . . 667
5.14.11 Coolant pipework for engine coolant pump, intake side – Removal . . . . . . . . . . . 670
M020124/02E 2009-02 © MTU

5.14.12 Coolant pipework, engine coolant pump, suction side – Cleaning . . . . . . . . . . . . 671
5.14.13 Coolant pipework, engine coolant pump, suction side – Check . . . . . . . . . . . . . . 672
5.14.14 Coolant pipework, engine coolant pump, suction side – Installation .......... 673
5.14.15 Coolant pipework after cylinder – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
5.14.16 Coolant pipework after cylinder – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
5.14.17 Coolant pipework after cylinder – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676
5.14.18 Coolant pipework after cylinder – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
5.14.19 Coolant pipework after cylinder – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
5.14.20 Engine coolant drain lines – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
5.14.21 Engine coolant drain lines – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
5.14.22 Engine coolant drain lines – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
5.14.23 Engine coolant drain lines – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682
5.14.24 Engine coolant drain lines – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
5.14.25 Engine coolant and charge air coolant ventilation – Overview . . . . . . . . . . . . . . . 684
5.14.26 Engine coolant and charge-air cooling vent – Removal . . . . . . . . . . . . . . . . . . . . 686
5.14.27 Ventilation, engine coolant and charge air coolant – Cleaning . . . . . . . . . . . . . . . 687
5.14.28 Ventilation, engine coolant and charge air coolant – Check ................ 688
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5.14.29 Engine coolant and charge-air cooling vent – Installation . . . . . . . . . . . . . . . . . . . 689
5.14.30 Coolant pipework from/to exhaust turbochargers – Overview . . . . . . . . . . . . . . . 690
5.14.31 Coolant pipework from/to exhaust turbochargers – Removal . . . . . . . . . . . . . . . . 691
5.14.32 Coolant pipework from/to exhaust turbochargers – Cleaning . . . . . . . . . . . . . . . . 692
5.14.33 Coolant pipework from/to turbochargers – Check . . . . . . . . . . . . . . . . . . . . . . . . 693
5.14.34 Coolant pipework from/to exhaust turbochargers – Installation . . . . . . . . . . . . . . 694
5.14.35 Charge-air coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
5.14.36 Charge-air coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697
5.14.37 Charge-air coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
5.14.38 Charge-air coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
5.14.39 Charge-air coolant pump – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
5.14.40 Charge-air coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
5.14.41 Charge-air coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709
5.14.42 Charge-air coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
5.14.43 Coolant pipework from/to intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . 717
5.14.44 Coolant pipework from/to intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 719
5.14.45 Coolant pipework from/to intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 720
5.14.46 Coolant pipework from/to intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
5.14.47 Coolant pipework from/to intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . 722
5.14.48 Coolant pipework with thermostat – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
5.14.49 Coolant pipework with thermostat – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724
5.14.50 Coolant pipework with thermostat – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
5.14.51 Coolant pipework with thermostat – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
5.14.52 Coolant pipework with thermostat – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 731
5.15 Power Supply, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734
5.15.1 Battery-charging generator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734
5.15.2 Battery-charging generator – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735
5.15.3 Battery-charging generator – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737
5.15.4 Battery-charging generator – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738
5.15.5 Battery-charging generator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739
5.15.6 Battery-charging generator – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740
5.16 Mounting/Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743
M020124/02E 2009-02 © MTU

5.16.1 Engine mounting / support – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743

5.16.2 Engine mounting – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744
5.16.3 Engine mount – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
5.16.4 Engine mount – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748
5.16.5 Engine mounts – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749
5.16.6 Engine mount – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
5.17 PTO Systems, Driving End and Free End (Coupling) . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
5.17.1 Geislinger steel-spring coupling – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754
5.17.2 Geislinger steel-spring coupling – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 756
5.17.3 Steel-spring coupling – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757
5.17.4 Geislinger steel-spring coupling – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758
5.17.5 Geislinger steel-spring coupling – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 760
5.17.6 Geislinger steel-spring coupling – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
5.17.7 Diaphragm coupling – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
5.17.8 Diaphragm coupling – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765
5.17.9 Diaphragm coupling – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766
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5.17.10 Diaphragm coupling – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767
5.17.11 Diaphragm coupling – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768
5.17.12 Auxiliary PTO, lateral – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 772
5.17.13 Auxiliary PTO – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
5.17.14 Auxiliary PTO – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777
5.17.15 Auxiliary PTO – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
5.17.16 Auxiliary PTO – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779
5.18 Monitoring and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783
5.18.1 Monitoring, control and regulation devices – Overview . . . . . . . . . . . . . . . . . . . . . 783
5.18.2 Cabling and engine wiring harnesses – Overview . . . . . . . . . . . . . . . . . . . . . . . . 784
5.18.3 Engine wiring harnesses – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788
5.18.4 Engine wiring harness – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791
5.18.5 Engine wiring harness – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
5.18.6 Engine wiring harnesses – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 793
5.18.7 Sensors, actuators and injectors – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795
5.18.8 Sensors, actuators and injectors – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799
5.18.9 Sensors, actuators and injectors – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
5.18.10 Sensors, actuators and injectors – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
6.1 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
6.2 Special tools – Overview .................................................. 810
6.3 General workshop equipment – Overview .................................... 937
6.4 Measuring tools – General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 943
6.5 Tools kits – Overview ..................................................... 948
M020124/02E 2009-02 © MTU

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M020124/02E 2009-02 © MTU

Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) – Instructions for Major Overhaul 59
Instructions for Major

Overhaul
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60 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) – Instructions for Major Overhaul
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M020124/02E 2009-02 © MTU

Maintenance Schedule 12V 4000 R41 / 16V 4000 R41 61
3 Maintenance Schedule 12V 4000 R41 / 16V 4000 R41
3.1 Maintenance
3.1.1 Preface
MTU maintenance concept

The maintenance system for MTU products is based on a preventive maintenance concept. Preventive maintenance
makes possible advance operational planning and ensures high operational availability.
The maintenance schedule is based on the load profile/load factor specified below. The intervals at
which maintenance work is to be performed and the scope of the inspection and maintenance activities
described are based on experience of average use and serve only as a guide. Additional maintenance
work and/or adaptation of maintenance intervals may prove necessary for special applications and technical
requirements. Maintenance personnel charged with carrying out maintenance work must be appropriately
qualified depending on the complexity of the task concerned. The various stages QL1 to QL4 correspond
to the scope of training offered by MTU and the tools included in the kits:
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QL1: Operational monitoring and maintenance work which may be performed without disas-
sembling the engine when it is out of operation.
QL3: Maintenance work requiring partial disassembly of the engine.
QL4: Maintenance work requiring complete disassembly of the engine.
The maintenance schedule matrix normally finishes with extended component maintenance. The maintenance
services must then be continued in accordance with specified intervals.
The “Task” numbers stated in the action list identify the various maintenance activities. They serve as a reference
for the scope of parts needed and also appear on the labels of the corresponding spare parts.
Notes on maintenance
Fluids and lubricants specifications, maintenance and replacement interval guidelines and the list of recommended
fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications A001061 and in the fluids
and lubricants specifications of the component manufacturers. They are therefore not listed in the maintenance
schedule (exception: deviations from the Fluids and Lubricants Specifications). Use only fluids and lubricants which
conform to MTU specifications or which are approved by the respective component manufacturers.
The user/customer must perform the following maintenance tasks:
• Parts made of rubber or synthetic materials shall be protected from oil, wiped clean with a dry
cloth only, and never cleaned with organic cleaning agents.
• Fuel prefilter:
The maintenance interval depends on the degree of fuel contamination. Paper elements in fuel
prefilters must be replaced every 2 years at the latest (task 9998).
• Battery:
Battery maintenance depends on their use and prevailing ambient conditions. Battery
manufacturer’s specifications shall apply.
Manufacturer’s specifications shall apply to the maintenance of all components not listed in this maintenance schedule.
Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
according to the Fluids and Lubricants Specifications, MTU Publication No. A001061.
TIM ID: 0000009016 – 002
Application group
2A Rail traction
M020124/02E 2009-02 © MTU

Load profile
Load profile table
Power 100% 90% 75% <15%
Corresponding runtime 10% 15% 15% 60%
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TIM ID: 0000009016 – 002
M020124/02E 2009-02 © MTU

3.1.2 Maintenance schedule matrix
0 - 21,000 Operating hours

Item Operating hours [h]
Limit years
10,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
21,000
11,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Daily
Engine oil filter 2
Engine running - x
Air filter - X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter - X X X X X X X X X X X X X X X X X X X X X
Valve gear - X x x x x x x x x x x x x x x x x x x x x
Fuel filter 2 x x x x x x x x x x x x x x x x x x x x x
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Crankcase ventilation - x x x x x x x x x x
Fuel injectors - x x x
Cylinder chambers - X X X
Air filter 2 X X X
Exhaust turbocharger - X X
Component maintenance - X X
Cylinder head - X
Extended component maintenance 18

TIM ID: 0000009017 – 001
M020124/02E 2009-02 © MTU

22,000 - 30,000 Operating hours

Limit years
22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
Engine oil filter 2
Engine running -
Air filter - x x x x x x x x x
Centrifugal oil filter - x x x x x x x x x
Valve gear - x x x x x x x x x
Fuel filter 2 x x x x x x x x x
Crankcase ventilation - x x x x x
Fuel injectors - x x
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Cylinder chambers - x x
Air filter 2 x x
Exhaust turbocharger - x
Component maintenance - x
Cylinder head - x
Extended component maintenance 18 x
TIM ID: 0000009017 – 001
M020124/02E 2009-02 © MTU

3.1.3 Maintenance tasks

Table of maintenance tasks
Qual- Interval Item Maintenance tasks TASK

ifica-
tion [hours] [years]
QL1 Engine oil filter Replace engine oil filter during oil change or at latest after Limit W1008
(years) (→Operating Instructions)
.
QL1 Engine operation Check engine oil level (→Operating Instructions ). W0500
Visually check for leaks and general condition of engine. W0501
Check intercooler drain line (if applicable). W0502
Check maintenance indicator of air filter (→Operating Instructions). W0503

m
Check telltale bores of HP fuel pump (→Operating Instructions). W0504
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Check relief bores of coolant pump(s) (→Operating Instructions). W0505
Check for abnormal running noises, exhaust gas color (→Operating W0506
Instructions) and vibrations.
Drain water and contaminants at fuel prefilter drain cock (if applicable) W0507
(→Operating Instructions).
Check contamination indicator position of fuel prefilter (if applicable) W0508

QL1 Centrifugal oil filter Centrifugal oil filter (if applicable): Check oil residue layer thickness, W1009
clean and replace filter sleeve (→Operating Instructions).
QL1 Fuel filter Replace fuel filter or fuel filter element (→Operating Instructions). W1001
QL1 Valve gear Check valve clearance (→Operating Instructions ). W1002
QL1 Belt Drive Check condition and tension of drive belt, (→Operating Instructions ) W1003
replace if necessary (→Operating Instructions).
QL1 Air filter Replace air filter (→Operating Instructions). W1005
QL1 Fuel injectors Replace fuel injectors (→Operating Instructions ). W1006
QL1 Cylinder chambers Carry out endoscopic inspection on cylinder chambers (→Operating W1011
Instructions ).
QL3 Exhaust turbocharger Overhaul exhaust turbocharger (→ Page 499). W1038
QL3 Component maintenance Before starting maintenance, drain coolant and flush coolant system W2000
(→ Page 67).
Check rocker arm, valve bridge, swing follower and swing follower W2001
support for wear (→ Page 396).
Clean air supply pipework (→ Page 526). W2002
Clean intercooler and check for leaks (→ Page 519). W2003

TIM ID: 0000009018 – 003
Replace HP fuel sensor (→ Page 795). W2004
Overhaul engine coolant pump (→ Page 645) and charge-air coolant W2005
pump (→ Page 695).
Check engine coolant thermostat and replace thermal actuator W2006

(→ Page 723).
M020124/02E 2009-02 © MTU


ifica-
Replace charge air coolant thermostat and thermal actuator W2007

(→ Page 723).
Check centrifugal oil filter (if applicable) for wear (→ Page 604). W2009
Overhaul starter (→ Page 572). W2010
Check vibration damper (→ Page 267). W2011
Replace seals on all disassembled components. W2062
QL3 Crankcase breather Crankcase breather: Replace filter or filter element (→ Page 171). W1046
QL3 Cylinder head Overhaul cylinder heads, visually check piston crowns and running W1063
pattern of cylinder liners (→ Page 322).
QL3 Fuel delivery pump Replace fuel delivery pump (→ Page 466). W1051
QL4 Extended component Perform complete engine disassembly. Inspect engine components W3000
maintenance acc. to assembly instructions, recondition or replace as necessary
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(→ Page 70).
Replace all elastomer components and seals. W3001
Replace piston rings (→ Page 280). W3002
Replace conrod bearings (→ Page 280). W3003
Replace crankshaft bearings (→ Page 213). W3004
Replace cylinder liners (→ Page 132). W3005
Replace auxiliary PTO antifriction bearing (→ Page 734). W3006
Replace HP fuel pump (→ Page 424). W3007
Overhaul generator (→ Page 734). W3042
TIM ID: 0000009018 – 003
M020124/02E 2009-02 © MTU

Task Schedules 67
4 Task Schedules
4.1 Engine – Checking condition before a major overhaul

Before the engine is removed, a brief test should be conducted to assist in evaluating
its condition and running behaviour.
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TIM ID: 0000000480 – 001
M020124/02E 2009-02 © MTU

Deviations from the Engine Acceptance Test Record Data found during the test run provide
valuable information for subsequent overhaul services.
Operations to be performed See
Preparations for putting into operation. (→Operating Instructions)
Initial operation, start engine. (→Operating Instructions)
Run engine warm. -
Perform operational checks. (→Operating Instructions)
Check operating states with fault code display, assess (→Operating Instructions)
discrepancies.
Check exhaust gas color. (→Operating Instructions)
Operate engine with adjustable zero-power speed. -
Check fuel line connections for leaks. -
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Remove cylinder head cover. (→Operating Instructions)
Check valve gear lubrication. -
Take engine oil sample. (→Operating Instructions)
Install cylinder head cover. (→Operating Instructions)
Check intercooler drain line for leaks. (→Operating Instructions)
Analyze engine oil sample (spot test, water content, MTU test kit
dilution with fuel).
Take engine coolant sample. (→Operating Instructions)
Examine engine coolant sample. MTU test kit
Check monitoring system and ECU. -
Shut down engine. (→Operating instructions)
If installed, lower coolant level in expansion tank and (→Operating instructions)

check level switch response.
Drain engine coolant. (→Operating instructions)
Drain charge air coolant. (→Operating Instructions)
Fill system with cleaning solution. -
Start engine. (→Operating Instructions)
Flush cooling system. -
Flush charge air cooling system. -

TIM ID: 0000000480 – 001
Shut down engine. (→Operating Instructions)
Perform endoscopic inspection. (→Operating Instructions)
M020124/02E 2009-02 © MTU

Task Schedules 69
4.2 Engine – Removal
Shut off fuel supply. –
Drain engine oil at operating temperature. (→Operating Instructions)
Examine oil sludge for metallic residues. –
Drain engine coolant. (→Operating Instructions)
Wash machinery plant (as required, without chemical –

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

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

transportation regulations.
TIM ID: 0000002889 – 003
M020124/02E 2009-02 © MTU

4.3 Engine – Disassembly

The sequence of the work steps stated below corresponds to practical assembly procedure.
Before disassembling the engine, it is advisable to take photographs from all sides or to make
a record of all components installed on the engine.
The exact task description must be taken from the respective functional group.
Remove PTO system. –
Remove intake silencer. –
Remove air intake. (→ Page 529)
Mark and disconnect electric cables. (→ Page 788)
Remove exhaust system after engine. (→ Page 568)
Remove exhaust system after exhaust (→ Page 562)

turbocharger.
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Remove air pipework to intercooler. (→ Page 547)
Disconnect oil supply to exhaust turbocharger. (→ Page 639)
Remove exhaust turbocharger. (→ Page 500)
Disconnect coolant supply to exhaust (→ Page 691)

turbocharger.
Remove couplings. (→ Page 765)
Remove MDEC. –
Remove coolant pipework, low-temperature (→ Page 719)

circuit.
Remove crankcase breather. (→ Page 174)
Remove charge air pipes. (→ Page 534)
Remove intercooler. (→ Page 521)
Remove engine coolant ventilation and (→ Page 686)

charge-air cooling.
Remove exhaust pipework. (→ Page 553)
Remove coolant pipework. (→ Page 675)
Remove centrifugal oil filter. (→ Page 607)
Remove oil cooler. (→ Page 619)
Remove thermostat housing. (→ Page 724)

TIM ID: 0000009008 – 003
Remove coolant pipework, high-temperature (→ Page 647)

circuit. (→ Page 670)
Remove coolant pump, low-temperature circuit. (→ Page 697)
Remove coolant pump, high-temperature (→ Page 647)

circuit.
M020124/02E 2009-02 © MTU

Task Schedules 71
Remove auxiliary PTO (→ Page 775)
Remove fuel pipework from fuel filter to HP (→ Page 489)

pump.
Remove leak-off fuel line. (→ Page 495)
Remove leak-off fuel monitoring system. (→ Page 495)
Remove HP fuel pump. (→ Page 426)
Remove fuel pump, low-temperature circuit. (→ Page 467)
Remove fuel filter. (→ Page 482)
Remove starter. (→ Page 574)
Remove HP fuel lines with HP accumulator. (→ Page 449)
Remove cylinder head covers. (→ Page 419)
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Remove valve drive. (→ Page 400)
DM_110_WM_055050_520A
Remove fuel injector. (→ Page 435)
Remove cylinder heads. (→ Page 330)
Remove vibration damper. (→ Page 269)
Remove coolant distribution housing. (→ Page 724)
Remove flywheel with timing wheel. (→ Page 255)
Disassemble crankcase. (→ Page 102)
Remove engine mounts. (→ Page 746)
Remove engine lifting attachment. (→ Page 156)
Install crankcase in crankcase rotation device. (→ Page 102)
Remove end housing, driving end. (→ Page 162)
Remove oil pan. (→ Page 147)
Remove gearcase, free end. (→ Page 186)
Remove oil pump with drive and pressure (→ Page 586)

reducing valve.
Remove piston and conrod. (→ Page 282)
Remove crankshaft. (→ Page 216)
Remove cylinder liners. (→ Page 134)

TIM ID: 0000009008 – 003
Remove oil pipework and oil spray nozzles. (→ Page 629)
Remove crankcase from crankcase rotation (→ Page 124)

device.
Remove camshaft drive with timing wheel. (→ Page 387)
M020124/02E 2009-02 © MTU

Replace camshaft axial alignment bearing. (→ Page 394)
Remove camshaft. (→ Page 370)
Remove end cover. (→ Page 102)
Remove studs. (→ Page 102)
Remove camshaft bearing bush. (→ Page 102)
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TIM ID: 0000009008 – 003
M020124/02E 2009-02 © MTU

Task Schedules 73
4.4 Engine – Assembly

Clean crankcase. (→ Page 105)
Check crankcase. (→ Page 110)
Assemble crankcase. (→ Page 124)
Install cylinder liners. (→ Page 142)
Install camshaft. (→ Page 379)
Install oil system in crankcase. (→ Page 634)
Install crankshaft. (→ Page 245)
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Install gearcase, free end. (→ Page 195)
Install end housing, driving end (→ Page 169)
Install piston with conrod. (→ Page 315)
Install lube-oil pump with drive. (→ Page 591)
Install oil pan. (→ Page 150)

device.
Install camshaft drive. (→ Page 391)
Install camshaft thrust bearing. (→ Page 394)
Install main oil gallery. (→ Page 124)
Install engine lifting eyes. (→ Page 750)
Install cylinder heads. (→ Page 364)
Install coolant distribution housing. (→ Page 731)
Install leak-off fuel pipework. (→ Page 498)
Install valve gear. (→ Page 414)

DM_110_WM_055050_720A
Install vibration damper on PTO, free end. (→ Page 276)
Install PTO flange, flywheel driving end. (→ Page 263)

TIM ID: 0000009009 – 003
Install engine lifting attachment. (→ Page 159)
Install fuel injector. (→ Page 441)
Install cylinder head cover. (→ Page 422)
Install thermostat housing. (→ Page 731)
Install oil cooler. (→ Page 624)
M020124/02E 2009-02 © MTU

Install HP fuel pump. (→ Page 430)
Install auxiliary PTO (→ Page 779)
Install crankcase ventilation. (→ Page 183)
Install oil filter housing. (→ Page 624)
Install centrifugal oil filter. (→ Page 617)
Install HP fuel line. (→ Page 459)
Install fuel delivery pump. (→ Page 471)
Install fuel filter. (→ Page 487)
Install fuel pipework from fuel filter to HP pump. (→ Page 492)
Install MDEC. –
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Install coolant pump, high-temperature circuit. (→ Page 665)
Install coolant pump, low-temperature circuit. (→ Page 715)
Install charge air manifolds. (→ Page 537)
Install starter. (→ Page 578)
Install intercooler. (→ Page 525)
Install coolant venting lines (→ Page 689)
Install coolant pipework, high-temperature circuit. (→ Page 673)
Install exhaust pipework. (→ Page 557)
Install coolant pipework after cylinder. (→ Page 678)
Install coolant pipework from/to intercooler. (→ Page 722)
Install exhaust turbocharger. (→ Page 518)
Install engine coolant drain lines. (→ Page 683)
Install coolant supply to exhaust turbocharger. (→ Page 694)
Install exhaust turbocharger oil supply. (→ Page 642)
Install air pipework to intercooler. (→ Page 550)
Install exhaust system after exhaust turbocharger. (→ Page 565)
Install air intake. (→ Page 532)
Install exhaust pipework after engine. (→ Page 571)

TIM ID: 0000009009 – 003
Install couplings. (→ Page 768)
Connect electrical lines. (→ Page 793)
Install intake silencer. –
Install PTO system. –
M020124/02E 2009-02 © MTU

Task Schedules 75
4.5 Engine – Installation
Open all connections, remove caps and rubber plugs. –
Attach engine at lifting eyes only and install as per (→Operating instructions)
transportation instructions.
Connect coolant lines, fuel lines and engine monitoring –

system.
Fill with engine coolant. (→Operating instructions)
Fill with charge-air coolant. (→Operating instructions)
Change/fill with engine oil. (→Operating instructions)
Align engine. –
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TIM ID: 0000002884 – 002
M020124/02E 2009-02 © MTU

4.6 Engine – Run-in procedure

Running in engine after replacing parts
• After replacing pistons, piston rings or cylinder liners, run in the engine according to the respective program.
Correct running in is decisive for the service life and operational reliability of the engine.
• To destroy the braking energy, use the alternator or brake.
• Power must be transmitted from the engine to the brake by means of a resilient coupling.
Adjust engine operational data
• Set temperatures, fuel and intake air in accordance with the temperature values in the
MTU Acceptance Test Record. Note the following:
• The coolant temperature depends on the operating range of the coolant thermostat.
• The fuel temperature depends on the volume of the day tank, as long as there is no
fuel cooling system available at the test bench.
• Note down operational data for power, fuel, oil, coolant, charge air and exhaust gas at every test point (time,
speed and effective power) in the “MTU diesel engine factory test” log under RUN IN ENGINE.
Install engine on test stand. -
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Connect engine to dynamometer or generator. -
Connect exhaust gas, coolant and fuel lines. -
Connect control device to MDEC, DDEC. -
Connect sensors and measuring lines for measuring -

fuel, oil, coolant, charge air and exhaust gas to the
corresponding measuring points.
Connect dialog unit to ECU. (→Acceptance Test Record)
Fill expansion tank with coolant with 2% corrosion (→Operating Instructions)

inhibitor oil up to max. mark.
Fill with charge-air coolant. (→Operating Instructions)
Bleed coolant lines until bubble-free coolant emerges. (→Operating Instructions)
Check that fuel in service or supply tank is to (→Fluids and Lubricants Specification)
specification.
Fill oil system with engine oil. (→Operating Instructions)
Prime valve gear with oil. (→Operating Instructions)
Check emergency shutdown system. -
Preheat coolant. (→Operating Instructions)
Prime engine oil circuit with external pump. -
Start engine using ECU. (→Operating Instructions)
After approx. 1 minute idling operation, switch off (→Operating Instructions)

TIM ID: 0000004051 – 002
engine and:
• Check oil level. If necessary, top up oil.
• Remove valve gear cover and check valve gear
lubrication.
Start engine and check idle speed. -
Check engine running noises. (→Operating Instructions)
M020124/02E 2009-02 © MTU

Task Schedules 77
Warm up engine. (→Operating Instructions)
Check coolant, oil and fuel lines for leaks. (→Operating Instructions)
Run in engine in accordance with run-in program and (→Acceptance Test Record)
record measured values.
Compare values with measured values in MTU (→Acceptance Test Record)

Acceptance Test Record and evaluate.
Check and enter fuel density and color of exhaust gas. -
Enter barometric pressure and relative air humidity in (→Acceptance Test Record)
Test Record.
Check engine for abnormal running noises and leaks. -
Check engine monitoring. -
Adjust speed-sensitive fuel limiter performance (→Acceptance test record, Control value sheet)
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according to Acceptance Test Record.
When the run-in program is completed, run down and (→Operating Instructions)
switch off engine.
Cut open one oil filter and check for residues. (→Operating Instructions)
Check oil level and prepare engine for measurement -

of oil consumption.
Carry out acceptance test as per Acceptance Test -

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

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

and switch off.
Carry out measurement of oil consumption. (→Operating Instructions)
Start engine. -
Set engine to operating power in accordance with MTU (→Acceptance Test Record)
Acceptance Test Record.
Switch off engine and carry out six start/stop -

procedures.
Carry out engine preservation run. (→Operating Instructions)
Switch off engine and disable the engine starter. -

TIM ID: 0000004051 – 002
Drain engine oil and coolant. (→Operating Instructions)
Take protective measures for sea transportation. -
Disconnect exhaust gas, coolant, and fuel lines. -
Disconnect control device to MDEC, DDEC. -
M020124/02E 2009-02 © MTU

Remove sensors and measuring lines and seal -

measuring points.
Remove engine from test stand. -
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TIM ID: 0000004051 – 002
M020124/02E 2009-02 © MTU

Task Schedules 79
4.7 Initial engine operation
Carry out services to put the engine into operation. (→Operating Instructions)
Preheat engine (optional). –
Carry out operational checks. (→Operating Instructions)
Check monitoring system and ECU. Contact Service.
Perform test run. (→Acceptance test record)
Measure intake depression (only for initial operation). Contact Service.
Measure exhaust backpressure (only for initial Contact Service.

operation).
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Perform after-shutdown service. (→Operating Instructions)
For extended out-of-service period: (→Fluids and Lubricants Specification)

• Carry out external preservation
• Disable engine start
• Seal air inlet and exhaust outlet
• Carry out internal preservation (air, oil, fuel)
TIM ID: 0000003804 – 001
M020124/02E 2009-02 © MTU

Crankcase



screws
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screws
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 81
Crank drive


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Sequence:
a Short arm
b Long arm

Sequence:
a Short arm
b Long arm

Sequence:
a Short arm
b Long arm
Piston crown screws

±0.1 mm.

0.1 mm.
2 Release screws
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Cylinder head
1 Tighten 25 Nm
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A Exhaust side
B Inlet side
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 83
Valve gear





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seal

high-pressure accumulator
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

specifications
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Exhaust pipework

x 120 P37
Charge air cooling

Starting equipment

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M020124/02E 2009-02 © MTU

Task Schedules 85
Lube-oil system

8/12/16 V engines

8/12/16 V engines
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equipment carrier

carrier
Mounting / support



carrier

crankcase

TIM ID: 0000003825 – 005
crankcase
M020124/02E 2009-02 © MTU


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screws 50 Nm

Screw M 20 x 50 500 Nm +50 Nm
Screw M 22 x 55 680 Nm + 68 Nm

TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 87

flange

housing

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

• Lube oil
• Charge air

pressure

pressure

oil
TIM ID: 0000003825 – 005

M020124/02E 2009-02 © MTU

Thread
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
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M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175

TIM ID: 0000003825 – 005
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
M020124/02E 2009-02 © MTU

Task Schedules 89
M6 9 12
M8 21 28
M8 x 1 24 30
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M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230

TIM ID: 0000003825 – 005
M30 1250 1575

M020124/02E 2009-02 © MTU


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TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 91
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TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

inserted in
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
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M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 93
inserted in
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
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TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

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Thread
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160

TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 95

Thread
(Nm)
M10 x 1 15
M16 x 1.5 30
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TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU


Thread
(Nm)
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
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M42 x 2 260
M48 x 2 320
1 Union nut
2 Union body
3 O-ring
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Descriptions 97
5 Task Descriptions
5.1 Crankcase and Externally Mounted Components
5.1.1 Engine layout
Illustration applies analogously to 8/12/16 V 4000 G, C and R
010
020
Crankcase and add-on components
Gear train
100
110
Intercooler
210
220
Power supply
Cooling air system
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030 Running gear 120 Air intake / air supply 230 Mounting system/support
040 Cylinder head 140 Exhaust pipework 250 PTO systems, driving and free
050 Valve gear 170 Starting equipment end (couplings)
070 Fuel system (high-pressure) 180 Lube oil system 500 Monitoring, control and regulating
080 Fuel system (low-pressure) 200 Engine cooling system devices, general electr. equipment
TIM ID: 0000008330 – 001
M020124/02E 2009-02 © MTU

5.1.2 Crankcase and attachments – Overview
Overview of crankcase and attachments
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1 Crankcase 8 Block
2 Camshaft bearing 9 Nut for main bearing cap
3 Crankshaft bearings 10 Socket-head screws
TIM ID: 0000000565 – 001
4 Stud 11 Main bearing cap

5 Crankshaft alignment bearing 12 Cylinder liner
6 Crankshaft alignment bearing cap 13 Oil filler neck
7 Oil pan 14 Oil dipstick
M020124/02E 2009-02 © MTU

5.1.3 Crankcase – Overview
Crankcase with cover
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1 Crankcase 9 Sealing ring 17 Washer
2 Block 10 Blanking plug 18 O-ring
3 Screw 11 Screw 19 O-ring
4 Drain valve 12 O-ring 20 Inspection port cover
5 Dowel pin 13 Holder 21 Gasket
6 Cover 14 Screw 22 Screw
7 Stud 15 O-ring
8 Plug 16 Screw
TIM ID: 0000000573 – 001
M020124/02E 2009-02 © MTU

Crankcase
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1 Crankcase 4 Stud * 7 Washer
2 Main bearing cap 5 Nut 8 End cover
3 Main bearing cap 6 Screw 9 Camshaft bearing
(*) Newly fitted studs must be elongated before initial tightening
TIM ID: 0000000573 – 001
M020124/02E 2009-02 © MTU

Oil filler neck with oil dipstick
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1 Inspection port cover 5 O-ring
2 Sealing ring 6 Cover for oil filler neck
3 Unions 7 Gasket
4 Oil dipstick 8 Hex screw
TIM ID: 0000000573 – 001
M020124/02E 2009-02 © MTU

5.1.4 Crankcase – Disassembly
Preconditions
• Preparatory steps have been completed.
Special tools
Designation / Use Part No. Qty.

Hydraulic kit F6557935 1
Camshaft bearing removal device F6783824 1
Hand pump kit B80146893 1
Swivel frame F6786993 1
Suspended load.
Danger to life!
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DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.
Removing externally mounted components

1. Remove cover (→ Page 99).
2. Remove guide tube (→ Page 99).
3. Remove oil filler neck, (not applicable to gas engines) (→ Page 99).
4. Remove inspection port cover (→ Page 99).
5. Remove all seals and O-rings.
Installing crankcase in crankcase rotation device

1. Attach supports (1) for swivel frame (2) on left
and right sides of crankcase.
2. Lift crankcase with lifting device and ropes.
3. Insert crankcase in swivel frame and secure.
TIM ID: 0000000586 – 009
M020124/02E 2009-02 © MTU

Removing crankshaft bearing cap and studs

1. Remove crankshaft bearing caps (→ Page 216).
Note: Remove studs only if damaged or
over-elongated. When removing, replace
studs in pairs.
2. Place installation/removal tool (arrow) on studs.

3. Remove respective studs using the
installation/removal tool.
Removing camshaft bearings
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1. Cover bottom of camshaft chamber to prevent
camshaft bearings from falling into the crank drive.
2. If only one bearing is replaced, protect the next
bearing (arrow) from damage.
3. Insert jig (6) in camshaft bearing (5).
4. Fit screw (1) and retainer (2) on cylinder (4)
using nut (3).
5. Press camshaft bearing (5) out of crankcase.
6. Follow the same procedure to remove the other
camshaft bearing bushings.
Removing last camshaft bearing with flywheel

housing attached
2. Removal is the same as for removal of the
camshaft bearings, with the difference that jig (1)
is used → 3. .
TIM ID: 0000000586 – 009
M020124/02E 2009-02 © MTU

Removing end cover

Note: Do not drill into end cover. Metal chippings
in the crankcase coolant chamber may
cause local overheating.
1. Using a drift and hammer, carefully knock the

edge of one side of the end cover inwards until
it tilts into the bore.
2. Use pliers to withdraw plug, taking care that end
cover does not fall into the bore.
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TIM ID: 0000000586 – 009
M020124/02E 2009-02 © MTU

5.1.5 Crankcase – Cleaning
Material

Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.
Excessive reaction time of cleaning agents on components.
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• Wear protective clothing, gloves, and goggles / safety mask.
Unsuitable cleaning tools.

• Use appropriate cleaning tool.
Crankcase – Cleaning
1. Use cleaner (Hakupur 312) to clean elastomer components.
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
3. Clean crankcase and all threaded bores and blow clear with compressed air.
Cleaning oil filler neck and oil dipstick

2. Blow oil filler neck and oil dipstick clear with compressed air.
3. Make sure parts are perfectly clean.
Cleaning crankshaft cover

1. Remove sealant from crankcase cover.
2. Clean oil bores thoroughly with a hole brush.
3. After cleaning, flush bores (under pressure if
possible) and blow clear with compressed air.
TIM ID: 0000000576 – 004
M020124/02E 2009-02 © MTU

Cleaning oil bores in crankcase

Note: During a major engine overhaul, or if
metal chippings have got into the engine
oil system.
1. Clean oil and coolant bores thoroughly with a

suitable hole brush. Never use a wire brush!
Cleaning crankshaft bearing cap
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1. Wipe bearing shell mating faces on crankshaft
bearing cap with chamois leather.
2. Clean mating faces on crankshaft bearing cap and
crankcase and blow clear with compressed air.
TIM ID: 0000000576 – 004
M020124/02E 2009-02 © MTU

5.1.6 Crankcase – Checking upper and lower cylinder liner fit
Spare parts

Crankcase
Checking area I of upper and lower fits

1. Check area I of upper and lower fits for corrosive
pitting.
Result: If corrosive pitting is visible in area I,
machine to repair stage. To be carried out only in
workshops authorized by MTU.
2. Check area I of upper and lower fit for hollows.
Result: If hollows in area I are larger than
0.500 mm over max. 30° of the circumference,
machine to repair size. To be carried out only in
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3. Check area I of lower fit for recesses.
Result: If recesses are visible in area I, machine to
repair stage. To be carried out only in workshops
authorized by MTU.
a Area I of upper and lower fits
Checking area II of upper and lower fits

1. Check area II of upper fit for corrosive pitting.
Result: If corrosive pitting in area II is larger than
0.600 mm, machine to repair stage. To be carried
out only in workshops authorized by MTU.
2. Check area II of lower fit for corrosive pitting.
Result: If corrosive pitting is visible in area II,
a Area II of upper and lower fits

TIM ID: 0000020077 – 001
M020124/02E 2009-02 © MTU

Exemplary illustrations showing corrosive pitting in

upper and lower fits
1. Upper fit
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2. Upper fit
TIM ID: 0000020077 – 001
M020124/02E 2009-02 © MTU

3. Lower fit
4. Lower fit
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5. Lower fit
6. If the assessment of the findings should be
unclear or extreme corrosive pitting was found,
(→Contact Service.).
TIM ID: 0000020077 – 001
M020124/02E 2009-02 © MTU

5.1.7 Crankcase – Check
Special tools

Endoscope Y20097353 1
Bore gauge, 275-300 mm Y20010175 1
C-frame micrometer, 275-300 mm Y20002705 1
Bore gauge, 160-280 mm Y20091483 1
Bore gauge, 18-100 mm Y20091481 1
Dial gauge Y20011268 1
Depth gauge, 500 mm Y20002779 1
cardiagn.com
Material

Aqueous developer (standard check) 40004 1
Dye penetrant, red 40488 1
Penetrant remover (standard check) 40002 1
Crack detection oil (No. 63) 40475 1
Crack detection agent (UV Apelux paste 1031) 40483 1
Corrosion inhibitor (Pfinder AP 11 F) 40355 1
Spare parts

Crankshaft bearing cap
Studs for main bearing
Socket-head screws for crankshaft bearing cap
Camshaft bearing
Oil filler neck, (not applicable to gas engines)
Oil dipstick
Cover
TIM ID: 0000000579 – 009
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
M020124/02E 2009-02 © MTU


Risk of injury!
cardiagn.com
TIM ID: 0000000579 – 009
M020124/02E 2009-02 © MTU

Crankcase – Check
Item Findings Task
Check crankcase for cracks using Signs of cracks Contact Service.

surface crack-testing method.
Use magnetic crack-testing method Signs of cracks Replace component.

to check crankshaft bearing caps for
cracks.
Check contact surface and upper and lower cylinder liner fits in crankcase (→ Page 107).
Check crankcase top for stress • Stress marks To be carried out only in workshops
marks, damage and cavitation. • Damage authorized by MTU. Rework
• Cavitation crankcase top.
visible
Check main bearing studs for Damaged Replace component.

damage.
Check socket-head screws for Damaged Replace component.
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lateral fixation of crankshaft bearing
cap for damage.
Check camshaft bearing and guide Damaged Replace component (→ Page 124).
bushings for wear and damage.
Check all mating and sealing faces Stress marks • Corrective work: Smooth with
and fits. oilstone or emery cloth.
• Replace
Check all threads for damage. Damaged Recut threads.
Check oil filler neck for damage (not Damaged • Corrective work
applicable to gas engine). • Replace
Check that oil dipstick fits correctly Damaged Replace component. Make sure
in guide tube and check for damage. that replacement oil dipstick is the
correct version.
Check cover for stress marks and • Stress marks • Corrective work
damage. • Damage • Replace
visible • Use a plastic plug to prevent
each bore from being soiled
until the crankcase has been
assembled.
Use a C-frame micrometer to Values exceeded. Replace cap.

measure width of crankshaft bearing
cap at upper and lower fits. Values
(→ Page 116)
Check stud for damage; measure • Damaged Replace (→ Page 124)

length of stud. Values (→ Page 116) • Values exceeded
TIM ID: 0000000579 – 009
M020124/02E 2009-02 © MTU

Checking oil bores in crankcase

Note: As part of every major overhaul or if metal
chips penetrate the engine oil system, all
oil and coolant bores must be checked
for particular cleanness using a cold light
source or endoscope.
1. Check oil supply bores for valve drive at

crankcase, sides A and B.
2. Check main oil supply bores for camshaft and
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main bearing in crankcase V.
3. Check oil bores (arrow) in camshaft chamber.

TIM ID: 0000000579 – 009
M020124/02E 2009-02 © MTU

4. Check oil bores in crankshaft bearing pedestal

(rear arrow) and in main bearings (front arrow).
5. Check all coolant and oil bores for contamination
in the same manner.
6. If the crankcase is then not immediately
reassembled or put back into service:
6.1. Dry oil bores.
6.2. Preserve oil bores.
6.3. Seal oil bores air-tight with suitable plugs.
Measuring bearing cap guides
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Note: Bearing cap guides not in swivel
frame (results in measuring errors).
1. Remove crankcase from swivel frame and place

on a flat surface.
2. Using a bore gauge (1), measure bearing
cap guides at upper and lower fits. Values
(→ Page 116).
Note: To be carried out only in workshops
authorized by MTU.
3. If values are exceeded: Machine respective

bearing cap guide to next repair size using
a boring mill.
4. Install crankcase in swivel frame.
Measuring crankshaft bearing bore

1. Install and tighten crankshaft bearing cap
according to specifications (→ Page 124).
2. Adjust bore gauge.
3. Using a bore gauge (2), measure the crankshaft
bearing bore (1).
4. Record measured values in data sheet. Measuring
planes as well as values (→ Page 116).
authorized by MTU.
TIM ID: 0000000579 – 009
5. If values are exceeded: Machine respective bore

to next repair size using a boring mill.
6. Mark repair stages of a crankcase main bore
with numeral punches.
7. When installing a new crankshaft bearing cap:
mark position of new crankshaft bearing cap
accordingly.
M020124/02E 2009-02 © MTU

Measuring camshaft bearing bushing bore.

1. Measure diameter of camshaft bearing bushing
bore (Ø B) with bore gauge. Values (→ Page 116).
2. If values are exceeded: Remove camshaft bearing
bushing (2) (→ Page 102).
3. After removal of camshaft bearing bushing:
Measure diameter (dia. A) of the main camshaft
bearing bore in the crankcase (1). Record
measured values in data sheet. Values
(→ Page 116).
authorized by MTU.

main camshaft bearing bore to next repair size
using a boring mill.
5. Mark repair stages with numeral punches.
6. Install camshaft bearing bushing (→ Page 124).
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Measuring crankcase bores for cylinder liners
1. Measure crankcase bore for cylinder liner in upper
and lower fits with bore gauge.
2. Record measured values in data sheet. Values
(→ Page 116).
authorized by MTU.

crankcase bore to next repair size using a
boring mill.
TIM ID: 0000000579 – 009
M020124/02E 2009-02 © MTU

5.1.8 Crankcase – Tolerances
Crankcase bore for crankshaft
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No. Designation Repair Tol. size Deviation Clearance Interference Wear limit
size Basic
lower upper min. max. min. max.
size
1 Crankcase bore 0 171.000 H6 0 +0.025 171.035

for crankshaft Trans-
bearing verse
ovality
max. 0.050
1 171.500 H6 171.535
Trans-
verse
TIM ID: 0000004151 – 008
ovality
max. 0.050
2 172.000 H6
a After the crankcase bore has been newly produced, it can be exceeded by 0.015 mm in the a-direction
when reinstalled.
M020124/02E 2009-02 © MTU

Crankcase bore for camshaft
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size Basic
size
1 Crankcase bore 0 97.000 H6 0 +0.022 0.058 0.130

for camshaft
bearing 1 97.500 H6
2 98.000 H6
Camshaft 0 97.080 0 +0.050

bearing, outer
Ø 1 97.580
removed
2 Camshaft 92.012 0 +0.052 0.084 0.171

bearing bush
bore
installed
Camshaft outer 92.000 e7 –0.107 –0.072

Ø
a Coaxiality of left and right bearing
TIM ID: 0000004151 – 008
b Between camshaft bearing bores 1 and 2
M020124/02E 2009-02 © MTU

Top deck and cylinder liner mating face
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size Basic
size
1 Cylinder liner 0 562.000 −0.150 +0.050

mating face
1 561.700
2 561.400
2 Top deck 0 562.500 −0.200 +0.200
1 562.200 −0.100 +0.100
2
TIM ID: 0000004151 – 008
M020124/02E 2009-02 © MTU

Crankcase bore for cylinder liner
cardiagn.com
size Basic
size
1 Crankcase bore 0 196.000 0 +0.046 0.059 0.016 +0.060

H7
upper fit
1 196.500
H7
2 197.000
H7
Cylinder liner 0 196.000j6 -0.013 +0.016

upper fit
1 196.500 j6
2 197.000 j6
2 Crankcase bore 0 189.000 0 +0.046 0.050 0.125 +0.060

H7
lower fit
1 189.500
H7
TIM ID: 0000004151 – 008
2 190.000
H7
Cylinder liner 0 189.000 f6 -0.079 -0.050

lower fit
1 189.500 f6
2 190.000 f6
M020124/02E 2009-02 © MTU

size Basic
size
Stage marking see reconditioning drawing
Machine all crankcase bores to the same repair size.
Main bearing cap
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size Basic
size
1 Bearing cap bed 0 298.000 +0.110 +0.240 0.022 0.184

E9
lower fit
1 298.500
E9
2 299.000
E9
Main bearing 0 298.000 p6 +0.056 +0.088

TIM ID: 0000004151 – 008
caps
lower fit 1 298.500 p6
2 299.000 p6
M020124/02E 2009-02 © MTU

size Basic
size
2 Bearing cap bed 0 298.000 0 +0.052 0.004 0.088

H7
upper fit
1 298.500
H7
2 299.000
H7
Main bearing 0 298.000 p6 +0.056 +0.088

caps
upper fit 1 298.500 p6
2 299.000 p6
3 Screw length 348.000 –0.500 +0.500
cardiagn.com
Main bearing bore
Install main bearing cap in crankcase according to installation instructions.

Measure main bearing bores:
TIM ID: 0000004151 – 008
• Determine diameters a, b1 and b2 in two measuring planes and calculate the averages for a, b1 and b2.
Check bore roundness:
• Possible deviations from roundness are a result of the average values for a, b1 and
b2 according to the formula: (b1+b2) /2 −a
Vertical ovality greater than (b1+b2) /2 is not permissible.
M020124/02E 2009-02 © MTU

Crankcase crankshaft bore coaxiality
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No. Max. permissible deviation of concentricity New Wear limit
a left/right bearing Ø 0.040 Ø 0.050
b 8V: from main bearing 1 to 5 Ø 0.060 Ø 0.100

c 12V: from main bearing 1 to 7 Ø 0.080 Ø 0.120
d 16V: from main bearing 1 to 9 Ø 0.120 Ø 0.140

e 20V: from main bearing 1 to 11 Ø 0.160 Ø 0.180
f applies to collar bearing mating faces 0.100 0.120

g applies to all bearings 0.010 0.035
h applies to all bearings, non-concave –0.010 –0.012
k applies to all bearings // 0.015 // 0.018

TIM ID: 0000004151 – 008
M020124/02E 2009-02 © MTU

Crankcase camshaft bore coaxiality
cardiagn.com
b 8V: from camshaft bearing 1 to 5 Ø 0.060 Ø 0.100

c 12V: from camshaft bearing 1 to 7 Ø 0.080 Ø 0.120
d 16V: from camshaft bearing 1 to 9 Ø 0.120 Ø 0.140

e 20V: from camshaft bearing 1 to 11 Ø 0.160 Ø 0.200
TIM ID: 0000004151 – 008
M020124/02E 2009-02 © MTU

5.1.9 Crankcase – Assembly
Special tools

Hydraulic screw pretensioner F6557186 2
Installation/removal tool for main bearing stud F6553646 1
Stop device for plug (main oil gallery) F6555771 1
Assembly jig for camshaft bearing F6555738 1
Assembly mandrel for end cover F30378754 1
Camshaft bearing shrink-on tool F30450446 1
Guide bushing for camshaft bearing shrink-on tool F6555763 1
Torque wrench, 20-100 Nm F30026582 1
Ratchet adapter F30027340 1
cardiagn.com
Material

Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Sealing paste (Elastosil N189) 50546 1
Screw locking compound Loctite No. 270 40083 1
Engine oil
Dry compressed air
Liquid nitrogen
Spare parts

Gasket
O-ring
O-ring
End cover
Camshaft bearing
Stud
Suspended load.
TIM ID: 0000000590 – 010
Danger to life!
Nitrogen is liquid (at -200°C).

Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Ventilate working area well.
M020124/02E 2009-02 © MTU


Risk of injury!
Contamination in blind hole.

CAUTION • Inspect and clean blind hole.
Installing end cover

1. End cover and crankcase bore must be free
of grease and dry.
2. Coat end cover seat with Loctite screw locking
compound.
3. Using a mandrel, drive end cover into the
crankcase bore.
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4. In case of leaks or sealing surface damage, the
end cover can be swaged in after it has been
driven in with a mandrel.
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

Installing camshaft bearings

1. Screw camshaft bearing stop and alignment
device (1) on to locating bore of swing-follower
shafts. Installation sequence: Start at driving end
and continue in succession towards free end.
2. Fit plastic installation mandrel (1) on assembly tool.
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3. Chill camshaft bearing bushing in liquid nitrogen.
4. Fit chilled camshaft bearing bushing on assembly
tool so that the spring-loaded locating mandrel
(3) of the assembly tool engages in the oil bore
(arrow) of the camshaft bearing bushing.
5. Withdraw installation mandrel from camshaft

bearing assembly tool.
6. Check position of camshaft bearing oil bore in
assembly tool (arrowed). TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

7. Use assembly tool (1) to insert camshaft bearing

bushing (2) from outside in main bore as far as
it will go. At the same time, the assembly tool
is positioned by the centering and positioning
mandrel.
8. Check that oil bores in bearing bushing and
crankcase are aligned.
Installing last camshaft bearing
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1. Install camshaft bearing stop and alignment device
from outside on free end of crankcase (2) when
installing last camshaft bearing.

bushing in main camshaft bore up to stop. At the
same time, the assembly tool is positioned by the
centering and positioning mandrel.
3. Check that the oil bores in bearing bushing and
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

Inserting studs for crankshaft bearing caps

1. Coat thread of stud (1) on shoulder side with
engine oil.
2. Insert stud (1) with the journal side in the threaded
bore.
3. Insert stud (1) up to stop with installation/removal
device (2) and torque wrench. Tightening torque,
see (→ Page 80).
Note: Replace studs only in pairs.
4. For initial fitting of studs, carry out the following

steps:
4.1. Tighten nut up to contact.
4.2. Tighten studs with hydraulic tensioner.
Tightening method: elongation.
Hydraulic pressure: 1500 bar.
4.4. Release studs.
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4.5. Tighten studs again with hydraulic tensioner.
4.6. Release studs.
Installing crankshaft bearing cap

1. Install bearing cap (→ Page 245).
2. Crankcase mating face (1) for strip (driving end)
must be dry and free of grease.
3. Coat contact surface with sealing paste (arrows)
and do not forget the end sides.
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

4. Align strip (1) on securing screw bores (arrows) in

crankcase (2).
5. Place strip (1) on surface coated with sealing
paste on crankcase.
6. Use socket-head screws (2) to fasten strip (1) on
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crankcase (3).
7. Using a straightedge, check the alignment of the
strip to the crankcase. The strip surface must form
a single plane with the crankcase joint so that the
oil pan will fit perfectly.
Installing cover
1. Mating faces on crankcase and cover (2) must be
dry and free of grease.
2. Coat new O-ring (1) with grease and insert
in groove.
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

3. Mount assembly jig for cover stop on driving end.

4. Coat mating surface (1) on crankcase with surface
sealant.
5. Coat new O-rings (arrowed) with grease and insert
in oil transfer bores.
6. Insert assembly pins (2) in the crankcase at two
diagonally opposite corner points.
7. Use lifting device to connect cover to assembly
pins and lower.
8. Align cover to assembly jig stop.
9. Tighten screws in accordance with tightening
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sequence.
• 8V 1-18
• 12V 1-26
• 16V 1-34
• 20V 1-42
10. Remove assembly device.
11. Coat O-ring with grease and fit on plug (1).

12. Insert plug in oil gallery and secure with lug (2).
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

Removing crankcase form swivel frame

1. Attach lifting appliance and lifting ropes to
crankcase. Make sure that lifting ropes are
tensioned evenly.
2. Release crankcase from swivel frame and lift out.
cardiagn.com
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

5.1.10 Cylinder liner – Overview
Overview of cylinder liner with scraper ring
cardiagn.com
1 Cylinder liner 2 Carbon scraper ring 3 Sealing ring
TIM ID: 0000000601 – 001
M020124/02E 2009-02 © MTU

Cylinder liner with scraper ring in crankcase
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1 Carbon scraper ring
2 Cylinder liner
3 Crankcase
4 Sealing ring
5 Sealing ring
TIM ID: 0000000601 – 001
M020124/02E 2009-02 © MTU

5.1.11 Cylinder liner – Removal
Special tools

Removal tool for carbon scraper ring F6782566 1
Removal tool for cylinder liner F6557114 1
Heavy object.
Risk of crushing!

Risk of injury!
Removing carbon scraper ring
cardiagn.com
1. Mount removal tool (3) on cylinder liner (1).
2. Remove carbon scraper ring (2) with removal tool
(3) from cylinder liner fit (1).
3. Remove removal tool (3).
4. Remove piston and conrod (→ Page 282).
TIM ID: 0000000614 – 008
M020124/02E 2009-02 © MTU

Cylinder liner – Removal

1. Mark installation position of cylinder liner to
crankcase with a marker pen (arrowed).
2. Insert removal tool into cylinder liner.
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3. Position removal tool at lower collar of cylinder
liner. Take care not to damage the oil spray nozzle.
4. To avoid tensioning the liner, only place fork in
position lightly.
5. Rotate the removal tool spindle until the cylinder
liner is released from the crankcase bore.
6. Remove removal tool.
7. Remove cylinder liner from crankcase.
8. Remove sealing rings from cylinder liner.
TIM ID: 0000000614 – 008
M020124/02E 2009-02 © MTU

5.1.12 Cylinder liner – Cleaning
Material

Cleaner is extremely caustic.

Risk of injury and suffocation!
WARNING • Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Take measures against electrostatic charging.
Compressed air.
Risk of injury!
WARNING
cardiagn.com
• Do not direct compressed-air jet at persons.

Cylinder liner – Cleaning

2. Blow out all parts with compressed air.
TIM ID: 0000000606 – 002
M020124/02E 2009-02 © MTU

5.1.13 Cylinder liner – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Material

Crack detection oil (No. 63 40475 1
cardiagn.com
Spare parts

Cylinder liner
Carbon scraper ring
Heavy object.
Risk of crushing!
TIM ID: 0000004047 – 005
M020124/02E 2009-02 © MTU

Cylinder liner – Check
Item Findings Task
Check cylinder liner with magnetic Signs of cracks Replace

crack testing method.
Check outer wall for corrosive Pitting visible. Replace

pitting.
Check sealing and mating faces for • Stress marks • Corrective work: Smooth with
wear and damage. • Damage oilstone.
visible • Replace
Check carbon scraper ring for • Scores Replace

scoring and pitting. • Pitting
visible
Check floating mount of the carbon Signs of jamming • Measure cylinder liner.
scraper ring in the cylinder liner. • Replace carbon scraper ring.
Check cylinder liner running surface • Scores Replace
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for scores and pitting. • Pitting
visible
Check reversal point of first piston Wear visible. Replace cylinder liner.
ring for wear.
Measure cylinder liner bore with Values exceeded. Replace

bore gauge and dial gauge.
Measurement plane and values
(→ Page 139)
TIM ID: 0000004047 – 005
M020124/02E 2009-02 © MTU

5.1.14 Cylinder liner – Tolerances
cardiagn.com
No. Designation Stage Toler- Deviation Clearance Interference Wear limit
anced
size lower upper min. max. min. max.
Basic
size
1 Crankcase bore 0 196.000 0 +0.046 0.059 0.016 +0.060

H7
upper fit
1 196.500
H7
2 197.000
H7
Cylinder liner 0 196.000j6 -0.013 +0.016

upper fit
1 196.500 j6
2 197.000j6
TIM ID: 0000004152 – 004
M020124/02E 2009-02 © MTU


anced
Basic
size
2 Crankcase bore 0 189.000 0 +0.046 0.050 0.125 +0.060

H7
lower fit
1 189.500
H7
2 190.000
H7
Cylinder liner 0 189.000 f6 -0.079 -0.050

lower fit
1 189.500 f6
2 190.000 f6
3 Cylinder liner ID 170.000 0 +0.040 0.014 0.094
cardiagn.com
H7
Scraper ring 170.000 g7 -0.054 -0.014

OD
4 Scraper ring ID 164.000 0 +0.063

H8
5 Cylinder liner ID 165.000 0 +0.040

H7
- installed
TIM ID: 0000004152 – 004
M020124/02E 2009-02 © MTU

Cylinder liner
cardiagn.com
anced
Basic
size
1 0 13.800 −0.100 0
1 14.100
2 14.400
Reconditioning instructions:
In case of cavitation at upper and/or lower fit of the crankcase bore:
• Introduce next repair stage and install cylinder liner of corresponding stage.
• Machine cylinder liner mating face on crankcase.
• To be carried out only in workshops authorized by MTU.
Check scraper ring OD and ID when fitted.

TIM ID: 0000004152 – 004
M020124/02E 2009-02 © MTU

5.1.15 Cylinder liner – Installation
Special tools

Press-in tool for cylinder liner F6787880 1
Bore gauge, 160-280 mm Y20091483 1
Micrometer, 150-175 mm Y20000326 1
Material

Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
cardiagn.com
Spare parts

Sealing ring
Heavy object.
Risk of crushing!

Risk of injury!
Installing cylinder liner

1. Clean cylinder liner, ensuring that the lower fit and
chamfer are dry and free of grease.
2. Coat sealing rings (2) with grease.
Note: The flat side of the sealing ring must be in
contact with the cylinder liner.
3. Fit sealing rings (2) in grooves on cylinder liner (1).

Note: Note marking when re-installing used
cylinder liners; the installation position is
irrelevant when installing new cylinder
liners.
4. Insert cylinder in the same installation position as

TIM ID: 0000000619 – 010
prior to removal in accordance with the marking on

liner and crankcase.
M020124/02E 2009-02 © MTU

5. On the opposite side, insert screws (1) of press-in

tool into threaded bores for cylinder head screws.
6. Fit pressure plate (3) on cylinder liner.
7. Rotate spindle (2) clockwise to insert cylinder liner
in crankcase bore.
Measuring cylinder liner ID
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1. Adjust bore gauge and dial gauge with micrometer
to basic cylinder liner bore dimension. Value and
measurement planes (→ Page 139).
2. Measure cylinder liner bore with bore gauge.
3. Record measured values in data sheet.
4. If out-of-round is measured:
4.1. Remove cylinder liner.
4.2. Remeasure cylinder liner bore and outer
diameter.
TIM ID: 0000000619 – 010
M020124/02E 2009-02 © MTU

Installing carbon scraper ring

Note: Insert carbon scraper ring after installing
piston (→ Page 315).
1. Spray cylinder liner and carbon scraper ring

with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
cardiagn.com
TIM ID: 0000000619 – 010
M020124/02E 2009-02 © MTU

5.1.16 Oil pan – Overview
cardiagn.com
1 Oil pan 8 Sealing ring 15 Hex bolt
2 Rubber profile 9 Flange 16 Washer
3 Hex bolt 10 Gasket 17 Plug-in pipe (suction pipe)
4 Washer 11 Hex bolt 18 O-ring
5 Hex bolt 12 Hex bolt 19 Connecting piece
6 Washer 13 Washer 20 Hex bolt
7 Plug 14 Suction basket 21 Washer
TIM ID: 0000008331 – 001
M020124/02E 2009-02 © MTU

View from free end
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1 Hex bolt 2 Washer 3 Oil pan
TIM ID: 0000008331 – 001
M020124/02E 2009-02 © MTU

5.1.17 Oil pan – Removal
Special tools

Eyebolts
Hook-ended chain sling (4 off)
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Oil pan – Removal
cardiagn.com
1. Install the engine in the swivel support and
rotate it 180°.
2. Remove hex bolts from oil pan (3).
3. Remove plugs on end faces and install eyebolts
(2).
4. Raise oil pan (3) with hook-ended chain sling (1)
and crane and lower onto suitable support.
5. Remove flanges on end faces.
6. Remove rubber profile.
Removing suction basket

1. Remove hex bolts (5) from connecting piece (2).
2. Remove connecting piece (2) with plug-in pipe (1).
3. Remove plug-in pipe (1) from connecting piece (2).
4. Remove O-rings.
5. Remove hex bolts (4) from suction basket (3).
6. Remove suction basket (3).
TIM ID: 0000008332 – 002
M020124/02E 2009-02 © MTU

5.1.18 Oil pan – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Oil pan – Cleaning
2. Thoroughly blow out oil pan and all threaded bores with compressed air.
TIM ID: 0000004049 – 002
M020124/02E 2009-02 © MTU

5.1.19 Oil pan – Check
Material

Red dye penetrant for surface crack test procedure
Spare parts

Oil pan
Cover
Gasket
Suction basket
Plug-in pipe
cardiagn.com
Connector
Heavy object.
Risk of crushing!
Clean oil pan (→ Page 148).
Oil pan – Check
Item Findings Task
Cracktest the oil pan using the Crack indication • Recondition: Contact Service.
surface cracktesting method and red • Replace
penetrant dye.
Check mating face of oil pan with Surface irregularity above 0.2 mm Recondition mating face.
crankcase for surface irregularities.
Check sealing surfaces and groove Damaged • Recondition

of rubber profile. • Replace
Check suction basket for damage. Damaged Replace
Check threaded bores for ease of Sluggish Replace thread inserts.

movement.
Check plug-in pipe, connecting Damaged • Recondition

piece and cover for damage. • Replace
TIM ID: 0000004541 – 002
M020124/02E 2009-02 © MTU

5.1.20 Oil pan – Installation
Special tools

Eyebolt T80092075 4
Material

Engine oil
Surface sealant (Loctite 518) 50592 1
cardiagn.com
Express dry cleaner (Loctite 7061) 50518 1
Silicone rubber (Loctite 5970) 50773 1
Spare parts

Rubber profile
Heavy object.
Risk of crushing!
Heavy object.
Risk of crushing!
Installing suction basket

Note: Minimize contamination!
1. Coat O-rings with grease.

2. Insert O-rings into groove as shown in overview drawing (→ Page 145).
3. Install suction basket with screws.
TIM ID: 0000008333 – 008
M020124/02E 2009-02 © MTU

Preparing oil pan for installation

1. Clean flange surfaces of oil pan, equipment
carrier and crankcase.
Note: Use a new rubber profile every time the oil
pan is installed.
2. Place rubber profile in the groove on the oil pan.

3. Coat the rubber profile with grease on the end
face of the free end (arrows).
4. Fit flanges for plug screws at both end faces.
5. Apply surface sealant to fornt cover.
cardiagn.com
6. Spray lint-free rag with express dry cleaner and
wipe off excess surface sealant on the exposed
flange faces.
7. Coat slit between equipment carrier/crankcase

with silicone rubber on both sides of the equipment
carrier (arrow), laying down a bead of approx.
5 mm.
TIM ID: 0000008333 – 008
M020124/02E 2009-02 © MTU

8. Coat slit (arrow) between strip/crankcase with

silicone rubber, laying down a bead of approx.
5 mm.
9. Screw eyebolts into bores for plugs on the oil pan.
cardiagn.com
10. Lift oil pan with lifting ropes and crane.
11. Lower oil pan onto contact surface of crankcase.
12. Align oil pan to bores in the contact surface
of crankcase.
Note: Washers for screw connections A, B and
C are different.
13. Screw in screws (1).

14. Use torque wrench to tighten oil pan screws
to the specified torque according to tightening
sequence (→ Page 153).
14.1. Screw ”A”
Name Size Type Lubricant Value/Standard

Screw M10 Tightening torque Engine oil 42 Nm +4 Nm
14.2. Screw "B”

14.3. Screw "C”

TIM ID: 0000008333 – 008
15. Install flanges with new gaskets.
M020124/02E 2009-02 © MTU

5.1.21 Tightening sequence for oil pan made of nodular cast iron (GGG)
cardiagn.com
Number of cylinders Screw joint Number of screws Item
12V A (long side) 28 1 to 14
12V to 20V B (driving end side) 8 -
12V to 20V C (free end side) 10 -
Bolt oil pan to crankcase and equipment carrier alternately and in several steps.
Threaded connections for oil pan made of nodular cast iron (GGG)
TIM ID: 0000008334 – 003
A Screw
B Screw
C Screw
M020124/02E 2009-02 © MTU

5.1.22 Engine lifting equipment - Overview
Overview
cardiagn.com
1 Lifting eye 2 Cylinder head screw
TIM ID: 0000000662 – 001
M020124/02E 2009-02 © MTU

Engine lifting equipment
cardiagn.com
1 Lifting eye 2 Thrust washer 3 Cylinder head screw
TIM ID: 0000000662 – 001
M020124/02E 2009-02 © MTU

5.1.23 Engine lifting equipment – Removal
Preconditions
Engine lifting equipment – Removal
1. Remove cylinder head screws (2).
2. Remove cylinder head screws and thrust
washers (1).
3. Remove lifting eye (3).
cardiagn.com
TIM ID: 0000000674 – 005
M020124/02E 2009-02 © MTU

5.1.24 Engine lifting equipment – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Engine lifting equipment – Cleaning
2. Blow all parts clear with compressed air.
TIM ID: 0000000666 – 002
M020124/02E 2009-02 © MTU

5.1.25 Engine lifting equipment – Check
Material

Spare parts

Lifting eyebolt
Thrust washer
Cylinder head screw
Engine lifting equipment – Check
cardiagn.com
Item Findings Task
Check engine lifting equipment for Damaged Replace

damage.
Check lifting eyebolt with magnetic Signs of cracks Replace the component with an
crack-testing method. original spare part.
Check mating and bolt-on faces for Damaged • Corrective work: Smooth with
damage. oilstone.
• Replace
Check threads in crankcase for ease Sluggish Corrective work: Recut threads
of movement.
Check cylinder head screws for Damaged Replace

damage.
Measure shaft length of the cylinder Value (→ Page 339) Replace

head screws with depth gauge. exceeded.
TIM ID: 0000000670 – 004
M020124/02E 2009-02 © MTU

5.1.26 Engine lifting equipment – Installation
Special tools

Check engine lifting equipment (→ Page 158)
Installing engine lifting equipment

1. Place lifting eye (3) on cylinder head and align to
the bores for the cylinder head screws.
Note: If only cylinder head screws at lifting eye
were undone just tighten these two cylinder
head screws to specified tightening torque.
cardiagn.com
2. Screw in cylinder head screw (2) with thrust
washer (1) and use torque wrench to tighten to
specified tightening torque (→ Page 80).
TIM ID: 0000000678 – 005
M020124/02E 2009-02 © MTU

5.1.27 End housing, driving end – Overview
End housing with attachments
cardiagn.com
1 Flywheel housing 12 Guard plate
2 Deadcenter indicator 13 Guard plate
3 Hex screw 14 Hex screw
4 Plug screw 15 Washer
5 Sealing ring 16 Guard plate
6 Sealing ring 17 Hex screw
7 Adapter union 18 Guard plate
10 Conical spring washer 21 Spacer bushing
11 O-ring 22 O-ring
TIM ID: 0000008335 – 002
M020124/02E 2009-02 © MTU

Configuration of guide bush for end housing installation and removal
cardiagn.com
1 Support 5 Nut
2 Guide bush 6 Socket-head screw
3 Guide 7 Flange
4 Washer 8 Flange
TIM ID: 0000008335 – 002
M020124/02E 2009-02 © MTU

5.1.28 End housing, driving end – Removal
Preconditions
Special tools

Bracket T80091102 1
Guide bushing F6554714 1
Support F6555724 1
Suspended load.
Danger to life!
cardiagn.com
Risk of injury!
End housing – Removal

Note: The TOP mark (arrow) on the front of the
guide bushing must face up, regardless of
whether the crankcase is in the installation
position or is turned through 180° .
1. Install support (2) on guide bushing (3)

(→ Page 160).
2. Screw bracket (1) on to end housing and attach to
crane using a slightly tensioned rope.
3. Remove all screws for end housing on crankcase
(→ Page 160).
4. Remove end housing from crankcase horizontally.
5. Remove O-rings.
TIM ID: 0000000693 – 005
M020124/02E 2009-02 © MTU

5.1.29 End housing, driving end – Disassembly
Special tools

Removal tool for main bearing, driving end F6557190 1
Lukas cylinder B80096717 1
Hand pump set B80146893 1
Equipment can drop off.

Liquid is highly pressurized.
WARNING Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
Heavy object.
Risk of crushing!
cardiagn.com
Remove end housing, driving end (→ Page 162).
Removing main bearing from end housing

1. Cut axial groove in crankshaft bearing, leaving wall
thickness of approx. 1 mm to relieve tension in
bearing.
2. Fit special tool (1), (2) on end housing.
3. Use special tool to press bearing out of end
housing.
4. Remove remaining parts as per overview drawing
(→ Page 160).
TIM ID: 0000000698 – 005
M020124/02E 2009-02 © MTU

5.1.30 End housing, driving end – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
End housing, driving end – Cleaning
2. Thoroughly blow end housing, driving end, and all threads clear with compressed air.
TIM ID: 0000000686 – 002
M020124/02E 2009-02 © MTU

5.1.31 End housing, driving end – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Retainer 0015890321/00 1
Material

cardiagn.com
Spare parts

Crankshaft bearing
End housing, driving end
End housing, driving end – Check
Item Findings Task
Use the magnetic crack-testing Signs of cracks Replace component.

method to check lifting carrier and
eyebolts for cracks.
Check dead-center indicator for Damaged Replace deadcenter indicator.

damage.
Check mating and bolt-on faces. Stress marks Smooth with oilstone.
Check threads for damage. Damaged Recut threads.
Check crankshaft bearings for • Stress marks Replace crankshaft bearings.

surface condition and wear *. • Damage
visible
Measure bore in end housing, Value exceeded Replace end housing.

driving end. Value (→ Page 166)
* Replace crankshaft bearings during "Extended component maintenance".

TIM ID: 0000004116 – 004
M020124/02E 2009-02 © MTU

5.1.32 End housing KS – Tolerances
cardiagn.com
No. Designation Stage Tol. size Deviation Clearance Interference Wear
Basic limit
size
1 Flywheel housing 223.000H6 0 +0.029 0.234 0.292

bore
Bearing outer Ø, 223.263 0 +0.029

removed
2 Bearing bush 210.142 0 +0.069 0.157 0.272

bore,
bearing pressed
in
Hub outer Ø 210.000 g7 -0.061 -0.015

TIM ID: 0000004153 – 001
M020124/02E 2009-02 © MTU

5.1.33 End housing, driving end – Assembly
Special tools

Installation tool F30378426 1
Locating device F6557153 1
Material

Liquid nitrogen

cardiagn.com
Suspended load.
Danger to life!

Risk of injury!
Check end housing, driving end (→ Page 165).
Installing main bearing in end housing

1. Place end housing on suitable surface to allow
installation of the main bearing in the correct
position.
2. Install stop (1) on rear side of end housing (2).
3. Secure stop (1) on front side of end housing
(2) using two nuts.
TIM ID: 0000000701 – 004
M020124/02E 2009-02 © MTU

4. Insert main bearing (3) in locating device (5).

5. Insert main bearing (3) and installation tool (2),
ensuring they are correctly positioned with regard
to each other (position mark/notch mark) (4).
6. Press down pins (1) and lock main bearing by
turning.
7. Chill main bearing (3) with insertion tool (2) in
liquid nitrogen.
8. Place main bearing with insertion tool (2) at end
cardiagn.com
housing (1) in 12 o’clock position (arrowed).
9. Insert chilled main bearing with insertion tool (2)
up to stop in end housing (1).
10. After a brief dwell period, unlock and remove
insertion tool (2).
11. Remove stop from rear side of end housing.
12. Install support bracket on end housing.
13. Install remaining parts as per overview drawing
(→ Page 160).
TIM ID: 0000000701 – 004
M020124/02E 2009-02 © MTU

5.1.34 End housing, driving end – Installation
Special tools

Support bracket T80091102 1
Guide sleeve F6554714 1
Support F6555724 1
Material

Fast cleaner (Loctite 7061) 50518 1
Petroleum jelly, white 40317 1
cardiagn.com
Suspended load.
Danger to life!

Risk of injury!
Assemble end housing, driving end (→ Page 167).
Installing end housing, driving end

1. Using fast cleaner 7061, clean mating face
(arrowed) between end housing and crankcase.
2. Apply a uniform coating of surface sealant 518 to
the sealing surface (arrowed) and smooth.
3. Coat O-rings (1) with petroleum jelly and insert
into bores.
TIM ID: 0000000704 – 004
M020124/02E 2009-02 © MTU

Note: The illustration shows the engine rotated

through 180°, i.e. the oil pan mating face
faces upwards.
4. Using fast cleaner 7061 clean mating face

(arrowed) on crankcase (1).
5. Screw guide sleeve (2) onto crankshaft end flange.
6. Install support bracket (1).
cardiagn.com
7. Position support (2) on end housing.
8. Using support bracket (1), attach end housing
to crane.
9. Position end housing on guide sleeve (3) and push
towards crankcase as far as it will go.
10. Install screws into bores, tightening them to
approx. 10 Nm.
11. Tighten two opposite screws in the inner circle of
the end housing to specified tightening torque
(→ Page 80).
12. Remove support (2) from end housing and install
screws. Note that the screws have different
lengths.
13. Install all screws and washers and tighten to
specified tightening torque (→ Page 80). Observe
the following tightening sequence:
13.1. First tighten the screws in the inner circle of
the end housing clockwise.
13.2. Then tighten the screws in the outer circle of
14. Remove excess sealant. TIM ID: 0000000704 – 004
M020124/02E 2009-02 © MTU

5.1.35 Crankcase ventilation – Overview
Crankcase ventilation, driving end, 16V
cardiagn.com
1 Vent line 17 Screw 33 Screw
2 Vent line 18 Guide sleeve 34 Pipe half-clamp
3 O-ring 19 Rubber sleeve 35 Pipe
4 Screw 20 Clamp 36 Adapter union
5 Rubber sleeve 21 Pipe 37 Sealing ring
6 Clamp 22 Nut 38 Flange
7 Vent line 23 Pipe 39 Gasket
8 O-ring 24 Nut 40 Screw
9 Screw 25 T-piece 41 Bracket
10 Oil separator 26 Rubber sleeve 42 Washer
11 Clamp 27 Clamp 43 Screw
12 Washer 28 Pipe 44 Screw
13 Spacer bush 29 Bracket 45 Grommet
14 Screw 30 Link 46 Pipe half-clamp
15 Nut 31 Pipe half-clamp 47 Pipe half-clamp
16 Bracket 32 Grommet 48 Washer
TIM ID: 0000008341 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Oil separator 12 Pipe 23 Bracket
2 Screw 13 Nut 24 Screw
3 Clamp 14 Pipe 25 Pipe half-clamp
4 Vent line 15 Nut 26 Grommet
5 O-ring 16 T-piece 27 Screw
6 Screw 17 Rubber sleeve 28 Adapter union
7 Vent line 18 Clamp 29 Sealing ring
8 Rubber sleeve 19 Vent line 30 Flange
9 Clamp 20 Vent line 31 Gasket
10 Vent line 21 Bracket 32 Screw
11 Screw 22 Screw 33 Oil pipe
TIM ID: 0000008341 – 001
M020124/02E 2009-02 © MTU

Crankcase ventilation, free end, 12V, 16V
cardiagn.com
1 Oil separator 17 Nut 33 Threaded bush
2 Bracket 18 Oil line 34 Sealing ring
3 Screw 19 Nut 35 Bracket
4 Screw 20 Pipe half-clamp 36 Spacer sleeve
5 Guide sleeve 21 Pipe half-clamp 37 Screw
6 Rubber sleeve 22 Grommet 38 Pipe half-clamp
7 Clamp 23 Screw 39 Grommet
8 Pipe 24 Washer 40 Screw
9 Screw 25 Washer 41 Blanking cone
10 Clamp 26 Rubber sleeve 42 Nut
11 Spacer sleeve 27 Clamp 43 Pipe half-clamp
12 Washer 28 T-piece 44 Grommet
13 Spacer sleeve 29 Oil line 45 Screw
14 Screw 30 Oil line 46 Bracket
15 Nut 31 Banjo screw 47 Screw
16 Oil line 32 Sealing ring
TIM ID: 0000008341 – 001
M020124/02E 2009-02 © MTU

5.1.36 Crankcase ventilation – Removal
Preconditions
Crankcase ventilation – Removal
1. Remove lines and oil separator as per overview drawings (→ Page 171).
2. After removal, seal all connections with suitable plugs.
3. Protect oil separator from damage. Even minor damage may cause oil separator failure.
cardiagn.com
TIM ID: 0000005139 – 007
M020124/02E 2009-02 © MTU

5.1.37 Crankcase ventilation – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Crankcase ventilation – Cleaning
Note: Protect rubber and synthetic parts from oil and fuel, rub dry only, never clean with organic cleaning
agents.
TIM ID: 0000005141 – 004
M020124/02E 2009-02 © MTU

5.1.38 Crankcase ventilation – Check
Material

Corrosion inhibitor
Spare parts

Piping
Oil separator
Clamp
Retainer
Guide sleeve
cardiagn.com
Spacer bush
Compressed air is pressurized.

Hot testing liquid.
WARNING Risk of injury and scalding!
• Pressure must not exceed 0.5 bar.
Clean crankcase ventilation (→ Page 175)
Crankcase ventilation – Check
Item Findings Task
Visually inspect components for Damaged Replace

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

faces for damage and wear. oilstone
• Replace
Check thread turns smoothly. Damaged • Recondition: Recut threads

• Replace
Pressure-test piping for leaks with Leaking • Recondition

air and corrosion inhibitor in water • Replace
bath.
• Air test pressure: 0.5 bar (do
not exceed test pressure)
• Water temperature min. 30 °C,
max. 40 °C
TIM ID: 0000005142 – 002
Inspect piping visually. • Mechanical damage Replace

• Chafing
• Indentation
Check operation of oil separator. Malfunction Replace
M020124/02E 2009-02 © MTU

5.1.39 Oil separator – Disassembly

Remove oil separator (→ Page 174).
Oil separator variant A – Disassembly

1. Undo band clamp (1).
2. Remove cover (4) and O-ring.
3. Remove filter element (2).
4. Remove O-ring (3).
cardiagn.com
5. Remove O-ring (arrow) from lower part.
TIM ID: 0000008363 – 002
M020124/02E 2009-02 © MTU

Hengst oil separator variant B – Disassembly

1. Remove securing screws (2) for cover (1) with
screwdriver (Torx 30).
3. Remove aerosol element (1) from oil separator
cardiagn.com
housing (2).
4. Remove securing screws for cover (1).

5. Remove cover (1), spring (2) and O-ring.
6. Remove diaphragm (3) from oil separator housing.
TIM ID: 0000008363 – 002
M020124/02E 2009-02 © MTU

5.1.40 Oil separator – Check
Spare parts

Oil separator
Clean oil separator (→ Page 175).
Oil separator variant A – Check
Item Findings Task

damage and wear.

• Replace
cardiagn.com
Hengst oil separator variant B – Check
Item Findings Task

damage and wear.

• Replace

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

with air in water bath.
Oil separator pressure control can only be checked when installed with engine in operation. Vacuum or
overpressure is measured (e.g. with water pressure gauge) over entire engine speed range. Values should lie
between minus 10 mbar and plus 10 mbar (100 mm water column).
TIM ID: 0000008365 – 002
M020124/02E 2009-02 © MTU

5.1.41 Oil separator – Assembly
Material

Petroleum jelly, white
Spare parts

Filter element with O-ring
O-rings
Check oil separator (→ Page 179).
Oil separator variant A – Assembly

1. Coat O-ring (3) with petroleum jelly and insert in oil
cardiagn.com
separator housing.
2. Insert filter element (2).
3. Coat O-ring with petroleum jelly and insert in
groove provided on oil separator housing.
4. Fit cover (4).
5. Tighten band clamp (1).
6. Insert O-ring (arrow) in lower part.
TIM ID: 0000008364 – 002
M020124/02E 2009-02 © MTU

Hengst oil separator variant B – Assembly

1. Coat O-ring (arrow) with petroleum jelly and insert
in groove provided on oil separator housing (3).
2. Insert diaphragm (2) in oil separator housing (3)
ensuring it is correctly positioned (curvature
facing up).
3. Fit spring (1) on diaphragm (2), ensuring spring (1)
is correctly seated at diaphragm (2).
4. Mount cover (1) on spring (2) in correct position.
cardiagn.com
5. Insert screws with screwdriver and tighten
diagonally and evenly to specified torque
(→ Page 80) .

groove (arrow) provided on oil separator housing
(2).
7. Insert aerosol element (1) in oil separator
housing (2), ensuring it is correctly positioned.
TIM ID: 0000008364 – 002
M020124/02E 2009-02 © MTU

8. Mount cover (1) on oil separator housing and insert

screws (2) with screwdriver and tighten diagonally
and evenly to specified torque (→ Page 80) .
9. Check oil separator for leaks (→ Page 179).
cardiagn.com
TIM ID: 0000008364 – 002
M020124/02E 2009-02 © MTU

5.1.42 Crankcase ventilation – Installation
Material

Spare parts

Gasket
O-ring
Rubber sleeve
Clamp
Crankcase ventilation – Installation
cardiagn.com
1. Remove all covers.
3. Install crankcase ventilation as per overview drawing (→ Page 171).
TIM ID: 0000005941 – 003
M020124/02E 2009-02 © MTU

5.2 Gear Train
5.2.1 Gearcase, free end – Overview
cardiagn.com
1 Equipment carrier 16 Oil pump 31 Seal carrier (free end)
2 O-ring 17 Threaded bush 32 Radial-lip shaft seal
3 Screw 18 Sealing ring 33 Axle, intermediate gear
4 Sealing ring 19 Plug screw 34 O-ring
5 Plug screw 20 Screw 35 O-ring
6 Main bearing, free end 21 Sealing ring 36 Drain plug
7 Idler gear, right side 22 Plug screw 37 O-ring
8 Idler gear, left side 23 Pipe clamp half/halves 38 Gasket
9 Washer 24 Oil line 39 Cover
10 Washer 25 Gasket 40 O-ring
11 Stud 26 Cover 41 Plug screw
12 Nut 27 Grommet 42 Sealing ring
13 Cover 28 Pressure reduction valve 43 Bearing bush
14 Gasket 29 Sealing ring(s) 44 Sealing ring
15 Stud 30 Banjo screw 45 Plug screw
TIM ID: 0000000778 – 003
M020124/02E 2009-02 © MTU

Arrangement of alignment tool for equipment carrier and equipment carrier cover
cardiagn.com
1 Equipment carrier 3 TOP/OBEN mark 5 Guide bush
2 Alignment tool 4 Screw 6 Screw
TIM ID: 0000000778 – 003
M020124/02E 2009-02 © MTU

5.2.2 Gearcase, free end – Removal
Preconditions
Special tools

Lifting gear T80091105 1
Suspended load.
Danger to life!
cardiagn.com
Gearcase – Removal
1. Insert two eyebolts (arrows) in gearcase.
2. Use rope to hook gearcase on to crane with
light initial load.
3. Unscrew screws (1) and (2) and remove with
sealing rings.
4. Unscrew and remove screws through bores in
idlers. If screws are not visible, turn crankshaft
accordingly.
5. Mark all screws on gearcase circumference

(arrows). Note that screws differ in length.
6. Remove all screws. TIM ID: 0000000790 – 008
M020124/02E 2009-02 © MTU

7. Loosen nuts (2) on left and right sides of crankcase

and remove with washers.
8. Carefully force gearcase (1) with rope slightly
pretensioned towards free end until it is released
from crankcase.
9. Remove O-rings.
10. Set gearcase down and protect from damage.
11. Seal openings with suitable covers.
cardiagn.com
TIM ID: 0000000790 – 008
M020124/02E 2009-02 © MTU

5.2.3 Gearcase, free end – Disassembly
Special tools

Adapter B80146411 1
Lucas cylinder B80096717 1
Press-out tool F6557191 1

cardiagn.com
Heavy object.
Risk of crushing!
Removing crankshaft bearing from equipment carrier

1. Replace crankshaft bearing if damaged or during extended component maintenance.
2. Using press-out tool, Lukas cylinder and hand pump, force crankshaft bearing out of equipment carrier.
Removing radial-lip shaft seal from seal carrier (if fitted)

1. Place seal carrier on a suitable surface.
2. Use suitable extractor to pull out radial-lip shaft seal.
TIM ID: 0000000794 – 004
M020124/02E 2009-02 © MTU

5.2.4 Equipment carrier free end – Cleaning
Material


Compressed air.
Risk of injury!
WARNING
cardiagn.com

Cleaning equipment carrier, free end

1. Clean elastomer parts with cleaner (Hakupur 312).
TIM ID: 0000000782 – 002
M020124/02E 2009-02 © MTU

5.2.5 Gearcase, free end – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Material

Spare parts
cardiagn.com
Equipment carrier
Crankshaft bearing
Heavy object.
Risk of crushing!
Gearcase, free end – Check
Item Findings Task
Use magnetic crack-testing method Signs of cracks Replace gearcase.

to check gearcase for cracks.
Check crankshaft bearings for wear, • Scores Replace crankshaft bearings.

scoring and indentation. • Indentations (→ Page 188)
Visible
Check threads in gearcase for ease Sluggish Recut threads

of movement.
Check thread and shaft of hex bolts Damaged Replace.

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

gearcase. Values (→ Page 191) (→ Page 188)
TIM ID: 0000000786 – 004
Measuring crankcase bearing bore Values exceeded. Replace gearcase.

in gearcase. Values (→ Page 191)
M020124/02E 2009-02 © MTU

5.2.6 Gearcase, free end – Tolerances
cardiagn.com
No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic
size
1 Gearcase bore 193.000 H6 0 +0.029 0.175 0.233 Interfer-

ence min.
Bearing outer 193.204 0 +0.029 0.150
dia.
removed
2 Bearing bush 180.121 0 +0.069 0.321 0.430 Clearance

bore max.
Bearing press- 0.450
fitted
Driver flange 179.800 -0.040 0

outer dia. h7
not press-fitted
TIM ID: 0000004154 – 002
M020124/02E 2009-02 © MTU

5.2.7 Gearcase, free end – Assembly
Special tools

Insertion tool F30378425 1
Installation mandrel for radial-lip shaft seal F30377680 1
Material

Denatured ethanol 40250 1
Loctite 7063 50594 1
Liquid nitrogen
cardiagn.com
Spare parts

Crankshaft bearing
Radial-lip shaft seal
Studs

Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
TIM ID: 0000000798 – 003
M020124/02E 2009-02 © MTU

Installing crankshaft bearing in equipment carrier

1. Insert eyebolts in equipment carrier.
2. Use rope to hook equipment carrier on to crane
with light initial load.
3. Lift equipment carrier and move to installation
position.
4. Place equipment carrier on a firm surface and
secure.
Note: Pay attention to “Oben/Top” (arrow) mark.
5. Install jig (1).
6. Clean crankshaft bearing with Loctite.
cardiagn.com
7. Insert crankshaft bearing (1) in locating device (2).
Note: Ensure that position marking on crankshaft
bearing (arrow) and notch mark on
insertion tool are aligned.
8. Insert insertion tool.
9. Lock crankshaft bearing (3) on insertion tool (2)

with tommy bars (1).
10. Chill insertion tool (2) with crankshaft bearing
(3) in liquid nitrogen.
TIM ID: 0000000798 – 003
M020124/02E 2009-02 © MTU

Note: Location specified is by means of an

asymmetrical pin guide.
11. Use insertion tool (2) to install chilled crankshaft

bearing (1) on inner side of equipment carrier
up to stop.
12. After 60 seconds, unlock and remove insertion
tool (2).
13. Check positions of oil bores on crankshaft bearing.
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Installing radial-lip shaft seal in seal carrier (if
applicable)
1. Push radial-lip shaft seal with sealing lip facing
down on to installation mandrel.
2. Clean and degrease sealing face for radial-lip shaft
seal in seal carrier.
3. Coat sealing face of radial-lip oil seal with ethanol.
4. Press-fit radial-lip shaft seal with drift into seal
carrier.
TIM ID: 0000000798 – 003
M020124/02E 2009-02 © MTU

5.2.8 Gearcase, free end – Installation
Special tools

Alignment tool (free end), equipment carrier F6782344 1
Guide bushing for equipment carrier F6557946 1
Eyebolt 0005800100000 1
Material

cardiagn.com
Spare parts

O-ring
Sealing ring
Suspended load.
Danger to life!

Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
TIM ID: 0000000802 – 005
M020124/02E 2009-02 © MTU

Installing equipment carrier

1. Install idler gears and axles (→ Page 207).
2. Install delivery valve (→ Page 627).
3. Install pressure reduction valve (→ Page 591).
4. Clean alignment tool (2) and guide bushing and
coat with engine oil.
Note: “TOP/BOTTOM” marking must face
upwards, independent of the position of
the crankcase.
5. Use screws (1) to install alignment tool (2) on

equipment carrier.
6. Clean tail shaft, free end.
7. Screw guide bushing with screw on to tail shaft.
8. Screw eyebolts (arrows) into equipment carrier.
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with light initial tension.
10. Clean contact surface (arrowed) with Loctite 7061,

ensuring that its is free of grease and dry.
11. Coat equipment carrier sealing face with Loctite
518.
12. Coat O-rings (1) with petroleum jelly and insert into
groove on equipment carrier.
Note: Woolen thread instructions do not apply to
disassembly if not fitted.
13. Lead woolen thread (2) past and close to O-ring

grooves (1).
TIM ID: 0000000802 – 005
M020124/02E 2009-02 © MTU

14. Using crane, move equipment carrier (3) over

crankshaft guide bushing (1). Always note:
14.1. The studs (2) must be aligned.
14.2. Both idler gears and the crankshaft gear
must be aligned with each other.
14.3. In each case, position one of the round
recesses on the idler gears so that screws
can be retightened. If the holes are not
visible, rotate engine accordingly.
15. Screw in nuts and washers and tighten.
Note: Relieve load on crane ropes before
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tightening nuts and screws.
16. Tighten screws in the sequence 5, 6, 3, 2, 4 and 1.
17. Insert screws (arrows) evenly and tighten.

18. Remove alignment device and guide bushing.
TIM ID: 0000000802 – 005
M020124/02E 2009-02 © MTU

19. Insert screws (1) and (2) with new sealing rings.
20. Remove ropes and eyebolts.
21. Install oil line (→ Page 591).
cardiagn.com
TIM ID: 0000000802 – 005
M020124/02E 2009-02 © MTU

5.2.9 Gear train, free end – Overview
cardiagn.com
Item no. Designation Number of Circumferential backlash Axial clearance
teeth (mm) (mm)
1 Gear, coolant pump, 32 0.201 ±0.065 to gear 9 —

low-temperature circuit

high-temperature circuit
TIM ID: 0000000807 – 002
3 Crankshaft gear 48 — —
4 Camshaft gear 96 0.286 ±0.081 to gear 3 0.1 to 0.18
5 Gear, H.P. fuel pump 32 0.201 ±0.065 to gear 6 —
6 Idler gear 89 0.285 ±0.080 to gear 3 0.2 to 0.6
M020124/02E 2009-02 © MTU


teeth (mm) (mm)
7 Gear, battery-charging generator 19 0.222 ±0.128 to gear 6 —
8 Gear, oil pump 34 0.279 ±0.077 to gear 9 —
10 Gear, hydrostatic pump 34 0.201 ±0.065 to gear 9 —
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1 Coolant pump drive gear 6 Gearcase, free end
2 Shaft 7 H.P. fuel pump drive gear
3 Idler gear 8 Main bearing, free end
4 Crankshaft 9 Drive flange, free end
5 Crankshaft gear 10 Drive gear
TIM ID: 0000000807 – 002
M020124/02E 2009-02 © MTU

5.2.10 Gear train, free end – Removal
Preconditions
Heavy object.
Risk of crushing!
Removing idler gears

1. Place equipment carrier on a clean and flat
surface.
2. Remove screws (1) and (2).
3. Insert jackscrews M8 with continuous thread in
thread (arrows) of axle (3).
4. Press off axle evenly.
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Removing axles
1. Mark respective axle according to installation
position and remove from equipment carrier.
2. Remove idler gears from fit.
3. Remove bearing bushing of idler gear
(→ Page 210).
TIM ID: 0000000819 – 003
M020124/02E 2009-02 © MTU

5.2.11 Gear train, free end – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Gear train, free end – Cleaning
1. Clean idler gears and oil bores of axles with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Thoroughly clean gear train, free end, by blowing clear with compressed air.
TIM ID: 0000000811 – 002
M020124/02E 2009-02 © MTU

5.2.12 Gear train, free end – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

cardiagn.com
Spare parts

Idler gears
Axle
TIM ID: 0000000815 – 006
M020124/02E 2009-02 © MTU

Gear train, free end – Check
Item Findings Task
Use magnetic crack-testing method Signs of cracks Replace idler gears.

to check idler gears for cracks.
Check surface quality of idler gear Damaged Replace idler gear.

tooth flanks with magnifying glass.
Check running surface of axles, • Scores • Corrective work: Smooth with

bearing bushes in idler gears and • Stress marks oilstone or emery cloth.
axial friction faces of gears for wear, visible • Replace
scores and stress marks.
Check taper seat and bolt-on • Scores • Corrective work

surface of axles for scoring and • Stress marks • Replace
stress marks. visible
Check screws for damage and • Damaged Replace screws

threads for ease of movement. • Sluggish
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Measure bearing bushing bore in Values exceeded Replace bearing bushing bore
idler gear. Values (→ Page 205) (→ Page 210).
Use micrometer to measure outer Values exceeded Replace axle.

diameter of axles at running surface.
Values (→ Page 205)
Measure equipment carrier bore Values exceeded Replace equipment carrier.

of idler gear axles. Values
(→ Page 205)
TIM ID: 0000000815 – 006
M020124/02E 2009-02 © MTU

5.2.13 Gear train, free end – Tolerances
cardiagn.com
Basic limit
size
1 Equipment carrier 81.000 H7 0 +0.035 0 0.070 Clear-

bore ance
max.
Axle outer dia. 81.000 H7 –0.035 0 0.080
2 Idler gear bore 80.000 H7 0 +0.030 0.029 0.078
Bush outer dia. 80.000 s6 +0.059 0.078
3 Cylinder liner ID
installed 75.000 H8 0 +0.046 0.060 0.136
removed 75.000 E6 +0.060 +0.079
Axle outer dia. 75.000 e7 –0.090 –0.060
4 Equipment carrier 75.000 P7 –0.051 –0.021 0.009 0.069 Clear-

bore ance
TIM ID: 0000004155 – 001
max.
Axle outer dia. 75.000 e7 –0.090 –0.060 0.080
M020124/02E 2009-02 © MTU


Basic limit
size
5 Equipment carrier 41.200 0 0.200 0.500 0.800 Clear-

width ance
max.
Idler gear width 40.700 –0.100 0 0.900
Measure equipment carrier width unclamped.
6 Crankcase
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TIM ID: 0000004155 – 001
M020124/02E 2009-02 © MTU

5.2.14 Gear train, free end – Installation
Special tools

Holder 0015890321/00 1
Material

Engine oil
Spare parts
cardiagn.com
O-ring
Suspended load.
Danger to life!
Check gear train, free end (→ Page 203).
Installing idler gear in equipment carrier

1. Coat bearing bushings in idler gear with engine oil.
2. Insert idler gear (2) through opening (arrow) into
equipment carrier (1), ensuring it is correctly
positioned.
TIM ID: 0000000823 – 003
M020124/02E 2009-02 © MTU

Installing axles
1. Ensure oil bores of axle (3) are perfectly clean.
2. Coat O-ring (1) and (2) with petroleum jelly.
3. Insert O-ring (2) into groove of equipment carrier
(4).
4. Fit O-ring (1) in groove in axle base.
5. Insert axles into equipment carrier. Pay attention
to fit of idler gear.
6. Press axle (3) into equipment carrier.
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7. Install hex screws (1) and tighten evenly.
8. Screw in screw (2).
TIM ID: 0000000823 – 003
M020124/02E 2009-02 © MTU

Checking axial clearance and backlash

1. Install two eyebolts in equipment carrier.
2. Attach equipment carrier to crane with ropes and
tension ropes equally.
3. Position equipment carrier vertically.
4. Mount magnetic dial-gauge holder (3) with dial
gauge (2) in equipment carrier.
5. Measure axial clearance:
5.1. Place dial gauge stylus with preload on
lateral collar of idler gear (1).
5.2. Set dial gauge to zero.
5.3. Check axial play by moving idler gear back
and forth in axial direction. Axial clearance
limit values (→ Page 199).
6. Measure backlash:
6.1. Position dial gauge stylus with preload on
a tooth flank of idler gear.
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6.3. Move idler gear back and forth in radial
direction to check backlash.
6.4. Compare with specified values in table
(→ Page 199).
7. If limit values are exceeded, replace idler gears.
TIM ID: 0000000823 – 003
M020124/02E 2009-02 © MTU

5.2.15 Bearing bushing of idler gear – Removal and installation
Material

Liquid nitrogen
Spare parts

Bushing

cardiagn.com
Component is hot.
Risk of burning!
Bearing bushing – Removal

1. Clean idler gear (→ Page 202)
2. Using a suitable sleeve and manual press, remove
bearing bushing (1) from idler gear (2).
TIM ID: 0000000827 – 005
M020124/02E 2009-02 © MTU

Bearing bushing – Installation

1. Measure main bore (3) in idler gear (2). Values
(→ Page 205)
2. Place idler gear on a suitable surface. Ensure that,
when inserting the bearing bushing (1), there is
no lateral projection.
3. Cool bearing bushing in liquid nitrogen and heat
idler gear to 80 °C.
4. Insert chilled bearing bushing in idler gear.
Observe distance (A) 0.35 mm ±0.15 mm.
cardiagn.com
TIM ID: 0000000827 – 005
M020124/02E 2009-02 © MTU

5.3 Crank Drive
5.3.1 Running gear – Overview
Running gear
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1 Flywheel 4 Conrod 7 Vibration damper
2 Ring gear 5 Crankshaft 8 Crankshaft counterweight
3 Piston 6 Crankshaft gear, free end
TIM ID: 0000000835 – 001
M020124/02E 2009-02 © MTU

5.3.2 Crankshaft – Overview
Crankshaft detail
cardiagn.com
1 Vibration damper 9 Crankcase 17 O-ring
2 Crankshaft bearing, free end 10 Conrod screw 18 Crankshaft
3 Gearcase, free end 11 Crankshaft counterweight 19 O-ring
4 Piston 12 Socket-head screw 20 Hex screw
5 Cylinder liner 13 Stud * 21 Seal carrier
6 O-ring 14 Nuts, crankshaft bearing cap 22 Drive flange
7 Oil spray nozzle 15 Crankshaft bearing cap
8 Conrod 16 Crankshaft gear
* New studs must be pretensioned prior to first tightening

TIM ID: 0000029835 – 001
M020124/02E 2009-02 © MTU

Crankshaft
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1 Crankshaft
2 Counterweight
3 Stress bolt
4 Plug
5 Crankshaft gear
TIM ID: 0000029835 – 001
M020124/02E 2009-02 © MTU

Crankshaft with bearings
cardiagn.com
1 Crankshaft bearing, top 3 Upper alignment bearing
2 Crankshaft bearing, bottom 4 Lower alignment bearing
TIM ID: 0000029835 – 001
M020124/02E 2009-02 © MTU

5.3.3 Crankshaft – Removal
Preconditions
Special tools

Crankshaft locating device F6553644 2
Removal tool for crankshaft bearing caps F6783568 1
Hydraulic set F6557936 1
High-pressure hose B80144827 1
Distributor B80144838 1
Measuring device Y4341947 1
cardiagn.com
Slide protection F6553645 2
Suspended load.
Danger to life!

Risk of injury!
Removing crankshaft bearing caps

1. Check marking (1) of the crankshaft bearing caps
in relation to the crankcase.
2. If there is no marking (1): starting at driving
end, emboss main bearing numbers making
sure they can be read from the same direction.
Height of numeral punch: 6 mm.
TIM ID: 0000000859 – 005
M020124/02E 2009-02 © MTU

3. Turn crankcase upside down in swivel frame with

oil pan mating horizontal and facing upwards.
4. Remove socket-head screws (arrows) and remove
strip (1) from crankcase (2).
5. Remove all lateral screws for crankshaft bearing
caps from crankcase.
6. Starting at 1st bearing cap (driving end), position
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hydraulic pretensioner on bearing cap studs.
7. Insert hydraulic screw pretensioner by hand.
8. Connect high-pressure hoses (1) of hydraulic
pump to hydraulic pretensioner (2).
9. Position magnetic holder and dial gauges on
crankcase mating face.
10. Center both gauge tips on the measuring points.
11. Set preloaded dial gauges to zero.
12. Operate hydraulic pump and simultaneously

elongate studs by a max. 0.25 mm.
13. Use a pin to loosen crankshaft bearing cap nut.
14. Release studs.
15. Position magnetic holder, dial gauges and
hydraulic pretensioner on next bearing cap.
16. Loosen and remove all nuts in the same sequence.
TIM ID: 0000000859 – 005
M020124/02E 2009-02 © MTU


1. Use removal tool to remove crankshaft bearing caps.
2. Remove bearing shell from crankshaft bearing cap and mark.
3. Protect bearing shells from damage.
Crankshaft – Removal
1. To protect the crankshaft, fit sliding protection
sleeves over studs of first and last bearings.
cardiagn.com
2. Using rope (1) and crane, lift crankshaft (2) clear
of crankcase.
3. Ensure horizontal positioning of the crankshaft
when lifting.
4. Lower crankshaft on to firm supports.
TIM ID: 0000000859 – 005
M020124/02E 2009-02 © MTU

5. Use removal jig to remove bearing shells from

bearing pedestals.
6. Mark bearing shells that point towards the driving
end with the number of the corresponding main
bearing (arrow).
7. The marking (arrow) must be made by etching or
with a permanent marker.
cardiagn.com
TIM ID: 0000000859 – 005
M020124/02E 2009-02 © MTU

5.3.4 Crankshaft – Disassembly

Heavy object.
Risk of crushing!

Risk of injury!
Removing counterweights
Note: If counterweights are to be removed, mark
relevant counterweight in its installation
position on the crankshaft prior to removal.
cardiagn.com
1. Determine and record distance A (web to
counterweight).
2. Check that counterweights are consecutively
numbered.
3. If the numbering is not visible, punch in new
numbers.
4. Lower crankshaft onto firm assembly frame.

5. Remove screws (2) and counterweight (1).
TIM ID: 0000000862 – 003
M020124/02E 2009-02 © MTU

5.3.5 Crankshaft - Cleaning
Preconditions
• Engine is stopped and starting disabled.
Material

Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!
cardiagn.com

Risk of injury!
Heavy object.
Damage to equipment due to falling components!
WARNING • Ensure that all components are secured during removal and installation work.


Crankshaft - Cleaning
2. Clean crankshaft and all threads with compressed air.
TIM ID: 0000000847 – 004
M020124/02E 2009-02 © MTU

5.3.6 Crankshaft – Check
Special tools

DynaMIC hardness tester Y20506341 1
Retainer 0015890321/00 1
Bore gauge, 100-160 mm Y20091482 1
Material
cardiagn.com
Spare parts

Crankshaft
Counterweight
Screw
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!
TIM ID: 0000000855 – 008
M020124/02E 2009-02 © MTU

Crankshaft – Check
Item Findings Task
Check mating faces of Wear visible Smooth with oilstone.

counterweights for wear.
Use micrometer to measure Values fallen short of. Corrective work: To be carried out
diameter and roundness of main only in workshops authorized by
bearing journals and crankpins. MTU.
Record measured values in data
sheet. Values (→ Page 226)
Check crankshaft counterweight Signs of cracks Replace crankshaft counterweight

with magnetic crack-testing method (→ Page 220).
for cracks.
Check crankshaft gear for stress Stress marks visible • Corrective work
marks. • Replace: To be carried out only
in workshops authorized by
MTU.
cardiagn.com
Using engineer’s blue, check that Unevenly fitted. Level mating face.
screw heads fit correctly.
Measure shaft length of screws with Dimension exceeded Replace screw.

depth gauge. Permissible shaft
length (→ Page 80)
Use magnetic crack-testing method Signs of cracks Replace screw.

with fluorescent magnetic powder to
check screws for cracks.
Make sure that threads are in perfect • Sluggish Replace screw.

condition. • Damaged
Checking crankshaft for cracks

1. Install crankshaft in longitudinal direction between
jaws of test device.
2. The specified magnetic field strength of 20 A/cm
to 60 A/cm must be applied at every part of
the component.
3. Use magnetic crack-testing method to check
crankshaft for longitudinal and transverse cracks.
Also check the oil and journal bores as well as the
mating faces on counterweights and threaded
bores.
Result: If there are signs of cracks, replace
crankshaft.
4. After crack-testing, demagnetize crankshaft. A
residual field strength of 2.5 A/cm to 4 A/cm
must not be exceeded.
TIM ID: 0000000855 – 008
M020124/02E 2009-02 © MTU

Checking crankshaft journal and taper

1. Check taper surfaces (arrows) for scoring and
damage.
2. Remove minor scoring and damage by polishing
with emery cloth.
3. Recondition taper: To be carried out only in
Checking hardness of journals
cardiagn.com
Note: Check hardness of all journals when
not installed.
1. Check hardness of all journals using the DynaMIC

tester or other suitable hardness tester. Required
hardness: 49 HRC to 53 HRC.
2. Check hardness of each journal at four points at
90° intervals around circumference.
Result: If values are fallen short of, contact
Service.
TIM ID: 0000000855 – 008
M020124/02E 2009-02 © MTU

cardiagn.com
Checking concentricity of crankshaft
1. Place crankshaft on rollers in main journals on main bearing.
• Main bearings 1 and 5 for 8 V
2. Use adjustable measuring holder and dial gauge to check bearing journals for concentricity.
3. If wear on circumference of journal is irregular, measure at transition from cylindrical section of journal to
radius. Values (→ Page 226).
Result: If measured values deviate: Recondition crankshaft only in workshops authorized by MTU.
TIM ID: 0000000855 – 008
M020124/02E 2009-02 © MTU

5.3.7 Crankshaft – Tolerances
Crankshaft bearing
cardiagn.com
Basic limit
size
1 Crankcase bore 0 171.000 H6 0 +0.025 171.035

bearing verse
ovality
max. 0.050
1 171.500 H6 171.535
Trans-
verse
ovality
max. 0.050
2 172.000 H6
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU


Basic limit
size
2 Alignment and 0-0 160.120 0 +0.054 0.120 0.199 Trans-

crankshaft verse
bearing Ø 0-1 159.620 ovality
installed 0-2 159.120 max. 0.050
0-3 158.620
1-0 160.120
1-1 159.620
1-2 159.120
1-3 158.620
Main bearing Ø 0-0 160.000 h6 –0.025 0 159.970
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0-1 159.500 h6 159.470
0-2 159.000 h6 158.970
0-3 158.500 h6 158.470
1-0 160.000 h6 159.970
1-1 159.500 h6 159.470
1-2 159.000 h6 158.970
1-3 158.500 h6 158.470

TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Conrod bearings
cardiagn.com
Basic limit
size
1 Conrod bore 126.000 0 +0.025

H6
2 Conrod bearing 0-0 117.082 0 +0.048 0.082 0.152

bore
Conrod bearing 0-1 116.882
installed 0-2 116.682
0-3 116.482
Conrod journal Ø 0-0 117.000 h6 –0.022 0
0-1 116.800 h6
0-2 116.600 h6
0-3 116.400 h6
3 Crankpin length 97.500 −0.100 +0.100 0.200 0.600
−0.100
TIM ID: 0000004156 – 002
Conrod width 48.600 0
4 Expanding 0-0 126.400 0 +1.000

dimension
shell, upper and 0-2 126.400
lower part
0-3 126.400
M020124/02E 2009-02 © MTU

Crankshaft bearing, alignment bearing – expanding dimension
cardiagn.com
Basic limit
size
1 Guide bearing, upper half
2 Guide bearing, lower half
3 Expanding 0-0 171.200 0 +0.500

dimension
Guide bearing, 0-1 171.200
upper and lower 0-2 171.200
part
0-3 171.200
1-0 171.700 0 +0.500
1-1 171.700
1-2 171.700
1-3 171.700
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft bearing – expanding dimension
cardiagn.com
Basic limit
size
1 Crankshaft bearing, upper half
2 Crankshaft bearing, lower half
3 Expanding 0-0 171.400 0 +1.000

dimension
Crankshaft 0-1 171.400
bearing, upper 0-2 171.400
and lower part
0-3 171.400
1-0 171.900 0 +1.000
1-1 171.900
1-2 171.900
1-3 171.900
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft axial play
cardiagn.com
Basic limit
size
1 Crankshaft axial 0.200 0.600 Clear-

play ance
min. 0.100
max. 0.700
2 Drive flange, 156.000 –0.010 +0.010

pressed on
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft bearing shells
cardiagn.com
Bearing shells installed and bearing caps tightened as per specification.
Measure crankshaft bearing bores:
• Determine diameters a, b1 and b2 in the measuring planes 1 and 2 and calculate
the average values for a, b1 and b2.
• Check roundness of crankshaft bearing bores.
b2 in the formula: (b1+b2) /2 −a
Replace bearing shells if:
• roundness deviation >0.040
• b1 : b2 is above/below 0.040
• vertical ovality a > (b1+b2) /2
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft gear, free end
cardiagn.com
Basic limit
size
1 Gear, pressed on 145.500 −0.300 +0.300

Crankshaft front
end to gear front
end
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Main bearing journal concentricity
cardiagn.com
Crankshaft (8V)
Max. permissible radial runout New Wear limit
From 1st main bearing journal, driving end, to last Concentricity: 0.100
main bearing journal, free end (arrow)
From main bearing journal to main bearing journal Concentricity: 0.050
Crankshaft (12V)
Crankshaft (16V)

TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft (20V)
cardiagn.com
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

5.3.8 Crankshaft - Assembly
Special tools

Spare parts

Crankshaft gear
End cover
Heavy object.
Risk of crushing!
cardiagn.com

Risk of injury!
Check crankshaft (→ Page 222).
Installing counterweights
1. Measure shaft lengths of counterweight screws.
Max. shaft length (→ Page 80).
2. Smooth mating surface for counterweight with
oilstone.
3. The mating faces of crankshaft and counterweight
(2) must be dry and free of grease.
4. Coat threads and screw head mating face of
screws (1) with engine oil.
5. Position counterweight on crankshaft according to
markings and slightly tighten screws.
TIM ID: 0000000865 – 003
M020124/02E 2009-02 © MTU

6. Align counterweight to marking (A) and tighten

screws to specified pretightening torque
(→ Page 80).
7. Check that the installation position of the
counterweight matches the markings or measured
dimensions made before installation.
8. Mark screw heads.
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9. Tighten screws to specified additional angle of
rotation.
10. After installing counterweights, check identification
marks on counterweights and webs.
11. Dynamically balance crankshaft. (→ Page 238).
12. Starting from driving end, mark counterweights
with number punch.
TIM ID: 0000000865 – 003
M020124/02E 2009-02 © MTU

5.3.9 Crankshaft – Balancing
Special tools

Master weights
Heavy object.
Risk of crushing!

Risk of injury!
Preparatory steps
cardiagn.com
1. Prior to balancing, seal all oil bores.
2. Support crankshaft at shaft journals.
3. Depending on stroke position (free residual moment), master weights must be used for dynamic balancing to
simulate the rotating and oscillating mass of conrod and piston.
TIM ID: 0000000851 – 003
M020124/02E 2009-02 © MTU

Dynamic balancing
Crankshaft (8V) Crankshaft (12V) Crankshaft (16V) Crankshaft (20V)
Maximum operating 2100 rpm 1900 rpm 2100 rpm 1900 rpm
speed
Support crankshaft 1 and 5 2 and 6 2 and 8 2 and 10

at shaft journals
Balancing assembly 463 kg 525 kg 775 kg 842 kg

mass
Balancing speed 150 rpm 150 rpm 150 rpm 150 rpm
Permissible residual 135 gcm 160 gcm 200 gcm 240 gcm
unbalance per
compensation level
for initial balancing
unbalance per
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compensation level
in other clamp or
balancing machine
(comparison)
Minimum wall 5 mm 5 mm 5 mm 5 mm
thickness around
bore
Bore values at counterweights

1. To balance crankshaft remove material from
counterweights by drilling with twist drill.
2. After balancing, recheck numbers on
counterweights and renumber if necessary.
A 5 ° (min.)
B 10 °
C 32 ° (min.)
D 8V, 12V, 16V: 18 mm (max. bore diameter); 20V:
TIM ID: 0000000851 – 003
20 mm (max. bore diameter)

E 40 mm (max. bore depth)
M020124/02E 2009-02 © MTU

5.3.10 Crankshaft bearing shells - Check

Remove crankshaft (→ Page 216).
Crankshaft bearing shells - Check

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

non-scheduled removal), check erosion or damage visible
bearing shells for surface wear,
scores, cracks, corrosion, erosion
and damage.
Check bearing shell butt and bearing Fretting corrosion visible Replace and determine cause.
rear side for damage and fretting Possible causes:
corrosion (pitting).
• Insufficient screw pretension
• Assembly error
• Spread dimension of bearing
shell out of tolerance
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• Faulty bearing support bore
Measure spread dimension. Determined value exceeded Replace bearing shell.

(→ Page 226).
Main bearing shells (grooved bearing), upper half
Running surface has following properties when new:

A approx. 75% slide layer
B approx. 25% intermediate layer
C 5% sputtered blocking layer
TIM ID: 0000000874 – 003
Assessment
Wear of the bearing running surfaces starts at the galvanized slide layer (a). In the event of further wear, the
difference between the intermediate layer (b) and slide layer (a) remains almost constant.
A magnifying glass is required for a more accurate assessment of the running surface
wear condition (magnification min. 5x).
M020124/02E 2009-02 © MTU

In doing so, the slide layer is visible as a dark zone and the intermediate layer as a light zone. The
following is decisive for the wear condition of the grooved bearing:
• Width of intermediate layer
• Width of groove
• Expansion of worn surface
The grooved bearing is still functional if the slide layer is partially missing in the grooves.
During each assessment of the condition of the grooves, the running surface in the area subject to
least load (groove mostly new) should be used for comparison.
The condition of the grooved bearings is assessed in five groups:
1. Continued use
2. Wear
3. Borderline wear and levelling
4. Slide layer fatigue fractures
5. Borderline slide layer continuous fractures and empty grooves
Main bearing shell (sputtered bearing), lower half
cardiagn.com
1 Slide layer
2 Blocking layer
3 Intermediate layer
4 Protective steel shell
Assessment
An important indicator for assessing the extent of wear on the bearing shell is the shape
and extent of the blocking layer areas exposed.
Wear of the bearing running surfaces starts at the galvanized slide layer (1).
The use of the bearing shell is already restricted in friction area once the slide 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.
Renew bearing shells at extended component maintenance.
TIM ID: 0000000874 – 003
Damage to bearing
Damage to bearings occurs mainly through foreign body scoring, impressions and embedding,
cavitation and corrosion, pitting, fatigue and installation faults.
Bearings showing such damage must be replaced.
M020124/02E 2009-02 © MTU

5.3.11 Crankshaft bearing bore – Check
Special tools

Bore gauge, 100-160 mm Y20091482 1
Installation/removal device F6553647 1
Installation aid F6553649 1
Retainer 0015890321/00 1
Material
cardiagn.com
Engine oil
Spare parts

Compressed air.
Risk of injury!

Risk of injury!
Note: The crankshaft bearing bore must first be checked without and subsequently with main bearings installed.
Measure crankshaft bearing bore with main bearings installed

TIM ID: 0000000877 – 005
M020124/02E 2009-02 © MTU

Measuring bearing shells

1. Turn crankcase in assembly dolly until oil pan
mating face is horizontal and facing upwards.
2. Wipe both sides of bores for crankshaft bearing in
crankcase and bearing shells with chamois leather.
3. Check codes for repair size and journal diameter
of new shells and bearing number of used
shells. These markings must be on sides facing
the driving end.
4. Compare crankcase data sheet and crankshaft
data sheet.
5. Manually press bearing shells on crankcase side
into crankcase bore to form a positive connection.
Ensure that oil bores (arrows) in bearing shells and
6. Insert bearing shells in crankshaft bearing caps
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according to markings or bearing number.
7. Position bearing shell so that bearing numbers are
aligned and facing driving end.
8. Position installation tool (1) between bearing
cap stud and rear face of shell on side where
open joint is.
9. Press bearing shell on cap side (2) against guide
bearing shell on crankcase side. Make sure that
the shell joint is closed.
10. Align bearing shells axially.
11. Install crankshaft bearing cap (→ Page 245).
12. Adjust bore gauge with adjusting ring or

micrometer to reference size of bearing bore.
13. Coat running surfaces of crankshaft bearing
shells with engine oil.
14. Measure crankshaft bearing bore ID with bore
gauge.
16. Compare measured values with specifications
(→ Page 226).
17. If values are exceeded, recondition bearing shells
to next repair size or replace.
18. After measuring crankshaft bearing bores, if
TIM ID: 0000000877 – 005
necessary mark bearing shells according to

bearing point number.
M020124/02E 2009-02 © MTU

Checking crankshaft bearing bore without main bearing installed

2. Remove bearing shells. Protect against damage.
4. Measure crankshaft bearing bore in same way as with installed bearing shells.
cardiagn.com
TIM ID: 0000000877 – 005
M020124/02E 2009-02 © MTU

5.3.12 Crankshaft – Installation
Special tools

Press-in tool F6555764 1
Alignment tool F6783003 1
cardiagn.com
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

Installing bearing shells

Note: Top and bottom bearing shells have
different part numbers. First crankshaft
bearing on driving end is designed as an
alignment bearing.
3. Use installation/removal tool to manually insert

the bearing shells on the crankcase side in
accordance with bearing numbers in crankcase
bore to form a positive connection.
4. Check stage of main crankshaft bearing bore and
stage of bearing shells. For data, see crankcase
data sheet and crankshaft data sheet.
5. Align alignment bearing shell and remaining
bearing shells with press-in tool in crankcase
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bores.
Crankshaft – Installation
1. Wipe bearing surfaces on crankshaft with chamois
leather.
2. Spray running faces of bearing shells on crankcase
side with engine oil.
3. To protect crankshaft, slide locating device (1)
over studs of first bearing (2).
4. Slide protective sleeve (2) over studs on last

bearing.
5. Lift crankshaft using rope slings (1) and crane.
6. Align crankshaft horizontally and vertically with
line of bores in crankcase and gradually lower
crankshaft.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

7. Remove protective sleeves and locating device.

Note: Do not rotate the crankshaft until the axial
alignment bearing has been installed.
8. Wipe lower bearing shell and crankshaft bearing

cap with chamois leather, spray running surface
with engine oil and install.
9. Check alignment of upper and lower bearing
shells. Bearing numbers on shells must be aligned
and all numbers must face driving end.
10. Position installation tool (1) between bearing cap
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stud and rear face of shell on side where joint is.
11. Compress bearing shell on cap side and press
against shell on crankcase side.
Result: The joint between the shells must be
closed.
12. Axially align bearing shells.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU


Note: Crankshaft bearing caps must not be
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interchanged!
2. Assign bearing cap to respective bearing

according to crankcase marking (1). If not present,
stamp numbers of main bearing (1), starting
at driving end.
3. Carefully position assigned bearing cap on

respective bearing.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

4. Tap crankshaft bearing cap lightly to move to

final position.
5. Coat threads and mating faces of studs (1) with
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engine oil.
6. Turn bearing cap nuts to mating face of bearing
caps.
7. Starting with 1st bearing cap (driving end or free

end), fit support sleeve (2) of hydraulic screw
pretensioner on studs (1) of respective crankshaft
bearing cap.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

8. Turn hydraulic screw pretensioner (1) by hand

until it is in position.
9. Connect high-pressure hose of hydraulic hand
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pump to hydraulic screw pretensioner.
10. Position magnetic holder with dial gauges on
crankcase mating face to measure stud elongation.
11. Position the two dial gauge tips centrally on the

respective measuring core (arrow) on the sleeve
measuring pin.
12. Set preloaded dial gauges to zero. TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

13. Operate hydraulic hand pump and elongate studs

at the same time (max. 1.15 mm +0.05 mm), use a
pin (arrow) to fit nuts on crankshaft bearing cap.
Note: Residual elongation of studs after release:
0.9 mm +0.05 mm
14. Relieve studs, check elongation of studs.

15. If residual elongation of studs is outside tolerance,
loosen nuts, and repeat nut tightening procedure; if
necessary, replace studs.
16. Mount dial gauges with magnetic holders and
hydraulic screw pretensioner on studs of adjacent
bearing cap and follow the same procedure to fit
all remaining nuts.
17. Coat screws (arrow) with engine oil.
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18. Insert screws (arrow) and use torque wrench to
tighten to specified torque (→ Page 80).
19. Install strip (driving end) (→ Page 124).
20. In order to avoid damage to the

crankshaft bearings, install locating device (1)
before cranking the crankshaft.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

21. Fit barring tool (2) with screws on crankshaft (1)

(free end).
22. Turn crankshaft with barring tool and check for
ease of movement.
Measuring axial play of crankshaft
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Note: Measure axial play only with drive flange or
flywheel mounted.
1. Mount magnetic dial gauge holder with dial gauge

(1) on crankcase.
2. Position dial gauge tip on face of crankshaft.
3. Use pry bar to press crankshaft axially as far as
it will go.
4. Set preloaded dial gauge to zero.
5. Move crankshaft from stop to stop (arrows) and
enter measured value (axial play) on data sheet.
6. If the determined value is out of tolerance
(→ Page 226), remove crankshaft and determine
the cause.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

5.3.13 PTO flange, driving end, flywheel – Overview
cardiagn.com
1 Flywheel 6 Spring pin 11 Cover
2 Graduated disc 7 Dished washer 12 Conical spring washer
3 Radial-lip shaft seal 8 Screw 13 Screw
4 Screw 9 O-ring 14 Cover
5 Conical spring washer 10 O-ring 15 O-ring
TIM ID: 0000000881 – 002
M020124/02E 2009-02 © MTU

Layout for installation/removal jig for flywheel
cardiagn.com
1 Spacer 6 Pressure sleeve 11 Nut
2 Screw 7 Tension spindle A Reference dimension: 363 mm
3 Adjusting mandrel 8 Hydraulic nut B Push-on dimension: 16.7 mm
4 Connection 9 Pressure line to 20 mm
5 Flange 10 Support C Press-fitted flush
TIM ID: 0000000881 – 002
M020124/02E 2009-02 © MTU

5.3.14 PTO flange, driving end, flywheel – Removal
Special tools

ZB Installation/removal tool F0140440 1
SKF hydraulic unit 5505890163/00 1
Hand pump set 5555890063/00 1
Trestle T80091387 1
Adapter F6555788 1
Impact extractor F30377999 1
Assembly sleeve F6557134 1
Suspended load.
Danger to life!
cardiagn.com

Removing flywheel
1. Remove screws (2) together with washers (3).
2. Remove plug (1) from flywheel.
3. Remove screws (4).
TIM ID: 0000000890 – 003
M020124/02E 2009-02 © MTU

4. Install adapter (2) for impact extractor (3) with

screws (5).
5. Remove cover (4) from flywheel (4) with impact
extractor (3).
6. Install installation/removal tool on crankcase
journal, driving end, as shown in overview drawing
(→ Page 253).
7. Turn crankshaft, until fixation (1) on spacer (2)
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engages in flywheel.
8. Insert tension spindle into crankshaft.

9. Measure check dimension ”A” (→ Page 253).
10. Slide pressure sleeve (2) and hydraulic nut (1) over
tension spindle and screw on nut (3) with support. TIM ID: 0000000890 – 003
M020124/02E 2009-02 © MTU

11. Remove screw for expanding bore in flywheel.

12. Screw HP line (1) on to connection (2).
13. Connect HP line (4) of hydraulic unit to hydraulic
nut (3).
14. Set hydraulic nut (3) to initial position (zero stroke).
15. Fully tighten hydraulic nut (3) to stop, then back off
nut for a distance equal to push-on dimension
(→ Page 253).
16. Fill up pumps (1) and (2) with engine oil SAE 10.
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17. Vent pumps (1) and (2) and line system until
bubble-free oil emerges.
18. Tighten HP line.
19. Actuate hydraulic unit (2) and to bring hydraulic
nut at minimum pressure p2 (start of pressure
increase) to attachment with flywheel.
20. Read off maximum expansion pressure pmax at
flywheel.
21. Actuate hand pump (1) for expanding the flywheel,
until half of the maximum expansion pressure
p1 is reached.
22. Maintain pressure p1 for approx. 5 minutes.
23. Increase expansion pressure gradually in steps of
0,1 x pmax with hold times of approx. 2 minutes
until the flywheel comes clear off the crankshaft.
Do not exceed maximum expansion pressure pmax.
24. Operate pump to maintain constant expansion
pressure.
25. Monitor pressure p2 in hydraulic nut. The release
of the flywheel from the taper seat is indicated by
rising pressure p2 .
26. Gradually drain oil in hydraulic nut, while at the
same time continuing to pump.
27. Relieve pumps (1) and (2).
28. Screw trestle into flywheel and attach flywheel to
crane with rope lightly pretensioned.
29. Remove HP line.
30. Remove nut, support, hydraulic nut and pressure
sleeve.
TIM ID: 0000000890 – 003
M020124/02E 2009-02 © MTU

31. Install assembly sleeve (arrow) with nut.

32. Lift flywheel through assembly sleeve (arrow)
out of end housing.
33. Place flywheel on a clean surface and secure.
34. Remove nut, assembly sleeve, flange and spacer.
35. Clean assembly surfaces on flywheel and
crankshaft.
36. Close openings using suitable covers.
cardiagn.com
TIM ID: 0000000890 – 003
M020124/02E 2009-02 © MTU

5.3.15 Radial-lip shaft seal, driving end – Removal

Removing radial-lip shaft seal from end housing
1. Remove end housing, driving end (→ Page 162).
2. Use a suitable extractor to extract radial-lip shaft seal from end housing. Do not damage end housing and
crankshaft.
cardiagn.com
TIM ID: 0000000893 – 003
M020124/02E 2009-02 © MTU

5.3.16 Flywheel on PTO flange, driving end – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Flywheel on PTO flange, driving end – Cleaning
2. Remove cleaner.
3. Thoroughly blow all threads clear with compressed air.
TIM ID: 0000000884 – 002
M020124/02E 2009-02 © MTU

5.3.17 Flywheel on PTO flange, driving end – Check
Material

Spare parts

Flywheel
End cover
Coiled spring pin
Heavy object.
cardiagn.com
Risk of crushing!
Flywheel on PTO flange, driving end – Check
Item Findings Task
Use magnetic crack-testing method Signs of cracks Replace.

to check flywheel and ring gear for
cracks.
Check mating faces on flywheel for • Stress marks • Corrective work

evenness, stress marks, scoring • Scores • Replace
and indentations. • Indentations
visible
Check ring gear for wear. Signs of wear • Corrective work

• Replace
Check end cover for wear. Signs of wear • Corrective work

• Replace
Measure outer diameter (hub) of Value fallen short of. Replace flywheel.
flywheel. Value (→ Page 166)
Check thread of expanding bore. Damaged Recut thread.

TIM ID: 0000000887 – 006
M020124/02E 2009-02 © MTU

5.3.18 Radial-lip shaft seal, driving end – Installation
Special tools

Material

Ethanol 40250 1
Spare parts

cardiagn.com
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Installing radial-lip shaft seal in end housing,

driving end
Note: Install radial-lip shaft seal only in mounted
end housing, driving end.
1. Install flange with spacer on front face of crankshaft

2. Fit radial-lip shaft seal, with sealing lip facing
outwards, on press-in tool.
3. Coat sealing face of radial-lip shaft seal with
ethanol.
4. Clean and degrease locating bore for radial-lip
shaft seal in end housing, driving end.
5. Position press-in tool and secure with hand screw.
6. Use press-in tool to install radial-lip shaft seal flush
in end housing, driving end.
7. Remove press-in tool with flange from crankshaft.
TIM ID: 0000000896 – 004
M020124/02E 2009-02 © MTU

5.3.19 PTO flange, driving end, flywheel – Installation
Special tools

Hand pump set 5555890063/00 1
Trestle T80091387 1
Material

cardiagn.com
Engine oil
Screw locking compound (Loctite 270) 40083 1
Spare parts

O-ring
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

Incorrect installation of components and lines.

CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
TIM ID: 0000000899 – 005
Check flywheel on PTO flange, driving end (→ Page 261).
M020124/02E 2009-02 © MTU

Installing timing wheel

1. Attach timing wheel (2) with screws (1) to flywheel,
do not tighten.
2. Drive spring pins (arrow) into flywheel.
3. Use torque wrench to tighten screws (1) to
Pressing on flywheel
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1. Prior to installation, remove all covers.
2. Clean and degrease taper surface on crankshaft
with cleaner and dry and degrease with lint-free
cloth.
3. Coat lip of radial-lip oil seal with petroleum jelly.
4. Screw in tension spindle (1) and measure
reference dimension “A” of tension spindle
(→ Page 253).
5. Install spacer (3) and flange (2) together with
screws on crankshaft face.

7. Use rope to attach flywheel to crane with rope
lightly pretensioned.
8. Use crane to insert flywheel through guide sleeve
into end housing,
9. Remove assembly sleeve (arrow).
TIM ID: 0000000899 – 005
M020124/02E 2009-02 © MTU

10. Calculate push-on distance by measuring distance

from end face of crankshaft to end face of flywheel
with depth gauge.
11. If measured value is smaller than push-on distance
“B”, check taper for dimensional accuracy.
12. Slide pressure sleeve and hydraulic nut (3) over
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tension spindle and screw on nut (5) with support.
nut (3).
19. Prior to press-fitting, moisten tapers fit with
expansion fluid. In doing so, actuate hand
pump (1), until expansion fluid emerges at hub
ends.
20. Actuate hydraulic unit (2) for hydraulic nut, and
attach at installation on flywheel using minimal
pressure.
TIM ID: 0000000899 – 005
flywheel.
22. Pump in expansion fluid until expansion
pressure (p1) can no longer be increased (do not
exceed expansion pressure Pmax ), then increase
force-on force by increasing force-on pressure (p2).
23. Select force-on force so that end position
(pressure bush is seated against flywheel) is
achieved in approx. 5 steps.
M020124/02E 2009-02 © MTU

24. Open valve screw on hand pump (1) to relieve

expansion pressure.
25. Maintain maximum force-on pressure for 60
minutes, to ensure that the expansion fluid is
expelled from the joint and static friction can build
up between the fixed components.
26. Unscrew HP lines.
27. Remove nut, support, hydraulic nut, pressure
sleeve and tension spindle after prescribed
soaking time.
28. Coat O-rings (8) with petroleum jelly and insert in
groove on cover (7).
29. Press cover (7) into flywheel.
30. Insert screws (6) and use torque wrench to tighten
to specified torque (→ Page 80).
31. Coat O-rings (1) and (3) with petroleum jelly and
insert in groove on plug (2).
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33. Coat screws (4) with Loctite 270 and screw in
together with washers (5).
35. Do not subject the press-fit connection to
operational load for at least 8 hours.
TIM ID: 0000000899 – 005
M020124/02E 2009-02 © MTU

5.3.20 Crankshaft PTO, Free end – Overview
cardiagn.com
1 Adapter flange 5 O-ring 9 Washer
2 O-ring 6 O-ring 10 Screw
3 Screw 7 Protective cover 11 Sealing ring
4 Washer 8 Screw
TIM ID: 0000029611 – 001
M020124/02E 2009-02 © MTU

Arrangement of the drive flange installation/removal tool
1
2
3
4
Draw spindle
Nut
Support
Connection
9
10
11
12
Drive flange
Crankshaft
Seal carrier
Screw
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5 Hydraulic nut A Reference dimension: 339 mm
6 Pressure sleeve B Push-on dimension: 76.95 mm
7 Flange to 77.05 mm
8 Spacer bushing a Push-on travel: 15.5 mm
TIM ID: 0000029611 – 001
M020124/02E 2009-02 © MTU

5.3.21 Vibration damper on PTO, free end – Removal
Preconditions
Special tools

Installation/removal tool F0140771 1
Flywheel positioning fixture F6557187 1
Adjusting mandrel F30379300 2
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Hook-ended chain sling (4 off) T80090748 1
Material

Engine oil SAE 10 W
Suspended load.
Danger to life!

TIM ID: 0000000912 – 012
M020124/02E 2009-02 © MTU

Removing vibration damper

1. Remove protective cover.
2. Block flywheel by securing with positioning fixture
on end housing.
3. Remove screws (2), one screw is left for securing
purposes.
4. Screw in two adjusting mandrels in opposing
threaded bore of drive flange.
5. Remove remaining screws.
6. Insert two jackscrews with continuous thread
in thread (1).
7. Press off vibration damper.
8. Attach vibration damper (1) with lifting gear (3)
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and support bracket to crane using a lightly
tensioned rope and remove.
9. Remove adjusting mandrels (2).
Pressing off drive flange

1. Screw draw spindle (4) into crankshaft.
2. Check reference dimension “A” (→ Page 267).
3. Read off push-on dimension at drive flange (1).
4. Mount installation/removal tool as per overview
drawing (→ Page 267).
5. Screw in connecting piece (2) in drive flange (1).
6. Connect HP line for drive flange expansion to
connecting piece.
7. Insert adapter in connection of hydraulic nut (3).
8. Connect HP line (6) to adapter.
TIM ID: 0000000912 – 012

10. Back off nut (5) for a distance equaling push-on
dimension.
M020124/02E 2009-02 © MTU

11. Fill hand pumps (1) and (2) with engine oil SAE 10.
12. Vent hand pumps (1) and (2) and line system until
14. Operate hand pump (2) to bring hydraulic nut at
minimum pressure p2 (start of pressure increase)
to attachment with drive flange.
15. Read off max. expansion pressure pmax at
drive flange.
16. Actuate hand pump (1) to expand the drive flange
until half the maximum expansion pressure p1
has been reached.
18. Increase expansion pressure gradually in
steps of 0.1 x pmax with hold times of approx.
2 minutes until the drive flange comes clear off the
crankshaft. Do not exceed maximum expansion
pressure pmax.
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pressure.
of the drive flange from the taper seat is indicated
by rising pressure p2.
21. Gradually relieve pressure in hydraulic nut while
steadily operating pump for expansion fluid.
22. Relieve hand pumps (1) and (2).
23. Screw eyebolt into drive flange and suspend drive
flange on crane with rope lightly tensioned.
24. Remove installation/removal tool.
25. Remove drive flange (1) from crankshaft (2).
26. Remove screws (4) from adapter flange (3).
27. Remove adapter flange (3).
TIM ID: 0000000912 – 012
M020124/02E 2009-02 © MTU

5.3.22 Vibration damper on PTO, free end – Disassembly
Vibration damper – Disassembly

Disassembly of this component is not planned.
This component is an exchange component (Reman) and is available via the normal exchange procedure.
cardiagn.com
TIM ID: 0000000915 – 002
M020124/02E 2009-02 © MTU

5.3.23 Vibration damper on PTO, free end – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning vibration damper

2. Remove cleaner.
3. Blow out components with compressed air.
TIM ID: 0000000906 – 002
M020124/02E 2009-02 © MTU

5.3.24 Vibration damper on PTO, free end – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Micrometer, 175-200 mm Y20001744 1
Holder 0015890321/00 1
Spare parts

Vibration damper
Drive flange
cardiagn.com
Heavy object.
Risk of crushing!

Risk of injury!
Vibration damper - Check
Item Findings Task
Visually inspect vibration damper for • Damage Replace vibration damper.

damage and wear. • Wear
visible
Using a precision bore gauge, Values exceeded. Replace vibration damper.

measure vibration damper bore.
Measure drive flange OD with Values below specification. Replace drive flange.
micrometer. Values (→ Page 275)
TIM ID: 0000000909 – 005
M020124/02E 2009-02 © MTU

5.3.25 Vibration damper on PTO, free end – Tolerances
cardiagn.com
Basic limit
size
1 ID of vibration 198.000 0 +0.046 0 0.059 0.016

damper H7
OD of driver 196.00 j6 –0.013 +0.016

flange
TIM ID: 0000004053 – 001
M020124/02E 2009-02 © MTU

5.3.26 Vibration damper on PTO, free end – Installation
Special tools

Removal/installation device F0140771 1
Hook-ended chain sling (quadruple branch) T80090748 1
cardiagn.com
Material

Engine oil
Spare parts

O-ring
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

TIM ID: 0000002645 – 013

M020124/02E 2009-02 © MTU

Installing adapter flange

1. Coat O-rings with grease and insert into groove.
2. Install adapter flange with O-rings as shown in the overview drawing (→ Page 267).
3. Use torque wrench to tighten screws to specified tightening torque (→ Page 80).
Hydraulic press-fitting drive flange

1. Clean, degrease and dry tapers of crankshaft
and vibration damper.
2. Coat running surfaces of crankshaft bearing and
drive flange with oil.
3. Push drive flange onto crankshaft taper by hand.
4. Measure distance from crankshaft end face to
drive flange end face using depth gauge and
note measured value.
5. Calculate difference (= push-on distance) between
measured dimension and push-on dimension
(→ Page 267).
6. Push-on dimension B = distance between
crankshaft end face and drive flange end face
cardiagn.com
after installation.
7. Read off push-on distance at drive flange.
8. If calculated push-on distance is less than
measured value, check dimensional accuracy
of tapers.
9. Screw puller spindle (4) into crankshaft.
10. Check reference dimension (A) (→ Page 267).
11. Mount installation/removal device as shown in the
overview drawing (→ Page 267).
12. Slide thrust sleeve (1) and hydraulic nut (3)
over puller spindle.
13. Set hydraulic nut (3) to initial position at zero
stroke.
14. Install nut (5) and hand-tighten.
15. Screw high-pressure line with connecting piece (2)
into drive flange.
16. Connect high-pressure line (6) of hydraulic unit
to hydraulic nut (3).
TIM ID: 0000002645 – 013
M020124/02E 2009-02 © MTU

17. Fill hand pump (1) and (2) with engine oil acc.
to SAE 10 W.
18. Vent hand pump (1) and (2) and pipework until
19. Tighten high-pressure line.
20. Prior to hydraulic press-fitting, moisten tapers fit
with expansion fluid. For this purpose, actuate
hand pump (1) until expansion fluid emerges
at drive flange end.
21. Operate hydraulic hand pump (2) for hydraulic
nut and, by applying minimum pressure on drive
flange, seat against drive flange.
22. Pump in expansion fluid until expansion pressure
p1 no longer rises. Then increase press-on force
by raising force-on pressure p2.
23. Repeat this process until drive flange is correctly
seated.
24. Select push-on pressure so as to achieve
positioning in approx. 5 steps.
cardiagn.com
25. Read off expansion pressure pmax at drive flange.
Ensure that, during installation, the required
expansion pressure is less than the maximum
expansion pressure pmax.
Result: Hydraulic installation is completed when
thrust sleeve is seated against crankshaft.
expansion pressure.
28. Disconnect high-pressure line.
29. Remove installation/removal device after specified
hold time has elapsed.
30. Check push-on dimension (B) between crankshaft
end face and drive flange end face (→ Page 267).
31. If push-on dimension is not established,
hydraulically remove drive flange and determine
the cause.
32. Do not subject press fitting to operating load
for at least 8 hours. TIM ID: 0000002645 – 013
M020124/02E 2009-02 © MTU

Installing vibration damper

1. Screw adjusting mandrels (1) into threaded hole
of drive flange.
2. Coat O-rings (2) with grease.
3. Fit O-rings (2) on drive flange.
4. Attach vibration damper (1) with lifting gear (3) and
cardiagn.com
support bracket to crane using a lightly tensioned
hook-ended chain sling.
5. Push vibration damper (1) onto adjusting
mandrels (2).
6. Remove lifting gear (3).
7. Coat thread and screw head mating faces with
engine oil and screw in.
8. Remove adjusting mandrels.
9. Install remaining screws and washers and tighten
to specified tightening torque (→ Page 80) using a
torque wrench.
10. Install protective cover.
11. Remove positioning fixture from end housing.
TIM ID: 0000002645 – 013
M020124/02E 2009-02 © MTU

5.3.27 Piston and conrod – Overview
Piston and conrod
cardiagn.com
1 Piston 3 Conrod cap 5 Conrod bearing shell, lower
2 Conrod 4 Conrod bearing shell, upper 6 Conrod screw
TIM ID: 0000029621 – 001
M020124/02E 2009-02 © MTU

Piston details
cardiagn.com
1 Snap ring 5 Oil control ring 9 Conrod
2 Piston pin 6 Piston 10 Conrod cap
3 Rectangular-section ring 7 Pressure plate 11 Conrod screw
4 Taper-face compression ring 8 Piston crown screw
TIM ID: 0000029621 – 001
M020124/02E 2009-02 © MTU

5.3.28 Piston and conrod – Removal
Special tools

Barring tool, 8V-16V F6555766 1
Barring tool, 20V F6783293 1
Barring tool for timing disc F6555791 1
Pointer for barring tool F6555792 1
Timing disc, free end Y4341124 1
Socket, 22 A/F, conrod screws F30378352 1
Lifting device for piston removal, 8V-16V T80091025 1
Lifting device for piston removal, 20V T80091496 1
Sliding block F6559604 1
cardiagn.com
Heavy object.
Risk of crushing!

Risk of injury!
Removing piston and conrod with oil pan installed

1. Remove combustion residues from cylinder liner.
2. Remove carbon scraper ring (arrowed)
(→ Page 134).
3. Install barring tool.
4. Remove left and right-side inspection port cover on
respective cylinder.
5. Position piston of respective cylinder at 20 to 25
mm before after (A-bank) and at 20 to 25 mm
before TDC (B-bank) as measured from the top
edge of the cylinder liner to the piston crown.
TIM ID: 0000005021 – 004
M020124/02E 2009-02 © MTU

6. Working through the inspection port (arrowed),

slacken conrod screws using a socket insert and
large ratchet.
7. For further removal, except for altered removal
position of crankcase: see "Removing piston and
conrod in assembly dolly" in next section.
8. Before removing the conrod from cylinder liner (3),
cardiagn.com
attach sliding block (2) to conrod (1).
Removing piston and conrod in assembly dolly

Note: Do not bar crankshaft unless the flywheel
or axial locating device is installed.
1. Turn crankcase in assembly dolly until conrod

bearing cap (1) of the piston to be removed
is horizontal.
2. Using socket (2), extension and ratchet, release
conrod screw (3).
TIM ID: 0000005021 – 004
M020124/02E 2009-02 © MTU

Note: Bearing cap and conrod are a single unit

and must not be interchanged.
3. Check marking (arrowed) of conrod bearing cap

and conrod. If necessary, mark components.
4. Remove conrod screws (arrowed) and take off
cardiagn.com
conrod bearing cap (1).
5. Remove bearing shell from conrod bearing cap.
Ensure that toothing on mating faces of conrod
and conrod bearing cap is not damaged.
6. Protect bearing shell and conrod bearing cap
from damage.
7. Check markings of bearing shell to conrod. If
necessary, mark components.
8. Turn crankcase in assembly dolly until the piston

and conrod to be removed are vertical. Ensure
that the oil spray nozzle is not damaged.
9. Remove bearing shell from conrod and protect
from damage.
10. Attach lifting device (1 ) to piston crown (2).
11. Using a crane, withdraw piston and conrod from
cylinder liner fit.
12. Carefully set down piston and conrod on soft
surface and remove from crane.
13. Remove lifting device from piston crown.
TIM ID: 0000005021 – 004
M020124/02E 2009-02 © MTU

5.3.29 Piston and conrod – Disassembly
Special tools

Piston-ring pliers F30378003 1
Heavy object.
Risk of crushing!

Risk of injury!
Removing conrod from piston

1. Place piston and conrod on workbench.
2. Check markings of conrod, piston and piston pin. If
cardiagn.com
necessary, mark components anew.
3. Using snap ring pliers (1), remove snap ring (2).
4. Use a piece of round wood to press out piston pin

(2), holding conrod (1) firmly in position.
5. Remove conrod from piston.
TIM ID: 0000000941 – 007
M020124/02E 2009-02 © MTU

Removing piston rings

1. Stretch piston rings until they can be removed
from the piston.
2. Remove piston rings with piston ring pliers in
sequence from top to bottom.
cardiagn.com
TIM ID: 0000000941 – 007
M020124/02E 2009-02 © MTU

5.3.30 Piston – Cleaning
Material

Cleaner (Sima Solv K6) 50632 1
Cleaner is an explosive and poisonous substance.

Danger to life, major material damage!
DANGER • Avoid open flames, electrical sparks and ignition sources.
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
cardiagn.com
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!

Risk of injury!

Piston cleaning
Note: The graphite layer on the piston skirt must not be mechanically removed or treated with strong cleaners!
1. Clean all metallic parts with the cleaner.

2. Clean area of piston ring grooves with rotating plastic brush.
3. After cleaning, blow out oil chamber and oil bores with compressed air.
TIM ID: 0000000928 – 005
M020124/02E 2009-02 © MTU

5.3.31 Piston – Check
Material

Dye penetrant (standard check) 40488 1
Spare parts

Piston
cardiagn.com
Piston pin
Oil-control ring
Taper-face compression ring
Rectangular-section ring
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000000933 – 003
M020124/02E 2009-02 © MTU

Piston – Check
Item Findings Task
Make sure that oil chamber and oil Not clean Clean
bores are particularly clean.
Check piston with fluorescent Signs of cracks Replace piston.

penetrant.
Check piston for wear • Contact erosion at piston edge Replace piston.
and valve clearance pockets
• Large area of polishing wear
on piston skirt (appears dull)
• Concentrated occurrence of
scoring
• Pitting
Measure piston pin boss. Values Values exceeded Replace piston.

(→ Page 291)
Check sliding surface of bronze • Stress marks Replace piston.
cardiagn.com
bush for stress marks and scoring. • Scores
visible
Check groove width with gauge Values exceeded. Replace piston.

blocks. If no gauge block is
available, alternatively a new piston
ring can be inserted in the groove
and the axial play checked with a
feeler gauge. Values (→ Page 291)
Check piston pin with magnetic Signs of cracks Replace piston pin.
crack-testing method for cracks.
Check condition of piston. • Traces of wear Replace piston pin.

• Scores
• Impact points
visible
Measure outer piston pin diameter Values exceeded. Replace piston pin.
with C-frame micrometer. Values
(→ Page 291)
Check piston rings. • Piston ring with burring, Replace

chipping or sharp edges
• If chrome layer has signs
of scoring, cracks or heat
discoloration.
TIM ID: 0000000933 – 003
M020124/02E 2009-02 © MTU

Piston rings – Check

1. Place piston ring (1) in ring gauge (3) to measure
piston ring end clearance. Ensure that piston ring
fits evenly in ring gauge.
2. Check ring end clearance with feeler gauge (2).
3. If values are exceeded (→ Page 291), replace
piston rings. Replace piston rings only in sets.
4. After installation of new piston rings, replace
cylinder liners (→ Page 134).
cardiagn.com
TIM ID: 0000000933 – 003
M020124/02E 2009-02 © MTU

5.3.32 Piston – Tolerances
Piston bearing
cardiagn.com
No. Designation Stage Tol. Deviation Clearance Interference Wear limit
size
Basic
size
1 Bush inner 68.000 +0.070 +0.080 0.070 0.085 Clearance max.

dia. 0.090
Piston pin 68.000 –0.005 0

outer dia.
2 Bush inner 68.000 +0.012 +0.022 0,012 0,027 Clearance max.

dia. 0.025
Piston pin 68,000 –0,005 0

outer dia.
3 MTU part number and stage stamped on

TIM ID: 0000004138 – 002
M020124/02E 2009-02 © MTU

Piston rings
cardiagn.com
No. Designa- Stage Tol. Deviation Clearance Interference Wear limit
tion size
Basic
size
1 Groove 4,000 +0,170 +0,190 0,170 0,225 Clearance max.

width 0.300
Rectan- 4,000 –0,035 0

gular-sec-
tion ring
2 Groove 4,000 0,080 0,100 0,080 0,135 Clearance max.

width 0.200
Taper- 4,000 –0,035 0

face com-
pression
ring

width 0.200
Oil control 5,000 –0,035 0

TIM ID: 0000004138 – 002
ring
M020124/02E 2009-02 © MTU


tion size
Basic
size
4 Joint clearance Clearance max.
Rectan- 0,400 0,700 0,900

gular-sec-
tion ring
Taper- 1,000 1,300 1,500

face com-
pression
ring
Oil control 0,450 0,800 1,000

ring
Measure joint clearance in ring gauge 165.000 H6.
cardiagn.com
TIM ID: 0000004138 – 002
M020124/02E 2009-02 © MTU

Piston clearance in cylinder liner
cardiagn.com
Basic size limit
1 Cylinder liner 165.000 H7 0 +0,040 0,184 0,246

dia.
Piston skirt 164,805 –0,011 +0,011

dia.
2 Cylinder liner 165.000 H7 0 +0,040 0,270 0,330

dia.
Piston skirt 164.720 –0.010 +0.010

dia.
3 Cylinder liner 165.000 H7 0 +0.040 0.400 0.480

dia.
Piston crown 164.580 –0.020 +0.020

dia.
4 Cylinder liner 165.000 H7 0 +0.040 0.455 0.495

dia.
TIM ID: 0000004138 – 002
Piston crown 164.525 –0.020 +0.020

dia.
5 Scraper ring 164.000 H8 0 +0.063 0.585 0.698

dia.
Piston crown 163.390 –0.025 +0.025

dia.
M020124/02E 2009-02 © MTU


Basic size limit
Dimensions 1 to 5 measured vertically in relation to pin axis.
6 Scraper ring 164.000 H8 0 +0.063 0.708 0.821

dia.
Piston crown 163.267 –0.025 +0.025

dia.
7 Piston skirt round falling oval

Skirt graphite-coated with two positions at 1 and 2 respectively free of graphite for measuring the diameter.
cardiagn.com
TIM ID: 0000004138 – 002
M020124/02E 2009-02 © MTU

Piston crown mounting
cardiagn.com
No. Designation Stage Tol. Deviation Clearance Interference Wear
size limit
Basic
upper max. min. max.
size lower min.
1 Screw length 49.000 –0.100 +0.100 max.

removed length
49.800
50.000 –0.100 +0.100 max.

length
50.800
TIM ID: 0000004138 – 002
M020124/02E 2009-02 © MTU

5.3.33 Conrod – Disassembly
Spare parts

Conrod
Conrod – Disassembly
1. Disassembly of conrod is not planned.
2. The conrod is an exchange component (Reman) and is available via the normal exchange procedure.
cardiagn.com
TIM ID: 0000000959 – 002
M020124/02E 2009-02 © MTU

5.3.34 Conrod – Cleaning
Material

Cleaning agent (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1
Compressed air.
Risk of injury!

cardiagn.com

Conrod – Cleaning
1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then rinse with cleaning agent (Hakupur 312).
2. Clean conrod oil bore with hole brush.
3. Use a brass brush to clean meshing on conrod and conrod bearing cap mating faces.
TIM ID: 0000000953 – 004
M020124/02E 2009-02 © MTU

5.3.35 Conrod – Check
Special tools

Testing device Y4341492 1
Test mandrel Y4341913 1
Bore gauge, 18-100 mm Y20091481 1
Bore gauge, 100-160 mm Y20091482 1
Material

cardiagn.com
Spare parts

Conrod
Conrod screw
Compressed air.
Risk of injury!
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Conrod – Check
Item Findings Task
Check conrod main bore for blue Blue discoloration Replace conrod.
discoloration.
Check conrod bushing for scores, Damaged • Corrective work

contamination, stress marks and • To be carried out only in
heat discoloration marks. workshops authorized by MTU.
Replace conrod bush.
Check conrod, conrod bearing cap Signs of cracks Replace

and conrod bearing screws for
cracks using magnetic crack-testing
method.
Check threads of conrod and conrod Damaged • Replace conrod.

screw for damage. • Replace conrod screw.
Check conrod screw length. Values Value exceeded Replace

(→ Page 306)
cardiagn.com
Check basic bore for stress marks • Stress marks • Corrective work
and scores. • Scores • Replace
visible
Inspect meshing for damage and Damaged Replace

check wear pattern with engineer’s
blue.
Measuring conrod basic bore

1. Assemble conrod (→ Page 310).
2. Before measuring, rub down basic bore (2) with
emery cloth.
3. Adjust bore gauge (1) and measure main conrod
bore (→ Page 306).
4. If values are exceeded, replace conrod.
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Measuring conrod main bore with bearing shells

1. Coat sliding surfaces of bearing shells with
engine oil.
2. Measure conrod bearing bore. Values
(→ Page 306).
3. Enter measured values in data sheet.
4. Replace bearing shells if limit values are fallen
short of or exceeded.
5. Remove conrod screws, conrod cap and bearing
shells.
Measuring conrod bush from piston pin end
cardiagn.com
1. Set bore gauge (1) to zero dimension of conrod
bushing bore and measure conrod bush bore (2).
Values (→ Page 306).
2. Values exceeded: Replace conrod bush only in
Checking conrod bush axial fit

1. Use test mandrel (1) and hydraulic press to
check conrod bush axial fit. Required test force F
(→ Page 306).
2. If test force is not reached, replace conrod.
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Checking conrod bore axial parallelism and twist
1 Dial gauge for axial parallelism

2 Test mandrel, small conrod bore
cardiagn.com
3 Dial gauge for conrod twist
4 Conrod
5 Test mandrel, large conrod bore
6 V-block
7 Base plate
8 Resilient stop
9 Adjustable dial gauge holder
1. Before inspection, install conrod bearing cap and

tighten conrod bearing screws.
2. Insert test mandrel (2) in large conrod bore so that
wide fit of test mandrel (arrow) faces conrod shaft
and narrow fit faces conrod bearing cap.
3. Clamp test mandrel (2) firmly with locking screw,
ensuring that test mandrel (2) does not tilt.
4. Insert test mandrel (1) in small conrod bore so that
and narrow fit faces oil bores of small conrod bore.
5. Clamp test mandrel (1) with locking screw.
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Checking axial parallelism

1. Insert conrod with test mandrel (3) in V-blocks
(4) of testing device.
2. Place test mandrel (2) on spring-mounted stop (5).
3. Adjust the rigid stop of adjustable stop so that
axle of test mandrel (2) is approx. 2.0 mm below
dial gauge pointer (1).
4. Adjust dial gauges so that their readings indicate
approx. 2 mm preload at highest point on test
mandrel axis, and set to zero.
5. Turn conrod through 180° and carefully place in
testing device.
6. Move test mandrel (2) through dial gauge pointers
at highest point on mandrel axis.
7. Determine and record deviations from zero on dial
gauges.
Checking axial twist
cardiagn.com
1. Set both dial gauges (1) for axial twist with setting
gauge (2) via dial gauge pointer to zero.
2. Remove setting gauge (2) from testing device (3).

(3) of testing device. Fixed support of adjustable
stop is set so that dial gauge pointer travel is
approx. 2 mm.
4. Press conrod at small conrod bore on fixed
support.
5. Read off and note values on dial gauges (1).
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Calculating axial parallelism

Note: The testing device is set for measuring
axial parallelism at 200 mm intervals.
1. In order to obtain the correct value to 100 mm

clearance (→ Page 306), calculate recorded value
on dial gauges as shown in the following example.
cardiagn.com
Description Value
Left dial gauge A = –0.05 mm
Right dial gauge B = +0.03 mm
Result = 0.08 mm
Result: Axial parallelism: 0.08 mm : 4 = 0.02 mm

2. Compare calculated value to (→ Page 306) .
3. If limit value is exceeded, replace conrod.
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Calculating axial twist

1. To determine axial twist of conrod bores, calculate
value measured at 100 mm intervals as shown in
example.
cardiagn.com
Description Value
Left dial gauge A1 = –0.06 mm
Right dial gauge A2 = +0.04 mm
Difference = 0.10 mm
Result: Axial twist A = 0.10 mm : 2 = 0.05 mm

TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

5.3.36 Conrod – Tolerances
Conrod bearings
cardiagn.com
Basic
size
1 Conrod bore 126.000 0 +0.025

H6
2 Conrod bearing 0-0 117.082 0 +0.048 0.082 0.152

bore
0-3 116.482
Crankpin Ø 0-0 117.000 h6 –0.022 0
0-1 116.800 h6
0-2 116.600 h6
0-3 116.400 h6
TIM ID: 0000004157 – 003
3 Crankpin length 97.500 −0.100 +0.100 0.200 0.600
Conrod width 48.600 −0.100 0
M020124/02E 2009-02 © MTU

Basic
size
4 Expanding 0-0 126.400 0 +1.000

dimension
lower part
0-3 126.400
Conrod screw length
No. Designation Stage Tol. size

Basic
Deviation
lower upper
Clearance
min. max.
Interference
min. max.
Wear limit cardiagn.com
size
1 Screw length 103.000 −0.400 +0.200 104.500

removed
TIM ID: 0000004157 – 003
M020124/02E 2009-02 © MTU

Conrod bore parallelism
cardiagn.com
Basic
size
1 Conrod length 354.000 −0.100 +0.100

8/12/16V
1 Conrod length 364.000 −0.100 +0.100

20V
2 Axial parallelism 0.070 over a distance of 100 mm Inclination

Inclination max. 0.100
3 Axial parallelism 0.250 over a distance of 100 mm Offset

Twist max. 0.350
Conrod weight 9.530 kg -0.060 +0.060

8/12/16V kg kg
Conrod weight 20V 9.580 kg -0.060 +0.060

kg kg
TIM ID: 0000004157 – 003
M020124/02E 2009-02 © MTU

Small conrod bore
cardiagn.com
Basic
size
1 Conrod bore 0 75.000 H6 0 +0.019 0.101 +0.139
1 75.200 H6
2 75.400 H6
Conrod bushing 0 75.000 v6 +0.120 +0.139

outer dia.
1 75.200 v6
2 75.400 v6
2 Conrod bushing 68.000 +0.070 +0.080

inner dia.
F Axial test force for 8/12/16V conrod: 17,000 N (tested conrod bushings are marked "X")
F Axial test force for 20V conrod: 30,000 N (tested conrod bushings are marked "X")
A Edges rounded
TIM ID: 0000004157 – 003
M020124/02E 2009-02 © MTU

5.3.37 Conrod – Assembly
Special tools

Socket, WAF 22 – conrod screws F30378352 1
Compressed air.
Risk of injury!
Preparing conrod
cardiagn.com
1. Blow out mating faces (arrowed) on conrod and
conrod bearing cap with compressed air and clean.
2. Wipe bearing shell mating faces on conrod and
conrod bearing cap.
3. Prior to installing bearing shells (1), compare

repair stage marking on connecting rod and in
crankshaft data sheet.
4. Mark bearing shells according to cylinder number
on front face (A). TIM ID: 0000000962 – 003
M020124/02E 2009-02 © MTU

5. Clamp conrod in assembly dolly or in bench

vise with aluminum jaws with mating face in
horizontal position.
6. Place lower conrod bearing (grooved bearing) (2)
in conrod bearing cap so that bearing shell recess
engages in locating pin.
7. Place upper conrod bearing (sputtered bearing) (1)
in conrod so that conrod bearing projects approx.
40° (arrowed) over short conrod arm.
8. Carefully press conrod bearing cap by hand
onto conrod.
9. Pay attention to locating pin and correct location of
bearing shell.
10. Coat threads of conrod bearing screw head
mating face and screw head seating surfaces
with engine oil.
Note: Thread must not be recut.
cardiagn.com
11. Carefully insert conrod bearing screw into bore in
conrod bearing cap by hand until initial contact
with thread flanks is established, then turn first
three turns without a tool.
12. Install conrod bearing screws until screw heads
make contact and use socket wrench to tighten
firmly by hand. Ensure that conrod and conrod cap
serrations is closed at short and long conrod arms.
13. Use torque wrench (1) to tighten conrod bearing
screws to specified tightening torque (→ Page 80).
TIM ID: 0000000962 – 003
M020124/02E 2009-02 © MTU

5.3.38 Piston – Assembly
Special tools

Heavy object.
Risk of crushing!

Risk of injury!
Installing piston rings

1. Turn coiled spring expander (2) in oil control ring
(1) in order to offset ring spring butting face (arrow)
cardiagn.com
to oil control ring butt by 180°.
2. Prepare piston rings as per installation sequence.

Note that new piston rings must be replaced in
sets.
3. After replacing piston rings, replace cylinder
liners (→ Page 134).
TIM ID: 0000000945 – 005
1 Rectangular-section ring
2 Taper-face compression ring
3 Oil control ring
M020124/02E 2009-02 © MTU

4. Stretch piston rings with pliers so that they can be

fitted over the piston.
5. Insert piston rings in sequence from bottom
upwards (oil control ring first) in the annular
grooves on the piston so that the TOP marking on
the piston rings faces the piston crown.
6. Check that piston rings move freely in their
grooves.
7. Wipe down piston pin, conrod bushing and piston
cardiagn.com
pin bore with chamois leather and coat with
engine oil.
8. Insert conrod (1) according to markings into
relevant piston (2) in such a way that the shorter
end (A) of the angle-split conrod faces piston
cooling oil bore (B).
9. Insert corresponding piston pin (2) in piston and

conrod (1) until it makes contact with installed
snap ring.
TIM ID: 0000000945 – 005
M020124/02E 2009-02 © MTU

10. Use snap ring pliers to insert second snap ring.

11. Ensure snap ring is perfectly seated and correctly
positioned (arrow).
cardiagn.com
TIM ID: 0000000945 – 005
M020124/02E 2009-02 © MTU

5.3.39 Piston and conrod – Installation
Special tools

Assembly jig F6553635 1
Lifting device for pistons, 8V-16V T80091025 1
Lifting device, 20V T80091496 1
Assembly sleeves F6557121 1
Socket, 22 A/F F30378352 1
Barring tool F6555791 1
cardiagn.com
Material

Engine oil
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Compressed air.
Risk of injury!
Assemble piston (→ Page 312).

TIM ID: 0000000948 – 007
M020124/02E 2009-02 © MTU

Preparing crankcase in assembly dolly

1. Rotate crankcase in assembly dolly until cylinder
liner (arrow) is vertical.
2. Turn crankpin of crankshaft of piston to be installed
and connecting rod to assembly position.
3. Wipe crankpin and running surface of cylinder
liner and spray with engine oil.
Preparing piston for installation
cardiagn.com
1. Spray the piston and piston rings with engine oil.
2. Ensure that piston rings (arrow) are evenly fitted at
120° around piston circumference.
3. Center piston rings and oil control ring in grooves.
Preparing conrod bearing for installation

1. Blow out interfaces (arrows) on connecting rod and
conrod bearing cap with compressed air and check
that they are clean.
2. Wipe bearing shell mating faces on connecting
rod and conrod cap.
TIM ID: 0000000948 – 007
M020124/02E 2009-02 © MTU

3. Fit bearing half shell of conrod bearing cap

(grooved bearing) in assembly device (1) so that
the recess (3) of the conrod bearing engages in
the locating pin (2) of the device.
4. Coat running surface of bearing shell with engine
oil.
5. Press assembly device (arrow) with bearing shell
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half by hand onto crankshaft crankpin.
6. Coat running surface of bearing half shell for

conrod (sputtered bearing) with engine oil.
7. Position bearing shell half (1) according to recess
for locating pin on crankpin (2) so that the two
recesses are aligned.
TIM ID: 0000000948 – 007
M020124/02E 2009-02 © MTU

Note: In order to guide the conrod and avoid damage

to the oil spray nozzle, piston installation must
be carried out by two people. Install piston
without carbon scraper ring.
Installing piston and conrod in cylinder liner

1. Attach lifting appliance (1) for piston (2).
2. Place piston assembly sleeve (3) with chamfered
side up on cylinder liner (4).
3. Oil assembly sleeve and cylinder liner inside.
4. Install piston into cylinder liner so that short arm
of conrod points outwards to air intake side.
Turn piston slightly so that oil spray nozzle is
not damaged.
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5. Place conrod on assembly device (2) for conrod
bearing.
6. Position assembly device with guide pin (1).
7. Remove assembly device and press conrod cap
by hand onto conrod. Pay attention to fit of locating
pin in recess in conrod cap.
TIM ID: 0000000948 – 007
M020124/02E 2009-02 © MTU

Installing conrod bearing cover

1. Coat thread and underside of screw head with
engine oil.
2. Insert conrod bearing screws (arrow) into screw
bore on conrod cap by hand, then turn first three
rotations without a tool.
3. Fit conrod bearing screws (arrow) up to screw head
and tighten firmly by hand using socket wrench,
ensuring that conrod serrations are closed.
4. Use torque wrench to pretighten conrod screws to
5. Check that conrod has axial play.
6. Use torque wrench to tighten conrod screws to
7. Check axial clearance of conrod.
8. Remove lifting device and assembly sleeve for
piston with conrod.
9. Bar crankshaft and ensure that there is ease of
movement between oil spray nozzle, piston
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and conrod.
Installing piston with connecting rod with oil pan

installed
2. Before installing piston and conrod, fit sliding block
(2) on conrod to be installed.
3. Further installation procedure with oil pan removed
(previous sections).
4. After installation, remove barring tool.
5. Install inspection port cover on left and right side of
TIM ID: 0000000948 – 007
M020124/02E 2009-02 © MTU

Checking conrod axial clearance in assembly dolly

1. Use feeler gauge to check distance between
crankshaft web and conrod or between conrod and
conrod, pressed towards each other.
2. If axial clearance is below the minimum of min. =
0.20 mm or above the maximum of max. = 0.60
mm, measure pressed at three levels, readjust
clearance.
3. Release conrod screws and compensate axial
clearance.
4. First tighten conrod cap screw on short conrod arm
and then on long conrod arm with torque wrench to
specified pretightening torque (→ Page 80).
5. Again check axial clearance.
6. Use torque wrench to tighten conrod bearing
screws to specified tightening torque (→ Page 80).
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1. Spray edge of cylinder liner and carbon scraper
ring with engine oil.
2. Insert carbon scraper ring.
Setting TDC indicator

1. Install pointer (1) on equipment carrier.
2. Install index plate (2) on crankshaft, free end, set
to TDC marking of A1 and tighten.
3. Set piston A1 to firing TDC.
TIM ID: 0000000948 – 007
M020124/02E 2009-02 © MTU

4. Install dial gauge (2) under preload in measuring

device (4) and clamp with screw (1).
5. Install measuring device into cylinder head and
secure with knurled-head screw (3).
6. Set dial gauge to zero.
7. Move piston several times up and down through
TDC until needle of dial gauge registers its highest
reading.
8. Set dial gauge to zero and readjust timing disc
accordingly.
9. Bar crankshaft in normal engine direction of
rotation to 5° before TDC, read dial gauge and
make a note of measured value.
10. Bar crankshaft past TDC to approx. 10° (to
take up bearing play).
11. Bar crankshaft against normal direction of engine
rotation to 5° after TDC, read dial gauge and make
a note of measured value.
12. Calculate mean value.
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13. Bar crankshaft to approx. 10° after TDC, then bar
in direction opposite to normal direction of rotation
until dial gauge shows calculated mean value.
14. Set pointer of timing disc to 5° after TDC and
tighten.
15. Rotate crankshaft to approx. 10° before TDC.
16. Repeat working steps 9 to 11 until measured
values at same degree figure are identical.
Result: Absolute TDC reached.
TIM ID: 0000000948 – 007
M020124/02E 2009-02 © MTU

5.4 Cylinder Head
5.4.1 Cylinder head and attachments – Overview
Cylinder head and attachments – Overview
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1 Cylinder head 6 Spring retainer
2 Inlet valve 7 Valve collet
3 Exhaust valve 8 Valve rotator
4 Valve spring, inner 10 Plug screw
5 Valve spring, outer 11 Sealing ring
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M020124/02E 2009-02 © MTU

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2 Valve-seat insert, inlet * 6 Valve guide 11 Cylinder head
3 Valve-seat insert, exhaust * 7 Plug * Only on cylinder heads of
4 O-ring 8 Plug corresponding design
5 Sleeve 9 Plug
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M020124/02E 2009-02 © MTU

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1 Sealing ring 3 Cylinder head screw 5 Cylinder head screw
2 Gasket 4 Thrust washer
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M020124/02E 2009-02 © MTU

5.4.2 Valve-seat turning machine for cylinder head
Working principle of valve-seat turning machine
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The valve-seat turning machine is an inside turning device. While the cutter (3) rotates around the valve-seat
(5), a feed gear mechanism ensures a continuous outward feed motion (1). The feed motion under the proper
valve-seat angle (4) is defined by an inclined slideway in the exchangeable adapter head.
TIM ID: 0000004274 – 002
M020124/02E 2009-02 © MTU

Installing the solid pilot
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Precondition:
Valve guide is installed and machined to finished dimension.
Valve guide was cleaned.
Cylinder head is securely clamped and valve guide accessible from both sides.
Mounting the supporting spider

To achieve maximum accuracy, the pilot must be supported by the supporting spider (7) below the valve seat. Slide
the supporting spider (7) over the pilot shaft to such position that the spring-loaded spider elements (1) rest just
below the valve seat level when the pilot is installed in the valve guide (4) and tighten the clamping screw (6).
Inserting the pilot into the valve guide
Remove clamping nut (3) from pilot and insert the threaded end of the pilot into the valve guide (4), until
the tapered portion (5) bears against the conical seating of the valve guide (4). The spring-loaded elements
TIM ID: 0000004274 – 002
(1) of the spider (7) will bear against the exhaust/inlet canal below the valve seat.
Locking the pilot
Screw clamping nut (3) onto the pilot and tighten with moderate force. Tighten the screws (6) on
top of the spider to lock the spring-loaded elements (1) of the spider (7). Apply standard machine
oil to the top and around the periphery of the pilot shaft.
M020124/02E 2009-02 © MTU

Setting up valve turning machine
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Mounting the cutter
Fit the appropriate tool holder of the cutter (8) with an indexable insert and attach to the tool slide (7).
Placing the valve-turning machine on the pilot
Take care that the cutter (8) does not bump against the cylinder head.
Slide the valve-seat cutting machine over the pilot (10) until either the depth stop (3) rests upon
the pilot (10) or the cutter (8) contacts the cylinder head.
Aligning the cutting edge with the valve-seat center
Turn rapid tool adjuster (11) to position cutting edge of cutter over the valve-seat center (9). Hold
the machine with one hand. Loosen screw (4) of depth stop (3) and allow machine to slide down
until the cutting edge contacts the valve seat (9) lightly. Push depth stop (3) slightly downward
against the pilot (10) and then tighten depth stop locking screw (4).
Connecting the machine to power supply
Insert the round plug of the outlet cable (6) of the power supply unit (5) into the corresponding socket
(1) on the driving assembly (2) and allow the securing latch to engage.
TIM ID: 0000004274 – 002
M020124/02E 2009-02 © MTU

Valve seat turning
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Positioning the cutter at the inner valve-seat edge
Slightly lift machine with one hand and then turn rapid tool adapter (11) with the other hand until the
cutting edge is just clear of the inner edge of the valve seat (10).
Setting cutting depth
To set the depth of cut, turn depth feed (3) counterclockwise. One notch of the depth-feed scale (4) corresponds
to a depth feed of 0.025 mm. As the valve seat (10) usually shows unequal wear, the depth of the first turning
cycle must be selected (max. 0.2 mm) to ensure that the entire valve-seat surface is undercut.
If the cutting edge is just scraping along the surface instead of undercutting the hard surface zone,
there is a risk of premature wear and chipping of the cutting edge.
Lubricating the valve seat
Apply a few drops of metalworking lubricant on hard valve-seat surfaces before turning.
Valve seat turning
Make sure that the pivoted lever (8) is engaged in the groove of the feed actuator (12). Select proper speed by
shifting the switch (6) at the power supply unit (5). Speed can be increased by changing over from 30 VDC to 42 VDC.
TIM ID: 0000004274 – 002
Hold driving unit (2) with both hands at the motors (1) and press pushbutton switch (7) to start the cutting pass.
Release the pushbutton switch (7) as soon as the cutter has been traversed beyond the top edge of the valve seat (10).
Repeating the cutting pass
Repeat steps with a cutting depth between 0.05 mm and 0.1 mm until the valve seat surface (10) is plane all around.
To ensure a smooth valve-seat surface (10) finish, proceed with a final pass at high speed with 0.025 mm cutting depth.
M020124/02E 2009-02 © MTU

Replacing the adapter head
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Removing the adapter head
Unscrew the two screws (1) from the adapter head (2).
Turn adapter head (2) in the direction of the arrow until the back of the toothed rack (4) is no longer engaged with
the pinion (4) in the gear housing (6). Now the adapter head can be withdrawn off the gear housing (6).
Mounting the adapter head
Place adapter head (2) onto gear housing (6) so that the pinion (5) projecting from the gear housing (6)
is seated in the corresponding bore of the adapter head (2).
The adapter head (2) must be seated flush with the gear housing (6).
Screw the two screws (1) loosely into the gear housing so that the adapter head (2) can still be moved
to adjust proper clearance between toothed rack (4) and pinion.
Adjust the adapter head so that the gap between the toothed side of the rack (4) and the opposite side of
the recess (3) is approximately 0.3 mm to 0.5 mm. Tighten both screws (1).
Turn the rapid tool adjuster to move the tool slide back and forth. If tool slide does not
move freely, readjust the adapter head.
TIM ID: 0000004274 – 002
M020124/02E 2009-02 © MTU

5.4.3 Cylinder head – Removal
Preconditions
Special tools

Removal tool F6553658 1
Plug B80144872 1
Installation/removal tool for plugs F30378956 1

Risk of injury!
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Heavy object.
Risk of crushing!
TIM ID: 0000005023 – 010
M020124/02E 2009-02 © MTU

Cylinder head – Removal

1. Release hex bolts (1) on the cylinder head with
power amplifier (2) evenly and unscrew.
2. Screw plug (2) on to installation/removal tool and
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lock it by turning the handle (1).
3. Screw plugs with installation/removal tool (1) into

oil supply line (arrow) in crankcase and spread.
4. Ensure that the plug is firmly anchored.
5. Release installation/removal tool (1) and remove.
TIM ID: 0000005023 – 010
M020124/02E 2009-02 © MTU

6. Suspend cylinder head (2) with support bracket (1)

on crane with rope lightly tensioned.
7. Lift off cylinder head (2) and lower onto a firm
surface.
8. Remove cylinder head gasket from mating face
of crankcase.
9. Remove plug from oil supply bore and close
with protective plug.
10. Use a screwdriver to remove sealing ring from
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lower side of cylinder head.
11. Seal openings with suitable plugs.
TIM ID: 0000005023 – 010
M020124/02E 2009-02 © MTU

5.4.4 Cylinder head – Disassembly
Special tools

Valve spring compressor F6783833 1
Socket F30377634 1
Heavy object.
Risk of crushing!

Risk of injury!
Spring/circlip/tensioning roller preload.

Risk of injury!
WARNING
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• Only use specified tool and equipment.
Removing valves
1. Place cylinder head on base plate (3).
2. Mount valve-spring compressor (2).
3. Screw in spindle (1) and compress valve springs
with valve-spring compressor (2) until the valve
collets (4) can be removed.
4. Remove valve collets (4) with a magnet.
5. Release valve springs and remove valve-spring
compressor (2).
TIM ID: 0000000987 – 005
M020124/02E 2009-02 © MTU

6. Remove valve spring retainer, valve springs

and valve rotators.
7. Lay cylinder head on its side.
8. Mark exhaust and inlet valves so that they can be
reinstalled in their original positions.
9. Place valves in storage rack (1).
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Removing sleeve
1. Secure cylinder head.
2. Using socket, remove sleeve from cylinder head.
3. Remove O-ring from sleeve.
TIM ID: 0000000987 – 005
M020124/02E 2009-02 © MTU

5.4.5 Cylinder head – Cleaning
Material

Cleaning agent (Snow-White 11-0) 40460
Cleaning agent (Hakupur 312) 30390
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!
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Risk of injury!


Cleaning the cylinder head

TIM ID: 0000000979 – 006
M020124/02E 2009-02 © MTU

5.4.6 Cylinder head – Check
Special tools

Alignment plug gauge, 11.00 mm H7 Y20090113 1
Check gauge for inlet valve seat Y4340442 1
Check gauge for exhaust valve seat Y4340443 1
Removal tool Y4343688 1
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Material

Corrosion inhibitor
Spare parts

Cylinder head
Sealing ring
Gasket
Cylinder head screws
Thrust washer
Valve guides
Valves
Sleeve
Valve springs
Sliding pin
Valve rotator
Spring retainer
TIM ID: 0000004276 – 008
Valve collet
Compressed air.
Risk of injury!
M020124/02E 2009-02 © MTU

Heavy object.
Risk of crushing!
Test liquid is hot and pressurized.

Risk of injury and scalding!
WARNING • Wear protective clothing, gloves, and goggles / safety mask.
Cylinder head check
Item Findings Task
Measure cylinder head height. Minimum height not reached Replace cylinder head.
Check cylinder head mating face Damaged • Recondition

(combustion chamber side) for • Replace cylinder head.
evenness and damage.
Check mating face of sleeve in • Scores • Recondition

cylinder head for scores and wear. • signs of wear • Replace cylinder head.
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visible.
Measure valve guides with alignment Not dimensionally accurate Replace valve guides.
plug gauge. Values (→ Page 339)
Check valve springs for damage. • Damaged Replace valve springs

Check spring power and length of • Values below specification
valve springs. Values (→ Page 339)
Check thread for ease of movement. Sluggish • Recondition

• Replace cylinder head.
Check valve seats on cylinder head Pitting or wear • Recondition: (→ Page 325)
for pitting and wear. • Replace cylinder head.
Check cylinder head screw threads, Damaged Replace

screw head mating faces and thrust
washer for damage.
Measure shaft length of the cylinder Values exceeded (→ Page 339). Replace
head screws with depth gauge.
Check valves for damage. • Chrome layer damaged Replace

Check valves for concentricity and • Valve keyways damaged or
dimensional accuracy. Values burnt
(→ Page 339) • Out-of-round
Check spring retainer and valve • Scores Replace

collet for scores and wear. • signs of wear
visible.
Replace valve guides and valve rotators during extended component repair.
Only for cylinder heads with valve bridge guides.

TIM ID: 0000004276 – 008
Check sliding pin and valve bridge • Signs of wear Replace sliding pin.
bore for wear and damage. Values • Damage visible
(→ Page 339) • Not dimensionally accurate
M020124/02E 2009-02 © MTU

Checking cylinder head for leaks

Note: Install sleeve prior to leak test (→ Page 359).
1. Prepare water for water bath with corrosion inhibitor.

2. Install pressure testing device.
3. Place cylinder head in a water bath heated to 80 °C until cylinder head has warmed up.
4. Pressure-test cylinder head with 0.5 bar compressed air.
5. Pressure must be maintained with cylinder head in water bath for at least 30 minutes. No air bubbles must
emerge.
6. Remove hydraulic pressure testing device.
7. Replace leaking sealing cover (→ Page 357).
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TIM ID: 0000004276 – 008
M020124/02E 2009-02 © MTU

5.4.7 Cylinder head – Tolerances
Cylinder head tolerances for heads with valve seat inserts and
exhaust emission certification
Inlet and exhaust valve guides
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Basic
size
1 Cylinder head 0 19.000 H7 0 +0.021 +0.007 +0.041

bore
1 19.100 H7
2 19.300 H7
Valve guide 0 19.000 r6 +0.028 +0.041

external
diameter 1 19.100r6
2 19.300 r6
2 Valve guide bore 11.000 H7 0 +0.018 0.055 0.093

installed
TIM ID: 0000004159 – 006
Valve stem 10.935 −0.010 +0.010

diameter
M020124/02E 2009-02 © MTU

Basic
size
2 Finished valve 11.000 H9 0 +0.043 0.055 0.118

guide bore
installed
Valve stem 10.935 −0.010 +0.010

diameter
Valve clearance
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Basic
size
1 Valve protrusion +0.100 up to max.

Exhaust 1.000
with valve seat
ring
2 Valve clearance 0.000 up to max.

or protrusion 1.100
TIM ID: 0000004159 – 006
Inlet
M020124/02E 2009-02 © MTU

Inlet and exhaust valve seat ring
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Basic
size
1 Valve seat ring 57.000 H6 0 +0.019

bore, exhaust
2 Valve-seat insert 11.200 −0.050 +0.050

- depth
3 Valve-seat insert 58.000 H6 0 +0.019

bore, inlet
Reconditioning note:
• If a valve-seat insert is replaced before reaching the reconditioning depth of 1.100 mm, it must be machined
to the depth of the contour to avoid that the valve-seat insert protrudes into the combustion chamber.
• Max. corrective machining or equalizing of valve-seat inserts by 0.300 mm in depth, without machining the
contour and the radius.
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Inlet and exhaust valve-seat insert
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Basic
size
1 Plug gauge 73.200 0 0

diameter
2 Plug gauge 87.130 0 0

diameter
3 Valve seat 4.800 −0.200 +0.200 up to min.

surface 3.700
Reference
dimension
Plug gauge
4 Cylinder head 13.800 0 +0.100

depth
Combustion
chamber sealing
ring surface
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Inlet valve elliptical chamfer
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Basic
size
1 Distance to valve 2.700 −0.150 +0.150

seat center
2 Chamfer −0.300
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Exhaust valve
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Basic
size
1 Valve head 56.000 −0.200 +0.200

external
diameter
2 Reference 54.000
dimension
with ring gauge
for
valve seat
diameter
Valve seat height 4.680 −0.200 +0.100 up to min.

3.480
3 Reference 3.700 −0.200 +0.100 up to min.

dimension 3.000
without ring
gauge for
valve seat height
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Inlet valve
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Basic
size
1 Valve head 57.000 −0.200 +0.200

external
diameter
2 Reference 54.000
dimension
with ring gauge
for
valve seat
diameter

3.350

dimension 3.000
without ring
gauge for
valve seat height
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Valve springs, outer
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Basic
size
1 Spring length 83.900

released

compressed
Spring length 65.100

when mod. valve
rotator is used
2.1 Spring force 530.000 N

at compressed
spring length

compressed

when mod. valve
rotator is used
TIM ID: 0000004159 – 006
3.1 Spring force at 952.000 N −39 N +39 N Spring

spring length force
pos. 3 min. 897.000 N
4 Spring length 47.700 Block

Block dimension dimension
max. 47.700
M020124/02E 2009-02 © MTU

Basic
size
5 Winding dia. 34.400
6 Wire dia. 5.300
e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.500
e2 Spring seat, permissible parallelism deviation max. 0.600
Valve springs, inner

Basic
size
Deviation
lower upper
Clearance
min. max.
Interference
min. max.
Wear limit
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released

compressed
TIM ID: 0000004159 – 006

when mod. valve
rotator is used

at compressed
spring length
M020124/02E 2009-02 © MTU

Basic
size

compressed

when mod. valve
rotator is used

spring length force
pos. 3 min. 420.000 N

max. 42.500
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6 Wire dia. 3.600
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Cylinder head – mating surface – protective sleeve
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Basic
size
1 Cylinder head 184.000 −0.100 +0.100 183.600

height
2 Protective sleeve 124.000 0 +0.200

mating surface
3 Protective sleeve 44.200 0 +0.100 0.100 0.300

bore
Protective sleeve 44.100 −0.100 0

external
diameter
4 Cylinder head M 24 x 1.5

and protective
sleeve thread
• Rework only until a satisfactory mating surface has been achieved.
• When reconditioning cylinder head height, reestablish the fire side contour of 13.800 +0.100.
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

cardiagn.com
Basic
size
1 Cylinder head 333.000 −0.300 +0.300

screw with
engine lifting eye
2 Cylinder head 283.000 −0.300 +0.300

screw
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

5.4.8 Cylinder head – Repair
Special tools

Tool kit without elliptical chamfer reconditioning F6783749 1
Tool kit (accessory equipment) for elliptical chamfer reconditioning F6783751 1
Tool kit for valve-seat insert removal F6784421 1
Indexable insert F30450433 1
Mounting plate for valve guide installation F6554300 1
Valve guide extractor F30450348 1
Valve guide mandrel F6781747 1
Reamer, Ø19.00 mm for stage 0 cylinder head bore F30091631 1
Reamer, Ø19.10 mm for stage I cylinder head bore F30047578 1
Reamer, Ø19.30 mm for stage II cylinder head bore F30028269 1
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Valve seat contour restoring tool for exhaust valve with valve-seat insert F30450631 1
Valve seat contour restoring tool for inlet valve with elliptical chamfer and F30450632 1
with/without valve-seat insert
Turning handle for valve seat contour restoring tool 8205890451/00 1
Exhaust valve gauge Y4340443 1
Inlet valve gauge Y4340442 1
Valve seat test device Y4341935 1
Countersink reamer tool F30451554 1
Inserting mandrel for valve-seat insert, inlet F30450751 1
Inserting mandrel for valve-seat insert, exhaust F30450750 1
Material

Liquid nitrogen
Corrosion inhibitor
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

Spare parts

Valve guide, inlet
Valve guide, exhaust

Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
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Removing the valve-seat insert

1. Clean valve guide using a hole brush.
2. Insert pilot into valve guide of cylinder head
(3) and secure.
3. Install head (2) and lathe tool on valve seat
lathe (1).
4. Position valve seat lathe (1) on pilot and install
steady rest.
5. Setup valve seat lathe (1) (→ Page 325).
6. Machine valve-seat insert so that the seat insert
extractor can be installed.
7. Remove steady rest, valve seat lathe (1) and pilot.
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

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

insert to be removed (2).
9. Using seat insert extractor (1), remove valve-seat
insert (2).
10. Check bore of valve-seat insert (1) in cylinder
head. Values (→ Page 339).
Result: Replace cylinder head if the value
is exceeded.
Removing the valve guide
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1. Place cylinder head on hydraulic press. Ensure
correct positioning of the cylinder head side.
2. Using the extractor and working from the
combustion side, press valve guide out of cylinder
head.
3. Check valve guide bore in cylinder head. Values
(→ Page 339).
Result: If the value is exceeded, recondition
bore to next stage.
4. Secure cylinder head on boring mill.
5. Ream valve guide bore in cylinder head.
Installing the valve guide

1. Prepare water for water bath with corrosion
inhibitor.
2. Place cylinder head (4) in water bath heated to
80°C until cylinder head (4) has warmed up.
3. Chill valve guide (2) in liquid nitrogen for approx.
20 to 30 mins.
4. Position heated cylinder head (4) on assembly
jig (3).
5. Using mandrel (1), position chilled valve guide
(2) in bore of cylinder head (4) until the stop of
assembly jig (3) is reached.
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

Installing the valve-seat insert

2. Place cylinder head in water bath heated to 80 °C until cylinder head has warmed up.
3. Chill valve-seat insert in liquid nitrogen for approx. 20 to 30 mins.
4. Position heated cylinder head on suitable surface.
5. Using the inserting mandrel, install chilled valve-seat insert into the cylinder head bore until the stop is reached.
Machining the valve seat surface

2. Insert pilot (3) and support (2) into valve guide of
cylinder head (1) and secure.
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3. Install suitable head (2) and lathe tool to valve
seat lathe (1).
steady rest.
Note: Note recondition dimension, required when
machining elliptical chamfer.
6. Only recondition valve seat surface until a

satisfactory surface has been established. Values
(→ Page 339).
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

8. Recondition valve seat surface (2) with associated

valve seat contour restoring tool (1).
9. Clean cylinder head after machining.
Checking valve seat concentricity
cardiagn.com
1. Insert pilot into valve guide.
2. Mount clamp ring (2) over inserted pilot and
secure.
3. Mount the tester (1) on clamp ring.
4. Set preloaded feeler of tester on valve seat
center (arrowed).
5. Check concentricity of valve seat in relation to
valve guide, values (→ Page 339).
Result: In event of deviation from test values,
recondition valve seat again.
6. Remove tester (1), clamp ring (2) and pilot.
Measuring valve seat depth

1. Adjust distance from plug gauge to ring gauge.
2. Set scale on dial gauge to zero.
3. Measure valve seat depth. Values (→ Page 339).
is exceeded.
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

Regrinding valve seats

1. Mount valve (1) as directly as possible behind
valve head in valve grinder (2).
2. Set valve seat grinding angle on valve seat grinder.
3. Using low feed, grind valve seat only until a
satisfactory surface is achieved.
4. Measure height of outer valve seat edge as well as
valve seat width. Value (→ Page 339).
Result: If the value is not reached, replace valve.
Reconditioning elliptical chamfer (if required)
cardiagn.com
1. Insert pilot (3) for elliptical chamfer (2) into valve
guide.
2. Mount tester (1) over inserted pilot (3) and secure.
3. Set preloaded tester pointer (1) to elliptical
chamfer (2).
4. Align pilot (3) and elliptical chamfer (2) using
tester (1).
5. Secure pilot (3).
6. Remove tester (1).
7. Install suitable head and lathe tool to valve seat
lathe.
8. Position valve seat lathe on pilot and install
steady rest.
9. Set up valve seat lathe (→ Page 325).
Note: Use recondition dimension as for
machining valve seat surface.
10. Only recondition elliptical chamfer (2) until a

satisfactory surface has been achieved.
11. Check elliptical chamfer (2). Value (→ Page 339).
is exceeded.
Reconditioning the protective sleeve mating face.

1. Install countersink reamer tool in bore for protective sleeve.
2. Recondition seating surface for protective sleeve with countersink reamer tool. Value (→ Page 339).
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

5.4.9 Cylinder head – Plug repair
Special tools

Mandrel, Ø 20 mm F30378617 1
Guide sleeve for mandrel F30377862 1
Mandrel, Ø 24 mm F30271842 1
Mandrel, Ø 30 mm F30377635 1
Material

cardiagn.com
Cleaner (Loctite 7063) 50594 1
Spare parts

Plug
Plug
Plug
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!

Risk of injury!

TIM ID: 0000004275 – 004
M020124/02E 2009-02 © MTU

Replacing plug
Note: Replace plug only if required.

2. Use pliers to withdraw end cover, taking care that
end cover does not fall into the bore.
3. Clean coolant chambers with cleaner
(Snow-White 11-0), then rinse with cleaner
(Hakupur 312).
4. Blow out coolant chambers with compressed air.
5. Clean mating surface of new plug and cylinder
head bore ensuring they are free of grease and dry.
6. Coat mating surface with screw locking compound.
7. Using a mandrel, knock plug into the cylinder
cardiagn.com
head bore until flush.
8. Check cylinder head for leaks (→ Page 336).
TIM ID: 0000004275 – 004
M020124/02E 2009-02 © MTU

5.4.10 Cylinder head – Assembly
Special tools

Retainer 0015890321/00 1
Torque wrench 20-100 Nm F30026582 1
Socket F30377634 1
Material
cardiagn.com
Engine oil
Spare parts

O-ring
Sealing ring

Risk of injury!
WARNING • Only use specified tool and equipment.
Heavy object.
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

Installing sleeve
1. Clean sealing surface (arrow).
2. Coat O-ring (2) with grease and insert in groove
of sleeve (1).
3. Clamp cylinder head firmly.
cardiagn.com
4. Clean sealing surface of cylinder head.
5. Use torque wrench to tighten prepared sleeve
to specified tightening torque .

Sleeve Tightening torque 60 Nm +6 Nm
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

Installing valves
2. Wipe valves with chamois leather and coat valve
stems with engine oil.
3. Insert valves in valve guides. Observe correct
valve arrangement. Markings are on the end
of the valve stems.
IN Inlet
EX Exhaust
4. The markings and installation positions of the
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valves are located on the upper side of the
cylinder head.
IN 2 x inlet (1)
EX 2 x exhaust (2)
5. The marking is visible on the lower side of the

valve in the form of a countersink.
• Inlet (1) = Ø 20 mm
• Exhaust (2) = Ø max. 8 mm
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

6. Mount supporting plate for valve spring

compressor on cylinder head.
7. Set cylinder head upright.
8. Slide valve rotator on to valve guide.
9. Fit outer and inner valve springs.
10. Fit valve spring retainers.
11. Mount valve spring compressor (2).
cardiagn.com
with valve-spring compressor (2).
13. Insert valve collets (4) in spring retainer and center.
14. Make sure that lip of valve collet fits firmly in
groove at end of stem.
15. Release valve springs.
16. After installation of all valve collets, remove valve
spring compressor (2) and mounting plate (3).
17. Place cylinder head in installation position or on

its side.
18. Make sure valves move freely.
19. Using a plastic mallet, lightly tap the valve stem to
ensure that the valve collets contact the valve
stem.
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

Measuring valve clearance to cylinder head

1. Install dial gauge (2) on dial-gauge holder (1).
2. Set dial gauge (2) with preload on to plane face
of cylinder head (4).
3. Set dial gauge to 0.
4. Position dial-gauge stylus on valve head of
valves (3) and measure valve clearance to plane
surface.
5. If the reading is not within the tolerance
(→ Page 339), check valve seat at cylinder head
and valve head.
cardiagn.com
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

5.4.11 Cylinder head – Installation
Special tools

Carrying bracket T80090944 1
Installation/removal tool for seal plug F30378956 1
Seal plug B80144872 1
Tightening tool (power amplifier) F6553658 1
Alignment tool for 8V and 12V cylinder heads F6558582 1
Measuring tool for angle of rotation Y20044010 1
cardiagn.com
Material

Engine oil
Spare parts

Sealing ring
Gasket

Risk of injury!
Heavy object.
Risk of crushing!
TIM ID: 0000000994 – 010

M020124/02E 2009-02 © MTU

Cylinder head – Installation

1. Insert adjusting mandrels (2) in crankcase upper
deck.
2. Fit gasket (1).
3. Ovalize sealing ring by tapping it lightly.
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4. Insert sealing ring with groove on combustion
chamber side of cylinder head.
5. When installing sealing ring, ensure position

is correct:
• A = Cylinder head side
• B = Piston side
TIM ID: 0000000994 – 010
M020124/02E 2009-02 © MTU

6. Remove seal plug.

7. Attach cylinder head (2) with carrying bracket (1)
and rope to crane, ensuring that the rope is
8. Place cylinder head (2) onto crankcase.
9. Coat thread, shaft and mating surfaces on heads
cardiagn.com
of cylinder head screws (1) with engine oil.
10. Observe assignment of cylinder head screws (1)
(engine lifting eye). Install cylinder head screws (1)
with thrust washers manually in crankcase.
11. Fit alignment tool (2) on inlet channels of cylinder
heads and tighten.
12. Align cylinder heads.
TIM ID: 0000000994 – 010
M020124/02E 2009-02 © MTU

13. Use power amplifier and torque wrench to tighten

cylinder head screws to specified tightening torque
in accordance with the tightening sequence.
A Exhaust side
B Inlet side
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Cylinder head screw M22 x 2 Preload torque Engine oil 25 Nm
Cylinder head screw M22 x 2 Residual torque 180 Nm +10 Nm
Cylinder head screw M22 x 2 Residual angle of rotation 180 ° +10 °
Cylinder head screw M22 x 2 Control torque 400 Nm
14. Remove alignment tool.

TIM ID: 0000000994 – 010
M020124/02E 2009-02 © MTU

5.5 Valve Gear
5.5.1 Valve gear – Overview
Valve gear – Overview
cardiagn.com
1 Camshaft gear 7 Pushrod, exhaust 13 Rocker shaft support
2 Swing follower, inlet 8 Axle 14 Valve bridge, exhaust
3 Swing follower, exhaust 9 Rocker arm, inlet 15 Hex nut
4 Swing follower shaft 10 Hex nut 16 Adjusting screw
5 Camshaft 11 Adjusting screw 17 Valve bridge, inlet
6 Pushrod, inlet 12 Rocker arm, exhaust
TIM ID: 0000001001 – 002
M020124/02E 2009-02 © MTU

5.5.2 Camshaft overview
Overview of camshaft
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2 Spring washer 6 Thrust bearing flange
3 Graduated disc 7 Dowel pin
4 Camshaft gear 8 Camshaft
TIM ID: 0000001007 – 001
M020124/02E 2009-02 © MTU

5.5.3 Camshaft – Removal
Preconditions
Special tools

Camshaft locating device F6553642 1
Camshaft installation/removal tool F30450435 1
Guide sleeve for camshaft 8V-16V F6782970 1
Guide sleeve for camshaft 20V F6781673 1
Guide sleeve for assembly on driving end F6781676 1
Guide sleeve for assembly on free end F6780579 1
cardiagn.com
Centering sleeve for assembly on free end F6780582 1
Heavy object.
Risk of crushing!
Camshaft drive – Removal

1. Remove camshaft gear as shown in overview drawing (→ Page 369).
2. To protect the crankcase from falling objects, cover equipment carrier from below.
Removing camshaft thrust bearing

2. Remove thrust bearing flange (2).
3. Check thrust bearing flange (→ Page 395).
TIM ID: 0000001016 – 004
M020124/02E 2009-02 © MTU

Camshaft – Removal
1. Install inner guide sleeve (2) on face of camshaft,
free end.
2. Fasten guide flange (1) on crankcase.
3. Fasten outer guide sleeve (3) with screws (1) on
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crankcase (2), driving end.
4. Screw inner guide sleeve (4), driving end, on to
camshaft.
5. Center guide sleeve to camshaft bearings.
6. Mount installation/removal tool on camshaft (2).

7. Attach camshaft with rope in middle (1) to crane.
8. Tension rope slightly and carefully withdraw
camshaft (2) horizontally from crankcase.
9. Remove guide sleeve.
TIM ID: 0000001016 – 004
M020124/02E 2009-02 © MTU

5.5.4 Camshaft – Cleaning
Material


Camshaft – Cleaning
1. Clean all parts with cleaning agent.
cardiagn.com
TIM ID: 0000001010 – 002
M020124/02E 2009-02 © MTU

5.5.5 Camshaft running surfaces and swing followers – Visual inspection
Special tools

Spare parts

Camshaft
Roller tappet
Visually inspecting camshaft running surfaces

and swing followers
1. Remove valve drive (swing followers remain
installed) DM_110_WM_055050_520A.
cardiagn.com
2. Insert endoscope into crank drive through every
pushrod bore.
3. Visually check roller surface of cams, roller running
surfaces on the camshaft as well as swing
followers for damage and wear.
4. Replace swing follower if signs of corrosion are
visible, see illustrations (→Workshop Manual).
5. Replace camshaft if signs of corrosion are visible,
see illustrations (→ Page 387).
Install valve drive DM_110_WM_055050_720A.

TIM ID: 0000008370 – 005
M020124/02E 2009-02 © MTU

5.5.6 Camshaft – Check
Special tools

Hardness tester DynaMIC Y20506341 1
Measuring stand 0015890321/00 1
Material

cardiagn.com
Spare parts

Camshaft
Camshaft gear
Timing wheel
Hex screw
Spring washer
TIM ID: 0000001013 – 004
M020124/02E 2009-02 © MTU

Camshaft – Check
Item Findings Measure
Using magnetic crack-test Crack indication Replace camshaft.

procedure, check camshaft for
cracks.
Check axial bearing flange with red Crack indication Replace camshaft.
dye penetrant for cracks.
Check mating face of camshaft gear. Stress marks visible • Recondition: Smooth with
oilstone or emery cloth.
• Replace
Check axial sliding surface, journal • Scores Replace camshaft.

faces and roller tracks of cams • Stress marks
for scores, stress marks and • Indentations
indentations. visible
Check tooth flank of camshaft gear Damaged Replace camshaft gear.

with magnifying glass.
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Check screws for damage. Damaged Replace
Checking hardness of cam and journal

1. Use hardness tester to check cam hardness
(inlet/exhaust rocker arms) and journals. Required
hardness: 60 HRC ±2 HRC
3. Replace camshaft if values are fallen short of.
TIM ID: 0000001013 – 004
M020124/02E 2009-02 © MTU

Checking concentricity and cam lift

1. Set camshaft at outer journals on to V-blocks
(2) or roller stands.
2. Place supporting mount (3) on center journal.
3. Measure radial run-out of cam base circle and
bearings with dial gauge (1). Values (→ Page 377).
cardiagn.com
TIM ID: 0000001013 – 004
M020124/02E 2009-02 © MTU

5.5.7 Camshaft – Tolerances
Concentricity of bearings
cardiagn.com
Max. permissible deviation of New Wear limit
concentricity
During the concentricity check, provide supports for and align the following bearings.
• 8V: bearing 3 beginning at driving end
from bearing 1 to bearing 2 0.050
a from bearing to bearing 0.025
b all cams 0.010

0.010
TIM ID: 0000004158 – 001
M020124/02E 2009-02 © MTU

Axial clearance
cardiagn.com
Basic limit
size
1 Camshaft gear 32.000 H7 0 +0.025 0 0.050

bore
Camshaft outer 32.000 H7 –0.025 0

dia.
2 Axial clearance 0.100 0.178 TIM ID: 0000004158 – 001
M020124/02E 2009-02 © MTU

5.5.8 Camshaft – Installation
Special tools

Guide sleeve for installation/removal from driving end F6781676 1
Guide sleeve for installation/removal from free end F6780579 1
Centering sleeve for installation/removal from free end F6780582 1
Graduated disc, free end Y4341124 1
cardiagn.com
Feeler gauge Y20010128 1
Holder 0015890321/00 1
Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!
TIM ID: 0000001019 – 008
Check camshaft (→ Page 374).
M020124/02E 2009-02 © MTU

Camshaft – Installation
1. Attach outer guide sleeve (1) at driving end
of crankcase and center carefully to camshaft
bearings with inner guide sleeve (2).
2. Center guide flange (1) with guide sleeve (2) on
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crankcase (free end) with regard to camshaft
bearings and secure.
3. Mount inner guide sleeve (2) on front face of

camshaft (1) and tighten.
TIM ID: 0000001019 – 008
M020124/02E 2009-02 © MTU

4. Attach camshaft (arrow) with rope at center

to crane and wipe.
5. Spray camshaft, camshaft bearing, and guide
sleeve with engine oil.
6. Install sliding block at outermost cam on camshaft.
7. Carefully insert camshaft up to second-last
bearing.
8. Position assembly extension (1) on camshaft (2)
cardiagn.com
and insert camshaft up to last bearing.
9. Locate camshaft axially and/or ensure that it
cannot fall out until thrust bearing is installed.
10. Remove inner/outer guide sleeve and assembly
extension.
Installing camshaft thrust bearing

1. Coat axial sliding surfaces with engine oil.
2. Cover bottom of equipment carrier so that no
screws can fall into crankcase.
3. Tighten thrust bearing flange (1) with screws (2).
TIM ID: 0000001019 – 008
M020124/02E 2009-02 © MTU

Installing locating device

1. Turn camshaft until locating bore (arrow), driving
end, is visible and at position shown.
2. Position locating device (1) on securing plane of
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swing-follower shaft, driving end.
3. Insert dowel pin of guide tube (3) into camshaft
bore (2) and screw locating device into place
(arrows).
Installing timing wheel (camshaft gear)

2. Install graduated disc (1) with barring tool on
crankshaft. Set to TDC mark of A1 and tighten.
3. Set piston A1 to firing TDC (→ Page 315).
TIM ID: 0000001019 – 008
M020124/02E 2009-02 © MTU


objects can fall into crankcase.
5. Insert camshaft gear (1) into camshaft so that
dowel pins (3) engage in camshaft gear bore in
a vertical line.
6. Slide timing wheel (2) over dowel pins (3) and
install.
7. Screw in screws (4) with spring washers and
tighten (→ Page 80). Note position of holes of
dowel pins to screw bores.
Measuring backlash
cardiagn.com
1. Remove camshaft locating device.
on crankcase (free end).
3. Mount dial gauge stylus with low preload on one
tooth flank of camshaft gear.
5. Check backlash by moving camshaft gear back
and forth. Circumferential backlash (→ Page 199).
Measuring camshaft axial clearance

2. Fit dial gauge stylus on timing wheel.
3. Press camshaft on camshaft gear axially as
far as it will go.
4. Set dial gauge with preload to zero.
5. Move camshaft from stop to stop and record
measurement value (axial clearance). Axial
clearance (→ Page 377)
6. If axial clearance is out of tolerance, replace thrust
TIM ID: 0000001019 – 008
bearing (→ Page 394).
M020124/02E 2009-02 © MTU

Installing speed sensor

1. Coat O-ring with petroleum jelly.
2. Turn speed sensor (2) slightly to install in
crankcase fit.
3. Screw in screw (1) and tighten.
Checking speed sensor clearance
cardiagn.com
1. Pull camshaft on camshaft gear axially toward free
end (arrow) as far as it will go.
2. Measure distance (X) with feeler gauge (specified
value 0.3 mm to 1 mm).
3. If distance is less than 0.3 mm:
3.1. Fit appropriate number of adjusting shims of
0.3 mm thickness.
3.2. Measure distance.
Checking camshaft timing

1. Determine TDC position of piston in the following
way:
1.1. Install measuring device (2) with dial
gauge (1) at cylinder head A1.
1.2. Fit TDC mark (graduated disc) on crankshaft
journal, free end.
1.3. Install suitable TDC pointer on equipment
carrier or crankcase, driving end.
1.4. Using the barring tool, bar the engine until
the piston of cylinder A1 is in the firing TDC.
The piston is at firing TDC when both rocker
TIM ID: 0000001019 – 008
arms are unloaded, i.e. have clearance.

2. Move piston up and down several times and then
position so that pointer on dial gauge shows its
maximum reading.
4. Rotate crankshaft against normal direction of
rotation by approx. 10°.
M020124/02E 2009-02 © MTU

5. Set crankshaft in direction of rotation to 0.3 mm

(dial gauge indicator) before TDC.
6. Apply exact line marking on graduated disc, driving
end, or crankshaft journal, free end, opposite
TDC pointer tip.
7. Bar crankshaft in direction of rotation approx. 10°
past TDC (to take up bearing clearance).
8. Bar crankshaft in direction opposite to normal
direction of rotation to 0.3 mm after TDC and
make a second mark. To prevent measurement
errors caused by bearing clearance, the piston
must move in direction of TDC.
9. Apply third mark at exact center between marks.
10. Align graduated disc so that mark for cylinder A1
corresponds to pointer.
11. Check TDC position.
12. Remove measuring device with dial gauge.
Measuring valve lift
cardiagn.com
1. Set cylinder A1 to firing TDC.
2. Release locknuts on adjusting screw.
3. Screw in adjusting screws until there is no longer
clearance.
4. Lightly tighten locknuts.
5. Mount magnetic-base indicator holder with dial
gauge on cylinder A1.
6. Place dial gauge stylus with slight preload on valve
bridge of inlet valve. Set scale to zero.
7. Slowly turn crankshaft further in direction of engine
rotation 360°. Set to exactly overlap TDC (line
marking on graduated disc).
8. Read valve lift from dial gauge and record readings
in Data Sheet.
9. Mount dial gauge stylus on valve bridge of exhaust
valve and set scale to zero.
10. Further rotate crankshaft slowly in engine direction
of rotation until pointer of dial gauge no longer
moves.
in Data Sheet.
12. Check that specified values are
observed. Specified values, see
DM_110_WM_000001_276A.
13. If the specified value is not attained, contact
Service.
14. Remove magnetic-base indicator holder with dial
gauge and TDC indicator.
15. Valve clearance at cylinder A1 (→Operating
TIM ID: 0000001019 – 008
Instructions).
M020124/02E 2009-02 © MTU

5.5.9 Camshaft drive – Overview
Camshaft drive – Overview
cardiagn.com
1 Hex screw 3 Graduated disc 5 Hex screw
2 Spring washer 4 Camshaft gear 6 Thrust bearing flange
TIM ID: 0000001022 – 001
M020124/02E 2009-02 © MTU

5.5.10 Camshaft drive – Removal
Special tools


1. Turn engine with barring tool in normal direction
of rotation until TDC mark and arrow on end
housing are aligned.
• If rocker arms on cylinder A1 are unloaded, the
piston is in firing TDC.
• If rocker arms on cylinder A1 are loaded, the
piston is in overlap TDC.
2. Remove valve drive DM_110_WM_055050_520A.
cardiagn.com
3. Disconnect electrical plug-in connection.
4. Remove screw (arrow).
5. Turn speed sensor (1) slightly to remove from
crankcase fit.
TIM ID: 0000001031 – 004
M020124/02E 2009-02 © MTU


cardiagn.com
swing follower shaft, driving end.
(arrows).
Removing timing wheel (camshaft gear)

2. Remove timing wheel (2) and camshaft gear (1)
from camshaft and dowel pins (3).
3. To protect the crankcase from falling objects, cover
equipment carrier from below.
4. Do not remove locating device.
TIM ID: 0000001031 – 004
M020124/02E 2009-02 © MTU

5.5.11 Camshaft drive – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Camshaft drive – Cleaning
1. Clean all components with cleaner.
3. Blow camshaft drive clear with compressed air.
TIM ID: 0000001025 – 002
M020124/02E 2009-02 © MTU

5.5.12 Camshaft drive – Check
Spare parts

Camshaft gear
Timing wheel
Screw
Spring washer
Camshaft drive – Check
Item Findings Task
Check surface condition of tooth • Scores • Corrective work

flanks with magnifying glass. • Stress marks • Replace
• Indentations
visible
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Check timing wheel and camshaft Damaged • Corrective work
gear for damage. • Replace
Check threads of hex bolts for Damaged Replace

damage.
Check spring washer for damage. Damaged Replace
TIM ID: 0000001028 – 003
M020124/02E 2009-02 © MTU

5.5.13 Camshaft drive – Installation
Special tools

Holder 0015890321/00 1
Material
cardiagn.com
Spare parts

O-ring
Heavy object.
Risk of crushing!
For camshaft drive installation, see section “Installing timing wheel (camshaft gear)” (→ Page 379).
TIM ID: 0000001034 – 004
M020124/02E 2009-02 © MTU

5.5.14 Camshaft thrust bearing – Overview
Overview of camshaft thrust bearing
cardiagn.com
1 Thrust bearing flange 2 Hex screw
TIM ID: 0000001037 – 001
M020124/02E 2009-02 © MTU

5.5.15 Camshaft thrust bearing – Cleaning
Material


Compressed air.
Risk of injury!
WARNING
cardiagn.com

Camshaft thrust bearing – Cleaning

3. Blow thrust bearing clear with compressed air.
TIM ID: 0000001040 – 003
M020124/02E 2009-02 © MTU

5.5.16 Camshaft thrust bearing – Replacement
Material

Engine oil
Spare parts

Thrust bearing flange
Hex screw
Camshaft thrust bearing – Replacement

1. Remove camshaft drive (→ Page 387).
2. Replace camshaft thrust bearing as shown in overview drawing (→ Page 392).
cardiagn.com
TIM ID: 0000001046 – 001
M020124/02E 2009-02 © MTU

5.5.17 Camshaft thrust bearing – Check
Material

Spare parts

Hex bolts
Camshaft thrust bearing – Check
cardiagn.com
Item Findings Task
Test trust bearing flange for cracks Signs of cracks Replace

using surface crack-test method.
Check mating faces, fits and sliding Damaged • Corrective work

surfaces for damage. • Replace
Check threads of hex bolts for ease Sluggish Replace

of movement.
TIM ID: 0000001043 – 003
M020124/02E 2009-02 © MTU

5.5.18 Valve drive – Overview
Rocker arm, swing follower assembly
cardiagn.com
1 Rocker shaft support 5 Snap ring 9 Swing follower, exhaust valve
2 Rocker arm, inlet valve 6 Valve bridge 10 Swing follower, inlet valve
3 Rocker arm, exhaust valve 7 Hex screw 11 Swing-follower shaft
4 Adjusting shim 8 Washer 12 Hex screw
TIM ID: 0000001055 – 003
M020124/02E 2009-02 © MTU

Rocker shaft support
cardiagn.com
1 Snap ring 8 Rocker shaft support
2 Adjusting shim 9 Coiled spring pin
3 Bush 10 Coiled spring pin
4 Adjusting screw 11 Sealing plug
5 Rocker arm, inlet valve 12 Axle
6 Nut 13 Rocker arm, exhaust valve
7 Grooved pin 14 Thrust pad
TIM ID: 0000001055 – 003
M020124/02E 2009-02 © MTU

Swing follower
cardiagn.com
1 Bush 4 Swing follower, inlet valve 7 Pin
2 Ball seat 5 Roller
3 Swing follower, exhaust valve 6 Bush
TIM ID: 0000001055 – 003
M020124/02E 2009-02 © MTU

Valve bridge
cardiagn.com
1 Valve bridge 2 Nut 3 Adjusting screw
TIM ID: 0000001055 – 003
M020124/02E 2009-02 © MTU

5.5.19 Valve drive – Removal

Removing rocker arms
1. Bar crankshaft to bring piston of appropriate
cylinder to firing TDC. The piston is at firing TDC
when both rocker arms are unloaded.
2. Remove screw (1) and remove rocker shaft support
(2) from cylinder head. Ensure that no pushrod is
removed by the suction effect on the ball socket.
cardiagn.com
3. Mark valve bridges (2) and remove from sliding
pin (3) in cylinder head.
4. Mark pushrods (1) and pull out.
Removing swing followers

2. Remove swing follower shaft with swing followers
(2) from crankcase.
TIM ID: 0000004311 – 006
M020124/02E 2009-02 © MTU

5.5.20 Valve drive - Disassembly

Risk of injury!
Remove valve drive DM_110_WM_055050_520A
Disassembling rocker arm

1. Clamp rocker shaft support in vice with aluminium
jaws.
2. Using snap ring pliers, remove snap ring (2)
from shaft.
3. Remove washer (1).
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4. Take off rocker arm (1) from axle.
5. Remove nut (2) and adjusting screw (3).
TIM ID: 0000001075 – 002
M020124/02E 2009-02 © MTU

6. Secure valve bridge (3) in vice with aluminium

jaws.
7. Slacken nut (1) and remove adjusting screw (2).
Removing swing follower bushing
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1. Check whether swing follower bushing must be
removed (→ Page 405) .
2. If removal is necessary, use mandrel and hydraulic
press to remove swing follower bushing (2) from
swing follower (1).
Removing pin and roller

1. Check whether pin and roller must be removed
(→ Page 405) .
2. If removal is necessary:
2.1. Place swing follower between two prisms so
that both sides of pin bore have sufficient
support.
2.2. Use mandrel and hydraulic press to pin
(1) from swing follower (2).
2.3. Remove roller (3) from installation position.
TIM ID: 0000001075 – 002
M020124/02E 2009-02 © MTU

Removing exhaust rocker arm bushing

1. Check whether rocker arm bushing must be
press to remove rocker arm bushing (1) from
exhaust rocker arm (2).
Removing inlet rocker arm bushing
cardiagn.com
1. Check whether rocker arm bushing must be
press to remove rocker arm bushing (1) from
inlet rocker arm (2).
TIM ID: 0000001075 – 002
M020124/02E 2009-02 © MTU

5.5.21 Valve drive – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning the valve drive

2. Thoroughly blow out all parts with compressed air.
TIM ID: 0000001058 – 006
M020124/02E 2009-02 © MTU

5.5.22 Valve drive – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Holder 0015890321/00 1
Material

Crack testing oil (Nr. 63) 40475 1
Crack testing paste (UV-Apelux Paste 1031) 40483 1
cardiagn.com
Spare parts

Snap ring
Lockwasher
Bearing bushing
Swing follower
Swing follower shaft
Valve bridge
Roller
Pushrod
Hex screw
Adjusting screw
TIM ID: 0000004265 – 005
M020124/02E 2009-02 © MTU

Checking valve drive
Item Findings Task
Using the magnetic crack-testing Cracks visible Replace

method, check the following
components for cracks.
• Rocker shaft support and axles
• Rocker arms
• Valve bridges
• Swing followers
• Roller
• Pin
• Swing follower shaft
• Pushrods
• Hex screws
• Adjusting screws
Check running surfaces of axles, • Wear • Recondition

rollers, valve bridges and rocker • Indentations • Replace
arms for wear, indentations and • Scores
cardiagn.com
scoring. visible
Check mating faces on rocker shaft Damaged • Recondition

support. • Replace
Check snap ring grooves of axles Damaged • Recondition

for condition. • Replace
Check ball element. The ball Sluggish Replace

element must not jam within the
swivel angle, on all sides at least
10°, and must move freely.
Check screws, nuts and adjusting Damaged Replace

screws for damage.
Check pushrod concentricity. Out-of-round Replace
Measuring diameter of bushing bore in rocker arm

1. Adjust bore gauge to basic size of bushing
bore and measure diameter of bore. Values
(→ Page 408).
2. If limits are exceeded, replace bearing bushing. TIM ID: 0000004265 – 005
M020124/02E 2009-02 © MTU

Measuring diameter of rocker shaft support axles

1. Using outside micrometer, measure outside
diameters of bearings. Values (→ Page 408).
2. If values are not attained, replace rocker shaft
support.
Measuring swing follower bushing bore
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1. Adjust bore gauge to basic size of bushing bore
and measure diameter of bore.
2. If limits are exceeded, replace bearing bushing.
3. Replace gaskets and sealing washers.
4. Make sure that oil bores are perfectly clean and
free of obstruction.
TIM ID: 0000004265 – 005
M020124/02E 2009-02 © MTU

5.5.23 Valve drive – Tolerances
Rocker shaft support, inlet and exhaust
cardiagn.com
size Basic
size
1 Rocker arm bore 50.000 H7 0 +0.025 0.018 0.059
Bush OD 50.000 s6 +0.043 +0.059
2 Bush bore
installed 45.000 0 +0.050 0.025 0.091 Clearance

max.
removed 45.000 E6 +0.050 +0.066 0.100
Rocker shaft OD 45.000 f6 –0.041 –0.025
3 Rocker shaft 45.000 U7 –0.086 –0.061 0.020 0.061

support bore
Rocker shaft OD 45.000 f6 –0.041 –0.025

TIM ID: 0000004162 – 003
M020124/02E 2009-02 © MTU

Swing follower support, inlet and exhaust
cardiagn.com
size Basic
size
1 Swing follower 36.000 H7 0 +0.025 0.018 0.059

bore
Bush OD 36.000 s6 +0.043 +0.059
2 Bush bore

max.
removed 32.000 E6 +0.050 +0.066 0.100
Shaft OD 32.000 f6 –0.041 –0.025
3 Roller bore 21.000 E7 +0.040 +0.061 0.040 0.082 Clearance

max.
Bush OD 21.000 H7 –0.021 0 0.090
4 Bush bore 14.000 E7 +0.032 +0.050 0.032 0.058 Clearance

max.
Pin OD 14.000 h5 –0.008 0 0.065
TIM ID: 0000004162 – 003
5 Swing follower 14.000 P6 –0.026 –0.015 0.007 0.026

bore
Bush OD 14.000 h5 –0.008 0
M020124/02E 2009-02 © MTU

5.5.24 Valve drive – Assembly
Material

Liquid nitrogen
Engine oil

Compressed air.
Risk of injury!
cardiagn.com
Component is hot.
Risk of burning!

Risk of injury!
Assembling rocker arm

1. Clamp rocker shaft support in vise with aluminum
jaws.
2. Insert adjusting screw (3) into rocker arm (1).
3. Screw nut (2) onto adjusting screw but do not
tighten.
4. Coat axles on rocker shaft support and bushes
of rocker arm with engine oil.
5. Fit rocker arm on axle.
6. Install second rocker arm similarly.
TIM ID: 0000004313 – 003
M020124/02E 2009-02 © MTU

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

8. Check whether snap ring is correctly seated.
9. Check minimum thrust distance of rocker arm.
10. Screw adjusting screw (2) into valve bridge (1).
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11. Screw nut (3) onto adjusting screw, but do not
tighten.
TIM ID: 0000004313 – 003
M020124/02E 2009-02 © MTU

Assembling swing followers for inlet and exhaust

1. Chill bushes (2) in liquid nitrogen and press fit in
swing follower (1) on both sides.
2. Observe bush clearance (A) of 0.5 mm ±0.5 mm.
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3. Heat swing follower to approx. 130° C to 150° C.
4. Insert roller (3) in swing follower.
5. Chill pin (1) in liquid nitrogen. Insert flush by hand
into swing follower (2). Subsequent pressing is
not permissible.
TIM ID: 0000004313 – 003
M020124/02E 2009-02 © MTU

Assembling rocker arm

1. Chill bush (1) in liquid nitrogen.
2. Heat exhaust rocker arm (2) to approx. 200 °C.
3. Insert bush so that it is flush. Protrusion is not
permissible.
cardiagn.com
TIM ID: 0000004313 – 003
M020124/02E 2009-02 © MTU

5.5.25 Valve drive – Installation
Special tools

Box wrench, 19 mm F30028351 1
Material
cardiagn.com
Engine oil
Compressed air.
Risk of injury!
Adjusting and mounting valve bridges

1. Measure sliding pin protrusion from cylinder
head surface.
2. Clamp valve bridge (1) in vise with aluminum jaws.
Loosen locknut (2) and back off adjusting screw (3)
by approx. three turns.
3. Check oil bores of valve bridges with compressed
air.
TIM ID: 0000004314 – 006
M020124/02E 2009-02 © MTU

4. Fit valve bridges on sliding pin in cylinder head in

accordance with the marking (installation position).
Adjusting screws must face charge air pipe.
5. Press down valve bridge and hold. Valve bridge
must contact valve stem (a).
6. With the valve bridge depressed, screw in
adjusting screw (arrow) with Allen key until
adjusting screw is slightly in contact with valve
stem and a thrust point can be felt.
7. Check clearance between valve bridge and valve
stem. Use a second feeler gauge (b) to check the
clearance at the opposite valve stem. Clearance
is adjusted correctly if a 0.05 mm feeler gauge
just passes the gap.
8. Hold adjusting screw with Allen key and fit locknut
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on valve bridges by hand.
9. Remove valve bridge.
10. Clamp valve bridge (1) in vise with aluminum jaws.

11. Use torque wrench to tighten locknut (2) to
TIM ID: 0000004314 – 006
M020124/02E 2009-02 © MTU

12. Fit valve bridge(s) on sliding pin in cylinder head in

accordance with the marking (installation position).
13. Check clearance between valve stem and valve
bridge (arrow) using a feeler gauge (0.05 mm).
14. Coat axle and bushes of swing followers with
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engine oil.
15. Fit exhaust and inlet swing follower on swing
follower shaft, ensuring they are correctly
positioned (arrows).
16. Coat rollers and camshaft with engine oil.

17. Match swing followers to left and right cylinder
banks and carefully insert into camshaft chamber.
TIM ID: 0000004314 – 006
M020124/02E 2009-02 © MTU


19. Ensure correct position of installation (arrow).
Installing pushrods
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1. Coat ball seats and ball heads of pushrods with
engine oil.
2. Insert pushrods (2) through cylinder head into ball
seat of swing follower.
3. For pushrods with collar: Fit tab washer (1).
Installing rocker arm

1. Release nuts (2) of adjusting screws (3) on rocker
arm (6) and back off adjusting screw.
2. Place rocker shaft support onto cylinder head.
Take care not to damage fit of notched pins.
3. Check position of ball joints in pushrods (1).
4. Take off tab washer, if fitted.
5. After initial assembly and after extended
out-of-service period: Fill adjusting screws with
engine oil (arrow).
6. Insert screw (4) with washer (5) into the cylinder
TIM ID: 0000004314 – 006
head and use torque wrench to tighten to the

specified torque (→ Page 80).
7. Adjust valve clearance (→Operating Instructions).
M020124/02E 2009-02 © MTU

5.5.26 Cylinder head cover – Overview
cardiagn.com
1 Seal 3 Screw
2 Cylinder head cover 4 Washer
TIM ID: 0000001086 – 002
M020124/02E 2009-02 © MTU

5.5.27 Cylinder head cover – Removal

Cylinder head cover – Removal
1. Remove screws.
2. Remove cylinder head cover and seal.
cardiagn.com
TIM ID: 0000001095 – 004
M020124/02E 2009-02 © MTU

5.5.28 Cylinder head cover – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cylinder head cover – Cleaning

1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then flush with cleaning agent (Hakupur 312).
TIM ID: 0000001089 – 004
M020124/02E 2009-02 © MTU

5.5.29 Cylinder head cover – Check
Special tools

Oilstone 8205893261/00 1
Spare parts

Cylinder head cover
Screw
Checking the cylinder head cover
Item Findings Action
cardiagn.com
Check cylinder head cover for Damaged • Corrective work: Smoothen
damage. with emery cloth or oilstone.
• Replace
Check threads of screws for ease of Sluggish • Corrective work: Recut threads
movement. • Replace
TIM ID: 0000001092 – 004
M020124/02E 2009-02 © MTU

5.5.30 Cylinder head cover – Installation
Material

Engine oil
Spare parts

Seal
Screw
Washer
cardiagn.com
Cylinder head cover – Installation

1. Install cylinder head cover with seal.
2. Tighten screws.
TIM ID: 0000001098 – 004
M020124/02E 2009-02 © MTU

5.6 High Pressure Fuel System
5.6.1 HP fuel system – Overview
cardiagn.com
1 Injector 4 Pressure-relief valve 7 HP fuel line, right engine side
2 HP fuel line 5 HP fuel line, left engine side
3 HP accumulator 6 HP fuel pump
TIM ID: 0000001113 – 002
M020124/02E 2009-02 © MTU

5.6.2 HP pump – Overview
cardiagn.com
1 HP pump 3 Washer
2 Screw 4 Washer
TIM ID: 0000028951 – 001
M020124/02E 2009-02 © MTU

Front view of HP pump
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1 HP line to right-hand engine side 3 HP line to left-hand engine side
2 Temperature sensor 4 HP sensor
TIM ID: 0000028951 – 001
M020124/02E 2009-02 © MTU

5.6.3 HP pump – Removal
Special tools

Lifting equipment for HP pump T80091799 1
Hot-air gun 0005388520 1
Fuels are combustible.

Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Heavy object.
Risk of crushing!
cardiagn.com
Component is hot.
Risk of burning!
HP pump – Removal
1. Install lifting equipment for HP pump (1).
3. Remove HP pump (1).
4. Seal all openings with suitable covers.
TIM ID: 0000001136 – 005
M020124/02E 2009-02 © MTU


6. Heat intermediate piece (2) to approx. 130°C to
free up screw locking compound.
7. Remove intermediate piece (2).
cardiagn.com
TIM ID: 0000001136 – 005
M020124/02E 2009-02 © MTU

5.6.4 High-pressure pump – Disassembly

This assembly is a replacement part (Reman). It is available within the scope of the service-exchange scheme.
cardiagn.com
TIM ID: 0000001140 – 002
M020124/02E 2009-02 © MTU

5.6.5 High-pressure pump – Check
Spare parts

High-pressure pump
Screw
High-pressure pump – Check
Item Findings Task
Check connection thread on No ease of movement • Recondition

high-pressure pump for damage. • Replace
Check drive gear for damage. Damaged Replace high-pressure pump.
cardiagn.com
Check wiring for damage. Damaged Replace wiring.
Check sealing faces for damage. Damaged • Recondition

• Replace
TIM ID: 0000001133 – 003
M020124/02E 2009-02 © MTU

5.6.6 HP pump – Installation
Special tools

Material

Engine oil
cardiagn.com
Spare parts

O-ring
Suspended load.
Danger to life!

HP pump – Installation
1. Remove all covers prior to installation.
2. Coat thread of intermediate piece (3) with screw
locking compound.
3. Screw intermediate piece (3) into shaft (2).
4. Coat O-ring (1) with grease and insert in groove.
TIM ID: 0000001143 – 006
M020124/02E 2009-02 © MTU


6. Insert HP pump (1) into bore.
7. Insert screws (2) and tighten.
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8. Remove lifting equipment from HP pump.
TIM ID: 0000001143 – 006
M020124/02E 2009-02 © MTU

5.6.7 H.P. fuel pump – Control block replacement
Preconditions
Special tools

Connector pliers 0135315483 1
Material

Engine oil
cardiagn.com
Spare parts

Control block
O-ring
Connector

• Do not smoke.
Removing control block

1. Remove fuel line (5) from control block (4). Collect
emerging fuel.
2. Release bayonet lock using pliers and disconnect
connector (6) from magnet.
connector (1) from sensor.
4. Remove sensor (1).
5. Remove screws (3) from control block (4).
6. Remove control block (4) from H.P. fuel pump (7).
TIM ID: 0000004092 – 003
Installing control block

1. Coat O-ring with engine oil and insert into groove.
2. Screw control unit (4) with screws (3) onto H.P. fuel pump (7) and tighten to specified torque (→ Page 80) .
M020124/02E 2009-02 © MTU

3. Connect connector (6) to magnet and tighten bayonet lock using pliers.
4. Coat O-ring of sensor with petroleum jelly.
5. Screw sensor (1) into bore by hand.
6. Tighten nut (2) with torque wrench to specified tightening torque (→ Page 80) .
7. Connect connector to sensor (1) and tighten bayonet lock using pliers.
8. Attach fuel line (5) to control block (4).
9. Vent fuel lines.
cardiagn.com
TIM ID: 0000004092 – 003
M020124/02E 2009-02 © MTU

5.6.8 Injector – Overview
Injector – Overview
cardiagn.com
1 Hold-down clamp 3 O-ring 5 O-ring
2 Hex screw 4 Injector 6 CE-ring
TIM ID: 0000029847 – 001
M020124/02E 2009-02 © MTU

5.6.9 Injector – Removal
Special tools

Puller F30377769 1
Puller bracket F6557991 1

• Do not smoke.
Remove injector
1. Remove H.P. line (2).
cardiagn.com
2. Remove screw (1) from hold-down clamp (2).
3. Take off hold-down clamp.
TIM ID: 0000001167 – 003
M020124/02E 2009-02 © MTU

4. Place puller (4) on injector (1).
5. Turn locking sleeve (2) of puller (1) from position
cardiagn.com
"a" to position "b".
6. Secure locking sleeve with nut.
7. Place puller bracket (2) on cylinder head.

8. Screw in threaded rod (3) in puller (5).
9. Secure nuts (4).
10. Withdraw fuel injector by turning nut (1) to the right.
11. Remove special tool.
12. Remove puller bracket and locking sleeve.
TIM ID: 0000001167 – 003
M020124/02E 2009-02 © MTU

13. Remove fuel injector.

14. Remove O-rings (2) from injector.
15. Remove sealing ring (1) from injector or use wire
hook to remove from cylinder head.
16. Seal all connections and installation bores with
covers or plugs.
cardiagn.com
TIM ID: 0000001167 – 003
M020124/02E 2009-02 © MTU

5.6.10 Fuel injector disassembly

This component is an exchange component (Reman) and is available through the usual exchange procedure.
cardiagn.com
TIM ID: 0000001171 – 001
M020124/02E 2009-02 © MTU

5.6.11 Injector – Cleaning
Material

Compressed air.
Risk of injury!

• Do not smoke.
cardiagn.com

Injector – Cleaning
2. Dry all components using compressed air.
TIM ID: 0000001158 – 002
M020124/02E 2009-02 © MTU

5.6.12 Injector – Check
Material

Crack testing oil (NR. 63) 40475 1
Spare parts

Fuel injector
Hold-down clamp
Screw
Check injector
cardiagn.com
Inspect fuel injector externally for Damaged Replace

damage.
Check screws and hold-down Indication of cracks Replace

clamp for cracks with magnetic
crack-testing method.
Check contact surfaces of hold-down Damaged • Rework: smooth with oilstone.

clamp. • Replace
Inspect sealing cone of fuel injector Damaged Replace injector.

for damage.
Check cable connections for Damaged Replace wiring harness.

damage.
Check thread on screw and injector Sluggish • Rework

valve for ease of movement. • Replace
TIM ID: 0000001162 – 002
M020124/02E 2009-02 © MTU

5.6.13 Injector – Installation
Special tools

Lever F6555197 1
Force-in lever F6557952 1
Material

Engine oil
Grease (Retinax EP2) 40388 1
cardiagn.com
Spare parts

O-rings
Sealing ring

• Do not smoke.
Check injector (→ Page 440).
Injector – Installation
1. Coat O-rings with petroleum jelly.
2. Fit O-rings on fuel injector.
TIM ID: 0000001175 – 004
M020124/02E 2009-02 © MTU

3. Use Retinax EP2 grease to fit sealing ring on

mating face of injector.
4. Fit sealing ring on injector so that the even contact
surface faces injector.
5. Insert fuel injector (1) in cylinder head. Ensure
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that injector is correctly aligned with H.P. fuel
line connection.
6. Fit force-in tool (2).
7. Lock force-in lever (1) of forces-in tool between

the pushrods.
8. Release palm grip (3) and move pressure element
(2) to correct position for force-in tool.
9. Secure palm grip and press injector (4) with
force-in lever into cylinder head.
10. Remove force-in tool.
TIM ID: 0000001175 – 004
M020124/02E 2009-02 © MTU

11. Fit hold-down clamp (2) in correct position by hand.

Note: Tighten screw of hold-down clamp only
after connecting the H.P. line.
12. Hand-tighten screw (1) so that the injector is

still rotatable.
13. Install H.P. lines between connecting piece and
injector (→ Page 459).
cardiagn.com
TIM ID: 0000001175 – 004
M020124/02E 2009-02 © MTU

5.6.14 High-pressure line – Overview
HP line from HP accumulator to injector
cardiagn.com
1 Hold-down clamp 4 Filter element 7 Fuel collecting line

2 Cable connection 5 Fuel return line 8 Limiting valve
3 Injector 6 HP line 9 HP accumulator
TIM ID: 0000029631 – 001
M020124/02E 2009-02 © MTU

HP line from HP pump to HP accumulator
cardiagn.com
1 HP line, left side 4 Pipe half-clamp 7 Pipe half-clamp
2 HP line, right side 5 Screw 8 Screw
3 Retainer 6 Retainer 9 Grommet
TIM ID: 0000029631 – 001
M020124/02E 2009-02 © MTU

HP accumulator and add-on components
cardiagn.com
1 HP accumulator 10 Screw 19 Plug-in pipe
2 Thrust element 11 Limiting valve 20 Plug-in pipe
3 Thrust element 12 HP line 21 Screw
4 Thrust screw 13 O-ring 22 Washer
5 O-ring 14 Plug-in pipe 23 O-ring
6 Pressure-relief valve 15 Sealing ring 24 O-ring
7 Adapter 16 Plug 25 O-ring
8 Thrust screw 17 Plug-in pipe 26 Snap ring
9 Connecting piece 18 Plug-in pipe
TIM ID: 0000029631 – 001
M020124/02E 2009-02 © MTU

HP accumulator, left engine side
cardiagn.com
1 O-ring 6 Plug-in pipe 11 Plug screw (telltale bore)
2 Thrust screw 7 Thrust element 12 HP accumulator
3 Thrust element 8 Screw 13 O-ring
4 Adapter for HP line 9 Thrust element 14 Plug-in pipe
5 Telltale bore 10 Plug-in pipe
HP accumulator, right engine side

TIM ID: 0000029631 – 001
M020124/02E 2009-02 © MTU

1 Screw 6 Telltale bore 11 Thrust element

2 Pressure-relief valve 7 Plug-in pipe 12 HP accumulator
3 Plug-in pipe 8 HP line 13 Plug screw (telltale bore)
4 Adapter for HP line 9 O-ring 14 Plug-in pipe
5 O-ring 10 Thrust screw 15 Thrust element
cardiagn.com
TIM ID: 0000029631 – 001
M020124/02E 2009-02 © MTU

5.6.15 HP fuel line – Removal
Special tools

Crowfoot box wrench for HP lines F30373588 1

• Do not smoke.
Removing HP line between HP pump and HP accumulator

Note: Prior to removing HP lines, it is advisable to take photographs of all fitted lines or to identify lines
with metal tags.
1. Release threaded union on HP lines and catch fuel emerging.
cardiagn.com
2. Remove HP fuel lines as per overview drawings (→ Page 444).
3. After removal of the lines, seal all connections with suitable plugs.
TIM ID: 0000001204 – 005
M020124/02E 2009-02 © MTU

Removing HP fuel lines

1. Remove HP lines between injector and HP
accumulator on injector side (arrow).
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accumulator on HP accumulator side (arrow).
TIM ID: 0000001204 – 005
M020124/02E 2009-02 © MTU

Removing HP accumulator
1. Remove fuel return line (1) on HP accumulator of
right engine side, driving end.
2. Remove pressure relief valve.
3. Withdraw plug-in pipe end section (2) and remove
O-ring.
cardiagn.com
4. Remove limiting valves (2) from connecting
pieces (3).
5. Withdraw plug-in pipe end section (1) from left HP
accumulator.
6. Carefully remove HP accumulator from connecting

pieces and plug-in pipes.
TIM ID: 0000001204 – 005
M020124/02E 2009-02 © MTU

7. Remove screws (4) from connecting piece (2)

and take off together with plug-in pipe (1) from
crankcase.
8. Remove O-ring (3) from connecting pieces.
cardiagn.com
TIM ID: 0000001204 – 005
M020124/02E 2009-02 © MTU

5.6.16 HP fuel line – Disassembly
Special tools

Retaining device for HP accumulator installation F6553674 1
Heavy object.
Risk of crushing!
Remove HP fuel line (→ Page 449).
Disassembling HP accumulator
1. Use retaining device (arrow) to clamp HP
accumulator in vice.
cardiagn.com
2. Unscrew thrust screw.
3. Remove thrust pad and pressure relief valve.
TIM ID: 0000001207 – 002
M020124/02E 2009-02 © MTU

5.6.17 HP fuel line – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

HP fuel line – Cleaning

2. Thoroughly blow all parts clear with compressed air.
TIM ID: 0000001198 – 003
M020124/02E 2009-02 © MTU

5.6.18 H.P. fuel line – Check
Material

Fluorescent magnetic powder for magnetic crack-testing procedure
Spare parts

H.P. accumulator
Pressure-relief valve
Plug-in pipe
Thrust pad
Limiting valve
cardiagn.com
Disassemble H.P. fuel line (→ Page 453).
H.P. fuel line – Check
Item Findings Task
Using the magnetic crack-testing Signs of cracks Replace pressure accumulator.

method, check H.P. accumulator for
cracks.
Check all threads for ease of Sluggish • Recondition: recut threads.

Check sealing tapers on thrust pads Damaged Replace

for damage.
Check sealing cone of pressure • Damage Replace

accumulator for damage and wear. • Wear
visible
Check that H.P. lines, plug-in pipes Damaged • Recondition

and fuel return line are in perfect • Replace
condition.
Check that H.P. lines and H.P. Contaminated Clean (→ Page 454)
accumulator are perfectly clean.
For checking limiting valves Damaged Contact Service.

and pressure relief valves, see
Manufacturer’s Documentation.
TIM ID: 0000001201 – 001
M020124/02E 2009-02 © MTU

5.6.19 HP fuel line – Assembly
Special tools

Material

Molykote G-n plus 40041 1
Engine oil
Spare parts
cardiagn.com
O-ring
Snap ring
Sealing ring
Washer
Thrust element, alternatives A and B
A Thrust element with thrust ring (X = 15.5 mm)

B Thrust element without thrust ring (Y = 23.5 mm)
TIM ID: 0000001210 – 005
M020124/02E 2009-02 © MTU

Pressing on thrust ring - Variant A only

1. Degrease and dry thrust element surfaces.
2. Coat surface (arrowed) with oil.
cardiagn.com
3. Press-fit thrust ring (2) with supporting washer (3)
on thrust element (1).
TIM ID: 0000001210 – 005
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Assembling HP fuel line, alternatives A and B

1. Coat mating surfaces between thrust screw and
thrust element as well as between thrust screw
and adapter with Molykote G-n plus.
2. Push thrust screw (1) onto thrust element (2).
3. Coat threads (arrowed) and taper (arrowed)
with engine oil.
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4. Preassemble HP accumulator:
4.1. Use retaining device to clamp HP
4.2. Insert prepared thrust pieces with thrust
screws as well as adapter and thrust screw
for pressure-relief valve (→ Page 444)in
seating bore and tighten with torque
wrench to the specified tightening torque
(→ Page 80).
4.3. Install pressure relief valve, and insert but
do not tighten socket-head screws.
TIM ID: 0000001210 – 005
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5.6.20 HP fuel line – Installation
Special tools

Alignment tool for HP accumulator F6557185 2
Slotted nut screwdriver F30379005 1
Material

Engine oil
cardiagn.com
Spare parts

O-ring
Gasket
Compressed air.
Risk of injury!

• Do not smoke.
TIM ID: 0000001213 – 008
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Preparing connecting pieces

2. Insert O-rings in grooves (arrowed) on connecting
piece.
Installing HP accumulator on crankcase
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1. Fit connecting pieces and plug-in pipes together in
alternating sequence.
Note: Align plug-in pipes with leak check outlet
facing downwards
2. Fit plug-in pipes over connecting piece O-rings.

3. Insert screws (arrows) for attaching the connecting
piece to the crankcase.
4. Insert HP accumulator in preassembled connecting

piece and plug-in pipe assembly.
TIM ID: 0000001213 – 008
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5. Insert alignment tools in tightened connecting

pieces (first and last connecting piece of respective
engine side).
6. Align HP accumulator until alignment tool taper is
centered in bore of HP accumulator.
7. Tighten alignment tool to 20 Nm +2 Nm.
8. Insert limiting valve into outlet openings (arrowed)
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of all connecting pieces.
9. If injectors have been removed, they must be

installed first (→ Page 441).
10. Using a slotted nut screwdriver, tighten thrust rings
(2) at the thread end to 10 Nm.
Result: Distance of pipe end to thrust ring A =
11.7 mm.
11. Coat O-rings with grease and insert in grooves.
12. Pretighten HP lines between limiting valve and
injector to 5 to 10 Nm.
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13. Use torque wrench to fasten HP lines to the limiting

valves (2) and tighten to specified tightening
torque (→ Page 80).
14. Use torque wrench to fasten HP lines to the
injectors (1) and tighten to specified tightening
16. Insert remaining limiting valves and tighten HP
lines as described.
17. Use torque wrench to tighten hold-down clamp with
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screw to specified tightening torque (→ Page 80).
18. Use torque wrench to tighten all screws for

attaching connecting pieces to the crankcase to
19. Complete HP accumulator (→ Page 444).
20. Remove all plugs (arrow).
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21. Coat thread and screw heads (3) with oil.

22. Install pressure relief valve (2) and fit screws (3)
evenly by hand.
23. Install return line (1) between fuel collecting line
and pressure relief valve.
24. Pressure relief valve:
• Variant A
Use torque wrench to tighten 3 screws (3) to
• Variant B
Tighten 6 screws (3), spherical washers and
conical sockets crosswise in stages to specified
tightening torque (→ Page 80).
Installing HP line between HP pump and HP accumulator
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1. Blow out HP lines with compressed air.
2. Install HP lines and securing hardware as per overview drawing (→ Page 444) or according to photos/markings,
ensuring that the connections are free of tension.
3. Leak test fuel system (high-pressure) (→ Page 464).
TIM ID: 0000001213 – 008
M020124/02E 2009-02 © MTU

5.6.21 H.P. fuel system – Leak check

Compressed air.
Risk of injury!
Checking common rail system for leaks

1. Remove pressure sensor (1) from high-pressure
pump (2).
2. Install H.P. inspection line and apply pressure to
system. Test pressure: 3 bar
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3. Fit control screws (arrow) on H.P. accumulator.
4. Check all threaded connections in system for leaks.
5. Again remove H.P. testing line from high-pressure
pump.
6. Insert pressure sensor on H.P. pump and tighten to
specified torque with torque wrench (→ Page 80) .
TIM ID: 0000001116 – 001
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5.7 Low Pressure Fuel System
5.7.1 Fuel system – Overview
Fuel system
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1 Fuel service tank 13 Measuring point, fuel pressure 24 Non-return valve after fuel
2 Non-return flap after H.P. pump delivery pump
3 Fuel prefilter 14 Measuring point, fuel temperature 25 Fuel ventilation
4 Fuel delivery pump, electric after fuel H.P. pump 26 Fuel restrictor
motor drive 15 Jacketed pipe 27 Overflow valve, fuel return
5 Non-return flap 16 Connection, leak-off fuel return from engine
6 Fuel filling connection from jacketed fuel line 28 Overflow valve, fuel return
7 Connection, fuel supply to engine 17 H.P. accumulator from engine
8 Fuel hand pump 18 pressure relief valve 29 Connection for leak-off fuel return
9 Fuel delivery pump with pressure 19 Injector 30 Leak-off fuel tank
relief valve 20 H.P. fuel pump
10 Fuel filling connection 21 Connection, return from fuel
11 Connection, fuel return from engine prefilter
12 Measuring point, fuel pressure 22 Connection, supply to fuel prefilter
after filter 23 Fuel filter
TIM ID: 0000003454 – 002
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5.7.2 Fuel delivery pump – Overview
Fuel delivery pump – Overview
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1 Fuel delivery pump 3 O-ring 5 Washer
2 Coupling element 4 Hex bolt 6 Hex bolt
TIM ID: 0000029644 – 001
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5.7.3 Fuel delivery pump – Removal
Preconditions

• Do not smoke.
Removing fuel delivery pump

1. Remove fuel delivery pump as per overview drawing (→ Page 466).
2. Remove coupling element from the drive shaft of the fuel delivery pump.
3. Remove O-ring.
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TIM ID: 0000004057 – 007
M020124/02E 2009-02 © MTU

5.7.4 Fuel delivery pump – Disassembly

Remove fuel delivery pump (→ Page 467).
Disassembling fuel delivery pump

In the event of wear or a complaint, the fuel delivery pump must be replaced.
cardiagn.com
TIM ID: 0000001242 – 002
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5.7.5 Fuel delivery pump – Cleaning
Material

Compressed air.
Risk of injury!

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Fuel delivery pump – Cleaning

2. Blow all parts clean thoroughly with compressed air.
TIM ID: 0000001234 – 002
M020124/02E 2009-02 © MTU

5.7.6 Fuel delivery pump – Check
Spare parts

Fuel delivery pump
Screw
Coupling

• Do not smoke.
Fuel delivery pump – Check
Item Findings Task
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Perform external check of fuel Damaged Replace fuel delivery pump
delivery pump for perfect condition.
Check coupling for stress marks and Damaged Replace coupling

damage.
Check driver of pump shaft for wear. Damaged • Recondition: Smooth with
• Refer to manufacturer’s
documentation when replacing
the driver.
Check threads of securing screws. Damaged Replace
TIM ID: 0000001237 – 003
M020124/02E 2009-02 © MTU

5.7.7 Fuel delivery pump – Installation
Material

Grease (Kluthe Hakuform 30–10/Emulgier) X00029933 1
Engine oil
Spare parts

O-ring

• Do not smoke.
cardiagn.com
Fuel delivery pump – Installation
2. Mount coupling element (2) on driver.
3. Align fuel delivery pump driver to coupling element.
4. Carefully insert fuel delivery pump in bore
and install as shown in overview drawing
(→ Page 466).
5. If the pump cannot be inserted up to the stop,
remove the pump again and check the position of
the driver to the coupling element.
TIM ID: 0000004059 – 005
M020124/02E 2009-02 © MTU

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1 Fuel delivery pump
TIM ID: 0000006055 – 001
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• Do not smoke.
Fuel delivery pump – Removal

1. Switch off fuel delivery pump and disconnect from power supply.
2. Remove fuel lines.
3. Collect emerging fuel in a suitable container.
4. Remove securing screws from fuel delivery pump.
5. Remove fuel delivery pump.
6. Seal all openings on the engine.
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TIM ID: 0000006056 – 002
M020124/02E 2009-02 © MTU

Material

Cleaning agent
Compressed air.
Risk of injury!

• Do not smoke.
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1. Clean all components using cleaning agent.
2. Remove cleaning agent.
3. Blow off all parts thoroughly with compressed air.
TIM ID: 0000006057 – 001
M020124/02E 2009-02 © MTU


• Do not smoke.
Clean fuel delivery pump (→ Page 474).

1. Open connections on engine.
2. Mount fuel delivery pump on foundation with securing screws.
3. Install fuel lines.
4. Connect fuel delivery pump to power supply.
cardiagn.com
TIM ID: 0000006059 – 002
M020124/02E 2009-02 © MTU

5.7.12 Fuel pipework from fuel delivery pump to fuel filter – Overview
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1 Plug-in pipe 6 O-ring 11 Flange
2 O-ring 7 Screw 12 Flange
3 Flange 8 Washer 13 O-ring
4 Non-return valve 9 Plug-in pipe 14 Screw
5 O-ring 10 O-ring 15 Washer
TIM ID: 0000029119 – 001
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5.7.13 Fuel lines from fuel delivery pump to fuel filter – Removal
Preconditions

• Do not smoke.
Removing fuel lines from fuel delivery pump to fuel filter

1. Before removing the lines, take photos or label add-on components and lines.
2. Disconnect fuel line and collect escaping fuel.
3. Remove fuel lines from fuel delivery pump to fuel filter as shown in overview drawing (→ Page 476).
cardiagn.com
TIM ID: 0000003457 – 009
M020124/02E 2009-02 © MTU

5.7.14 Fuel lines from pump to filter – Cleaning
Material

Cleaning agent
Compressed air.
Risk of injury!

Remove fuel lines (→ Page 477).
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Cleaning fuel lines
1. Clean fuel lines and non-return valve with cleaning agent.
3. Thoroughly blow out fuel lines and non-return valve with compressed air.
TIM ID: 0000004060 – 003
M020124/02E 2009-02 © MTU

5.7.15 Fuel lines from fuel delivery pump to fuel filter – Check
Spare parts

Non-return valve
Flange
Plug-in pipe

Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
Fuel lines from fuel delivery pump to fuel filter – Check
Item Findings Task
cardiagn.com
Visually check plug-in pipes, flanges and Damaged Replace
non-return valve for damage and wear.
Check plug-in pipes for leaks with air Leaking Replace

in water bath as necessary. A water
temperature of min = 30 °C or max = 40 °C
and a test pressure of 0.5 bar must be
maintained.
Check non-return valve for leaks and • Leaking Replace

check opening pressure. • Opening pressure
incorrect.
TIM ID: 0000008427 – 002
M020124/02E 2009-02 © MTU

5.7.16 Fuel lines from fuel delivery pump to fuel filter – Installation
Material

Spare parts

O-ring

• Do not smoke.
cardiagn.com
Fuel lines from fuel delivery pump to fuel filter – Installation

2. Install O-rings on plug-in pipes and coat with grease.
3. Install fuel lines as per overview drawing (→ Page 476).
TIM ID: 0000008429 – 006
M020124/02E 2009-02 © MTU

5.7.17 Fuel duplex filter – Overview
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1 Valve (0.5 bar) 11 Fuel hand pump 21 Threaded nipple
2 Plug screw 12 Plug screw 22 Plug screw
3 Plug screw 13 Threaded union 23 Plug screw
4 Valve (1 bar) 14 Blanking cone 24 Filter head
5 Plug screw 15 Nut 25 Threaded union
6 Threaded union 16 O-ring 26 Blanking cone
7 Fuel line 17 Elbow 27 Nut
8 Plug screw 18 Screw 28 Threaded union
9 Screw 19 Threaded nipple 29 Threaded union
10 O-ring 20 Easy-change fuel filter 30 O-ring
TIM ID: 0000008168 – 003
M020124/02E 2009-02 © MTU

5.7.18 Fuel duplex filter – Removal
Preconditions
Special tools

Filter wrench F30379104 1

• Do not smoke.
Fuel duplex filter – Removal

1. Remove filter elements using filter wrench (1).
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2. Collect emerging fuel.
3. Remove filter head as shown in overview drawing
(→ Page 481).
TIM ID: 0000004062 – 006
M020124/02E 2009-02 © MTU

5.7.19 Fuel duplex filter – Disassembly

• Do not smoke.
Fuel duplex filter – Disassembly

1. Remove and disassemble hand pump as shown in overview drawing (→ Page 481).
2. Disassemble filter head as shown in overview drawing.
cardiagn.com
TIM ID: 0000004063 – 003
M020124/02E 2009-02 © MTU

5.7.20 Fuel filter – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Fuel filter – Cleaning

3. Thoroughly blow out all parts using compressed air.
TIM ID: 0000004064 – 002
M020124/02E 2009-02 © MTU

5.7.21 Fuel filter – Check

Risk of injury!
Checking fuel filter
Visually inspect filter head and hand Damaged Replace

pump for damage and condition
Check sealing and bolt-on faces for Damaged • Smooth with oilstone
damage • Replace
Check all threads and threaded Damaged • Rework: recut thread.

holes. • Replace
Leak-test filter head using air and Leaking • Replace plugs and sealing
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water bath. Install filter elements rings
before carrying out leak test. Test • Replace filter head
temperature: min. 30 °C, max.
40 °C, if oil filter housing has to be
held in hands. Test pressure: 0.5
bar.
TIM ID: 0000004065 – 003
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5.7.22 Fuel duplex filter – Assembly
Material

Engine oil
Spare parts

Plug screw
O-ring

cardiagn.com
• Do not smoke.
Fuel duplex filter – Assembly

Note: Coat O-rings with grease.
1. Assemble filter head as shown in overview drawing (→ Page 481).

2. Assemble hand pump as shown in overview drawing and install on filter head (→ Page 481).
TIM ID: 0000004066 – 003
M020124/02E 2009-02 © MTU

5.7.23 Fuel duplex filter – Installation
Material


• Do not smoke.
Installing fuel duplex filter

1. Remove all plugs.
3. Install fuel duplex filter as shown in overview drawing (→ Page 481).
Installing easy-change fuel filter
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1. Coat sealing rings (arrow) of filters with fuel.
2. Install filter and tighten by hand.
TIM ID: 0000004067 – 005
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5.7.24 Fuel pipework from fuel filter to HP pump – Overview
Fuel line
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1 Fuel line 4 Pipe half-clamp 7 Screw
2 Union 5 Grommet
3 Pipe half-clamp 6 Washer
TIM ID: 0000033769 – 001
M020124/02E 2009-02 © MTU

5.7.25 Fuel pipework from fuel filter to HP pump – Removal
Preconditions

• Do not smoke.
Fuel pipework from fuel filter to HP pump – Removal

1. Release threaded union on fuel line and catch fuel as it escapes.
2. Remove fuel line with securing hardware as shown in overview drawing (→ Page 488).
3. After removal of the fuel lines, seal all connections with suitable plugs.
cardiagn.com
TIM ID: 0000004068 – 005
M020124/02E 2009-02 © MTU

5.7.26 Fuel pipework from fuel filter to high-pressure pump – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Fuel pipework from fuel filter to high-pressure pump – Cleaning

TIM ID: 0000004069 – 002
M020124/02E 2009-02 © MTU

5.7.27 Fuel pipework from fuel filter to high-pressure pump – Check
Spare parts

Fuel line
Retainer

Risk of injury!
Fuel pipework from fuel filter to high-pressure pump – Check
Item Findings Task
Visually inspect fuel lines for Damaged • Corrective work
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damage. • Replace
Pressure-test fuel line with air Leaking Replace

in water bath for leaks. A water
temperature of min. = 30 °C or
max. = 40 °C and a test pressure of
0.5 bar must be maintained.
Check sealing and bolt-on faces for Damaged • Corrective work: Smooth with
damage. oilstone.
• Replace
Check threads of union nuts Sluggish • Corrective work: Recut threads

and threaded unions for ease of • Replace
movement.
Check securing elements on fuel Damaged Replace

lines for damage.
TIM ID: 0000004070 – 002
M020124/02E 2009-02 © MTU

5.7.28 Fuel pipework from fuel filter to HP pump – Installation
Material

Engine oil
Spare parts

Grommet

• Do not smoke.
cardiagn.com

Fuel pipework from fuel filter to HP pump – Installation

2. Install fuel pipework from fuel filter to HP pump as per overview drawing (→ Page 488).
TIM ID: 0000004071 – 005
M020124/02E 2009-02 © MTU

5.7.29 Leak-off fuel pipework – Overview
Fuel return lines
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1 Fuel return line 13 Retainer 25 Sealing ring
2 Union 14 Grommet 26 T adapter
3 Sealing ring 15 Grommet 27 Fuel return line
4 Fuel collecting line 16 Screw 28 Fuel return line
5 Fuel collecting line 17 Screw 29 Grommet
6 Union 18 Pipe half-clamp 30 Grommet
7 Sealing ring 19 Pipe half-clamp 31 Pipe half-clamp
8 Sealing cone 20 Fuel return line 32 Pipe half-clamp
9 Plug nut 21 Fuel return line 33 Screw
10 Pipe half-clamp 22 Fuel return line 34 Pipe half-clamp
11 Screw 23 Fuel return line 35 Union
12 Grommet 24 Banjo screw
TIM ID: 0000033770 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Leak-off fuel housing 10 Threaded adapter 19 Screw
2 Screw 11 Sealing ring 20 Pipe half-clamp
3 Washer 12 Sealing cone 21 Pipe half-clamp
4 Adapter 13 Nut 22 Screw
5 Union 14 Retainer 23 Grommet
6 Sealing ring 15 Retainer 24 Screw
7 Plug screw 16 Grommet 25 Pipe half-clamp
8 Leak-off fuel line 17 Pipe half-clamp
TIM ID: 0000033770 – 001
M020124/02E 2009-02 © MTU

5.7.30 Leak-off fuel line – Removal
Preconditions

• Do not smoke.
Removing leak-off fuel line

1. Prior to removal of the lines take photos or mark add-on components and lines.
3. Remove fuel lines with securing hardware as per overview drawing (→ Page 493).
cardiagn.com
TIM ID: 0000004072 – 007
M020124/02E 2009-02 © MTU

5.7.31 Leak-off fuel pipework – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Leak-off fuel pipework – Cleaning

TIM ID: 0000004073 – 002
M020124/02E 2009-02 © MTU

5.7.32 Leak-off fuel pipework – Check
Spare parts

Sealing rings

Risk of injury!
Leak-off fuel pipework – Check
Item Findings Task
Visually inspect all leak-off fuel lines Damaged • Corrective work

for damage. • Replace
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Pressure-test leak-off fuel lines with Leaking Replace
air in water bath for leaks. A water
temperature of min = 30°C and
max = 40°C and a test pressure of
Check banjo screws for damage and • Damaged • Corrective work: Recut threads
threads for ease of movement. • Threads sluggish. • Replace
damage oilstone.
• Replace
TIM ID: 0000004074 – 002
M020124/02E 2009-02 © MTU

5.7.33 Leak-off fuel line – Installation
Spare parts

Sealing ring
Grommet

• Do not smoke.
cardiagn.com
Installing leak-off fuel line

2. Install leak-off fuel line according to overview drawing (→ Page 493) or according to photos/markings.
TIM ID: 0000004075 – 007
M020124/02E 2009-02 © MTU

5.8 Exhaust Turbocharger
5.8.1 Exhaust turbochargers – Overview
Exhaust turbochargers – Overview
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10 Exhaust turbocharger, left 14 Adapter 25 Nut
engine side 16 Screw 30 Sealing ring
11 Exhaust turbocharger, right 18 Screw 35 Screw
engine side 19 Washer 40 Spacer sleeve
13 Locking plate
TIM ID: 0000029658 – 001
M020124/02E 2009-02 © MTU

5.8.2 Exhaust turbocharger – Removal
Preconditions
Special tools

Heavy object.
Risk of crushing!
Exhaust turbocharger – Removal

1. Insert eyebolt into bearing housing of exhaust turbocharger.
2. Secure exhaust turbocharger with crane and hook-ended chain sling.
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3. Remove nuts and sleeves for exhaust turbocharger as per overview drawing (→ Page 499).
4. Remove exhaust turbocharger from exhaust manifold.
5. Remove sealing rings.
6. Remove studs from exhaust manifold.
TIM ID: 0000005962 – 006
M020124/02E 2009-02 © MTU

5.8.3 Exhaust turbocharger – Disassembly
Special tools

Vibe jaw F70144375 2
T torque wrench F30520703 1
Snap ring pliers F30376601 1


Risk of injury!
cardiagn.com
Exhaust turbocharger – Disassembly

1. Mark positions of compressor casing (1) and
turbine housing (4) to the bearing housing (2) and
to the back wall of the compressor (arrows).
2. Mount turbine housing (4) on the gas intake
flange with braces.
3. Remove tensioning segments (3) from turbine
housing.
4. Carefully take turbine housing (4) off bearing
housing, in doing so do not tilt housing. Tilting
can cause damage to the blade.
5. If the turbine housing (4) sticks, use rust-removing
agent. If necessary, use copper hammer.
TIM ID: 0000019345 – 001
M020124/02E 2009-02 © MTU

6. Remove nuts (1) and tensioning segments (2) from

compressor casing.
7. Carefully take compressor casing off bearing
housing. Take care that the blade is not damaged.
8. If the turbine housing sticks, use a rubber mallet.
9. Mount impeller on the hub in the vibe jaw (3).
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Note: Left-hand thread
10. Remove self-locking nut (2) with two-armed

wrench (1).
11. The nut is only loosened with the two-armed
wrench so that the impeller shaft is not damaged.
12. Pull compressor wheel (1) off compressor shaft, if

necessary press the impeller out with a handpress
(arrow).
TIM ID: 0000019345 – 001
M020124/02E 2009-02 © MTU

13. Carefully remove impeller shaft (2) from bearing

housing (1).
14. Center heat shield (3) and remove from the
impeller shaft, in doing so observe piston rings.
15. Remove piston rings (1) with pliers from the
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impeller shaft.
16. Mount bearing housing between both flange faces

in bench vise (use braces).
17. Remove screws (1), take back wall (2) off bearing
housing and remove O-rings.
TIM ID: 0000019345 – 001
M020124/02E 2009-02 © MTU

18. Press sealing bushing (1) out of back wall (3).

sealing bushing (1).
20. Remove oil thrower ring (1), oil retainer (2), bearing
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collar (3), axial bearing washer (6), bushing (5)
and bearing collar (4) from bearing housing.
21. Install snap rings (1) and bearing bushing (2) at

the compressor side and then remove snap rings
(3) and bearing bushing (4) at the turbine side.
TIM ID: 0000019345 – 001
M020124/02E 2009-02 © MTU

5.8.4 Exhaust turbocharger – Cleaning
Material

Cleaning agent
Compressed air.
Risk of injury!

• Do not smoke.
cardiagn.com
Disassemble exhaust turbocharger (→ Page 501).
Exhaust turbocharger – Cleaning

3. Thoroughly blow off all parts with compressed air.
Wet sand blasting

1. Protect bearing bores and piston ring sealing faces on the bearing housing and shaft and piston ring sealing
faces on the back wall from cast-steel shots.
2. Wet sand blast housing, impeller, compressor wheel, back wall and heat shield.
TIM ID: 0000019450 – 001
M020124/02E 2009-02 © MTU

5.8.5 Exhaust turbocharger – Check
Spare parts

Bearing housing
Turbine housing
Compressor housing
Rotor
Compressor wheel
Exhaust turbocharger check
Visually check housing, guide vane • Cracks Replace
cardiagn.com
ring, heat shield and impellers for • Foreign objects
cracks, foreign objects and scoring. • Scoring
visible
Check oil supply bores in bearing Foreign objects visible. Replace

housing for foreign objects.
Check piston sealing faces and Damaged Replace

bearing points for damage.
Check turbine housing for scaling. Scale visible on gas inlet land or Replace
circumference.
Check gas inlet flange and gas Flange uneven. • Corrective work: Smooth using
outlet flange for flatness. oilstone.
• Replace
Check impellers for bent or broken Damaged Replace

blades and check impeller shaft for
scored bearings.
Check piston seat in rear wall and • Scores Replace

bearing housing for scoring and • Damage
damage. visible
Self-locking nuts Replace

O-rings
Wear parts and rotating parts that display cracks must be replaced.
Replace clamping segments, nut, shaft nut, piston rings, cylinder head bolts and washers, O-rings, oil deflector,
thrust washer, snap rings, bearing bushings and screws during overhaul.
TIM ID: 0000019347 – 002
Bearing housing
Note: The segment mating faces must not display severe corrosion.
1. Measure max. bore ID at the bearing points using a bore gauge.

• Max. bore ID = 22.272 mm
2. If the limit value is exceeded, replace bearing housing.
M020124/02E 2009-02 © MTU

Turbine housing
1. Radial cracks of up to 10 mm in length in the area
of lug (2) and partition wall (1) are permissible.
2. Complete cracking is not permissible.
3. Slight scoring in the circumferential area is
permissible.
4. Replace component if the gas inlet flange or gas
outlet flange is distorted.
Compressor housing
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1. Check circumferential area (arrowed) for scoring
and deformation. Scoring of up to 0.2 mm
is permissible.
2. Replace compressor housing if deformed.
Rotor
1. Check rotor shaft for roundness:
1.1. Position rotor shaft on two V-blocks at
the bearing points.
1.2. Position measuring sensor on the shaft
at a distance of 5 mm to the end of the
compressor wheel seat.
1.3. Evenly press rotor shaft onto the V-blocks
during testing.
1.4. Maximum permissible radial runout <
0.008 mm.
TIM ID: 0000019347 – 002
1.5. Replace rotor if the permissible radial

runout is exceeded.
2. Measure shaft diameter at the bearing points and
piston ring groove width.
• Min. diameter = 14.25 mm
• Max. groove width = 3.32 mm
3. Replace shaft if limit values are violated.
M020124/02E 2009-02 © MTU

Note: During production, all compressor wheels and

shafts are balanced separately. Deposits and
contamination on the compressor and turbine
wheels can lead to unbalance during operation.
Unless a new rotor assembly is installed,
the entire rotor assembly must be balanced
during each repair.
Balancing rotor assembly

1. Clean all parts of the rotor assembly (rotors,
bearing collar, seal bushing (oil deflector ring),
bush, compressor wheel and shaft nut) prior
to balancing.
2. The position of the parts relative to each other
must be marked.
Note: The rotor assembly must only be balanced
in planes A and B!
3. Support rotor assembly at bearing points (arrowed)
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in balancing device.
4. Impermissible residual unbalance of the rotor
assembly must be reduced by taking off material
(see following paragraphs) in planes A and B to
the max. values stated in the table.
Turbocharger type Balancing plane A (C) in mmg Balancing plane B (T) in mmg
K 36 4.0 3.1
K 37 4.6 3.6
Removing material at compressor wheel

1. During material removal in the area of the blade
base a minimum distance (X) of 2 mm must
be adhered to.
2. Any hollows must not show edges to the
surrounding area.
TIM ID: 0000019347 – 002
M020124/02E 2009-02 © MTU

Removing material at turbine wheel

1. Material removal during balancing in a circle
segment of max. 150°.
surrounding area.
Max. permissible material removal
cardiagn.com
Turbocharger Compressor wheel Turbine wheel
type
D R F G H
(mm) (mm) (mm) (mm) (mm)
K 36 4 4 2.5 4.0 1.5
K 37 4 5 2.5 4.0 1.5

TIM ID: 0000019347 – 002
M020124/02E 2009-02 © MTU

5.8.6 Exhaust turbocharger – Tolerances
cardiagn.com
Admissible contour clearance for K36
Gap clearance between min. (mm) max. (mm)
A Compressor wheel contour 0.35 0.8
B Compressor wheel rear side – –
C Turbine wheel contour 0.62 1.06
D Turbine wheel rear side 0.8 1.2

– Axial clearance 0.08 0.135
– Radial clearance, max. with – 0.58
83 mm distance between
TIM ID: 0000019348 – 001
bearings
bearings
M020124/02E 2009-02 © MTU


B Compressor wheel rear side 0.8 –

bearings
bearings
cardiagn.com
TIM ID: 0000019348 – 001
M020124/02E 2009-02 © MTU

5.8.7 Exhaust turbocharger – Assembly
Special tools

Assembly jaws F70144375 2.
Tee torque wrench, 10-90 Nm F30520703 1
Angle of rotation measuring device Y20044010 1
Dynamometer Y20504961 1
Material

Engine oil 40453 1
cardiagn.com
Assembly paste Ultra-Therm MTU 50547 1
Loctite 640 40105 1
Spare parts

O-rings
Spring pins
Piston rings
Bearing bushings
Piston rings
Snap ring
Heavy object.
Risk of crushing!

TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

Exhaust turbocharger – Assembly

1. Check that all parts are perfectly clean, clean if
required.
2. Oil the following bearing components prior
to installation:
• Rotor bearing seats
• Bearing bushings
• Thrust washer
• Sealing bushing
• Oil control ring
• Bearing collar
• Piston rings
• Bushing
3. Install snap rings (1) and bearing bushing (2) from
compressor side, then snap rings (3) and bearing
bushing (4) from turbine side in bearing housing.
4. Insert snap rings with the round edge facing the
bearing bushing. Ensure that the snap ring is
properly seated in the groove!
cardiagn.com
5. Clamp rotor shaft in bench vise (use protective
jaws).
6. Carefully fit piston rings (1) on shaft, aligning the
piston ring joints (arrow) arranged with an offset
of 180°.
7. Center piston rings on rotor shaft.
8. Carefully place heat shield (1) over piston rings on

turbine wheel.
9. Insert a sheet strip (2) of 1 mm thickness between
heat shield and rear side of turbine wheel to
ensure that the piston rings are properly guided in
the bearing housing bore.
TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

10. If the rotor assembly has been rebalanced,

observe the associated position markings.
11. Move sleeve onto rotor shaft to protect the thread.
12. Carefully move bearing housing (4) onto rotor
shaft, ensuring that the oil supply bore of the
bearing housing is arranged with an offset of 90°
towards the piston ring joint.
Note: The piston rings are properly seated when
heat shield and bearing housing can
easily be rotated.
13. Move first bearing collar (5) and bushing (2)

onto rotor shaft.
14. Insert thrust washer (3) in bearing housing,
ensuring that the centering pins (arrows) are
properly seated.
15. Move second bearing collar (1) onto rotor shaft.
16. Place oil baffle plate (1) on thrust washer, ensuring
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that the oil baffle plate is properly seated (arrows).
17. Move oil control ring (3) with smaller collar facing
downwards onto rotor shaft.
18. Coat new O-ring (2) with petroleum jelly and insert
in groove in bearing housing.
19. Carefully install two piston rings (2) on sealing

bushing (1).
20. Arrange piston ring joints with 180° offset.
21. Install sealing bushing with chamfer (arrow)
facing compressor wheel rear side (upwards) in
rear wall (3).
Note: If necessary, compress piston ring with
screwdriver.
22. Position sealing bushing so that oil supply bore

of bearing housing is arranged at 90° offset
towards piston ring joint.
TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

23. Clean threads of screws (1) and in bearing

housing, ensuring that they are free of grease
and dry.
24. Coat screw threads with Loctite.
25. Place rear wall (2) according to the markings
onto bearing housing.
Note: Loctite curing process is completed after
approx. 24 hours only.
26. Install screws and washers and use torque wrench

to tighten to specified tightening torque. Values
(→ Page 80).
27. Remove sheet strip (3) between heat shield and
turbine wheel rear side.
28. Measuring turbine-side contour clearance:
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28.1. Insert core assembly, without compressor
wheel and shaft nut, in turbine housing and
tighten with screws.
28.2. Position dial-gauge anvil on turbine wheel
hub.
28.3. Press down rotor and set dial gauge to zero.
28.4. Press rotor against dial-gauge anvil and
note down measured value.
28.5. Required contour clearance (→ Page 510).
29. Following this measurement, remove turbine
housing.
30. Measuring compressor-side contour clearance:

30.1. Push compressor wheel onto shaft. Insert
core assembly, without shaft nut, in
compressor housing and tighten with nuts.
30.2. Position dial-gauge anvil on compressor
wheel hub and set dial gauge to “0”.
30.3. Lift compressor wheel as far as it will go and
31. Following this measurement, remove compressor
housing.
TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

Note: Do not subject shaft to bending stress.
32. Tighten new shaft nut (2) with Tee torque

wrench (1) to specified pretightening torque and
angle of further rotation. Values (→ Page 80).
Note: The turbine-side piston rings are properly
seated if heat shield and bearing housing
can easily be rotated after the compressor
wheel has been installed.
33. Secure shaft nut and threaded journal of rotor with

screw locking varnish (arrow).
34. Measuring axial clearance:
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34.1. Place dial-gauge anvil under preload on
turbine wheel hub.
note down measured value. Values
(→ Page 510).
35. Measuring radial clearance:

Note: Radial clearance measurement is
required on turbine side only.
35.1. Place dial gauge stylus in the center of the

seating taper (arrow 1) of the turbine wheel.
35.2. Use dynamometer to pull down turbine
wheel hub at 50 N measurement force
(arrow 2).
35.4. Use dynamometer to pull up turbine wheel
hub at 50 N measurement force (arrow 2).
TIM ID: 0000019346 – 001
35.5. Note the reading at the dial gauge. Values

(→ Page 510).
35.6. Rotate rotor through 90°.
35.7. Repeat measurement.
M020124/02E 2009-02 © MTU

in groove in rear wall.
37. Place compressor housing (1) onto rear wall,
ensuring that it is not tilted. Observe the markings
made prior to removal.
38. Fit clamping segments (2) and screw on new
cardiagn.com
nuts (1).
39. Use torque wrench to tighten nuts (1) to specified
tightening torque. Values (→ Page 80).
40. Place turbine housing (3) onto bearing housing,

41. Coat thread of screws (1) with assembly paste.
42. Fit clamping segments (2) and insert screws (1).
specified tightening torque. Values (→ Page 80).
44. Check rotor shaft for ease of movement.
TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

5.8.8 Exhaust turbocharger – Installation
Special tools

Material

Assembly paste (Ultra Therm) 50547 1
Spare parts

cardiagn.com
Sealing ring
Sleeve
Heavy object.
Risk of crushing!
Exhaust turbocharger – Installation

1. Coat studs at threaded end with assembly paste.
2. Install studs and use torque wrench to tighten to specified tightening torque (→ Page 80).
3. Fit new sealing rings in exhaust manifold.
4. Position exhaust turbocharger with crane and hook-ended chain sling.
5. Coat thread and nut contact faces with assembly paste.
6. Screw on nuts with sleeves and use torque wrench to tighten crosswise to specified tightening torque
(→ Page 80).
7. Check-tighten with same tightening torque.
TIM ID: 0000008438 – 003
M020124/02E 2009-02 © MTU

5.9 Charge-Air Cooling
5.9.1 Intercooler – Overview
Intercooler
1
2
3
Elbow, left side
Vent line
End housing, top
6
A
B
Elbow, right side
Air inlet (from turbocharger)
Air outlet (to cylinder)
cardiagn.com
4 Intercooler core C Coolant inlet
5 End housing, bottom D Coolant outlet
TIM ID: 0000030093 – 001
M020124/02E 2009-02 © MTU

Intercooler and attachments
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1 Intercooler 8 Mounting bracket 15 Mounting bracket
2 Plug screw 9 Mounting bracket 16 Hex bolt
3 Connection housing, bottom 10 Screw 17 Washer
4 Dowel pin 11 Washer 18 Hex bolt
5 Rubber profile 12 Screw 19 Washer
6 Hex bolt 13 Screw
7 Washer 14 Mounting bracket
TIM ID: 0000030093 – 001
M020124/02E 2009-02 © MTU

5.9.2 Intercooler – Removal
Preconditions
Heavy object.
Risk of crushing!
Intercooler – Removal
1. Remove intercooler and elbow as per overview
2. Attach intercooler to crane with rope and carefully
raise from engine.
3. After removing intercooler, seal all connections on
engine with suitable plugs and covers.
4. Protect intercooler from damage. Cover cooler
meshes.
cardiagn.com
TIM ID: 0000003462 – 008
M020124/02E 2009-02 © MTU

5.9.3 Intercooler – Cleaning

Work on the intercooler must always be carried out by qualified personnel.
The following sections contain instructions for the cleaning company.
Air-side cleaning
In the event of grease and oil contamination on the intercooler’s air side, it is to be cleaned in a closed
cleaning unit. The cleaner must circulate in the opposite direction of the cooling air.
It is essential to avoid damaging the cooler, especially the cooling fins.
To remove deposits, only use a cleaner that does not attack metal surfaces (→Operating Instructions ).
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits.
Water-side cleaning
It is recommended that the water side is cleaned in a closed cleaning unit with forced flushing and filter.
The water side can also be cleaned in an immersion or ultrasonic bath.
Intercooler – Flushing
cardiagn.com
After cleaning, flush the intercooler with water until the pH values of the clean water and the flushing
water are the same (permissible difference pH value: 1 pH).
Intercooler – Drying and preservation
If the cooler is not to be put into operation immediately after cleaning, the cooler is to be dried in a
drying oven for approx. 3 hours at a temperature of 110 to 120 °C.
After drying, preserve the cooler with a preservative.
TIM ID: 0000008440 – 003
M020124/02E 2009-02 © MTU

5.9.4 Intercooler – Check
Material

Emery cloth
Spare parts

Intercooler
Elbow
Holder
Plug-in pipe with bell
Plug-in pipe
cardiagn.com
Drain valve
Compressed air.
Risk of injury!
Component is hot.
Risk of burning!

Hot testing liquid.
Intercooler – Check
Item Findings Task
Visually inspect all components for Damaged • Recondition

damage. • Replace
Check all sealing, mating and • Damaged • Recondition:

contact faces for damage and • Uneven smooth with oilstone or emery
unevenness. cloth.
• Replace
Intercooler – Leak check

TIM ID: 0000008441 – 002
1. Seal coolant chamber connections on intercooler with suitable sleeves and covers with gaskets and clamps.
2. Connect compressed air line at plug.
3. Preheat test bath to 80 °C.
4. Immerse intercooler in test bath.
5. Open compressed air supply and set pressure reducer to 0.5 bar.
6. Pressure-test intercoolers with air in water bath for leaks. Verify that no bubbles rise to the surface.
M020124/02E 2009-02 © MTU

7. Replace intercooler if leaks are found.

8. After checking, blow through cooling air ducts with compressed air in vertical direction.
cardiagn.com
TIM ID: 0000008441 – 002
M020124/02E 2009-02 © MTU

5.9.5 Intercooler – Installation
Material

Spare parts

O-ring
Heavy object.
Risk of crushing!
Intercooler – Installation
cardiagn.com
2. Coat O-ring with petroleum jelly and place on
elbow flange.
3. Use crane to place intercooler on engine.
4. Screw screws (5) into mounting brackets (1).
5. Install elbow (3) to intercooler and secure with
screws (2) and nuts (4).
TIM ID: 0000008445 – 003
M020124/02E 2009-02 © MTU

5.10 Air Intake/Air Supply
5.10.1 Air intake / air supply – Overview
cardiagn.com
1 Intercooler 6 Air intake 11 Charge air line
2 Charge air manifold 7 Exhaust turbocharger, left 12 Connecting elbow
3 Connecting elbow 8 Exhaust turbocharger, right 13 Charge air manifold
4 Exhaust turbocharger, left 9 Air intake
5 Charge air line 10 Exhaust turbocharger, right
TIM ID: 0000008446 – 001
M020124/02E 2009-02 © MTU

5.10.2 Intake housing – Overview
Air Intake
cardiagn.com
1 Connecting piece
2 Rubber sleeve
3 Clamp
4 Clamp
5 Plug
TIM ID: 0000029662 – 001
M020124/02E 2009-02 © MTU

Air Intake
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1 Elbow 2 Clamp
TIM ID: 0000029662 – 001
M020124/02E 2009-02 © MTU

5.10.3 Intake housing – Removal
Preconditions
Intake housing – Removal
1. Release clamps and remove air intake as shown in overview drawing (→ Page 527).
cardiagn.com
TIM ID: 0000008449 – 005
M020124/02E 2009-02 © MTU

5.10.4 Intake housing – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Remove intake housing (→ Page 529).
cardiagn.com
Intake housing – Cleaning
2. Remove cleaner.
3. Thoroughly blow out all components with compressed air.
TIM ID: 0000008450 – 001
M020124/02E 2009-02 © MTU

5.10.5 Intake housing – Check
Spare parts

Elbow
Rubber sleeve
Clamp
Plug
Connector
Clean intake housing (→ Page 530).
Intake housing – Check
cardiagn.com
Check connector, elbow and rubber • Wear • Recondition
sleeve for wear, cracks and damage. • Cracks • Replace
• Damage
visible
Check clamps, plug for ease of Sluggish • Recondition

TIM ID: 0000008451 – 001
M020124/02E 2009-02 © MTU

5.10.6 Intake housing – Installation

Intake housing – Installation
1. Remove all seals and plugs.
2. Install air pipework as per overview drawing (→ Page 527).
cardiagn.com
TIM ID: 0000008452 – 004
M020124/02E 2009-02 © MTU

5.10.7 Intake air system to cylinders, left – Overview
cardiagn.com
1 Charge air manifold 5 Hex screw
2 Charge air manifold 6 Washer
3 O-ring 7 Plug
4 Gasket 8 Sealing ring
TIM ID: 0000004079 – 001
M020124/02E 2009-02 © MTU

5.10.8 Air supply system to cylinders, left-hand side – Removal
Preconditions
Removing charge-air pipe
1. Remove charge-air pipe as shown in overview drawing, starting with the free end (→ Page 533).
2. Remove gaskets and O-rings.
3. After removal, seal all openings with plugs or covers.
cardiagn.com
TIM ID: 0000004080 – 006
M020124/02E 2009-02 © MTU

5.10.9 Air supply system to cylinders, left – Cleaning
Material

Cleaner (Snow-White 11-0) 40460
Cleaner (Hakupur 312) 30390
Compressed air.
Risk of injury!

cardiagn.com

Cleaning charge-air manifold

1. Clean left charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow out charge-air manifold with compressed air.
TIM ID: 0000004081 – 002
M020124/02E 2009-02 © MTU

5.10.10 Air supply to cylinders, left side – Check
Material

Spare parts

Charge air manifold
Sealing ring
Screws
cardiagn.com
Plug screw
Compressed air.
Risk of injury!
Checking air supply to cylinders, LHS
Item Findings Task
Check charge air manifold for cracks Cracks visible Replace

with red dye penetrant.
Perform leak test on charge air Leaks • Replace blanking plug.

manifold with air in water bath at a • at blanking plugs • Replace charge air manifold.
maximum air pressure of 0.5 bar. • at charge air manifold
Check sealing and mating faces for • Uneven • Recondition: smooth with
evenness and damage. • Damaged oilstone.
• Replace
Check threads for ease of Sluggish • Recut threads.

movement. • Replace thread inserts.
Check screws and plugs for damage. Damaged Replace

TIM ID: 0000004082 – 003
M020124/02E 2009-02 © MTU

5.10.11 Air supply system to cylinders, left-hand side – Installation
Material

Engine oil
Spare parts

O-ring
Gasket
cardiagn.com

Installing air supply system to cylinders, left-hand

side
2. Coat O-ring with grease and fit on charge air
manifold union (2).
3. Coat gaskets with grease and place on sealing
faces (arrows).
4. Install charge-air manifolds (1) as shown in
overview drawing (→ Page 533), beginning
with driving end.
5. Insert screws with washer and retainer in charge
air manifold (1) and tighten.
TIM ID: 0000004083 – 005
M020124/02E 2009-02 © MTU

5.10.12 Air supply system to cylinders, right – Overview
cardiagn.com
1 Charge air manifold 5 Hex screw 9 Threaded bush
2 Charge air manifold 6 Washer 10 Sealing ring
3 O-ring 7 Plug 11 Plug
4 Gasket 8 Sealing ring 12 Sealing ring
TIM ID: 0000004084 – 001
M020124/02E 2009-02 © MTU

5.10.13 Air supply system to cylinders, right-hand side – Removal
Preconditions
Removing charge air manifold
1. Remove charge-air manifold as per overview drawing starting from the free end . (→ Page 538)
3. After removal, seal all openings with suitable plugs or covers.
cardiagn.com
TIM ID: 0000004087 – 006
M020124/02E 2009-02 © MTU

5.10.14 Air supply system to cylinders, right – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning the charge-air manifold

1. Clean right charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
TIM ID: 0000004085 – 002
M020124/02E 2009-02 © MTU

5.10.15 Air supply to cylinders, RHS – Check
Material

Spare parts

Charge air manifold
Sealing ring
Screws
cardiagn.com
Plug screw
Compressed air.
Risk of injury!
Checking air supply to cylinders, RHS
Item Findings Task


• Replace


TIM ID: 0000004086 – 003
M020124/02E 2009-02 © MTU

5.10.16 Air supply system to cylinders, right-hand side – Installation
Material

Engine oil
Spare parts

O-ring
Gasket
cardiagn.com

Installing charge air manifold

manifold union (2).
faces (arrows).
with driving end.
TIM ID: 0000004088 – 006
M020124/02E 2009-02 © MTU

5.10.17 Air pipework from turbocharger to intercooler – Overview
Air pipework 12V
cardiagn.com
1 Connection housing 10 Plug-in pipe 19 O-ring
2 O-ring 11 O-ring 20 Clamp
3 Spacer sleeve 12 O-ring 21 Rubber sleeve
4 Spacer sleeve 13 Elbow 22 Clamp
5 Screw 14 O-ring 23 Elbow
7 Connecting piece 16 Washer 25 Screw
8 O-ring 17 Nut 26 Washer
9 Clamp 18 Connecting piece 27 Nut
TIM ID: 0000030095 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Connecting piece 11 Pipe half-clamp 21 Retainer
2 O-ring 12 Screw 22 Washer
3 Clamp 13 Washer 23 Screw
4 Charge-air pipe 14 Nut 24 Pipe half-clamp
5 Rubber sleeve 15 Connecting piece 25 Pipe half-clamp
6 Clamp 16 O-ring 26 Screw
7 Retainer 17 Clamp 27 Washer
8 Washer 18 Charge-air pipe 28 Nut
9 Screw 19 Rubber sleeve
10 Pipe half-clamp 20 Clamp
TIM ID: 0000030095 – 001
M020124/02E 2009-02 © MTU

Air pipework 16V
cardiagn.com
1 Connection housing 19 Washer 37 Connecting piece
2 O-ring 20 Nut 38 O-ring
3 Spacer sleeve 21 Retainer 39 Screw
4 Spacer sleeve 22 Washer 40 Washer
5 Screw 23 Washer 41 Elbow
7 Connecting piece 25 Pipe half-clamp 43 Screw
8 O-ring 26 Pipe half-clamp 44 Washer
9 Screw 27 Screw 45 Nut
10 Washer 28 Washer 46 Retainer
11 Charge-air pipe 29 Nut 47 Washer
12 Rubber sleeve 30 Connecting piece 48 Washer
14 Plug-in pipe 32 Screw 50 Pipe half-clamp
15 O-ring 33 Washer 51 Pipe half-clamp
16 Elbow 34 Charge-air pipe 52 Screw
17 O-ring 35 Rubber sleeve 53 Washer
18 Screw 36 Clamp 54 Nut
TIM ID: 0000030095 – 001
M020124/02E 2009-02 © MTU

Intercooler elbow
cardiagn.com
1 Elbow 4 Elbow 7 Screw
2 Plug screw 5 Plug screw 8 Nut
3 Plug screw 6 O-ring 9 O-ring
TIM ID: 0000030095 – 001
M020124/02E 2009-02 © MTU

5.10.18 Air pipework from exhaust turbocharger to intercooler – Removal
Preconditions
Air pipework from exhaust turbochargers to intercooler – Removal
1. Remove air pipework as per overview drawing (→ Page 543).
cardiagn.com
TIM ID: 0000008455 – 003
M020124/02E 2009-02 © MTU

5.10.19 Air supply from turbocharger to intercooler – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning air pipework

TIM ID: 0000008456 – 002
M020124/02E 2009-02 © MTU

5.10.20 Air ducts from turbocharger to intercooler – Check
Material

Red penetrant dye for surface crack-testing procedure
Spare parts

Charge air line
Connecting housing
Connecting elbow
Connector
Plug-in pipe
cardiagn.com
Rubber sleeve
Elbow
Spacer sleeve
Screw
Nut
Clamp
Bracket
Clean air ducts from turbocharger to intercooler (→ Page 548).
Air ducts from turbocharger to intercooler – Check
Using the fluorescent penetrant dye method, check the Crack indication Replace
connecting housing, elbow, bracket and connection
elbow for cracks.
Check elbow and connection elbow with air under Leaking: • Replace blanking
water, max. air pressure 0.5 bar, for leaks. • at blanking plugs plug.
• at elbow • Replace elbow.
Check sealing and bolt-on faces for evenness and • Uneven • Recondition:
damage. • Damaged Smooth with
oilstone.
• Replace
Check all threads for ease of movement. Sluggish • Recut thread.

• Replace thread
inserts.
TIM ID: 0000008457 – 001
Check connector, plug-in pipe, charge air line, screws, Damaged Replace
clamps and plugs for damage and wear.
M020124/02E 2009-02 © MTU

5.10.21 Air pipework from turbocharger to intercooler – Installation
Material

Spare parts

O-rings
cardiagn.com
Air pipework from turbocharger to intercooler – Installation
TIM ID: 0000008458 – 003
M020124/02E 2009-02 © MTU

5.11 Exhaust System
5.11.1 Exhaust system – Overview
Exhaust system
cardiagn.com
1 Exhaust turbocharger, left 4 Exhaust turbocharger, right 7 Exhaust turbocharger, right
2 Exhaust system 5 Exhaust pipework connection
3 Exhaust turbocharger, left 6 Exhaust system
TIM ID: 0000008460 – 001
M020124/02E 2009-02 © MTU

5.11.2 Exhaust pipework after cylinder head – Overview
Exhaust pipework 16V (also applicable to 8V / 12V)
cardiagn.com
1 Exhaust pipe 6 V-band clamp
2 Exhaust pipe 7 Insulation
3 Exhaust pipe 8 Gasket
4 Exhaust pipe 9 Screw
5 Bellows 10 Spacer
TIM ID: 0000029668 – 001
M020124/02E 2009-02 © MTU

5.11.3 Exhaust pipework after cylinder head – Removal
Preconditions

Risk of injury!
Exhaust pipework – Removal

1. Remove gasket (1).
2. Screw nut onto stud (2) and secure with second
nut.
3. Remove stud (2).
cardiagn.com
4. Remove screws (1) from band clamps (2).
5. Take off band clamps carefully.
6. Take off insulation.
7. Remove other insulation parts in the same way.
TIM ID: 0000030002 – 001
M020124/02E 2009-02 © MTU

8. Remove V-band clamps (2) from bellows (1).

9. Remove bellows (1).
10. Remove other bellows in the same way.
11. Remove all screws (1) from exhaust pipes and
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take off spacers (2).
12. Remove all exhaust pipes.
13. Seal exhaust ports on cylinder head with suitable
plugs.
TIM ID: 0000030002 – 001
M020124/02E 2009-02 © MTU

5.11.4 Exhaust pipework after cylinder head – Clean
Material

Compressed air.
Risk of injury!
Compressed air.
Risk of injury!
cardiagn.com

Cleaning exhaust pipework after exhaust turbocharger

1. Clean all parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Place components with deposits in a container with decarbonizer. Time for cleaning depends on the layer
thickness of the deposits.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
4. If deposits are stubborn, use synthetic shot-blasting pellets (nominal size 16 to 20) to help cleaning.
5. Remove cleaner.
6. Thoroughly blow all parts clean with compressed air.
TIM ID: 0000029122 – 001
M020124/02E 2009-02 © MTU

5.11.5 Exhaust pipework after cylinder head – Check
Material

Spare parts

Exhaust pipe
Bellows
Hex screw
cardiagn.com
Gasket
Exhaust pipework after cylinder head – Check
Using the surface crack-test Crack indication Replace

method and red penetrant
dye, check exhaust pipe and
bellows for cracks.
Check hex screws for Damaged Replace

damage.
Check parts for stress marks, • Stress marks Replace

wear and distortion. • Wear
• Distortion
visible
Check sealing and mating • Uneven • Recondition: Smooth with oilstone

faces for evenness and • Damaged • Replace
damage.
TIM ID: 0000032573 – 001
M020124/02E 2009-02 © MTU

5.11.6 Exhaust pipework after cylinder head – Installation
Special tools

Material

Engine oil 40453 1
Spare parts
cardiagn.com
Gasket
Heavy object.
Risk of crushing!
Exhaust pipework – Installation

2. Fit gaskets (1) on all cylinder head exhaust flanges.
TIM ID: 0000030005 – 001
M020124/02E 2009-02 © MTU

3. Position exhaust pipe starting from engine free

end.
4. Coat screws (1) with engine oil.
5. Insert screws (1) with spacers (2).
6. Tighten screws crosswise.
7. Fit gaskets (arrow) on both flange faces of the
cardiagn.com
exhaust pipe bellows.
8. Fit two V-band clamps (2) over exhaust pipe

bellows.
9. Position exhaust pipe bellows between exhaust
pipe flanges.
10. Use alignment device (1) to align collar of exhaust
pipe flange and exhaust pipe bellows flush.
TIM ID: 0000030005 – 001
M020124/02E 2009-02 © MTU

11. Push V-band clamp (2) centrally over flange collar

of exhaust pipe flange and exhaust pipe bellows
and secure with screws.
12. Remove alignment device (1).
13. Push second V-band clamp centrally over flange
collar of exhaust pipe flange and exhaust pipe
bellows and secure with screws.
14. Install further exhaust pipe bellows in the same
way.
15. Fit insulation (2) over exhaust pipe bellows and
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secure with band clamps (1).
16. Position band clamps (1) so that screws are
accessible in horizontal position.
17. Tighten screws.
18. Install further insulation parts in the same way.
19. Fit gaskets (1).

20. Insert studs (2) with the small thread ahead into
the flange for the exhaust turbocharger.
21. Tighten studs with locknuts.
TIM ID: 0000030005 – 001
M020124/02E 2009-02 © MTU

5.11.7 Exhaust pipework after exhaust turbocharger – Overview
Exhaust pipework
cardiagn.com
1 Exhaust elbow 2 Screw 3 Washer
TIM ID: 0000029672 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Bellows
2 Sealing ring
3 Clamp
4 Sealing ring
5 Clamp
TIM ID: 0000029672 – 001
M020124/02E 2009-02 © MTU

5.11.8 Exhaust pipework after exhaust turbocharger – Removal
Preconditions
Exhaust pipework after exhaust turbocharger – Removal
1. Remove exhaust pipework as per overview drawing (→ Page 560).
cardiagn.com
TIM ID: 0000008521 – 009
M020124/02E 2009-02 © MTU

5.11.9 Exhaust pipework after turbocharger – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Remove exhaust pipework after exhaust turbocharger (→ Page 562).
cardiagn.com
Exhaust pipework after turbocharger – Cleaning
2. Place parts displaying soot deposits in a bath containing carbon-deposit remover. Dwell time depends on
thickness of deposits.
3. After cleaning with carbon-deposit remover, rinse components in water until no further residues are washed off.
5. Remove cleaner.
6. Blow out exhaust lines thoroughly.
TIM ID: 0000003743 – 001
M020124/02E 2009-02 © MTU

5.11.10 Exhaust pipework after exhaust turbocharger – Check
Material

Spare parts

Exhaust elbow
Washer
Bellows
cardiagn.com
Clamp
Checking exhaust pipework after exhaust turbocharger
Item Findings Task
Check exhaust elbow with red dye Crack indication Replace

penetrant for cracks.
Check parts for stress marks, wear • Stress marks Replace

and deformation. • Wear
• Deformation
visible
Check sealing and mating faces for • Uneven • Corrective work: Smoothen
flatness and damage. • Damaged with oilstone
• Replace
TIM ID: 0000008522 – 002
M020124/02E 2009-02 © MTU

5.11.11 Exhaust pipework after exhaust turbocharger – Installation
Material

Assembly paste (Ultra-Therm MTU) 50547 1
Spare parts

Sealing ring
Exhaust pipework after exhaust turbocharger – Installation

1. Prior to assembly, coat screw threads with assembly paste.
2. Install exhaust elbow and bellows as per overview drawing (→ Page 560).
cardiagn.com
TIM ID: 0000008523 – 005
M020124/02E 2009-02 © MTU

5.11.12 Exhaust pipework after engine – Overview
Exhaust pipe bellows
cardiagn.com
1 Bellows 3 Clamp
2 Sealing ring 4 Insulation
TIM ID: 0000008524 – 001
M020124/02E 2009-02 © MTU

Companion flange
cardiagn.com
1 Flange
TIM ID: 0000008524 – 001
M020124/02E 2009-02 © MTU

5.11.13 Exhaust pipework after engine – Removal

Exhaust pipework after engine – Removal
1. Remove exhaust pipework according to overview drawing (→ Page 566).
2. After removal, seal all openings.
cardiagn.com
TIM ID: 0000008525 – 002
M020124/02E 2009-02 © MTU

5.11.14 Exhaust pipework after engine – Cleaning
Material

Cleaner
Decarbonizer
Compressed air.
Risk of injury!

cardiagn.com
Remove exhaust pipework after engine (→ Page 568).
Exhaust pipework after engine – Cleaning

5. Remove cleaner.
TIM ID: 0000008526 – 001
M020124/02E 2009-02 © MTU

5.11.15 Exhaust pipework after engine – Check
Spare parts

Flange
Clamp
Insulation
Clean exhaust pipework after engine (→ Page 569).
IExhaust pipework after engine – Check
Check exhaust pipe bellows and flange for wear • Traces of wear Replace
and distortion. • Wear
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• Deformation
visible
Check insulation for damage Damaged Replace
Check clamps for ease of movement. Sluggish • Recondition

• Replace
Check sealing and mating faces for evenness and • Uneven • Recondition: smooth
damage. • Damaged with oilstone
• Replace
TIM ID: 0000008527 – 001
M020124/02E 2009-02 © MTU

5.11.16 Exhaust pipework after engine – Installation
Material

Spare parts

Sealing ring
Check exhaust pipework after engine (→ Page 570).
Exhaust pipework after engine – Installation

2. Install exhaust pipe bellows as shown in overview drawing (→ Page 566).
cardiagn.com
TIM ID: 0000008528 – 002
M020124/02E 2009-02 © MTU

5.12 Starting Equipment
5.12.1 Electric starter – Overview
cardiagn.com
1 Starter (for 12V/16V on left
engine side)
2 Starter, right engine side
3 Hex screw / Allen screw
4 Gear ring
TIM ID: 0000001747 – 002
M020124/02E 2009-02 © MTU

cardiagn.com
1 Terminal 45 5 Engagement relay 9 Driver housing
2 Terminal 30 6 Commutator cover 10 Terminal 30
3 Terminal 50 7 Terminal 31
4 Housing for engagement lever 8 Starter housing
TIM ID: 0000001747 – 002
M020124/02E 2009-02 © MTU

5.12.2 Starter – Removal
Preconditions
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!
Disconnecting and removing starter

1. Before disconnecting, mark all cables with writable
adhesive tape for identification.
• Connection terminal 30 = positive cable
• Connection terminal 50 = control cable
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• Connection terminal 31 = ground cable
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Depending on the version, remove hex screws or
Allen screws (1) from starter.
5. Remove starter.
6. Protect starter from damage.
TIM ID: 0000001758 – 003
M020124/02E 2009-02 © MTU

5.12.3 Starter – Disassembly
Starter – Disassembly
Entrust starter overhaul to an authorized and specialized company only.
cardiagn.com
TIM ID: 0000001761 – 003
M020124/02E 2009-02 © MTU

5.12.4 Starter – Cleaning

Compressed air.
Risk of injury!
Starter – Cleaning
1. Clean starter with compressed air; do not wet-clean.
2. Protect starter against humidity.
cardiagn.com
TIM ID: 0000001751 – 002
M020124/02E 2009-02 © MTU

5.12.5 Starter – Check
Spare parts

Starter
Compressed air.
Risk of injury!
Starter – Check
Item Findings Task
Check tooth flanks of drive gear for • Wear • Recondition

wear, indentations and chipping. • Indentations • Replace
cardiagn.com
• Chipping
visible
Check nuts and studs for condition Sluggish Replace

and check threads for ease of
movement.
Check mating face on end housing Wear traces are found. Recondition: smooth with oilstone
for wear. or emery cloth.
TIM ID: 0000001755 – 002
M020124/02E 2009-02 © MTU

5.12.6 Starter – Installation
Material

Long-life grease (Longtherm 2 Plus) 40336 1
Electrical voltage.
Heavy object.
Risk of crushing!
Installing starter
1. Coat starter pinion with long-life grease.
cardiagn.com
2. Attach starter to crane.
3. Insert starter into opening on end housing.
4. Align bores for securing screws on starter with
those on flange.
5. Secure starter to flange with screws (1).
Connecting starter cables

1. Connect cables as per marking on starter (→ Page 574).
• (1) = terminal 45 = internal control cable (already connected)
• (2) = terminal 30 = positive cable
• (3) = terminal 50 = control cable
• (4) = terminal 31 = ground cable
2. Check operation of starter.
TIM ID: 0000001764 – 003
M020124/02E 2009-02 © MTU

5.12.7 Flame starting system – Overview
Attachments for flame starting system
cardiagn.com
1 Flange 11 Fuel line
2 Insulating washer 12 Fuel line
3 Nut 13 T-piece
4 Fuel nipple 14 Fuel line
5 Sealing element 15 Fuel line
6 Protective shroud 16 Fuel line
7 Screw 17 Bracket
8 Screw 18 Pipe half-clamp
9 Fuel line 19 Grommet
10 T-piece 20 Screw
TIM ID: 0000005115 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Bracket 27 Adapter 53 Fuel line
2 Bracket 28 Sealing ring 54 Non-return valve
3 Screw 29 Pipe half-clamp 55 Bracket
4 Screw 30 Grommet 56 Pipe half-clamp
5 Screw 31 Screw 57 Grommet
6 Washer 32 Fuel line 58 Screw
7 Pressure regulator 33 Bracket 59 Fuel line
8 Screw 34 Screw 60 Fuel line
9 Spacer bush 35 Washer 61 Blanking cone
10 Pipe half-clamp 36 Pipe half-clamp 62 Nut
11 Screw 37 Pipe half-clamp 63 Fuel line
12 Union 38 Grommet 64 Non-return valve
13 Sealing ring 39 Screw 65 Fuel line
14 Bracket 40 Fuel line 66 Grommet
15 Screw 41 Bracket 67 Grommet
16 Screw 42 Screw 68 Pipe half-clamp
17 T-piece 43 Pipe half-clamp 69 Pipe half-clamp
18 Fuel line 44 Grommet 70 Pipe half-clamp
19 Adapter 45 Screw 71 Pipe half-clamp
20 Sealing ring 46 Fuel line 72 Washer
21 Fuel line 47 Bracket 73 Spacer pipe
22 Adapter 48 Pipe half-clamp 74 Screw
23 Sealing ring 49 Grommet 75 Bracket
24 Adapter 50 Screw 76 Screw
TIM ID: 0000005115 – 001
25 Sealing ring 51 Fuel line 77 Grommet

26 Fuel line 52 Non-return valve 78 Pipe half-clamp
M020124/02E 2009-02 © MTU

5.12.8 Flame starting system – Removal

• Do not smoke.
Removing flame torches

1. Remove screws (arrowed) from protective cover.
2. Hold sealing element (2) securely and carefully
remove protective cover.
cardiagn.com
3. Removing fuel lines (1).
5. Disconnect control cable at connections (arrowed).
6. Remove sealing element (2).
7. Release flange (4).
8. Remove flame torch (3).
9. Remove insulating washer (5).
Removing fuel lines and externally mounted components

1. Before removing the lines, take photos or mark lines and externally mounted components.
2. Remove lines as shown in the overview drawing (→ Page 579).
3. After removal, seal all connections with plugs.
TIM ID: 0000005111 – 002
M020124/02E 2009-02 © MTU

5.12.9 Flame starting system – Cleaning
Material

Cleaning agent
Compressed air.
Risk of injury!

Remove flame starting system (→ Page 581).
cardiagn.com
Flame starting system – Cleaning
1. Clean all components with cleaning agent.
3. Blow out all components thoroughly with compressed air.
TIM ID: 0000005114 – 001
M020124/02E 2009-02 © MTU

5.12.10 Flame starting system – Check
Spare parts

Flange
Insulating washer
Nut
Fuel nipple
Sealing element
Protective shroud
Fuel line
T-piece
Bracket
Bracket
cardiagn.com
Pressure regulator
Spacer bush
Union

Risk of injury!
Clean flame starting system (→ Page 582).
Flame starting system – Check
Visually check all fuel lines and attachments for Damaged • Recondition
damage. • Replace
Check fuel lines with air bottom water for leaks. Leaking Replace
Maintain a coolant temperature of min. = 30 °C or
max. = 40 °C at a test pressure of 0.5 bar.
Check all threads for damage and ease of • Damaged • Recondition:

movement. • Thread sluggish. Recut thread.
• Replace
Check sealing and screw-on surfaces for damage. Damaged • Recondition:

Smooth with
oilstone.
• Replace
TIM ID: 0000005113 – 001
M020124/02E 2009-02 © MTU

5.12.11 Flame starting system – Installation
Spare parts

Sealing ring
Grommet

• Do not smoke.
cardiagn.com
Check flame starting system (→ Page 583).
Install flame starting system

2. Blow fuel lines clear with compressed air.
3. Install fuel lines without tension as shown in the overview drawing (→ Page 579) or as per photos/marks
made during removal.
TIM ID: 0000005112 – 003
M020124/02E 2009-02 © MTU

5.13 Lube Oil System, Lube Oil Circuit
5.13.1 Lube-oil pump with drive – Overview
cardiagn.com
1 Oil pump 6 Banjo screw 11 Grommet
2 Screw 7 Sealing ring 12 Screw
3 Washer 8 Oil line 13 Spacer sleeve
4 Screw 9 Retainer
5 Pressure reducing valve 10 Pipe half-clamp
TIM ID: 0000032414 – 001
M020124/02E 2009-02 © MTU

5.13.2 Lube-oil pump with drive – Removal
Special tools

Heavy object.
Risk of crushing!
Removing oil pump with safety valve

Note: The illustration does not show engine in
installation position.
1. Unscrew all screws (1) on the oil pump (2).

2. Attach support bracket to oil pump and with rope,
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slightly tensioned, to crane.
3. Remove oil pump from equipment carrier and
place aside.
Removing oil line and pressure reducing valve

1. Remove oil line from equipment carrier as per overview drawing (→ Page 585).
2. Remove pressure reducing valve from equipment carrier.
4. Seal connections with suitable plug.
5. Protect oil line from damage.
TIM ID: 0000004096 – 005
M020124/02E 2009-02 © MTU

5.13.3 Lube-oil pump with drive – Disassembly

Lube-oil pump – Disassembly
1. Do not disassemble lube oil pump.
2. Contact Service.
cardiagn.com
TIM ID: 0000004097 – 002
M020124/02E 2009-02 © MTU

5.13.4 Lube oil pump with drive – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning oil line

TIM ID: 0000004094 – 003
M020124/02E 2009-02 © MTU

5.13.5 Lube-oil pump with drive – Check
Material

Spare parts

Oil pump
Pressure reduction valve
Oil line
cardiagn.com
Banjo screw
Screw
Pipe half-clamp

TIM ID: 0000004095 – 003
M020124/02E 2009-02 © MTU

Lube-oil pump with drive – Check
Item Findings Task
Visually inspect outside of lube-oil Damaged Have lube-oil pump operation

pump for damage and defects. checked and repaired at
manufacturer.
Visually inspect oil line for damage. Damaged • Corrective work

• Replace
Check sealing faces for irregularities. Uneven • Corrective work and check for
evenness with ink-check plate.
• Replace
Check banjo screws for damage and • Damaged Replace

Check drive gear with dye penetrant Signs of cracks Replace

for cracks.
Check tooth flanks of drive gear • Stress marks • Corrective work
cardiagn.com
for stress marks, indentations and • Indentations • Replace lube-oil pump
chipping. • Chipping
visible
Check breather valve for opening Opening pressure not reached or Replace
pressure of 15 bar. Test medium: exceeded.
Engine oil SAE 30 medium
temperature: from 90 °C to 100 °C.
Disassembly of the pressure Damaged Replace

reduction valve is not planned;
check for damage by visual
inspection only.
Check pressure reduction valve Opening pressure not reached, or Replace

opening pressure. Operation: The exceeded.
valve limits the oil flow so that a
constant pressure of 5.5 +1 bar is
maintained at the last crankshaft
bearing. Medium temperature: from
90 °C to 100 °C, design pressure at
n/min 1.5 bar at n/max 7 bar of oil
pump.
TIM ID: 0000004095 – 003
M020124/02E 2009-02 © MTU

5.13.6 Lube oil pump with drive – Installation
Special tools

Material

Engine oil
cardiagn.com
Spare parts

Sealing ring
Grommet
O-ring
Heavy object.
Risk of crushing!
Heavy object.
Risk of crushing!
Compressed air.
Risk of injury!
TIM ID: 0000004098 – 007
M020124/02E 2009-02 © MTU

Installing lube oil pump on equipment carrier

1. Degrease sealing face on equipment carrier
and lube-oil pump.
2. Apply surface sealant to sealing surface on
equipment carrier.
3. Attach oil pump with carrying bracket to crane.
4. Insert oil pump into equipment carrier, making
sure gears engage correctly.
5. Screw in screws (1) and (2) for oil pump and use
torque wrench to tighten diagonally to specified
tightening torque .
cardiagn.com
Installing pressure reducing valve

1. Coat O-ring with grease and insert in groove of
pressure reducing valve (arrow).
2. Insert pressure reducing valve (1) in equipment
carrier and tighten to specified torque using a
torque wrench .

Pressure reducing Tightening torque Engine oil 60 Nm +20 Nm
valve
Installing oil line

1. Prior to installation, remove all blanking plugs.
2. Blow out oil line with compressed air.
TIM ID: 0000004098 – 007
3. Install oil line loosely using attaching parts as per overview drawing (→ Page 585).
M020124/02E 2009-02 © MTU

5.13.7 Oil filter – Overview
Oil filter housing
cardiagn.com
1 Oil filter housing 5 Washer 9 Hex screw
2 O-ring 6 Bracket 10 Hex screw
3 O-ring 7 O-ring 11 Oil Filter
4 Hex screw 8 O-ring
TIM ID: 0000003497 – 001
M020124/02E 2009-02 © MTU

Differential pressure monitor
cardiagn.com
1 Sealing ring 4 Connector 7 Differential pressure monitor
2 Washer 5 Pipe
3 Hex nut 6 Adapter
TIM ID: 0000003497 – 001
M020124/02E 2009-02 © MTU

5.13.8 Oil filter with oil filter housing – Removal
Special tools

Removing oil filter

1. Remove oil filter with filter wrench.
2. Drain oil from oil filter into a suitable container.
cardiagn.com
Removing oil filter housing
1. Remove oil filter housing according to overview
2. Seal connections (arrows) with plugs.
TIM ID: 0000003500 – 005
M020124/02E 2009-02 © MTU

5.13.9 Oil filter housing – Disassembly

Remove oil filter housing (→ Page 595).
Oil filter housing – Disassembly

1. Remove threaded fittings (3) from oil filter housing
(2).
2. Unscrew all plugs.
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3. Remove O-rings (5).
4. Remove plug (3) and remove valve.
TIM ID: 0000008529 – 001
M020124/02E 2009-02 © MTU

5.13.10 Oil filter housing – Clean
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning oil filter housing

2. Blow out/off all parts with compressed air.
TIM ID: 0000003498 – 005
M020124/02E 2009-02 © MTU

5.13.11 Oil filter housing – Check
Special tools

Test bath
Spare parts

Oil filter housing
Bracket
Connector
Pipe
Adapter
cardiagn.com
Nut
Washer

Hot testing liquid.
Clean oil filter housing (→ Page 597).
TIM ID: 0000008530 – 001
M020124/02E 2009-02 © MTU

Oil filter housing – Check
Check all sealing, mating and • Wear • Recondition: smooth with oilstone or
sliding surfaces for wear, scoring • Scores emery cloth.
and indentations. • Indentations • Replace
visible.
Check all threads and threaded Damaged • Recondition: recut thread.

bores. • Replace
Pressure-test oil filter housing Leaking • Replace plugs.

with air in water bath for leaks. • Replace valve.
Install filter inserts before carrying • Replace oil filter housing.
out leak check. Test temperature:
min. 30 °C, max. 40 °C, if oil filter
housing has to be held in hands.
Test pressure: 0.5 bar.
Check differential pressure Damaged Replace

monitor, bracket and line for
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mechanical damage.
Check spring of pressure limiting Wear Replace

valve for wear.
TIM ID: 0000008530 – 001
M020124/02E 2009-02 © MTU

5.13.12 Oil filter housing – Assembly
Material

Spare parts

O-rings
Plugs
cardiagn.com
Check oil filter housing (→ Page 598).
Oil filter housing – Assembly

1. Screw threaded fittings (3) into oil filter housing (2).
2. Coat O-rings for plugs (4) with petroleum jelly.
3. Screw in plugs.
TIM ID: 0000008531 – 001
M020124/02E 2009-02 © MTU

4. Coat O-rings for grooves with petroleum jelly.

5. Insert valve with spring in bore (3).
6. Insert plug (3).
7. Insert O-rings in grooves.
cardiagn.com
TIM ID: 0000008531 – 001
M020124/02E 2009-02 © MTU

5.13.13 Oil filter with oil filter housing – Installation
Material

Engine oil
Spare parts

O-rings
cardiagn.com
Assemble oil filter housing (→ Page 600)
TIM ID: 0000008532 – 002
M020124/02E 2009-02 © MTU

Installing oil filter housing

2. Install oil filter housing as shown in overview
cardiagn.com
4. Insert O-ring in groove (1) of oil filter housing (2).
Installing oil filter

1. Coat sealing ring of oil filter with oil.
2. Install oil filter and tighten by hand.
TIM ID: 0000008532 – 002
M020124/02E 2009-02 © MTU

5.13.14 Centrifugal oil filter– Overview
Centrifugal oil filter with attachments
cardiagn.com
1 Centrifugal oil filter 6 Adapter
2 Hex screw 7 Sealing ring
3 Washer 8 Oil line
4 Sealing ring 9 Hex nut
5 Sealing ring 10 Screw
TIM ID: 0000008533 – 001
M020124/02E 2009-02 © MTU

Centrifugal oil filter with flange
cardiagn.com
1 Centrifugal oil filter 3 O-ring
2 Flange 4 Screw
TIM ID: 0000008533 – 001
M020124/02E 2009-02 © MTU

Centrifugal oil filter assembly
cardiagn.com
1 Housing 10 Cover screw 19 Standpipe
2 Valve 11 Screw 20 Snap ring
3 Sealing ring 12 Pin 21 O-ring
4 Valve piston 13 O-ring 22 Pin
5 Plug 14 Drain screw 23 Knurled nut
6 Compression spring 15 Clamp 24 Insertion sleeve
7 O-ring 16 Rotor unit 25 Reinforcing plate
8 Cover 17 Nozzle
9 Cover 18 Substructure with bearing
TIM ID: 0000008533 – 001
M020124/02E 2009-02 © MTU

5.13.15 Centrifugal oil filter – Removal
Preconditions
Centrifugal oil filter – Removal
1. Remove centrifugal oil filter as shown in overview drawing (→ Page 604).
cardiagn.com
TIM ID: 0000001888 – 005
M020124/02E 2009-02 © MTU

5.13.16 Centrifugal oil filter – Disassembly

Disassembling centrifugal oil filter
1. Release nut with toggle (2) and remove V-band
clamp (1).
cardiagn.com
2. Release screw from cover (1).
3. Remove cover (1) from housing (2).
4. Drain residual oil from centrifugal oil filter into a

suitable container.
5. Carefully remove rotor unit (1) from
shaft/housing (3). Avoid damaging bearing
or shaft.
7. Remove valve piston, plug and pressure spring as
shown in the overview drawing (→ Page 604).
TIM ID: 0000001891 – 003
M020124/02E 2009-02 © MTU

Note: Take care not to interchange rotors

belonging to different centrifugal filters
because rotor hood and substructure are
aligned to one another during manufacture.
8. Release knurled nut (1) and remove rotor hood (3)

with cover plate (2) from rotor substructure (4).
9. Remove paper element from rotor hood (3).
10. Remove pipe (1) from rotor (2).
cardiagn.com
TIM ID: 0000001891 – 003
M020124/02E 2009-02 © MTU

5.13.17 Centrifugal oil filter – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning the rotor unit

TIM ID: 0000001872 – 004
M020124/02E 2009-02 © MTU

5.13.18 Centrifugal oil filter – Check
Material

Spare parts

Housing
Rotor
Nozzle
Pipe
Screw
cardiagn.com
Compression spring
Valve plunger
Plug
Centrifugal oil filter – Check
Item Findings Task
Check all sealing, mating and sliding • Wear • Recondition: smooth with
surfaces for wear, scoring and • Scores oilstone or emery cloth.
indentations. • Indentations • Replace
visible.
Using red penetrant dye, check the Cracks indicated Replace rotor unit.
housing and substructure for cracks.
Check all threads and threaded Damaged • Recondition: recut threads.

bores. • Replace
Check journals on rotor and bearing Wear visible • Recondition: smooth with
running surfaces on shaft for wear. oilstone or emery cloth.
• Replace
Check valve piston and spring Wear visible • Recondition

(→ Page 604) for wear traces. • Replace
TIM ID: 0000001885 – 002
M020124/02E 2009-02 © MTU

5.13.19 Centrifugal oil filter - Bearing clearance check
Special tools

Retainer 0015890321/00 1
Spare parts

Rotor
Clean centrifugal oil filter (→ Page 610).
Checking bearing clearance of rotor

1. Arrange dial gauge with dial gauge stylus opposite rotor.
cardiagn.com
2. Align dial gauge stylus to upper rotor edge, set dial gauge to zero.
3. Rotate rotor in 4 steps of 90°. Read dial gauge and record reading. Max. measured value = bearing clearance,
specified value ≤ 0.08 mm.
4. With bearing clearance > 0.25 mm, replace complete rotor unit.
5. Align dial gauge stylus to lower rotor edge, set dial gauge to zero.
8. Measure bearing diameter:
• Diameter at upper bearing running surface of shaft: 14.98 mm
• Diameter at lower bearing running surface of shaft: 21.63 mm
• Inner diameter of upper bearing: 15.06 mm
• Inner diameter of lower bearing: 21.69 mm
TIM ID: 0000001869 – 003
M020124/02E 2009-02 © MTU

5.13.20 Centrifugal oil filter – Assembly
Special tools

Material

Engine oil
Spare parts
cardiagn.com
Paper element
O-ring
Sealing ring
Heavy object.
Risk of crushing!
TIM ID: 0000001894 – 004
M020124/02E 2009-02 © MTU

Assembling rotor unit

1. Fit pipe (1) on rotor (2).
cardiagn.com
2. Insert gaiter (2) in cover (1).
3. Coat O-ring (arrowed) with grease and insert
in groove on cover.
4. Fit cover (1) with new paper element (2) on rotor.
5. Turn cover (1) so that chase (3) and pin (4) are
flush with one another. TIM ID: 0000001894 – 004
M020124/02E 2009-02 © MTU

6. Install cover plate (2) and tighten knurled nut (1)

by hand.
7. Coat shaft with engine oil.
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8. Carefully insert rotor unit in housing (2).
9. Check that rotor rotates freely.
10. Coat O-ring with grease and insert in groove (1)
on housing (2).
11. Place cover (1) on housing (2) and use torque

wrench to tighten cover screw to specified
TIM ID: 0000001894 – 004
M020124/02E 2009-02 © MTU

12. Install V-band clamp (1) and use torque wrench

to tighten nut (2) to specified tightening torque
(→ Page 80).
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TIM ID: 0000001894 – 004
M020124/02E 2009-02 © MTU

5.13.21 Centrifugal oil filter – Installation
Material

Spare parts

O-ring
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Centrifugal oil filter – Installation

2. Coat O-ring with grease and insert.
3. Install centrifugal oil filter as shown in overview drawing (→ Page 604).
TIM ID: 0000001897 – 004
M020124/02E 2009-02 © MTU

5.13.22 Oil heat exchanger – Overview
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1 Insert 6 Nut 11 Retainer
2 O-ring 7 Screw 12 Nut
3 Housing 8 Screw 13 O-ring
4 O-ring 9 Plug-in pipe
5 Washer 10 O-ring
TIM ID: 0000008538 – 003
M020124/02E 2009-02 © MTU

5.13.23 Oil heat exchanger – Removal
Preconditions
Special tools

Eyebolt B80090843 2
Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Heavy object.
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Risk of crushing!
Removing oil heat exchanger

1. Remove screws (3) from oil heat exchanger
housing.
2. Remove nuts (1).
3. Screw eyebolts (2) into the left and right oil heat
exchanger housing.
4. Using crane and rope, remove oil heat exchanger
housing from coolant distribution housing.
TIM ID: 0000003509 – 007
M020124/02E 2009-02 © MTU

5. Remove sealing washers (1).

6. Carefully remove oil heat exchanger (arrowed)
vertically upwards from coolant distribution
housing fit.
7. Seal all openings and connections with suitable
plugs.
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TIM ID: 0000003509 – 007
M020124/02E 2009-02 © MTU

5.13.24 Oil heat exchanger – Cleaning
Material

Cleaning agent

Cleaning oil heat exchanger housing and plug-in pipe
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1. Clean oil heat exchanger housing and plug-in pipe with cleaner.
Cleaning oil heat exchanger on water and oil side.
Note: If swarf has got into the engine oil system, e.g. as a result of piston scuffing or bearing damage, replace oil
heat exchanger.
Cleaning water side

1. Examine the degree of contamination.
2. In event of visible encrustation as a result of hardness structure, contamination and oil deposits, clean with
suitable cleaners, e.g. Porodox (from Henkel) or Porozink (from Parobe-Chemie, Basel). Always follow
manufacturer’s instructions.
3. After cleaning, flush the oil heat exchanger with water until pH values of clean water and flushing liquid are
approximately the same (difference 1 pH).
4. If the oil heat exchanger is not put into operation immediately after cleaning, dry and preserve coolant side.
Cleaning oil side

1. Connect oil heat exchanger (oil side) to a closed flushing system with a filter system of 0.05 mm mesh size.
2. Clean oil heat exchanger with suitable cleaner, e.g. buffered alkaline agents such as 3 to 5% solution
of Henkel P3 FD.
3. Ensure flow direction of cleaner is against normal direction of oil flow during operation.
4. After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are
roughly equal (permissible difference 1pH).
5. If the oil heat exchanger is not put into operation immediately after cleaning, dry and preserve oil side.
Drying and preserving oil heat exchanger

1. Dry oil heat exchanger in oven at 110 °C to 120 °C for approx. 3 hours.
TIM ID: 0000008539 – 003
2. Spray preservative (Branorol 32/10 from Brangs & Heinrich) into the oil heat exchanger. A dosage of max.
2 ml Branorol 32/10 per litter of cooling volume must be observed. The preservative vaporizes and forms a
protective film on all interior surfaces.
3. After preservation, seal all openings airtight with suitable plugs.
M020124/02E 2009-02 © MTU

5.13.25 Oil heat exchanger – Check
Material

Red dye penetrant for surface crack-testing procedure
Spare parts

Oil heat exchanger housing
Heat exchanger core
Retainer
Plug-in pipe
Compressed air.
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Risk of injury!

Hot testing liquid.
Component is hot.
Risk of burning!
Oil heat exchanger check
Visually inspect all components for Damaged • Corrective work

damage. • Replace
Check all sealing, mating and • Damaged • Corrective work:

contact faces for damage and • Uneven Smooth with oilstone or crocus
unevenness. cloth.
• Replace
Check thread for easy movement. Sluggish • Recut

TIM ID: 0000008541 – 005
• Replace
Check oil heat exchanger housing Cracks indicated Replace

for cracks with red dye penetrant.
M020124/02E 2009-02 © MTU

Heat exchanger core leak check

1. Seal oil chamber connections of heat exchanger
core (3) with suitable sleeves, blanking plugs,
plugs (2) and clamps.
2. Connect pressure line (1) at plug (2).
4. Immerse heat exchanger core (3) in test bath.
5. Open compressed air supply and set pressure
reducer (1) to 0.5 bar.
6. Pressuretest heat exchanger core (3) for leaks
with air in water bath; no bubbles should emerge.
7. Replace heat exchanger core (3) if leaky.
8. Remove compressed-air line (1), sleeves and
plug (2).
9. Blow out cooling fins of heat exchanger core (3)
with compressed air in vertical direction.
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TIM ID: 0000008541 – 005
M020124/02E 2009-02 © MTU

5.13.26 Oil heat exchanger – Installation
Special tools

Eyebolt B80090843 2
Material

Engine oil (MZK engine oil HD 10W) 40453 1
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Spare parts

O-ring
O-ring
Heavy object.
Risk of crushing!
Installing oil cooler

1. Remove all plugs from coolant distribution housing.
2. Clean oil chambers and oil galleries (arrowed).
TIM ID: 0000008542 – 005
M020124/02E 2009-02 © MTU

3. Coat O-rings on heat exchanger core with grease.

4. Place heat exchanger core in coolant distribution
housing with label “IN” towards the driving end.
5. Place disks (1) on the threads of the heat
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exchanger cores.
6. Coat O-ring (3) with grease and insert into groove
on the elbow (2).
7. Loosen screws on elbow (2).

on the oil heat exchanger housing (2).
TIM ID: 0000008542 – 005
M020124/02E 2009-02 © MTU

9. Coat O-rings on plug-in pipe (2) with grease

before installation.
10. Mount plug-in pipe (2) with retainer (3) on oil heat
exchanger housing (1).
11. Screw eyebolts into the oil heat exchanger
housing (1).
12. Using crane and rope, position oil heat exchanger
housing (1) on coolant distribution housing.
13. Screw oil heat exchanger housing (1) into place
with the screws on the coolant distribution housing.
14. Remove eyebolts (2) from both oil heat exchanger
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housings.
16. Screw on nuts (1) and tighten with torque wrench
to the specified tightening torque (→ Page 80).
17. Tighten the screws (2) on the elbow (1) of the

coolant distribution housing.
TIM ID: 0000008542 – 005
M020124/02E 2009-02 © MTU

5.13.27 Oil system in crankcase – Overview
Oil system
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1 Delivery valve 10 Pipe 19 O-ring
2 O-ring 11 Pipe 20 O-ring
3 O-ring 12 Oil spray nozzle 21 Retainer
4 Circlip 13 Screw 22 Retainer
5 Washer 14 Circlip 23 Pipe
6 O-ring 15 Delivery valve 24 Pipe
7 O-ring 16 O-ring 25 Oil spray nozzle
8 Retainer 17 O-ring 26 Screw
9 Retainer 18 Washer
TIM ID: 0000029132 – 001
M020124/02E 2009-02 © MTU

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1 Delivery valve 4 O-ring 7 Retainer
2 O-ring 5 Pipe 8 Retainer
3 Washer 6 Retainer 9 Oil spray nozzle
TIM ID: 0000029132 – 001
M020124/02E 2009-02 © MTU

5.13.28 Oil system in crankcase – Removal
Preconditions
Special tools


Risk of injury!
Removing bracket for oil spray nozzle

1. Install barring device at crankshaft (→ Page 245).
2. Turn crankshaft with barring device until oil spray
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nozzle (1) to be removed is accessible.
3. Remove screws (arrows).
4. Remove oil spray nozzle (1) from retainer (2).
5. Mark oil spray nozzle (1) with a pen according to
cylinder side and cylinder number.
6. Protect oil spray nozzle (1) against damage.
Removing oil pipe connection

1. Remove screw (arrows).
2. Remove holder (2) from oil pipe fit (3).
3. Remove oil pipe (1) from retainer (2).
4. Remove all other oil spray nozzles in same
manner.
TIM ID: 0000004102 – 006
M020124/02E 2009-02 © MTU

Removing washer (sealing fit)

1. Remove washer (2) from crankcase (1).
2. Remove O-rings.
3. Protect washer (2) against damage.
Removing delivery valve
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1. Remove pressure valve as per overview drawing
(→ Page 627).
2. Unscrew plug screws.
3. Remove snap ring (1) from housing.
4. Remove delivery valve (3) from housing.
5. Remove O-rings (2) and (4)
TIM ID: 0000004102 – 006
M020124/02E 2009-02 © MTU

5.13.29 Oil pipework in crankcase – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning oil spray nozzles and oil pipes

2. Remove cleaner.
3. Blow oil pipes, retainers and oil spray nozzle dry with compressed air.
Cleaning washer (sealing fit)

2. Remove cleaner.
3. Then blow washer dry (sealing fit) with compressed air.
TIM ID: 0000004100 – 002
M020124/02E 2009-02 © MTU

5.13.30 Oil pipework in crankcase – Check
Special tools

Material

Spare parts
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Oil spray nozzle
Pipe
Retainer
Washer (sealing fit)
Delivery valve
Component to be tested is under pressure.

Risk of explosion!
DANGER • Observe test specification.

Risk of injury!
TIM ID: 0000004101 – 004
M020124/02E 2009-02 © MTU

Oil pipework in crankcase – Check
Item Findings Task
Check oil spray nozzles with dye Signs of cracks Replace

Check oil bore of oil spray nozzles Contamination visible. • Corrective work: Clean
for obstruction and ensure it is • Replace
particularly clean.
Check oil spray nozzle with testing Deformation of oil spray nozzle. Replace
device for deformation.
Test oil pipes for leaks with air in Leaking Replace

water bath as necessary. Maintain a
water temperature of min. = 30 °C
or max. = 40 °C and a test pressure
of 0.5 bar.
Check threads for ease of Sluggish • Corrective work: Recut threads

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Check mating and sealing faces of • Damaged • Corrective work: Smooth with
oil spray nozzle. • Stress marks oilstone or emery cloth.
visible • Replace
Check washer (sealing fit) for wear, • Stress marks Replace

cracks and damage. • Cracks
• Damage
visible
Check bore in crankcase for wear. Visible signs of wear. Smooth with emery cloth.
Do not disassemble delivery valve! Damaged Replace

Visually inspect delivery valve for
damage.
Check delivery valve for read Fallen short of or exceeded Replace delivery valve.
opening pressure ± 0.25 bar.
Check sealing face of delivery valve Uneven • Corrective work: Smooth with
for evenness. oilstone.
• Replace
TIM ID: 0000004101 – 004
M020124/02E 2009-02 © MTU

5.13.31 Oil system in crankcase – Installation
Special tools

Material

Engine oil
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Spare parts

O-rings
Snap ring
Compressed air.
Risk of injury!
Compressed air.
Risk of injury!
Installing oil spray nozzle bracket and oil pipes

2. Install bracket (1) so that dimension "a" points
towards crankcase.
TIM ID: 0000004103 – 005
M020124/02E 2009-02 © MTU

3. Coat O-rings with grease and insert into grooves in

oil pipes (1) and (3).
4. Fit oil pipes (1) and (3) in retainer (2) and secure
with screws (arrow) on crankcase.
5. Install oil spray nozzle (1) on retainer and align
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with alignment device (3).
specified tightening torque.

7. After installing, bar engine and ensure there is

clearance between oil spray nozzle and piston.
TIM ID: 0000004103 – 005
M020124/02E 2009-02 © MTU

Installing washer (sealing fit)

1. Coat O-rings with grease and insert into grooves
(arrows) of washer.
2. Align oil pipe so that inner O-ring is not damaged.
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3. Press-fit washer (2) manually in crankcase (3).
TIM ID: 0000004103 – 005
M020124/02E 2009-02 © MTU

Installing delivery valve

1. Coat O-ring (arrow) with grease and insert in
groove (arrow).
2. Coat O-ring (arrow) with grease and insert into
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groove on delivery valve.
3. Insert delivery valve (3) into bore of housing

as far as it will go.
4. Secure delivery valve with snap ring (1) and
install plug screw.
TIM ID: 0000004103 – 005
M020124/02E 2009-02 © MTU

5.13.32 Turbocharger oil supply – Overview
ETC oil supply
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1 Oil line 19 Washer 37 Grommet
3 Screw 21 Pipe half-clamp 39 Screw
4 O-ring 22 Grommet 40 Retainer
5 Threaded adapter 23 Washer 41 Washer
6 O-ring 24 Screw 42 Screw
7 Retainer 25 Oil line 43 Washer
8 Washer 26 O-ring 44 Pipe half-clamp
10 Washer 28 O-ring 46 Grommet
11 Pipe half-clamp 29 Threaded adapter 47 Washer
12 Pipe half-clamp 30 O-ring 48 Screw
13 Grommet 31 Retainer 49 Oil line
14 Washer 32 Washer 50 Oil line
15 Screw 33 Screw 51 Gasket
16 Retainer 34 Washer 52 Screw
17 Washer 35 Pipe half-clamp 53 Gasket
18 Screw 36 Pipe half-clamp 54 Nut
TIM ID: 0000029676 – 001
M020124/02E 2009-02 © MTU

5.13.33 Turbocharger oil supply – Removal
Preconditions
Turbocharger oil supply – Removal
1. Remove oil line, unions and fixtures as per overview drawing (→ Page 638).
2. Remove all sealing elements.
4. Protect oil lines from damage.
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TIM ID: 0000005988 – 004
M020124/02E 2009-02 © MTU

5.13.34 Turbocharger oil supply – Cleaning
Material

Compressed air.
Risk of injury!

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Turbocharger oil supply – Cleaning

2. Remove cleaner.
3. Blow turbocharger oil supply pipework dry with compressed air.
TIM ID: 0000008544 – 002
M020124/02E 2009-02 © MTU

5.13.35 Turbocharger oil supply – Check
Spare parts

Pipe
Flange
Adapter
Strap
Compressed air.
Risk of injury!

Risk of injury!
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Turbocharger oil supply – Check
Item Findings Task
Visually inspect oil return line for Damaged Replace

damage.
Pressure-test oil return line with air Leaking Replace

in water bath for leaks. Maintain a
of 0.5 bar.
Check connection parts and Damaged Replace

securing elements on oil return lines
for damage.
Check sealing and bolt-on faces. Damaged • Corrective work: Smooth with
• Replace

TIM ID: 0000008545 – 002
M020124/02E 2009-02 © MTU

5.13.36 Turbocharger oil supply – Installation
Material

Engine oil
Spare parts

O-rings
Grommet
Sealing ring
Pipe half-clamp
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Compressed air.
Risk of injury!

Turbocharger oil supply – Installation

2. Coat O-rings with grease and insert.
3. Insert sealing rings.
4. Install turbocharger oil supply (→ Page 638).
5. After starting the engine, visually inspect oil lines for leaks. TIM ID: 0000008546 – 005
M020124/02E 2009-02 © MTU

5.14 Coolant System
5.14.1 Coolant system – Overview
Coolant circuit with internal thermostat
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1 Intercooler 11 Connection, engine coolant inlet 19 Crankcase
2 Connection, engine coolant from cooler (low-temperature 20 Coolant pump for charge air
vent line (low-temperature coolant circuit) cooling circuit
coolant circuit) 12 Connection, engine coolant 21 Engine coolant thermostat
3 Connection, engine coolant expansion line (low-temperature (low-temperature coolant circuit)
vent line (high-temperature coolant circuit) 22 Thermostat, engine coolant
coolant circuit) 13 Connection, engine coolant preheating unit
4 Engine coolant expansion tank outlet to cooler (high-temperature 23 Circulation pump for preheating unit
5 Engine coolant heat exchanger coolant circuit) 24 Coolant preheating unit
(low-temperature coolant circuit) 14 Connection, engine coolant inlet
6 Fan cooler from cooler (high-temperature
7 Thermostat (cooler fan in charge coolant circuit)
air coolant system) 15 Connection, engine coolant
8 Engine coolant heat exchanger expansion line (high-temperature
(high-temperature coolant circuit) coolant circuit)
9 Thermostat for cooler fan 16 Engine coolant thermostat
TIM ID: 0000009007 – 001
10 Connection, engine coolant (high-temperature coolant circuit)

outlet to cooler (low-temperature 17 Lube oil heat exchanger
coolant circuit) 18 Engine coolant pump
M020124/02E 2009-02 © MTU

Coolant circuit with external thermostat
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2 Connection, engine coolant from cooler (low-temperature 18 Thermostat, engine coolant
vent line (low-temperature coolant circuit) preheating unit
coolant circuit) 11 Engine coolant thermostat 19 Circulation pump for preheating unit
3 Connection, engine coolant (low-temperature coolant circuit) 20 Coolant preheating unit
vent line (high-temperature 12 Connection, engine coolant 21 Coolant pump for charge air
coolant circuit) expansion line (low-temperature cooling circuit
4 Engine coolant expansion tank coolant circuit) 22 Thermostat (cooler fan in charge
5 Engine coolant heat exchanger 13 Connection, engine coolant air coolant system)
(low-temperature coolant circuit) outlet to cooler (high-temperature 23 Lube oil heat exchanger
6 Fan cooler coolant circuit) 24 Dummy thermostat, open, blocked
7 Engine coolant heat exchanger 14 Connection, engine coolant inlet
(high-temperature coolant circuit) from cooler (high-temperature
8 Engine coolant thermostat coolant circuit)
(high-temperature coolant circuit) 15 Connection, engine coolant
9 Connection, engine coolant expansion line (high-temperature
outlet to cooler (low-temperature coolant circuit)
TIM ID: 0000009007 – 001
M020124/02E 2009-02 © MTU

5.14.2 Engine coolant pump – Overview
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1 Engine coolant pump 4 Screw 7 Washer
2 O-ring 5 Screw
3 Screw 6 Nut
TIM ID: 0000004132 – 003
M020124/02E 2009-02 © MTU

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1 Water pump shaft 11 Shaft seal
2 Impeller 12 Rotary seal
3 Bearing housing 13 O-ring
4 Seal carrier 14 Screw
5 Volute 15 Washer
6 Spacer sleeve 16 O-ring
7 Gear 17 Screw
8 Angular-contact ball bearing 18 Washer
9 Cylindrical roller bearing 19 Sealing ring
10 Snap ring 20 Plug screw
TIM ID: 0000004132 – 003
M020124/02E 2009-02 © MTU

5.14.3 Engine coolant pump – Removal
Preconditions
Special tools

Heavy object.
Risk of crushing!

Risk of injury!
cardiagn.com
Engine coolant pump – Removal
1. Attach engine coolant pump with lifting gear and support bracket to crane using a slightly tensioned rope.
2. remove screws for engine coolant pump as per overview drawing (→ Page 645).
3. Use crowbar to separate engine coolant pump from front cover and remove.
4. Remove O-ring.
TIM ID: 0000004133 – 006
M020124/02E 2009-02 © MTU

5.14.4 Engine coolant pump – Disassembly
Special tools

Hydraulic spindle F6781539 1
Puller tool for impeller F6780562 1
Puller tool for gear F6780561 1
Holding fixture F6781573 1
Carrier for several mandrels F30275611 1
Impact extractor for shaft seal F30450991 1
Heavy object.
Risk of crushing!
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Risk of injury!
Engine coolant pump – Disassembly

1. Mark installation position of bearing housing (1)
and volute (3) in relation to one another.
2. Remove all bolts (2).
3. Use crowbar to separate volute (3) from bearing
housing (1) and remove it.
TIM ID: 0000004130 – 007
M020124/02E 2009-02 © MTU

4. Place engine coolant pump in (2) retaining

device (1).
5. Use hydraulic spindle (1) and puller tool for impeller
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(2) to remove impeller (3) from pump shaft.
6. Holding the gear firmly in the retaining device
throughout.
7. Take off impeller (3) from engine coolant pump.
8. Remove bellows joint seal from pump shaft.
9. Take engine coolant pump out of retaining device.
10. Place bearing housing (3) with pump shaft in vise

with aluminum jaws.
11. Use hydraulic spindle (1) and puller tool (2) to
remove gear from water pump shaft.
TIM ID: 0000004130 – 007
M020124/02E 2009-02 © MTU

12. Use snap ring pliers (4) to remove snap ring (2)
for cylindrical roller bearing (3) from bearing
housing (1).
13. Remove all screws (1) using box wrench (2).
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14. Take bearing housing (2) out of vise and take
off seal carrier (1).
TIM ID: 0000004130 – 007
M020124/02E 2009-02 © MTU

15. Use hydraulic press (1) to force pump shaft (2) off
bearing housing (3).
16. Place pump shaft (2) in holding fixture (6).
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17. Use hydraulic press (1) to force pump shaft
(2) out of inner race (3), spacer sleeve (4) and
angular-contact ball bearing (5).
18. Use hydraulic press (1) and mandrel (2) to

press cylindrical roller bearing (3) out of bearing
housing (4).
TIM ID: 0000004130 – 007
M020124/02E 2009-02 © MTU

19. Press counterring (1) off bearing housing (3).

20. Use impact extractor to remove shaft seal (2) from
21. Remove all O-rings.
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TIM ID: 0000004130 – 007
M020124/02E 2009-02 © MTU

5.14.5 Engine coolant pump – Cleaning
Material

Compressed air.
Risk of injury!

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Cleaning the engine coolant pump

TIM ID: 0000004221 – 005
M020124/02E 2009-02 © MTU

5.14.6 Engine coolant pump – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

Penetrant remover (Standard-Check) 40002 1
Aqueous developer (Standard-Check) 40004 1
Dye penetrant (Standard-Check) 40488 1
Crack-test oil (No. 63) 40475 1
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Crack-test paste (UV-Apelux paste 1031) 40483 1
Spare parts

Engine coolant pump
Water pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000004134 – 006
M020124/02E 2009-02 © MTU

Engine coolant pump – Check
Item Findings Task
Check volute and impeller for Cavitation visible. Replace

cavitation.
Check bearing housing, impeller Crack indication Replace

and volute with red dye penetrant
for cracks.
Check water pump shaft with Crack indication Replace

magnetic crack-testing procedure
for cracks.
Check coolant pump shaft for wear • Wear • Recondition: smooth minor
and damage. • Damage traces of wear with emery cloth.
visible • Replace
Visually inspect sealing surfaces for • Wear • Recondition: smooth with

wear, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
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visible
Check gear for indentations, traces • Wear • Recondition: smooth with

of wear and damage. • Indentations oilstone or emery cloth.
• Damage • Replace gear.
visible
Measure bearing seats and Not dimensionally accurate Replace

diameters on engine coolant pump,
impeller, seal carrier and bearing
housing and gear with inside and
outside micrometer. Values and
measuring points (→ Page 656)
TIM ID: 0000004134 – 006
M020124/02E 2009-02 © MTU

5.14.7 Engine coolant pump – Tolerances
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size Basic
size
1 Seal carrier 90.000 K7 −0.025 +0.010 0.025 0.025
Angular-contact 90.000 −0.015 0

ball bearing
outer diam.
2 Bearing housing 90.000 K7 −0.025 +0.010 0.025 0.025

bore

ball bearing
outer diam.
3 Angular contact 40.000 −0.012 0 0.002 0.025

ball bearing bore
Shaft outer diam. 40.000 k5 +0.002 +0.013
4 Spacer sleeve 40.000 N7 −0.033 –0.008 0.010 0.046

bore
TIM ID: 0000004163 – 003

bore
Cylindrical roller 80.000 −0.013 0

bearing
M020124/02E 2009-02 © MTU

size Basic
size
6 Cylindrical roller 40.000 −0.012 0 0.002 0.025

bearing bore
7 Gear bore 39.000 H7 0 +0.025 0.018 0.059
Shaft outer diam. 39.000 s6 +0.043 +0.059
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size Basic
size
1 Seal carrier bore 72.000 H8 0 +0.046 0.084 0.230
Shaft seal outer 72.000 +0.130 +0.230

diam.
2 Shaft outer diam. 48.000 −0.100 0
If running surface is worn: Recondition pump shaft by spray-metallizing and plunge-cut grinding.
TIM ID: 0000004163 – 003
3 Rotary seal 35.000 h8 −0.039 0 0.040 0.100

inner diam.
Rotary seal outer 78.200 −0.030 0

diam.
M020124/02E 2009-02 © MTU

size Basic
size
4 Impeller bore 35.000 H5 0 +0.009 0.032 0.050
Shaft outer diam. 35.000 t5 +0.048 +0.059
5 Rotary seal
Counterring
If wear traces are found: Replace components together
s1 : 0.7 to 1.1
s2 : 0.6 to 1.5
s3 : 0.5 to 0.65
s4 : 0.08 to 0.5
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TIM ID: 0000004163 – 003
M020124/02E 2009-02 © MTU

5.14.8 Engine coolant pump – Assembly
Special tools

Press-fit tool for angular-contact ball bearings F30378152 1
Press-fit tool for roller bearings F30378153 1
Press-fit tool for shaft seal F30450990 1
Press-in tool for rotary seal F6784612 1
Fixture for bearing housing F6780563 1
Fixture for shaft with bearing F6781573 1
Retaining device F6780561 1
Pliers for snap ring F30002760 1
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Material

Ethanol 40250 1
Engine oil
Spare parts

Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Shaft seal
Rotary seal
O-ring
Component is hot.
Risk of burning!
Heavy object.
Risk of crushing!
TIM ID: 0000004131 – 006

Risk of injury!
M020124/02E 2009-02 © MTU

Engine coolant pump – Assembly

Note: Apply press-in pressure to bearing
outer ring.
1. Use hydraulic press (1) and mandrel (2) to press

cylindrical roller bearing into bearing housing (4).
2. Insert snap ring (2) in groove of bearing
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housing (3), using snap ring pliers (1).
3. Check that snap ring (2) fits correctly.

angular-contact ball bearing (3) on to pump
shaft (4).
TIM ID: 0000004131 – 006
M020124/02E 2009-02 © MTU


spacer sleeve (3) on to pump shaft (4).
cardiagn.com
inner ring (2) of cylindrical roller bearing on to
pump shaft (3).
Note: Apply press-in pressure to bearing outer

ring (3).

pump shaft into bearing housing (4).
TIM ID: 0000004131 – 006
M020124/02E 2009-02 © MTU

Note: Make sure that shaft seal (2) is in the

correct position.
8. Insert shaft seal (2) in press-in mandrel (1).
cardiagn.com
shaft seal into seal carrier (3).
10. Coat O-ring with grease and insert in groove.

11. Place bearing housing (1) in fixture (4).
12. Use screws (2) to install seal carrier on bearing
housing (1) and tighten them evenly. TIM ID: 0000004131 – 006
M020124/02E 2009-02 © MTU

13. Heat gear (2) to 200 °C.

14. Place bearing housing (3) with seal carrier and
holding fixture (4) on to hydraulic press (1).
15. Use hydraulic press (1) to push heated gear (2) on
to shaft up to stop and hold until shrink connection
between shaft and gear is firm.
16. Coat O-ring on counterring (2) with grease and
cardiagn.com
insert in bearing housing (2).
17. Clean sliding surface on counterring (2) with
ethanol.
18. Coat inner diameter of bellows seal (1) with low
surface tension water.
19. Clean sliding surface on bellows seal (1) with
ethanol.
20. Fit bellows seal (1) on shaft (4) and use press-in
tool to push it up to the counterring (2).
21. Heat impeller (1) to 210 °C.
22. Place engine coolant pump on hydraulic press (1).

23. Place two feeler plates (clearance
S1 = 0.7 mm to 1.1 mm) on seal carrier (3),
arranged at 180° towards one another.
24. Push heated impeller (2) with hydraulic press (1)
until it stops at feeler plates.
25. Measure clearance S1 between impeller (2) and
seal carrier (3) with feeler gauge.
26. If measured value is out of tolerance, determine
the cause and replace components, if necessary.
TIM ID: 0000004131 – 006
M020124/02E 2009-02 © MTU

27. Set volute (3) down on bearing housing (1)

according to the installation position marking
made before removal.
28. Tighten screws (2).
29. Turn pump shaft to check ease of movement.
30. Measure clearance S2 (0.6 mm to 1.5 mm)
between impeller and volute (3) with feeler gauge.
31. If gap clearance is out of tolerance, determine the
cause and replace components, if necessary.
cardiagn.com
TIM ID: 0000004131 – 006
M020124/02E 2009-02 © MTU

5.14.9 Engine coolant pump – Installation
Special tools

Material

Engine oil
Spare parts
cardiagn.com
O-ring
Heavy object.
Risk of crushing!

Risk of injury!
Engine coolant pump – Installation

2. Coat O-ring (1) with grease.
3. Insert O-ring (1) in groove on bearing housing of
engine coolant pump.
TIM ID: 0000004135 – 006
M020124/02E 2009-02 © MTU

4. Attach engine coolant pump with lifting gear

and support bracket to crane using a slightly
pretensioned rope.
Note: Make sure that gears are correctly meshed.
5. Install coolant pump (1) in bore on equipment

carrier, ensuring it is correctly positioned.
6. Insert screws (2) and washers and tighten evenly.
7. Remove lifting gear and support bracket.
cardiagn.com
TIM ID: 0000004135 – 006
M020124/02E 2009-02 © MTU

5.14.10 Coolant pipework of engine coolant pump, intake side – Overview
Elbow with attachments
cardiagn.com
1 Elbow 6 Washer 11 Connector
2 Plug screw 7 Holder 12 Banjo screw
3 Sealing ring 8 Screw 13 Sealing ring
4 O-ring 9 Washer
5 Screw 10 Drain valve
TIM ID: 0000008551 – 002
M020124/02E 2009-02 © MTU

Plug-in pipe with flange
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1 Plug-in pipe
2 O-ring
3 Flange
4 Screw
5 O-ring
TIM ID: 0000008551 – 002
M020124/02E 2009-02 © MTU

Coolant pipework
cardiagn.com
1 Plug-in pipe 4 Screw 7 O-ring
2 O-ring 5 O-ring 8 Flange
3 Flange 6 Plug-in pipe 9 Screw
TIM ID: 0000008551 – 002
M020124/02E 2009-02 © MTU

5.14.11 Coolant pipework for engine coolant pump, intake side – Removal
Preconditions
Coolant pipework for engine coolant pump, intake side – Removal
2. Remove all monitoring units installed in coolant lines.
3. Remove coolant pipework for engine coolant pump on intake side as shown in overview drawing (→ Page 667).
cardiagn.com
TIM ID: 0000003518 – 005
M020124/02E 2009-02 © MTU

5.14.12 Coolant pipework, engine coolant pump, suction side – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning coolant lines

3. Blow dry coolant lines with compressed air and preserve in oil bath.
TIM ID: 0000028467 – 002
M020124/02E 2009-02 © MTU

5.14.13 Coolant pipework, engine coolant pump, suction side – Check
Spare parts

Elbow
Flange
Plug-in pipe
Retainer
Connecting piece
Drain valve

Risk of injury!
cardiagn.com
Coolant pipework, engine coolant pump, suction side, check
Visually inspect retainers, plug • Wear • Corrective work: smooth with

connections and annular grooves on • Pitting oilstone or crocus cloth.
elbows and connecting lines for wear, • Cavitation • Replace
pitting and cavitation. visible
Check sealing and mating faces for Damaged • Corrective work: smooth with
wear and damage. oilstone or crocus cloth.
• Replace
Pressure-test coolant lines with air Leaking Replace

in water bath for leaks as necessary.
Maintain a coolant temperature of min.
= 30 °C or max. = 40 °C at a test
pressure of 0.5 bar.
Check operation of drain valve. Damaged Replace
TIM ID: 0000008552 – 003
M020124/02E 2009-02 © MTU

5.14.14 Coolant pipework, engine coolant pump, suction side – Installation
Material

Engine oil
Spare parts

Sealing rings
O-rings
Compressed air.
Risk of injury!
cardiagn.com
Install coolant lines

2. Blow out coolant lines with compressed air.
3. Coat all O-rings with grease.
4. Install coolant lines without tension using new sealing and O-rings as shown in the overview drawing
(→ Page 667).
5. Install all monitoring units in coolant lines.
TIM ID: 0000008553 – 003
M020124/02E 2009-02 © MTU

5.14.15 Coolant pipework after cylinder – Overview
Coolant pipework after cylinder – Overview

Also applies analogously to 12 V.
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1 Connecting piece 7 O-ring 13 O-ring
2 Screw 8 Plug screw 14 O-ring
3 O-ring 9 Engine coolant collecting line 15 O-ring
4 Connecting piece 10 Engine coolant collecting line 16 Screw
5 Screw 11 Engine coolant collecting line 17 Screw
6 Screw 12 Engine coolant collecting line
TIM ID: 0000008554 – 002
M020124/02E 2009-02 © MTU

5.14.16 Coolant pipework after cylinder – Removal
Preconditions
Coolant pipework after cylinder– Removal
1. Remove manifolds as per overview drawing (→ Page 674).
cardiagn.com
TIM ID: 0000008555 – 005
M020124/02E 2009-02 © MTU

5.14.17 Coolant pipework after cylinder – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning coolant pipework after cylinder

TIM ID: 0000004120 – 004
M020124/02E 2009-02 © MTU

5.14.18 Coolant pipework after cylinder – Check
Spare parts

Manifold
Connecting piece
Compressed air.
Risk of injury!

Hot testing liquid.
cardiagn.com
Checking coolant pipework after cylinder
Visually inspect plug connections and Damaged • Corrective work: smooth with
annular grooves on connecting piece and oilstone or crocus cloth.
manifold for wear, pitting and cavitation. • Replace
Check manifold with air and corrosion Leaking Replace

inhibitor in water bath for leaks. Maintain
a coolant temperature of min. = 30 °C or
TIM ID: 0000008556 – 003
M020124/02E 2009-02 © MTU

5.14.19 Coolant pipework after cylinder – Installation
Material

Engine oil
Spare parts

O-ring
Compressed air.
Risk of injury!
cardiagn.com
Coolant pipework after cylinder – Installation
2. Blow out manifolds with compressed air.
4. Install manifolds free of tension as shown in overview drawing (→ Page 674).
TIM ID: 0000008557 – 005
M020124/02E 2009-02 © MTU

5.14.20 Engine coolant drain lines – Overview
Coolant lines
cardiagn.com
1 Pipe 10 Sealing cone 19 Spacer bushing
2 Sealing cone 11 Nut 20 Retainer
3 Nut 12 Retainer 21 Hex screw
4 Pipe 13 Pipe half-clamp 22 Spacer bushing
5 Pipe 14 Grommet 23 Pipe half-clamp
6 Sealing cone 15 Hex screw 24 Pipe half-clamp
7 Nut 16 Washer 25 Grommet
8 Pipe 17 Hex nut 26 Hex screw
9 T adapter 18 Hex screw
TIM ID: 0000008558 – 002
M020124/02E 2009-02 © MTU

5.14.21 Engine coolant drain lines – Removal

Removing drain lines
1. Before removing the lines it is advisable to take photographs of the fitted lines or to mark lines and externally
mounted components.
cardiagn.com
TIM ID: 0000004121 – 003
M020124/02E 2009-02 © MTU

5.14.22 Engine coolant drain lines – Cleaning
Special tools

Cleaning brush
Material

Cleaning agent
Compressed air.
Risk of injury!
cardiagn.com

Remove engine coolant drain lines (→ Page 680).
Cleaning engine coolant drain lines

1. Clean coolant drain lines with cleaning agent and cleaning brush.
3. Blow dry coolant drain lines with compressed air and preserve in oil bath.
TIM ID: 0000004122 – 002
M020124/02E 2009-02 © MTU

5.14.23 Engine coolant drain lines – Check
Spare parts

Pipe
Sealing cone
T adapter
Retainer
Spacer bushing

Risk of injury!
Compressed air.
cardiagn.com
Risk of injury!
Checking engine coolant drain lines
Check T piece, retainers and lines for Damaged Replace

damage.
Pressure-test lines with air and Leaking Replace

corrosion inhibitor in water bath for
leaks as necessary. Maintain a coolant
temperature of min. = 30 °C or max.
= 40 °C at a test pressure of 0.5 bar.
Check thread for damage and easy Damaged or sluggish • Corrective work: recut threads
movement • Replace
TIM ID: 0000008559 – 002
M020124/02E 2009-02 © MTU

5.14.24 Engine coolant drain lines – Installation
Material

Engine oil
Spare parts

Grommet
Compressed air.
Risk of injury!
cardiagn.com
Installing engine coolant drain lines
2. Blow out coolant drain lines with compressed air.
3. Install engine coolant drain lines as shown in the overview drawing (→ Page 679) without tension and secure
with pipe half-clamps.
TIM ID: 0000004123 – 003
M020124/02E 2009-02 © MTU

5.14.25 Engine coolant and charge air coolant ventilation – Overview
Coolant vent lines (also applies to 16V)
cardiagn.com
25 Union 195 T-piece 505 Bracket
30 Sealing ring 205 Vent line 510 Pipe half-clamp
45 Vent line 210 Union 515 Grommet
55 Bracket 215 Sealing ring 520 Screw
60 Washer 225 Vent line 525 Vent line
65 Screw 235 Adapter 535 Bracket
70 Pipe half-clamp 240 Sealing ring 540 Pipe half-clamp
75 Grommet 260 Vent line 545 Grommet
80 Screw 265 Adapter 550 Screw
90 Union 270 O-ring 553 Vent line
95 Sealing ring 305 Bracket 555 Vent line
100 Vent line 310 Pipe half-clamp 565 Bracket
120 Bracket 325 Grommet 575 Grommet
125 Pipe half-clamp 330 Screw 580 Screw
130 Grommet 340 Spacer bush 585 Spacer bush
135 Screw 460 Adapter 590 Pipe half-clamp
145 T-piece 465 O-ring 595 Grommet
155 Vent line 470 Vent line 600 Screw
165 Vent line 475 Adapter 605 Pipe
TIM ID: 0000008899 – 002
170 Union 480 Sealing ring 610 Adapter

175 Sealing ring 490 Threaded union 615 Sealing ring
185 Vent line 495 Vent line
M020124/02E 2009-02 © MTU

cardiagn.com
250 T-piece 380 Grommet 440 Pipe half-clamp
280 Vent line 390 Distributor 445 Grommet
290 Union 395 Bracket 450 Screw
295 Sealing ring 400 Screw 621 Union
350 Vent line 402 Plug 622 Sealing ring
355 Threaded union 403 Plug 630 Pipe
365 Bracket 410 Threaded union 640 T-piece
366 Screw 415 Pipe 650 Pipe
367 Washer 420 Union 655 Elbow
370 Pipe half-clamp 425 Sealing ring 700 Threaded union
375 Pipe half-clamp 435 Pipe half-clamp
TIM ID: 0000008899 – 002
M020124/02E 2009-02 © MTU

5.14.26 Engine coolant and charge-air cooling vent – Removal
Preconditions
Engine coolant and charge-air cooling vent – Removal
1. Prior to removal of the lines take photos or mark attachments and lines.
2. Remove engine coolant and charge-air cooling vent (→ Page 684).
cardiagn.com
TIM ID: 0000004125 – 005
M020124/02E 2009-02 © MTU

5.14.27 Ventilation, engine coolant and charge air coolant – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning ventilation, engine coolant and charge air coolant

2. Thoroughly blow out coolant and charge air cooling ventilation with compressed air and preserve in oil bath.
TIM ID: 0000008802 – 004
M020124/02E 2009-02 © MTU

5.14.28 Ventilation, engine coolant and charge air coolant – Check
Spare parts

Pipe
Elbow
Vent line
Distributor piece
T adapter
Retainer
Bracket
Spacer sleeve
cardiagn.com
Risk of injury!
Compressed air.
Risk of injury!
Checking ventilation, engine coolant and charge air coolant
Check lines, elbow, distributor, T piece, retainer, Damaged Replace

bracket and spacer sleeve for damage.
Check coolant lines for leaks in water bath, using Leaking Replace
compressed air and corrosion inhibitor. Maintain a
coolant temperature of min. = 30 °C or max. = 40 °C
at a test pressure of 0.5 bar.
Check thread for damage and easy movement. Damaged or sluggish • Corrective work: recut
threads
• Replace TIM ID: 0000008803 – 003
M020124/02E 2009-02 © MTU

5.14.29 Engine coolant and charge-air cooling vent – Installation
Material

Engine oil
Spare parts

Grommet
Pipe clamp half
Compressed air.
Risk of injury!
cardiagn.com

Engine coolant and charge-air cooling vent – Installation

2. Install engine coolant and charge-air cooling vent as shown in overview drawing (→ Page 684).
TIM ID: 0000004963 – 005
M020124/02E 2009-02 © MTU

5.14.30 Coolant pipework from/to exhaust turbochargers – Overview
cardiagn.com
1 Adapter 14 Sealing ring 27 Grommet
2 Sealing ring 15 Coolant line 28 Washer
3 Coolant line 16 Adapter 29 Screw
4 Adapter 17 Sealing ring 30 Adapter
5 Sealing ring 18 Coolant line 31 Sealing ring
6 Coolant line 19 Adapter 32 Coolant line
7 Holder 20 Sealing ring 33 Pipe half-clamp
8 Pipe half-clamp 21 Coolant line 34 Pipe half-clamp
9 Pipe half-clamp 22 Adapter 35 Grommet
10 Grommet 23 Sealing ring 36 Washer
11 Washer 24 Coolant line 37 Screw
13 Adapter 26 Pipe half-clamp
TIM ID: 0000008804 – 002
M020124/02E 2009-02 © MTU

5.14.31 Coolant pipework from/to exhaust turbochargers – Removal
Preconditions
Removing coolant lines
2. Remove coolant pipework from/to exhaust turbochargers as shown in overview drawing (→ Page 690).
cardiagn.com
TIM ID: 0000008805 – 009
M020124/02E 2009-02 © MTU

5.14.32 Coolant pipework from/to exhaust turbochargers – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com


Coolant pipework from/to exhaust turbochargers – Cleaning

1. Clean parts with cleaning agent and cleaning brush.
TIM ID: 0000003529 – 005
M020124/02E 2009-02 © MTU

5.14.33 Coolant pipework from/to turbochargers – Check
Spare parts

Coolant line
Bracket
Pipe half-clamp
Grommet

Risk of injury!
Compressed air.
Risk of injury!
cardiagn.com
Clean coolant pipework from/to exhaust turbochargers (→ Page 692).
Coolant pipework from/to turbochargers – Check
Visually check lines, pipe clamp halves, Damaged Replace

grommets and brackets for damage.
Check coolant lines for leaks in water bath, Leaking Replace

using compressed air and corrosion inhibitor.
Maintain a coolant temperature of min. = 30 °C
or max. = 40 °C at a test pressure of 0.5 bar.
TIM ID: 0000008806 – 001
M020124/02E 2009-02 © MTU

5.14.34 Coolant pipework from/to exhaust turbochargers – Installation
Material

Engine oil

Coolant pipework from/to exhaust turbochargers - Installation
cardiagn.com
1. Before installation, remove all covers.
2. Install coolant pipework from/to exhaust turbochargers as shown in the overview drawing (→ Page 690).
TIM ID: 0000008807 – 009
M020124/02E 2009-02 © MTU

5.14.35 Charge-air coolant pump – Overview
cardiagn.com
1 Charge-air coolant pump 4 Screw 7 Drain valve
2 O-ring 5 Nut
3 Screw 6 Washer
TIM ID: 0000006030 – 002
M020124/02E 2009-02 © MTU

Charge-air coolant pump – Overview
cardiagn.com
1 Water pump shaft 8 Angular-contact ball bearing 15 Washer
2 Impeller 9 Cylindrical roller bearing 16 O-ring
3 Bearing housing 10 Snap ring 17 Screw
4 Seal carrier 11 Shaft seal 18 Washer
5 Volute 12 Rotary seal 19 Plug screw
7 Gear 14 Screw
TIM ID: 0000006030 – 002
M020124/02E 2009-02 © MTU

5.14.36 Charge-air coolant pump – Removal
Preconditions
Heavy object.
Risk of crushing!

Risk of injury!
Charge-air coolant pump – Removal

1. Remove securing screws for charge-air coolant pump as shown in overview drawing (→ Page 695).
2. Use crowbar to release charge-air coolant pump from equipment carrier and remove.
3. Mask installation hole for charge-air coolant pump.
4. Remove O-ring from charge-air coolant pump.
cardiagn.com
TIM ID: 0000004368 – 007
M020124/02E 2009-02 © MTU

5.14.37 Charge-air coolant pump – Disassembly
Special tools

Impact extractor for shaft seal F30450991 1
Heavy object.
Risk of crushing!
cardiagn.com

Risk of injury!
Charge-air coolant pump – Disassembly

TIM ID: 0000006033 – 003
M020124/02E 2009-02 © MTU


device (1).
5. Use hydraulic spindle (1) and removal tool for
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impeller (2) to remove impeller (3) from water
pump shaft.
throughout.
8. Remove bellows seal from pump shaft.
9. Remove charge-air coolant pump from retaining
device.
10. Place bearing housing (3) with pump shaft in vice

with aluminum jaws.
11. Use hydraulic spindle (1) and removal tool (2) to
remove gear from water pump shaft.
TIM ID: 0000006033 – 003
M020124/02E 2009-02 © MTU

housing (1).
13. Remove all bolts (1) using box wrench (2).
cardiagn.com
TIM ID: 0000006033 – 003
M020124/02E 2009-02 © MTU

cardiagn.com

cylindrical roller bearing out of bearing housing (4).
TIM ID: 0000006033 – 003
M020124/02E 2009-02 © MTU

19. Press out counterring (1).

20. Use impact extractor to remove shaft seal (2) from
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TIM ID: 0000006033 – 003
M020124/02E 2009-02 © MTU

5.14.38 Charge-air coolant pump – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Charge-air coolant pump – Cleaning

2. Blow all components thoroughly with compressed air.
TIM ID: 0000006031 – 003
M020124/02E 2009-02 © MTU

5.14.39 Charge-air coolant pump – Tolerances
cardiagn.com
size Basic
size
1 Seal carrier 90.000 K7 –0.025 +0.010 0.025 0.025
Angular contact 90.000 –0.015 0

ball bearing
outer Ø
2 Bearing housing 90.000 K7 –0.025 +0.010 0.025 0.025

bore
Angular contact 90.000 –0.015 0

ball bearing
outer Ø
3 Angular contact 40.000 –0.012 0 0.002 0.025

ball bearing bore
Shaft outer Ø 40.000 k5 +0.002 +0.013
4 Spacer sleeve 40.000 N7 –0.033 –0.008 0.010 0.046

bore
TIM ID: 0000004168 – 003
Shaft outer Ø 40.000 k5 +0.002 +0.013

bore
Cylindrical roller 80.000 –0.013 0

bearing
M020124/02E 2009-02 © MTU

size Basic
size
6 Cylindrical roller 40.000 –0.012 0 0.002 0.025

bearing bore
Shaft outer Ø 40.000 k5 +0.002 +0.013
7 Gear bore 39.000 H7 0 +0.025 0.018 0.059
Shaft outer Ø 39.000 s6 +0.043 +0.059
cardiagn.com
TIM ID: 0000004168 – 003
M020124/02E 2009-02 © MTU

cardiagn.com
size Basic
size
Shaft seal 72.000 +0.130 +0.230

outer Ø
2 Shaft outer Ø 50.000 –0.100 0
3 Shaft seal 35.000 h8 –0.030 0 0.040 0.100

inner Ø
4 Impeller bore 35.000 H5 0 +0.011 0.032 0.050
Shaft outer Ø 35.000 t5 +0.048 +0.059
5 Rotary seal
Counterring
s1 : 0.4 to 0.6
TIM ID: 0000004168 – 003
s2 : 0.6 to 1.52
s3 : 0.08 to 0.5
M020124/02E 2009-02 © MTU

5.14.40 Charge-air coolant pump – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

Dye penetrant remover (Standard-Check) 40002 1
cardiagn.com
Spare parts

Charge-air coolant pump
Pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000006032 – 004
M020124/02E 2009-02 © MTU

Charge-air coolant pump - Check
Item Findings Task

cavitation.

for cracks.
Using the magnetic crack-testing Crack indication Replace

method, check water pump shaft for
cracks.
Check pump shaft for wear and • Wear traces • Recondition: smooth minor
damage. • Damage traces of wear with emery cloth.
visible • Replace

cardiagn.com
visible
Check gear for indentations, traces • Wear traces • Recondition: smooth with
visible

diameters on pump shaft, impeller,
seal carrier and bearing housing
and gear with inside and outside
micrometer. Values and measuring
points (→ Page 704)
TIM ID: 0000006032 – 004
M020124/02E 2009-02 © MTU

5.14.41 Charge-air coolant pump – Assembly
Special tools

Installation tool for angular-contact ball bearing F30378152 1
Installation tool for roller bearing F30378153 1
Installation tool for shaft seal F30450990 1
Installation tool for rotary seal F6784612 1
Bearing housing support F6780563 1
Support for shaft with bearing F6781573 1
Support for various mandrels F30275611 1
cardiagn.com
Material

Ethanol 40250 1
Corrosion inhibitor oil
Spare parts

Snap ring
Shaft seal
Rotary seal
O-ring
Component is hot.
Risk of burning!
Heavy object.
Risk of crushing!
TIM ID: 0000006034 – 004

Risk of injury!
M020124/02E 2009-02 © MTU

Assembling charge-air coolant pump

Note: Apply pressure to bearing outer ring.

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2. Place snap ring (2) in groove of bearing
3. Check that snap ring (2) is correctly seated.
TIM ID: 0000006034 – 004
M020124/02E 2009-02 © MTU

4. Force angular-contact ball bearing (3) onto pump

shaft (4) using hydraulic press (1) and mandrel (2).
5. Force spacer sleeve (3) onto pump shaft (4) using
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hydraulic press (1) and mandrel (2).
6. Force inner ring (2) of cylindrical roller bearing

onto pump shaft (3) using hydraulic press and
mandrel (1).
TIM ID: 0000006034 – 004
M020124/02E 2009-02 © MTU

Note: Apply pressure to bearing outer ring (3).

pump shaft (2) into bearing housing (4).
Note: Make sure shaft seal (2) is in the correct
cardiagn.com
position.
8. Insert shaft seal (2) into press-in mandrel (1).

TIM ID: 0000006034 – 004
M020124/02E 2009-02 © MTU

10. Position intermediate washer in sealing ring

retainer (4).
11. Coat rotary seal (3) with liquid soap and water
(1:2).
rotary seal (3) into seal carrier (4).
13. Clean sliding surface with denatured ethanol
after assembly.
14. Coat O-ring with grease and place into groove.
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15. Place bearing housing (1) in holding fixture (4).
housing (1) and tighten evenly.
17. Heat gear (2) to 200 °C.

holding fixture (4) onto hydraulic press (1).
19. Use hydraulic press (1) to push heated gear (2)
onto shaft to stop position and hold until shrink
connection between shaft and gear is fixed.
TIM ID: 0000006034 – 004
M020124/02E 2009-02 © MTU

20. Coat O-ring of counterring (2) with grease and

insert in bearing housing (2).
21. Clean sliding surface on counterring (2) using
ethanol.
22. Coat inner diameter of bellows seal (1) with
wetted water.
23. Clean sliding surface on bellows seal (1) using
ethanol.
24. Position bellows seal (1) on shaft (4) and push up
to counterring (2) using installation tool.
26. Place charge-air coolant pump on hydraulic
cardiagn.com
press (1).
27. Use hydraulic press (1) to push heated impeller (2)
onto coolant pump shaft to stop position.
28. Set volute (3) onto bearing housing (1) according

to the installation position marking made before
removal.
30. Turn pump shaft to check ease of movement.
31. Use feeler gauge to check clearance S2 (0.6 mm to
1.5 mm) between impeller and volute (3).
32. If measured clearance is out of tolerance,
determine the cause and replace components,
if necessary.
TIM ID: 0000006034 – 004
M020124/02E 2009-02 © MTU

5.14.42 Charge-air coolant pump – Installation
Material

Grease (Kluthe Hakuform 30–10/emulsifier) X00029933 1
Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!
cardiagn.com
Risk of injury!
Preparing charge-air coolant pump for installation

charge-air coolant pump.
TIM ID: 0000006035 – 005
M020124/02E 2009-02 © MTU

Note: Make sure that gears are correctly meshed.
4. Insert charge-air coolant pump (1) in correct

position in bore on equipment carrier.
5. Insert screws (2) with washers.
6. Tighten screws (2) evenly.
cardiagn.com
TIM ID: 0000006035 – 005
M020124/02E 2009-02 © MTU

5.14.43 Coolant pipework from/to intercooler – Overview
cardiagn.com
1 Pipe 10 Rubber sleeve 19 Clamp
2 Gasket 11 Clamp 20 Holder
3 Screw 12 Holder 21 Spacer washer
4 Holder 13 Spacer washer 22 Screw
6 Nut 15 Coolant line 24 Screw
7 Coolant line 16 Coolant line 25 Washer
8 Plug screw 17 Coolant line 26 Plug screw
9 Coolant line 18 Rubber sleeve 27 Sealing ring
TIM ID: 0000003533 – 002
M020124/02E 2009-02 © MTU

cardiagn.com
1 Adapter union 11 Drain line
2 Sealing ring 12 Drain valve
3 Drain line 13 Holder
4 Drain valve 14 Screw
5 Holder 15 Washer
6 Screw 16 Spacer bushing
7 Washer 17 Pipe half-clamp
8 Pipe half-clamp 18 Grommet
9 Grommet 19 Screw
TIM ID: 0000003533 – 002
M020124/02E 2009-02 © MTU

5.14.44 Coolant pipework from/to intercooler – Removal
Preconditions
Removing coolant pipework
1. Before removing the lines, it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove lines as per overview drawing (→ Page 717).
3. Remove sealant.
cardiagn.com
TIM ID: 0000004128 – 006
M020124/02E 2009-02 © MTU

5.14.45 Coolant pipework from/to intercooler – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com


Cleaning coolant pipework from/to intercooler

TIM ID: 0000008808 – 004
M020124/02E 2009-02 © MTU

5.14.46 Coolant pipework from/to intercooler – Check
Spare parts

Coolant line
Pipe
Rubber sleeve
Gasket
Retainer
Drain valve
Screw
Hex nut
Spacer washer
Spacer bushing
cardiagn.com
Plug screw

Risk of injury!
Compressed air.
Risk of injury!
Checking coolant pipework from/to intercooler
Check sealing surfaces for flatness. Uneven • Corrective work: smooth

with oilstone or crocus
cloth.
• Replace
Check all components for damage. Damaged Replace
Check thread for easy movement and Damaged or sluggish • Corrective work: recut
damage. threads
• Replace
Pressure-test coolant lines with air and Leaking Replace

corrosion inhibitor in water bath for leaks as
necessary. Maintain a coolant temperature
of min. = 30 °C or max. = 40 °C at a test
TIM ID: 0000008809 – 002
M020124/02E 2009-02 © MTU

5.14.47 Coolant pipework from/to intercooler – Installation
Material

Engine oil
White petroleum jelly 40314 1
Compressed air.
Risk of injury!
Installing coolant pipework from/to intercooler

2. Blow out coolant pipework from/to intercooler with compressed air.
3. Install coolant pipework from/to intercooler as shown in the overview drawing (→ Page 717) and secure with
cardiagn.com
pipe half-clamps, ensuring the installation is free of tension.
TIM ID: 0000008810 – 004
M020124/02E 2009-02 © MTU

5.14.48 Coolant pipework with thermostat – Overview
Coolant pipework with thermostat
cardiagn.com
1 Coolant distribution housing 13 O-ring 24 O-ring
2 Cover 14 O-ring 25 Screw
5 Cover 17 Screw 28 Restrictor
6 Screw 18 O-ring 29 Thermostat housing (low-
7 Blind flange 19 Screw temperature circuit)
8 O-ring 20 Screw 30 Thermostat insert
9 Screw 21 Thermostat housing (high- 31 Sealing ring
10 Elbow temperature circuit) 32 Screw
11 Gasket 22 Thermostat insert 33 Screw
12 Screw 23 Sealing ring 34 Washer
TIM ID: 0000003722 – 002
M020124/02E 2009-02 © MTU

5.14.49 Coolant pipework with thermostat – Removal
Preconditions
Suspended load.
Danger to life!
Removing thermostat housing (high temperature

circuit)
1. Remove screws from flanges (1) and (2).
2. Press the flanges off the sealing surfaces.
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3. Remove pipes (3) and (4) as shown in the
4. Remove flange (1).
5. Remove screws (2) from thermostat housing (5).
TIM ID: 0000003725 – 007
M020124/02E 2009-02 © MTU

6. Replace two screws from thermostat housing with

guide pins (arrowed).
7. Remove thermostat housing from coolant
distribution housing.
8. Remove thermostat inserts, sealing rings, and
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O-rings.
Removing coolant distribution housing

1. Screw eyebolts into coolant distribution housing
and suspend the housing using crane and rope.
2. Remove screws and washers for coolant
distribution housing as shown in the overview
3. Using crane and rope, remove coolant distribution
housing from gearcase.
4. Remove O-rings.
TIM ID: 0000003725 – 007
M020124/02E 2009-02 © MTU

Removing thermostat housing (low temperature circuit)

1. Remove screws from thermostat housing.
2. Remove thermostat housing as shown in the overview drawing (→ Page 723).
cardiagn.com
TIM ID: 0000003725 – 007
M020124/02E 2009-02 © MTU

5.14.50 Coolant pipework with thermostat – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning coolant pipework with thermostat

TIM ID: 0000003723 – 004
M020124/02E 2009-02 © MTU

5.14.51 Coolant pipework with thermostat – Check
Material

Spare parts

Coolant distribution housing
Thermostat housing
Thermostat insert
Cover
Blind flange
cardiagn.com
Elbow
Restrictor
Compressed air.
Risk of injury!
Component is hot.
Risk of burning!
TIM ID: 0000003724 – 002
M020124/02E 2009-02 © MTU

Checking coolant pipework with thermostat
Check all components for condition Damaged Replace

and damage.
Using red penetrant dye, check the Cracks indicated Replace

coolant distribution housing and
thermostat housing for cracks.
Check all mating and sealing • Wear • Corrective work: smooth with
surfaces for wear and damage. • Damage oilstone or crocus cloth.
visible • Replace
Check support bores of thermostat Damaged • Corrective work: smooth with

elements for damage. crocus cloth.
• Replace
Check threads in coolant distribution Sluggish Replace thread inserts.

housing for easy movement.
cardiagn.com
Gaskets, sealing rings and O-rings – Replace
Check coolant and oil chambers Leaking Replace

of coolant distribution housing for
leaks with air and corrosion inhibitor
under water. Maintain a coolant
TIM ID: 0000003724 – 002
M020124/02E 2009-02 © MTU

Checking thermostat element (high- and

low-temperature circuits)
Technical data, thermostat elements
cardiagn.com
Hightemperature circuit Start of Full open-
opening (A) =
ing (B) = 88 °C ± 2 °C
75 °C ± 2 °C
Lowtemperature circuit Start of Full open-

opening (A)
ing (B) = 51
= 38 °C ± 2 °C
°C ± 2 °C
Note: The thermostat element must not be in

contact with the container.
1. Suspend the thermostat element by means of a

wire in a container filled with water.
2. Heat water with suitable heat source.
Note: Start-of-opening temperature is stamped
on thermostat insert.
3. Check thermostat insert for start of opening

with heat supply uniform and water constantly
circulated. At approx. 10°C below opening
temperature (B), the heating speed must not
exceed 1°C per minute.
4. Replace thermostat insert if results of check
are negative.
5. Continue to heat coolant to full-opening
TIM ID: 0000003724 – 002
temperature (A).
Result: Thermostat insert must be completely
open after 6 to 8 minutes.
6. Measure stroke travel of thermostat insert. Stroke
must be min. 9.5 mm.
7. If stroke travel is less than 9.5 mm, replace
thermostat insert.
M020124/02E 2009-02 © MTU

5.14.52 Coolant pipework with thermostat – Installation
Special tools

Eyebolt 000580010000 2
Driving mandrel F30379297 1
Material

Engine oil
cardiagn.com
Spare parts

O-rings
Suspended load.
Danger to life!
Installing coolant distribution housing

1. Coat Orings with petroleum jelly and insert into
grooves (1) in equipment carrier.
2. Insert plug screw (2).
3. Coat mating face of coolant distribution housing on
equipment carrier with Loctite 518 (arrowed).
TIM ID: 0000003726 – 004
M020124/02E 2009-02 © MTU

Note: When fitting coolant distribution housing

in position, make sure O-rings are not
damaged.
4. Carefully place coolant distribution housing on

equipment carrier with crane and rope and align.
5. Secure coolant distribution housing as shown in
the overview drawing (→ Page 723).
Installing thermostat elements
cardiagn.com
1. Fit sealing ring (2) with flat side to installation
mandrel (1).
2. Drive sealing rings with installation mandrel flush
into thermostat housing.
3. Coat sealing surfaces (arrowed) of thermostat

elements with petroleum jelly.
4. Insert thermostat elements.
6. Insert O-rings in groove.
TIM ID: 0000003726 – 004
M020124/02E 2009-02 © MTU

Installing thermostat housing (high-temperature

circuit)
1. Insert restrictor (arrowed) into support bore.
2. Install thermostat housing on coolant distribution
housing by means of guide pins.
3. Insert securing screws (2) of thermostat
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housing (5).
4. Install flange (1).
5. Install pipelines (3,4) as shown in the overview
6. Install flange (1,2).

TIM ID: 0000003726 – 004
M020124/02E 2009-02 © MTU

5.15 Power Supply, Engine Side
5.15.1 Battery-charging generator - Overview
cardiagn.com
1 Battery-charging generator 10 Grooved ball bearing 19 Guard plate
2 Coupling 11 Shaft seal 20 Holder
3 Carrier 12 O-ring 21 Screw
4 Shaft 13 Screw 23 Washer
5 Gear 14 Washer 24 Holder
6 Snap ring 15 Screw 25 Screw
7 Cylindrical roller bearing 16 Washer 26 Washer
8 Spacer ring 17 Generator bracket 27 Screw
9 Spacer ring 18 Screw
TIM ID: 0000009066 – 001
M020124/02E 2009-02 © MTU

5.15.2 Battery-charging generator – Removal
Special tools

Retaining jig F6782572 1
Heavy object.
Risk of crushing!
Removing battery-charging generator

1. Mark and disconnect battery-charging generator
cables.
3. Remove holder (6) and bracket (3).
4. Remove screws (1) and plate (5).
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5. Withdraw battery-charging generator (4) from
carrier seating and coupling.
Removing coupling from battery-charging generator

1. Install battery-charging generator in support (1).
2. Remove nut (3).
3. Remove battery-charging generator from support.
4. Remove coupling (2) from support.
TIM ID: 0000009069 – 002
M020124/02E 2009-02 © MTU

Removing coupling from shaft

1. Remove screw (2).
2. Remove coupling (3).
cardiagn.com
TIM ID: 0000009069 – 002
M020124/02E 2009-02 © MTU

5.15.3 Battery-charging generator – Disassembly
Disassembling battery-charging generator

Have battery-charging generator overhauled by an authorized workshop only.
cardiagn.com
TIM ID: 0000009071 – 002
M020124/02E 2009-02 © MTU

5.15.4 Battery-charging generator – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning battery-charging generator

1. Clean generator with compressed air only; do not use any liquids in cleaning process.
2. Clean all metal parts using cleaner (Snow-White 11-0) and rinse with cleaner (Hakupur 312).
TIM ID: 0000009067 – 002
M020124/02E 2009-02 © MTU

5.15.5 Battery-charging generator - Check
Spare parts

Coupling
Carrier
Shaft
Gear
Spacer ring
Grooved ball bearing
Gear
Bracket
cardiagn.com
Guard plate
Holder
Clean battery-charging generator (→ Page 738).
Checking battery-charging generator
Item Findings Task
Inspect battery-charging generator Damaged Replace

externally for damage.
Check all contact and mating Damaged • Recondition: Re-surface with

surfaces for damage. oil stone or crocus cloth.
• Replace
Check thread for ease of movement. No ease of movement • Recondition: Re-cut thread(s).
• Replace
Check battery-charging generator Abnormal running noises Contact Service.

drive for abnormal running noises.
Check gear for indentations, signs • Indentations • Recondition: Re-surface with

of wear and damage. • Signs of wear crocus cloth or oil stone.
visible
Check coupling for cracks and • Swellings Replace

swellings. • Cracks
visible.
TIM ID: 0000009068 – 001
M020124/02E 2009-02 © MTU

5.15.6 Battery-charging generator – Installation
Special tools

Positioning fixture F6557187 1
Material

Engine oil
cardiagn.com
Spare parts

Shaft seal
Heavy object.
Risk of crushing!
Check battery-charging generator (→ Page 739).
Installing antifriction bearings and gear on carrier

1. Install antifriction bearings (5-9) on carrier (1).
2. Coat sealing lip of radial-lip shaft seal (10) with
engine oil.
3. Press radial-lip shaft seal into carrier until the
stop is reached.
Note: Heat gear to 180°C +20°C.
4. Install shaft (3) and gear (4) using the press-in

tool and ensuring that an thrust distance of 0.1 to
0.88 mm is achieved.
5. Coat O-ring (2) with petroleum jelly and position
in groove.
TIM ID: 0000009070 – 002
M020124/02E 2009-02 © MTU

Installing coupling on shaft

1. Check screws (1) for correct tightening torque
(→ Page 80).
2. Install coupling (3) ensuring correct positioning.
3. Install positioning fixture to lock the engine.
4. Install screw (2) and tighten to specified tightening
Installing battery-charging generator drive
cardiagn.com
1. Install coupling (2) in installation tool (1).
2. Fit generator in installation tool.
3. Position Woodruff key on shaft.
4. Tighten nut to specified tightening torque
(→ Page 80).
TIM ID: 0000009070 – 002
M020124/02E 2009-02 © MTU

Installing battery-charging generator

Note: Ensure correct positioning of pins (1).
1. Install battery-charging generator (4) with

coupling (3) to coupling (2) ensuring there is no gap
between the resilient element and the intermediate
plate. Torsion of max. 1.0 mm is permissible.
2. Install holder (6) with bracket (3), ensuring that
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parts are not placed under tension.
4. Align battery-charging generator (4).
5. Tighten screws (2) to specified tightening torque
using a torque wrench (→ Page 80).
6. Install plate (5) using screws (1).
7. Connect cables as per marking.
TIM ID: 0000009070 – 002
M020124/02E 2009-02 © MTU

5.16 Mounting/Support
5.16.1 Engine mounting / support – Overview
Engine mounting / support
cardiagn.com
1 Engine mounting bracket 2 Engine mount
TIM ID: 0000004112 – 001
M020124/02E 2009-02 © MTU

5.16.2 Engine mounting – Overview
cardiagn.com
1 Washer 6 Hex screw
2 Hex screw 7 Washer
3 Nut 8 Engine mounting bracket
4 Washer 9 Dowel pin
5 Resilient mount 10 O-ring
TIM ID: 0000034050 – 001
M020124/02E 2009-02 © MTU

Engine mounting brackets
cardiagn.com
1 Engine mounting bracket 3 Engine mounting bracket 5 Screw
TIM ID: 0000034050 – 001
M020124/02E 2009-02 © MTU

5.16.3 Engine mount – Removal
Special tools

Box wrench F30379609 1
Engine can tilt over.

Danger to life!
Suspended load.
Danger to life!
Engine mount – Removal

Note: Replace rubber mounts individually, one
cardiagn.com
after the other.
1. Install engine supports with engine installed.

2. Insert engine support jackscrews until they make
contact with the foundation and secure the engine
against damping element static deflection.
3. Unscrew all foundation screw fittings on damping
element to be removed.
4. Use locking screws (5) to pull damping elements
together evenly until engine carrier can be
removed.
5. If the gap between base mount and foundation is
not large enough, proceed as follows:
5.1. Remove protective cap (1) and loosen
nut (3).
5.2. Insert height adjusting screw (4) as far as
possible in bearing cap. Make sure not to
twist central buffer. Hold firmly in position at
hexagon (2) if necessary.
6. Remove screws (1,2,4) with washers (3) from
engine mounting bracket.
7. Remove engine mount from crankcase.
TIM ID: 0000003538 – 005
M020124/02E 2009-02 © MTU

Removing engine support

Note: Remove engine support only if necessary. Make sure that supports are not stressed by engine.
1. Remove screws and washers from engine support (→ Page 744).

2. Remove engine support from crankcase.
cardiagn.com
TIM ID: 0000003538 – 005
M020124/02E 2009-02 © MTU

5.16.4 Engine mount – Cleaning

Compressed air.
Risk of injury!
Engine mount – Cleaning

Note: Do not allow resilient rubber mounts to come into contact with oil and fuel.
1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Blow out all parts thoroughly with compressed air.
cardiagn.com
TIM ID: 0000003536 – 003
M020124/02E 2009-02 © MTU

5.16.5 Engine mounts – Check
Material

Spare parts

Engine mounting bracket
Damper mount
Dowel pin
cardiagn.com
Checking engine mounts
Check engine mounting bracket for cracks Sign of cracks Replace

with red penetrant dye.
Using the magnetic crack-testing method, Sign of cracks Replace

check central buffer for cracks.
Check central buffer for wear and damage. • Traces of wear Replace
• Damage
Visible
Check resilient rubber mounts for cracks and • Damage Replace

deformation (visual inspection). • Cracks
• Deformation
Visible
Check thread for ease of movement. Sluggish • Rework: recut thread.

• Replace
Check bolt-on faces for flatness. Uneven • Rework: smooth with oilstone.
• Replace
Check grooves for O-rings for damage. Damaged • Rework

• Replace
TIM ID: 0000003537 – 002
M020124/02E 2009-02 © MTU

5.16.6 Engine mount – Installation
Special tools

Material

Engine oil
cardiagn.com
Spare parts

O-ring

Danger to life!
Suspended load.
Danger to life!

Installing engine supports

1. Install engine supports with screws and washers as shown in overview drawing (→ Page 744).
2. Tighten screws and washers of engine supports.
TIM ID: 0000003539 – 005
M020124/02E 2009-02 © MTU

Installing engine mounting bracket with resilient

mount
Note: The resilient mounts are supplied in
preadjusted and locked condition.
1. Prior to installation, check presettings of resilient

mounts. Readjust if required.
A Marking 30 = 6.0 mm buffer clearanceMarking 40

= 8.0 mm buffer clearance
cardiagn.com
B Unloaded 152.5 mm
C Serial number
D Shore hardness
E Type
F Unloaded 50 mm
G Initial dimension 5 mm
2. Degrease engine mounting bracket (3) and flange

mating face (1).
4. Insert O-ring (2) in groove.
5. Chill dowel pins (arrows) in liquid nitrogen.
6. Press dowel pins (arrows) into engine mounting
bracket.
7. Use depth gauge to measure and check blind
hole in crankcase.
Result: Protrusion of dowel pin in engine mounting
bracket must not be greater than depth of blind
hole.
TIM ID: 0000003539 – 005
M020124/02E 2009-02 © MTU

8. Install assembly pins (1).

9. Mount engine mount on engine mounting bracket
(2).
10. Tighten nut manually.
11. Install engine mounting bracket (2) with screws (3)
and washers as shown in overview drawing
(→ Page 744).
12. Use torque wrench to tighten screws to specified
13. Remove assembly pins (1).
14. Align base mounts of resilient mounts in
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longitudinal direction.
15. Loosen screws on engine supports.
16. Lower engine on to foundation by turning all
jackscrews alternately and evenly.
17. Back off jackscrews.
18. Remove locking screws (6), washers (5) and nuts
(4) or jackscrews and store somewhere safe.
19. Check engine alignment (→Height adjustment ).
20. Screw bearing element on to foundation.
21. Use feeler gauge to measure buffer clearance on
resilient mount through measuring groove (3),
readjust central buffer if required.
22. Tighten nut (2) with torque wrench to specified
23. Prevent central buffer from turning by holding
hexagon (1) firmly in place.
Note: Make sure that no oil drips on to rubber
mount.
24. Coat nut mating face and threads of central

buffer with engine oil.
25. Shut down the engine with the locking screws
released for at least 48 hours.
Result: The rubber mounts are compressed.
26. Measure height and height angle.
Result: The dimensions of the shims required to
be installed under the relevant base mount are
defined.
TIM ID: 0000003539 – 005
27. After flanging the engine with alternator or

gearbox, align the unit in longitudinal and
transverse direction in accordance with the
alignment instructions.
M020124/02E 2009-02 © MTU

Adjusting central buffer

Note: Target measured values with locking
system removed and engine filled with
engine coolant and engine oil.
1. Remove protective cap and loosen nut.

2. Screw central buffer clockwise into upper stop
position.
3. Unscrew central buffer counterclockwise by the
dimension of clearance (A).
4. Check clearance with feeler gauge through
measuring groove in base mount.
5. Use torque wrench to tighten nut to specified
6. Fit protective cap.
A Model RD 314 B 3 mm +0.3 mm

A Model RD 315 HD 4 mm +0.3 mm.
cardiagn.com
Height adjustment
1. Remove protective cap (1) and release nut (2).
Note: Make sure not to twist central buffer.
2. Lock bearing cap by fitting a locking screw (4).

3. Using height adjusting nut (3), adjust height by
max. 10 mm.
4. If the required height adjustment is still not
achieved, adjust the height by using shims under
the base mount (5).
5. Tighten nut (2) and protect central buffer from
twisting.
6. Seal protective cap and remove locking screw.
TIM ID: 0000003539 – 005
M020124/02E 2009-02 © MTU

5.17 PTO Systems, Driving End and Free End (Coupling)
5.17.1 Geislinger steel-spring coupling – Removal
Special tools

Adjusting mandrels F30379307 2
Heavy object.
Risk of crushing!
cardiagn.com
Removing steel-spring coupling

1. Mount positioning fixture (1) on flywheel.
2. Depending on the position of the steel-spring
coupling, remove screws (2) for lifting device.
TIM ID: 0000004108 – 003
M020124/02E 2009-02 © MTU

3. Fit lifting device (2) on steel-spring coupling (1)

and attach to crane with a lightly tensioned rope.
4. Remove screws (1) from steel-spring coupling (2)
cardiagn.com
to flywheel (3).
5. Screw in adjusting mandrels (1).

6. Remove both screws (2) for forcing thread.
7. Install removal device.
8. Using removal tool, force steel-spring coupling off
flywheel.
9. Place steel-spring coupling on a suitable surface.
10. Remove O-rings.
TIM ID: 0000004108 – 003
M020124/02E 2009-02 © MTU

5.17.2 Geislinger steel-spring coupling – Disassembly

Heavy object.
Risk of crushing!
Remove Geislinger steel-spring coupling (→ Page 754).
Geislinger steel-spring coupling – Disassembly

1. Place steel-spring coupling (1) on flange of inner
star.
2. Remove sealing ring screws (2).
3. Press sealing ring (3) with two sealing ring screws
(2) off forcing thread (4) and remove.
cardiagn.com
4. Turn over steel-spring coupling and place coupling
intermediate section on wooden blocks.
5. Remove hex screws (3).
6. Remove inner star (1) with split bearing and
bearing retainer (4).
7. Raise bearing retainer (4) in direction inner star (1).
8. Remove split bearing by radially withdrawing
the bearing shells.
9. Remove bearing retainer (4) from inner star (1).
10. Remove retaining screws (2) from coupling
intermediate section.
11. Raise side plate from intermediate element spring
unit.
Result: This arrangement permits a complete
inspection of the steel-spring coupling.
Further disassembly is permitted only at the
manufacturer’s or at a Geislinger Service Point.
TIM ID: 0000004109 – 001
M020124/02E 2009-02 © MTU

5.17.3 Steel-spring coupling – Cleaning
Material

Cleaning agent
Diesel fuel

• Do not smoke.
Compressed air.
Risk of injury!
cardiagn.com
Steel-spring coupling – Cleaning

4. Treat parts with diesel fuel to protect against corrosion.
TIM ID: 0000004106 – 002
M020124/02E 2009-02 © MTU

5.17.4 Geislinger steel-spring coupling – Check
Spare parts

Steel-spring coupling
Heavy object.
Risk of crushing!
Clean Geislinger steel-spring coupling (→ Page 757).
Geislinger steel-spring coupling – Check
Item Findings Task
Check bearing running surfaces for Abrasion visible • Replace damaged parts.
cardiagn.com
abrasion. • Contact Geislinger or a
Geislinger Service Point.
Check bearing clearance from inner Sluggish • Recondition: Recut threads.

star to bearing bush and sealing • Replace
ring.
Wear test for spring leaves

Note: Wear or deformation of the bronze packing
pieces located between the spring leaves
is perfectly normal.
1. Check max. permissible wear “X” per side of the

inner end of the centre leaf.
2. If wear exceeds the max. permissible wear
dimension “X”, have all spring packs replaced by
Geislinger or a Geislinger Service Point.
X max. permissible wear = 2.4 mm

TIM ID: 0000004107 – 001
M020124/02E 2009-02 © MTU

Wear test for inner star

1. Check maximum wear of groove flanks.
2. If wear exceeds max. permissible dimension “A”,
replace inner star or recondition groove flank.
Contact Geislinger or a Geislinger Service Point.
cardiagn.com
A max. permissible wear = 1 mm
TIM ID: 0000004107 – 001
M020124/02E 2009-02 © MTU

5.17.5 Geislinger steel-spring coupling – Assembly
Material

Engine oil
Lubricating grease
Spare parts

Dished washer
O-rings
Heavy object.
cardiagn.com
Risk of crushing!
Check Geislinger steel-spring coupling (→ Page 758).
Geislinger steel-spring coupling – Assembly

1. The procedure is the same disassembly but in reverse sequence.
2. The following additional instructions must be observed.
2.1. Replace all sealing elements.
2.2. Replace all dished washers.
2.3. Coat bearings and bearing running surfaces with lubricating grease.
2.4. Coat O-rings with petroleum jelly.
2.5. Insert O-rings in grooves.
TIM ID: 0000004110 – 001
M020124/02E 2009-02 © MTU

5.17.6 Geislinger steel-spring coupling – Installation
Special tools

Material

cardiagn.com
Denaturated ethanol 40250 1
Spare parts

O-ring
Heavy object.
Risk of crushing!

Assemble Geislinger steel-spring coupling (→ Page 760).

TIM ID: 0000004111 – 003
M020124/02E 2009-02 © MTU

Installing Geislinger steel-spring coupling

1. Degrease and dry-clean flanging surfaces and
centering devices.
2. Screw adjusting mandrels (1) on to flywheel (2).
3. Coat O-ring (3) with petroleum jelly.
4. Insert O-ring (3) in flywheel.
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6. Insert O-ring (1) in groove of steel-spring coupling.
7. Prior to installation, ensure positioning pin (2) is
correctly positioned in relation to flywheel.
8. Install lifting equipment (2) with support bracket on

steel-spring coupling (1).
9. Attach steel-spring coupling (1) and lifting
equipment (2) to crane with a lightly tensioned
rope.
TIM ID: 0000004111 – 003
M020124/02E 2009-02 © MTU

10. Use crane to position steel-spring coupling (3) on

flywheel (1) and slide on to adjusting mandrels (2).
11. Place entire steel-spring coupling (3) on
flywheel (1).
12. Screw in steel-spring coupling (3) diagonally with
4 screws and dish washers without Loctite 270.
13. Tighten screws to specified tightening torque using
a torque wrench (→ Page 80).
14. Remove lifting equipment with support bracket
from steel-spring coupling (3).
15. Install positioning fixture(1) on flywheel (2).
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16. Apply Loctite 270 to both sides of dish washers
for screws (3).
17. Insert 8 screws (3) with dish washers in
18. Tighten opposing screws (3) to specified tightening
torque using a torque wrench (→ Page 80).
19. Remove the 4 assembly screws.
20. Coat both sides of dish washers for assembly
screws with Loctite 270.
21. Tighten opposing screws to specified tightening
22. Coat both sides of dish washers for slotted

screws (1) with Loctite 270.
23. Insert slotted screws (1) in lifting thread bores
and tighten to specified tightening torque using a
torque wrench (→ Page 80).
24. Remove positioning fixture.
TIM ID: 0000004111 – 003
M020124/02E 2009-02 © MTU

5.17.7 Diaphragm coupling – Overview
Diaphragm coupling
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1 Diaphragm coupling 5 Washer
2 Screw 6 Screw
3 Washer 7 Screw
4 Washer 8 Washer
TIM ID: 0000008850 – 001
M020124/02E 2009-02 © MTU

5.17.8 Diaphragm coupling – Removal

Electrical voltage.
Suspended load.
Danger to life!
Diaphragm coupling – Removal

1. Secure generator with rope and crane.
2. Remove guard plates from flywheel housing.
3. Remove screws (2) and (7) with washers (8) as per overview drawing (→ Page 764).
4. Carefully separate generator from engine.
5. Remove screws (6) as per overview drawing (→ Page 764).
6. Remove diaphragm coupling.
cardiagn.com
TIM ID: 0000008851 – 002
M020124/02E 2009-02 © MTU

5.17.9 Diaphragm coupling – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Remove diaphragm coupling (→ Page 765).
cardiagn.com
Diaphragm coupling – Cleaning
1. Clean diaphragm coupling with cleaner.
2. Remove cleaner.
3. Rub diaphragm coupling dry with cloth.
TIM ID: 0000008852 – 001
M020124/02E 2009-02 © MTU

5.17.10 Diaphragm coupling – Check
Material

Spare parts

Diaphragm coupling
Washer
Heavy object.
Risk of crushing!
cardiagn.com
Clean diaphragm coupling (→ Page 766).
Diaphragm coupling – Check
Visually inspect all components for damage Damaged, deformation visible Replace
and deformation.
Check varnish coat of diaphragm coupling for Damaged Replace

damage.
Check thread for ease of movement. Sluggish • Recut

• Replace
Check diaphragm coupling with red penetrant Cracks indicated Replace

dye for cracks.
TIM ID: 0000008853 – 001
M020124/02E 2009-02 © MTU

5.17.11 Diaphragm coupling – Installation

Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.
Heavy object.
Risk of crushing!
Check diaphragm coupling (→ Page 767).
Installing diaphragm coupling on generator shaft
Measurement values table
Σ = (pressed + pulled) / 2
X (engine) Y (generator)
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No. pressed pulled pressed pulled
Mean value
1. Fit diaphragm coupling on generator shaft.

2. Install 4 screws (M16 x 60) offset 90° and tighten
crosswise and evenly to specified tightening
3. Measure dimension Y with generator shaft
pressed.
4. Enter measurement value in table.
pressed.
7. Repeat same measurement procedure at another
position.
8. Enter measurement values in table.
9. Add pressed measurement values, determine
mean value and enter in table.
10. Add pulled measurement values, determine mean
value and enter in table.
11. Determine overall mean value from pressed and
pulled mean values and enter in table.
TIM ID: 0000008854 – 002
M020124/02E 2009-02 © MTU

12. Measure dimension X with crankshaft pressed.

14. Measure dimension X with crankshaft pulled.
position.
Note: If necessary, disassemble diaphragm
coupling and correct dimension Y by
means of adjusting shims.
21. Check result (specified value Y = X -0.2 to -0.5).
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22. Screw in remaining screws (M16 x 60) and tighten
to specified tightening torque (→ Page 80).
23. Replace angular plates in generator fan gap with
more easily detachable shims (1).
TIM ID: 0000008854 – 002
M020124/02E 2009-02 © MTU

24. Screw 2 guide pins (1) into diaphragm coupling

and into flywheel housing and tighten.
Installing generator housing on flywheel housing
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1. Secure generator housing (2) with rope (1) and
crane.
2. Join generator housing to flywheel housing (3) and
diaphragm coupling (4) into flywheel, positioning
by means of guide pins (arrow).
3. Fit generator housing screws (M12 x 40).
4. Tighten 2 screws simultaneously, or, if not possible,
then alternately in stages of 30° angle of rotation,
5. Remove guide pins, replace with screws (M12 x
40) and tighten.
6. Support genset on generator side at bearing points.
7. Detach starter from crane.
8. Remove shims from generator fan gap.
TIM ID: 0000008854 – 002
M020124/02E 2009-02 © MTU

Installing diaphragm coupling with generator shaft

on flywheel
1. Insert screws (1) (M16 x 40) via flywheel housing
openings.
2. Replace guide pins with screws.
3. Tighten 2 opposite screws simultaneously to
4. Use a suitable tool to rotate crankshaft further via
flywheel housing opening until all screws have
been pretightened.
5. Tighten screws, again diagonally and evenly or
alternately in stages of 30° angle of rotation, to
specified tightening torque (→ Page 80) .
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Concentricity check
Note: If concentricity is above 0.13 mm, remove generator and repeat installation with new installation
position of flywheel and coupling.
1. Measure concentricity of diaphragm coupling (max. permissible 0.13 mm).

2. Note measured values.
TIM ID: 0000008854 – 002
M020124/02E 2009-02 © MTU

5.17.12 Auxiliary PTO, lateral – Overview
Auxiliary PTO, lateral
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1 Cover 6 Housing 11 Guard plate
3 Screw 8 Washer 13 Washer
5 Gear 10 Flange
TIM ID: 0000030048 – 001
M020124/02E 2009-02 © MTU

Auxiliary PTO externally mounted components
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1 Flange 8 Washer 15 Screw
2 Cover 9 Screw 16 Washer
3 O-ring 10 Washer 17 Screw
4 Washer 11 Plate 18 Washer
5 Screw 12 Retainer 19 Coupling
6 Retainer 13 Screw 20 Screw
TIM ID: 0000030048 – 001
M020124/02E 2009-02 © MTU

Arrangement of installation/removal device for auxiliary PTO flange
1 Connection, SKF oil pressure

hand pump
2 Thrust sleeve
3 Bush
5
6
7
A
Draw spindle
Flange
Housing
Reference dimension = 185 mm
B Push-on dimension = 5.1mm –
7.5mm (measured from inner face
of flange to face of gear shaft).
C Check surface = Press-fitted flush
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4 Removal/installation device
TIM ID: 0000030048 – 001
M020124/02E 2009-02 © MTU

5.17.13 Auxiliary PTO – Removal
Special tools

Installation/removal device, hydraulic pump drive flange F0140044 1
Hydraulic hand pump, 0-3000 bar F6557936 1

Removing auxiliary PTO

1. Remove hydropump and coupling with externally
mounted components as shown in the overview
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2. Screw draw spindle (3) into flange (2).
3. Install installation/removal device.

4. Screw hydraulic HP fuel line (5) into flange.
5. Install nut (4) and fit by hand.
6. Vent oil pressure hand pump and pipework until
bubblefree oil emerges.
7. Connect HP line to oil pressure hand pump.
8. Read off maximum expansion pressure Pmax
at flange.
9. Operate hydraulic hand pump for expanding the
flange taper until expansion pressure is half the
permitted maximum.
10. Maintain this pressure for approx. 5 minutes.
11. Raise expansion pressure in stages of 0.1 x Pmax,
TIM ID: 0000005487 – 004
observing holding times of approx. 2 minutes.

Ensure that Pmax is not exceeded.
12. Slowly back off nut (4) until flange (2) is completely
released from shaft.
13. Release hand pump pressure and unscrew
HP line.
14. Remove installation/removal device and draw
spindle.
M020124/02E 2009-02 © MTU

15. Remove flange from shaft.

16. Remove housing (1 in the overview drawing
(→ Page 772)).
Removing shaft with gear

1. Press gear shaft (5 in the overview drawing (→ Page 772)) from fit and remove.
2. Unscrew all screws (3 in the overview drawing) from cover (1 in the overview drawing) and remove cover.
3. Press sealing ring (9 in the overview drawing) from fit and remove.
4. Use a suitable puller to remove cylindrical roller bearing (4 in the overview drawing) from shaft.
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TIM ID: 0000005487 – 004
M020124/02E 2009-02 © MTU

5.17.14 Auxiliary PTO – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Remove auxiliary PTO (→ Page 775).
cardiagn.com
Auxiliary PTO – Cleaning
1. Clean all parts with cleaner.
2. Remove cleaner.
3. Blow clean all parts thoroughly with compressed air.
TIM ID: 0000005497 – 001
M020124/02E 2009-02 © MTU

5.17.15 Auxiliary PTO – Check
Material

Fluorescent magnetic powder for magnetic crack-testing method
Spare parts

Cover
Gear
Housing
Flange
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Guard plate
Bracket
Plate (optional)
Coupling
Clean auxiliary PTO (→ Page 777).
Checking auxiliary PTO
Item Findings Task
Using the magnetic crack-testing method and Signs of cracks Replace

fluorescent magnetic powder, check housing,
shaft and gear for cracks.
Visually check sealing surfaces, annular Damaged • Reconditioning:

grooves on cover, flange and housing for wear, Smooth with emery
pitting and cavitation. cloth or oilstone.
• Replace
Check shaft with gear for wear and damage. • Slight wear • Reconditioning:
• Damage Smooth with emery
visible cloth or oilstone.
• Replace
Measure bearing seats on shaft with Limit values exceeded Replace

micrometer.
Visually inspect cylindrical roller bearing Damaged Replace

for damage. Always replace during major
overhaul.
TIM ID: 0000005494 – 002
Check thread for ease of movement. Sluggish Recut
Check coupling visually for wear and damage. Heavy wear, damage visible Replace
M020124/02E 2009-02 © MTU

5.17.16 Auxiliary PTO – Installation
Special tools

Installation/removal device assembly, hydraulic pump drive flange F0140044 1
Hydraulic hand pump 0-3000 bar F6557936 1
Draw spindle F6557108 1
Thrust sleeve F6555733 1
Installation tool, radial-lip shaft seal with support F30378655 1
Pressin tool for cylindrical roller bearing 30378656 1
Material
cardiagn.com
Engine oil
Heavy object.
Risk of crushing!

Check auxiliary PTO (→ Page 778).
Preparing gear shaft

Note: Bearing inner race and outer race are
seen as a single unit and must not be
interchanged.
1. Coat contact surfaces of shaft (4) and track ring (3)

of cylindrical roller bearing with engine oil.
2. Press-fit track ring (3) of cylindrical roller bearing
with jig (1,2) onto gear shaft (4), ensuring it is
gap-free and correctly positioned.
3. Rotate gear shaft and press-fit track ring of
opposite side accordingly.
TIM ID: 0000005503 – 003
M020124/02E 2009-02 © MTU

Preparing housing
1. Coat O-ring (2) with petroleum jelly and insert in
groove of housing (3).
2. Coat housing bearing with engine oil.
3. Press-fit cylindrical roller bearing (1) with suitable
tool into housing (3).
4. Turn housing through 180°.
5. Clean and degrease housing bore for sealing
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ring (1).
6. Press-fit sealing ring (1) so that it is flush with
housing (2).
Installing flange
1. Coat O-ring of cover with petroleum jelly.
2. Install cover (1 in the overview drawing
(→ Page 772)) with screws (3 in the overview
drawing).
TIM ID: 0000005503 – 003
M020124/02E 2009-02 © MTU

3. Coat cylindrical roller bearing (2) with engine oil.

4. Drive cylindrical roller bearing (2) with jig (1)
carefully into housing bore (3).
5. Insert gear shaft (2) up to stop into cylindrical
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roller bearing.
6. Position water cock (1) suitably for housing
installation.
7. Screw 2 guide pins (2) into equipment carrier (1).

8. Position housing (3) with small bore (4) down on
guide pins (2).
9. Insert housing (3) via guide pins (2) into equipment
carrier (1).
10. Secure housing with screws.
TIM ID: 0000005503 – 003
M020124/02E 2009-02 © MTU

11. Coat contact surfaces of flange bore (1) with

engine oil.
12. Fit flange (1) on gear shaft (2) by hand up to stop.
Note: Push-on dimension = 5.1mm – 7.5mm,
measured from inner face of flange
(arrowed) to face of gear shaft (arrowed).
13. Push-on dimension check.
14. Install draw spindle (3), thrust sleeve and jig.
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15. Connect HP fuel line (5) to flange (2).
16. Vent hand pumps and pipework until bubblefree oil
emerges.
17. Tighten nut (4).
18. Using hand pump, generate expansion pressure
until flange (2) with nut (4) can be easily screwed
on.
19. Do not exceed maximum permissible expansion
pressure.
20. Retain expansion pressure and screw on flange
21. Release expansion pressure.
22. Remove HP fuel line (5).
23. Leave jig approx. 60 mins. at rest.
24. Remove jig, thrust sleeve and draw spindle.
Installing Centa coupling and externally mounted components

1. Install Centa coupling – see Special Publication M060715.
2. Install externally mounted components as shown in the overview drawing (→ Page 772).
TIM ID: 0000005503 – 003
M020124/02E 2009-02 © MTU

5.18 Monitoring and Control System
5.18.1 Monitoring, control and regulation devices – Overview
Engine Control Unit (ECU)
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TIM ID: 0000004300 – 001
M020124/02E 2009-02 © MTU

5.18.2 Cabling and engine wiring harnesses – Overview
Designation Pin assignment
Engine wiring harness X2 ECU 4

W2
B1 Camshaft speed
B3 Intake air temperature
B5 Oil pressure
B6 Engine coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
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B26 Charge-air coolant temperature
B34 Fuel pressure after filter
B50 Crankcase pressure
F25 Lube oil differential pressure
F46 Leak-off fuel

W3
B33 Fuel temperature
B48 Fuel pressure after HP pump
M8 HP fuel pump actuator

W4
For 8V
Y39.1 to Y39.4 Injectors, engine side A
Y39.11 to Y39.14 Injectors, engine side B
For 12V
For 16V

TIM ID: 0000034004 – 001
System cable W003 X5 ECU4

(power supply)

(generator control)
M020124/02E 2009-02 © MTU

Engine wiring harness W2
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1 Wiring harness W2 5 O-ring 9 Sealing ring
2 Pressure sensor 6 Pressure sensor 10 Speed sensor
4 Bush 8 Temperature sensor 12 Temperature sensor
TIM ID: 0000034004 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Wiring harness W3 2 Pressure sensor 3 HP fuel pump actuator M8
TIM ID: 0000034004 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
A1 Injector Y39.1 A8 Injector Y39.8** B7 Injector Y39.17**
A2 Injector Y39.2 B1 Injector Y39.11 B8 Injector Y39.18**
A3 Injector Y39.3 B2 Injector Y39.12 X4 Connector to ECU 4
A4 Injector Y39.4 B3 Injector Y39.13 * Only for 12V and 16V
A5 Injector Y39.5* B4 Injector Y39.14 ** Only for 16V
A6 Injector Y39.6* B5 Injector Y39.15*
A7 Injector Y39.7** B6 Injector Y39.16*
TIM ID: 0000034004 – 001
M020124/02E 2009-02 © MTU

5.18.3 Engine wiring harnesses – Removal
Preconditions
Special tools

Hot oil.
Coolant is hot and under pressure.
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WARNING • Let the engine cool down.
Removing engine wiring harnesses W2 and W3

1. Identify wiring harness by labeling (near ECU
connector) and determine route.
2. Unscrew bayonet connector at ECU 4 with
connector pliers.
3. Unscrew connectors of connected
sensors/actuators.
Note: Note position of cable clamps/ties. New
cable clamps/ties must be fitted in the
same places when reinstalling.
4. Remove cable clamps/ties (1) secured to the

wiring harness (2) which is to be replaced.
TIM ID: 0000034006 – 001
M020124/02E 2009-02 © MTU

5. Open and remove all locking clips (1) on all cable

retainers (2) using a screwdriver (see arrow tip for
point of application).
6. Pull wiring harness (3) out of all open cable
retainers.
7. Carefully remove wiring harness.
Removing engine wiring harness W4
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connector pliers.
sensors/actuators.


retainers.
TIM ID: 0000034006 – 001
M020124/02E 2009-02 © MTU

7. Remove cylinder head covers (→ Page 419).

8. Unscrew spade lugs (1) on injector (2).
9. Undo cable entry (3) and carefully pull connecting
wires out of the cable entry.
10. Remove wiring harness.
cardiagn.com
TIM ID: 0000034006 – 001
M020124/02E 2009-02 © MTU

5.18.4 Engine wiring harness – Clean
Material

Cleaner (Hakupur 312 at 2% concentration)


Cleaning engine wiring harness
cardiagn.com
1. Clean engine wiring harness with cleaning agent.
2. Remove cleaner.
TIM ID: 0000029141 – 001
M020124/02E 2009-02 © MTU

5.18.5 Engine wiring harness – Check
Material

Cable tie
Insulating tape
Heat-shrinkable hose
Spare parts

Engine wiring harness
Checking engine wiring harness

1. The engine governor continuously monitors all engine wiring harnesses.
cardiagn.com
2. The engine governor detects and reports the following errors to the connected monitoring system:
• Defective electrical assemblies
• Cabling damage
• Short circuits
• Sensor values outside of the plausibility range.
3. Carry out following checks and maintenance:
Check engine wiring harness for • Cracks • Rework: repair using insulating
cracks, kinks and chafing • Kinks tape or heat-shrinkable hose.
• Chafing • Replace engine wiring harness.
visible
Check shrink-formed components Damaged Replace shrink-formed components.

for damage.
Check plug connections for Damaged • Rework: Straighten plug

damages. connections.
• Replace plug connector.
Check engine wiring harness for Loose engine wiring harness Re-fix engine wiring harness with
tight seating. cable tie.
TIM ID: 0000029142 – 001
M020124/02E 2009-02 © MTU

5.18.6 Engine wiring harnesses – Installation
Special tools

Spare parts

Cable clamps/ties
Installing engine wiring harnesses W2 and W3

1. Position the wiring harness (3), but do not press it
into the cable retainers (2) yet.
2. Route wiring harness such that it runs between
connected sensors/actuators without tension.
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3. Engage and tighten connectors to
sensors/actuators.
4. Press wiring harness into cable retainers.
5. Press locking clips (1) firmly onto cable retainers
until they are fully engaged.
Note: Fit cable clamps/ties (1) in the same places

when installing.
6. Secure cables/wiring harnesses (2) with cable

clamps/ties (1).
7. Connect bayonet connector to ECU 4.
8. Screw union nut of bayonet connector onto ECU 4
with connector pliers.
TIM ID: 0000034068 – 001
M020124/02E 2009-02 © MTU

Installing engine wiring harness W4

connected injectors without tension.
3. Press wiring harness into cable retainers. Finally
press the locking clips (1) firmly onto the cable
retainers until they engage audibly.
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when installing.
4. Secure cables/wiring harnesses with cable

clamps/ties (1).
7. Insert connecting wires in cable entries (3).

8. Twist the wires four times to a suitable length
before connecting them to the injector.
9. Connect spade lugs (1) on injector (2).
10. Install cylinder head cover (→ Page 422).
TIM ID: 0000034068 – 001
M020124/02E 2009-02 © MTU

5.18.7 Sensors, actuators and injectors – Overview
cardiagn.com
1 F46 (leak-off fuel level) 2 F25 (lube oil differential pressure)
TIM ID: 0000034106 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 B6 (coolant temperature) 3 B34 (fuel pressure after filter) 5 B1 (camshaft speed)
2 B5 (lube oil pressure) 4 B33 (fuel temperature) 6 B48 (fuel high pressure)
TIM ID: 0000034106 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 B13 (crankshaft speed) 2 B9 (charge-air temperature) 3 B10 (charge-air pressure)
TIM ID: 0000034106 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 B50 (crankcase pressure)
2 B7 (lube oil temperature)
3 B26 (charge-air coolant
temperature)
4 B3 (intake air temperature)
The injectors are located below the cylinder head covers. Injector replacement and necessary activities (→ Page 435).
TIM ID: 0000034106 – 001
M020124/02E 2009-02 © MTU

5.18.8 Sensors, actuators and injectors – Removal

• Do not smoke.
Hot oil.

Removing temperature sensors (B3, B6, B7, B9,
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B26, B33)
1. Always note:
• The sensors are identical with regard to
design and electrical function. Removal is
also identical.
• Arrangement and position of sensors
(→ Page 795).
2. Observe the following prior to removal:
B6 (coolant temperature) Task description and safety instructions (→Operating Instructions)
B7 (oil temperature) During removal, small amounts of engine oil may emerge. Catch engine
oil in a suitable container.
B33 (fuel temperature) During removal, small amounts of fuel may emerge. Catch fuel in a
suitable container.
3. Release bayonet lock (1) and remove connector

(2).
4. Screw out sensor at nut (3).
TIM ID: 0000029692 – 002
M020124/02E 2009-02 © MTU

Removing pressure sensors (B5, B10)

1. Always note:
also identical.
(→ Page 795).
• During removal of sensor B5 (oil pressure),
small amounts of engine oil may emerge. Catch
engine oil in a suitable container.
(2).
Removing pressure sensor (B34)
cardiagn.com
1. Always note:
• Arrangement and position of sensor
(→ Page 795).
• During removal of sensor B34 (fuel pressure
after filter), small amounts of fuel may emerge.
Catch fuel in a suitable container.
(2).

1. Always note:
(→ Page 795).
• During removal of sensor B48 (fuel high
pressure), small amounts of fuel may emerge.
(2).
TIM ID: 0000029692 – 002
M020124/02E 2009-02 © MTU


1. Always note:
(→ Page 795).
(2).
Removing speed sensors (B1, B13)
cardiagn.com
1. Always note:
also identical.
(→ Page 795).
2. Release bayonet lock (1) of speed sensor (2) and
remove connector (3) from engine wiring system.
4. Remove speed sensor (2).
Removing differential pressure monitor (F25)

1. Always note:
(→ Page 795).
• During removal of sensor F25, small amounts of
engine oil may emerge. Catch engine oil in a
suitable container.
2. Release screw (1) of connector and remove
connector (2).
3. Release nut (3) and screw out sensor (4) from
measuring block (6).
4. Remove copper sealing ring (5).
TIM ID: 0000029692 – 002
M020124/02E 2009-02 © MTU

Removing level probe (F46)

1. Always note:
(→ Page 795).
2. Release bayonet lock and pull off connector.
cardiagn.com
TIM ID: 0000029692 – 002
M020124/02E 2009-02 © MTU

5.18.9 Sensors, actuators and injectors – Check
Material

Isopropyl alcohol
Spare parts

Pressure sensor
Pressure monitor
Speed sensor
Temperature sensor
Level monitor
cardiagn.com
Sensors, actuators and injectors – Check
1. Always note:
• The governor is able to detect defective electric assemblies, wire breaks, short circuits and deviating
sensor values.
2. Carry out the following checks:
Item Findings Task
Check sensors and actuators for Loose sensors or actuators. Retighten securing screws.
secure seating.
Check security of plug connections. Loose plug connections. Connect plug connections properly
and tighten.
Check sensors, actuators and Damaged Replace

plug connections for mechanical
damage.
Check sensors, actuators and plug Contamination visible. Clean relevant assembly with
connections for contamination (e.g. isopropyl alcohol.
oil sludge).
TIM ID: 0000028437 – 001
M020124/02E 2009-02 © MTU

5.18.10 Sensors, actuators and injectors – Installation
Material

Spare parts

O-ring
Sealing ring
Adjusting washer
Check sensors, actuators and injectors (→ Page 803).
Installing temperature sensors (B3, B6, B7, B9,
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B26, B33)
1. Always note:
• The sensors are identical with regard to design
and electrical function. Installation is identical.
(→ Page 795).
3. Insert sensor in bore by hand.
5. Fit connector (2) and tighten bayonet lock (1).
Installing pressure sensors (B5, B10)

1. Always note:
(→ Page 795).
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU

Installing pressure sensor (B34)

1. Always note:
(→ Page 795).
cardiagn.com
1. Always note:
(→ Page 795).

1. Always note:
(→ Page 795).
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU

Installing speed sensor (B13)

1. Always note:
(→ Page 795).
3. Determine clearance “A” see table below. Fit
adjusting washer at installation bore if required.
cardiagn.com
Clearance “A” (between sensor and timing wheel)
MDEC 1 mm to 1.3 mm
DDEC 0.5 mm to 1 mm
4. Fit sensor in bore and press in.

5. Tighten sensor (2) with screw (4).
6. Insert connector for speed sensor (2) in bush (3) of
engine wiring system. Tighten bayonet lock (1).
7. If necessary, roll up sensor cable to correct length
and secure with cable clamps.

1. Always note:
(→ Page 795).
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU

Installing differential pressure monitor (F25)

1. Always note:
(→ Page 795).
2. Fit new sealing ring (5).
3. Screw in sensor (4) in bore of measurement
block (6) by hand.
5. Fit connector (2) and tighten screw (1).
Level probe (F46)
cardiagn.com
1. Always note:
(→ Page 795).
3. Screw in sensor and tighten nut (1).
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU

Special Tools 809
6 Special Tools
6.1 Standard tools – Overview
Order no. Designation Quan-

Use tity
8205891159/00 General tool kit 1
cardiagn.com
TIM ID: 0000009214 – 003
M020124/02E 2009-02 © MTU

6.2 Special tools – Overview
Part No. Designation / Use Qty.
Y20097353 Endoscope 1
cardiagn.com
Y20010175 Bore gauge, 275-300 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 811
Y20002705 C-frame micrometer, 275-300 1

mm
cardiagn.com
Y20091483 Bore gauge, 160-280 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


mm
cardiagn.com
mm
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 813
Y20091481 Bore gauge, 18-100 mm 1
cardiagn.com
mm
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20011268 Dial gauge 1
cardiagn.com
Y20002779 Depth gauge, 500 mm 1
F0099994 Swivel frame 1

TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 815
F6557935 Hydraulic kit 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6783824 Camshaft bearing removal 1

device
cardiagn.com
B80146893 Hand pump kit 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 817
cardiagn.com
F6557186 Hydraulic screw pretensioner 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6553646 Installation/removal tool for 1

main bearing stud
cardiagn.com
F6555771 Stop device for plug (main oil 1
gallery)
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 819
F6555738 Assembly jig for camshaft 1

bearing
cardiagn.com
F30378754 Assembly mandrel for end 1
cover
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30450446 Camshaft bearing shrink-on 1

tool
cardiagn.com
F6555763 Guide bushing for camshaft 1
bearing shrink-on tool
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 821
F30026582 Torque wrench, 20-100 Nm 1
cardiagn.com
F30027340 Ratchet adapter 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6782566 Removal tool for carbon 1

scraper ring
cardiagn.com
F6557114 Removal tool for cylinder liner 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 823
F6787880 Press-in tool for cylinder liner 1
cardiagn.com
Y20000326 Micrometer, 150-175 mm 1
Eyebolts

TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

T80092075 Eyebolt 4
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 825
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


mm
cardiagn.com
0015890321/00 Retainer 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 827
T80091102 Bracket 1
cardiagn.com
F6554714 Guide bushing 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6555724 Support 1
cardiagn.com
F6557190 Removal tool for main 1
bearing, driving end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 829
B80096717 Lukas cylinder 1
cardiagn.com
B80146893 Hand pump set 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378426 Installation tool 1
cardiagn.com
F6557153 Locating device 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 831
T80091102 Support bracket 1
cardiagn.com
F6554714 Guide sleeve 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 833
T80091105 Lifting gear 1
cardiagn.com
B80146411 Adapter 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

B80096717 Lucas cylinder 1
cardiagn.com
F6557191 Press-out tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 835
F30378425 Insertion tool 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30377680 Installation mandrel for 1

radial-lip shaft seal
cardiagn.com
F6782344 Alignment tool (free end), 1
equipment carrier
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 837
F6557946 Guide bushing for equipment 1

carrier
cardiagn.com
0005800100000 Eyebolt 1

mm
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


mm
cardiagn.com
0015890321/00 Holder 1
Master weights
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 839

mm
cardiagn.com
Y20506341 DynaMIC hardness tester 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20091482 Bore gauge, 100-160 mm 1
cardiagn.com
F6553644 Crankshaft locating device 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 841
F6783568 Removal tool for crankshaft 1

bearing caps
cardiagn.com
F6557936 Hydraulic set 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

B80144827 High-pressure hose 1
cardiagn.com
B80144838 Distributor 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 843
Y4341947 Measuring device 1
cardiagn.com
F6553645 Slide protection 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6555764 Press-in tool 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 845
cardiagn.com
F6783003 Alignment tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6553649 Installation aid 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 847
F6553647 Installation/removal device 1
cardiagn.com
F0140440 ZB Installation/removal tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

5505890163/00 SKF hydraulic unit 1
cardiagn.com
5555890063/00 Hand pump set 1
T80091387 Trestle 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 849
F6555788 Adapter 1
cardiagn.com
F30377999 Impact extractor 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6557134 Assembly sleeve 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 851
Y20001744 Micrometer, 175-200 mm 1
cardiagn.com
F0140771 Installation/removal tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 853
cardiagn.com
F6557187 Flywheel positioning fixture 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30379300 Adjusting mandrel 2
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 855
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

T80090748 Hook-ended chain sling (4 off) 1
cardiagn.com
F0140771 Removal/installation device 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 857
T80090748 Hook-ended chain sling 1

(quadruple branch)
cardiagn.com
F6555766 Barring tool, 8V-16V 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6783293 Barring tool, 20V 1
cardiagn.com
F6555791 Barring tool for timing disc 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 859
F6555792 Pointer for barring tool 1
cardiagn.com
Y4341124 Timing disc, free end 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378352 Socket, 22 A/F, conrod screws 1
cardiagn.com
T80091025 Lifting device for piston 1
removal, 8V-16V
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 861

removal, 20V
cardiagn.com
F6559604 Sliding block 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378003 Piston-ring pliers 1
cardiagn.com
F6553635 Assembly jig 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 863
T80091025 Lifting device for pistons, 1

8V-16V
cardiagn.com
T80091496 Lifting device, 20V 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6557121 Assembly sleeves 1
cardiagn.com
F30378352 Socket, 22 A/F 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 865
F6555791 Barring tool 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y4341492 Testing device 1
cardiagn.com
Y4341913 Test mandrel 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 867
cardiagn.com
F30378352 Socket, WAF 22 – conrod 1
screws
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20090113 Alignment plug gauge, 11.00 1

mm H7
cardiagn.com
mm H9
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 869

mm H7
cardiagn.com
mm H7
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


mm H7
cardiagn.com
Y4340442 Check gauge for inlet valve 1
seat
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 871
Y4340443 Check gauge for exhaust 1

valve seat
cardiagn.com
Y4343688 Removal tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20000083 C-frame micrometer, 0-25 mm 1
cardiagn.com
F6553658 Removal tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 873
B80144872 Plug 1
cardiagn.com
plugs
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
F6783833 Valve spring compressor 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 875
F30377634 Socket 1
cardiagn.com
F6783749 Tool kit without elliptical 1
chamfer reconditioning
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6783751 Tool kit (accessory 1

equipment) for elliptical
cardiagn.com
F6784421 Tool kit for valve-seat insert 1
removal
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 877
F30450433 Indexable insert 1
cardiagn.com
F6554300 Mounting plate for valve guide 1
installation
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30450348 Valve guide extractor 1
cardiagn.com
F6781747 Valve guide mandrel 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 879
F30091631 Reamer, Ø19.00 mm for stage 1

0 cylinder head bore
cardiagn.com
I cylinder head bore
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


II cylinder head bore
cardiagn.com
F30450631 Valve seat contour restoring 1
tool for exhaust valve with
valve-seatinsert
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 881

tool for inlet valve with
ellipticalchamfer and
with/without valve-seat
insert
cardiagn.com
8205890451/00 Turning handle for valve seat 1
contour restoring tool
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y4340443 Exhaust valve gauge 1
cardiagn.com
Y4340442 Inlet valve gauge 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 883
Y4341935 Valve seat test device 1
cardiagn.com
F30451554 Countersink reamer tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30450751 Inserting mandrel for 1

valve-seat insert, inlet
cardiagn.com
valve-seat insert, exhaust
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 885
F30026582 Torque wrench 20-100 Nm 1
cardiagn.com
T80090944 Carrying bracket 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


seal plug
cardiagn.com
B80144872 Seal plug 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 887
F6553658 Tightening tool (power 1

amplifier)
cardiagn.com
F6558582 Alignment tool for 8V and 12V 1
cylinder heads
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6553648 Alignment tool for 16V and 1

20V cylinder heads
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 889
Y20044010 Measuring tool for angle of 1

rotation
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378617 Mandrel, Ø 20 mm 1
cardiagn.com
F30377862 Guide sleeve for mandrel 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 891
F30271842 Mandrel, Ø 24 mm 1
cardiagn.com
F30377635 Mandrel, Ø 30 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
Y20506341 Hardness tester DynaMIC 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 893
0015890321/00 Measuring stand 1
cardiagn.com
F6553642 Camshaft locating device 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30450435 Camshaft installation/removal 1

tool
cardiagn.com
F6782970 Guide sleeve for camshaft 1
8V-16V
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 895

20V
cardiagn.com
F6781676 Guide sleeve for assembly on 1
driving end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


driving end
cardiagn.com
free end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 897
F6780582 Centering sleeve for assembly 1

on free end
cardiagn.com
F6781676 Guide sleeve for 1
installation/removal from
driving end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


driving end
cardiagn.com
free end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 899
F6780582 Centering sleeve for 1

free end
cardiagn.com
Y4341124 Graduated disc, free end 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20010128 Feeler gauge 1
cardiagn.com
F30028351 Box wrench, 19 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 901
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

8205893261/00 Oilstone 1
cardiagn.com
T80091799 Lifting equipment for HP 1
pump
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 903
0005388520 Hot-air gun 1
cardiagn.com
0135315483 Connector pliers 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
F30377769 Puller 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 905
F6557991 Puller bracket 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6555197 Lever 1
cardiagn.com
F6557952 Force-in lever 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 907
F30373588 Crowfoot box wrench for HP 1

lines
cardiagn.com
F6553674 Retaining device for HP 1
accumulator installation
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6557185 Alignment tool for HP 2

accumulator
cardiagn.com
F30379005 Slotted nut screwdriver 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 909
F30379104 Filter wrench 1
cardiagn.com
F70144375 Vibe jaw 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30520703 T torque wrench 1
cardiagn.com
F30376601 Snap ring pliers 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 911
F70144375 Assembly jaws 2.
cardiagn.com
F30520703 Tee torque wrench, 10-90 Nm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20044010 Angle of rotation measuring 1

device
cardiagn.com
Y20504961 Dynamometer 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 913
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
Test bath
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 915
cardiagn.com
B80090843 Eyebolt 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 917
cardiagn.com
F6781539 Hydraulic spindle 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6780562 Puller tool for impeller 1
cardiagn.com
F6780561 Puller tool for gear 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 919
F6781573 Holding fixture 1
cardiagn.com
F30275611 Carrier for several mandrels 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30450991 Impact extractor for shaft seal 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 921
F30378152 Press-fit tool for 1

angular-contact ball bearings
cardiagn.com
F30378153 Press-fit tool for roller 1
bearings
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30450990 Press-fit tool for shaft seal 1
cardiagn.com
F6784612 Press-in tool for rotary seal 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 923
F6780563 Fixture for bearing housing 1
cardiagn.com
F6781573 Fixture for shaft with bearing 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6780561 Retaining device 1
cardiagn.com
F30002760 Pliers for snap ring 1
Cleaning brush
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 925
F30378152 Installation tool for 1

angular-contact ball bearing
cardiagn.com
F30378153 Installation tool for roller 1
bearing
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30450990 Installation tool for shaft seal 1
cardiagn.com
F6784612 Installation tool for rotary seal 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 927
F6780563 Bearing housing support 1
cardiagn.com
F6781573 Support for shaft with bearing 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30275611 Support for various mandrels 1
cardiagn.com
000580010000 Eyebolt 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 929
F30379297 Driving mandrel 1
cardiagn.com
F6782572 Retaining jig 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
F6557187 Positioning fixture 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 931
F30379609 Box wrench 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
F30379307 Adjusting mandrels 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 933
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F0140044 Installation/removal device, 1

hydraulic pump drive flange
cardiagn.com
F6557936 Hydraulic hand pump, 1
0-3000 bar
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 935

assembly, hydraulic pump
driveflange
cardiagn.com
F6557936 Hydraulic hand pump 1
0-3000 bar
F6557108 Draw spindle 1

TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6555733 Thrust sleeve 1
cardiagn.com
F30378655 Installation tool, radial-lip 1
shaft seal with support
30378656 Pressin tool for cylindrical 1

roller bearing
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 937
6.3 General workshop equipment – Overview

Use tity
F30004455 Open-end wrench 1
cardiagn.com
F30006068 Double open-end 1
wrench
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU


Use tity
F30025896 Open end wrench 1

bit
cardiagn.com
bit
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU

Special Tools 939

Use tity

bit
cardiagn.com
bit
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU


Use tity
F30047446 Torque wrench 1
cardiagn.com
F30450902 Ratchet bit 1
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU

Special Tools 941

Use tity
F30501631 Starter wrench 1
cardiagn.com
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU


Use tity
5505890921/00 Compression 1
pressure recorder
cardiagn.com
5505890921/06 Diagram sheets 1
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU

Special Tools 943
6.4 Measuring tools – General overview

Use tity
Y20000088 Outside micrometer 1
cardiagn.com
TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU


Use tity
Y20000665 Adjusting ring 1

(9 mm)
cardiagn.com
Y20000918 Depth gauge 1
TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU

Special Tools 945

Use tity
Y20001743 Caliper gauge 1
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Y20016482 Bore gauge 1
TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU


Use tity
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TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU

Special Tools 947

Use tity
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TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU

6.5 Tools kits – Overview
Part No. Designation Qty.

Use
F30378882 W4 tool kit for Series 1

4000
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TIM ID: 0000019250 – 001
M020124/02E 2009-02 © MTU

Diesel Engine 12V 4000 R41 /

16V 4000 R41 (2)
Instructions for Major Overhaul .............................................. 959
7 Maintenance Schedule 12V 4000 R41 / 16V 4000 R41 ................................. 961
7.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 961
7.1.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 961
7.1.2 Maintenance schedule matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 963
7.1.3 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965
8 Task Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 967
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8.1 Engine – Checking condition before a major overhaul .......................... 967
8.2 Engine – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 969
8.3 Engine – Disassembly .................................................... 970
8.4 Engine – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 973
8.5 Engine – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 975
8.6 Engine – Run-in procedure ................................................ 976
8.7 Initial engine operation ................................................... 979
9 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997
9.1 Crankcase and Externally Mounted Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997
9.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997
9.1.2 Crankcase and attachments – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 998
9.1.3 Crankcase – Overview ............................................ 999
9.1.4 Crankcase – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
9.1.5 Crankcase – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005
9.1.6 Crankcase – Checking upper and lower cylinder liner fit . . . . . . . . . . . . . . . . . . . 1007
9.1.7 Crankcase – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010
9.1.8 Crankcase – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016
9.1.9 Crankcase – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024
9.1.10 Cylinder liner – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1032
9.1.11 Cylinder liner – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1034
9.1.12 Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1036
9.1.13 Cylinder liner – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1037
9.1.14 Cylinder liner – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1039
9.1.15 Cylinder liner – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1042
9.1.16 Oil pan – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1045
9.1.17 Oil pan – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1047
9.1.18 Oil pan – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048
9.1.19 Oil pan – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1049
M020124/02E 2009-02 © MTU

9.1.20 Oil pan – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050

9.1.21 Tightening sequence for oil pan made of nodular cast iron (GGG) . . . . . . . . . . . . 1053
9.1.22 Engine lifting equipment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1054
9.1.23 Engine lifting equipment – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056
9.1.24 Engine lifting equipment – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1057
9.1.25 Engine lifting equipment – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058
9.1.26 Engine lifting equipment – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1059
9.1.27 End housing, driving end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060
9.1.28 End housing, driving end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1062
9.1.29 End housing, driving end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1063
9.1.30 End housing, driving end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1064
9.1.31 End housing, driving end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065
9.1.32 End housing KS – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066
9.1.33 End housing, driving end – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1067
9.1.34 End housing, driving end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1069
9.1.35 Crankcase ventilation – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1071
9.1.36 Crankcase ventilation – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1074
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9.1.37 Crankcase ventilation – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1075
9.1.38 Crankcase ventilation – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076
9.1.39 Oil separator – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1077
9.1.40 Oil separator – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1079
9.1.41 Oil separator – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1080
9.1.42 Crankcase ventilation – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1083
9.2 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1084
9.2.1 Gearcase, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1084
9.2.2 Gearcase, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086
9.2.3 Gearcase, free end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088
9.2.4 Equipment carrier free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1089
9.2.5 Gearcase, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1090
9.2.6 Gearcase, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1091
9.2.7 Gearcase, free end – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1092
9.2.8 Gearcase, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1095
9.2.9 Gear train, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1099
9.2.10 Gear train, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1101
9.2.11 Gear train, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1102
9.2.12 Gear train, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103
9.2.13 Gear train, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1105
9.2.14 Gear train, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1107
9.2.15 Bearing bushing of idler gear – Removal and installation . . . . . . . . . . . . . . . . . . . 1110
9.3 Crank Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112
9.3.1 Running gear – Overview .......................................... 1112
9.3.2 Crankshaft – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113
9.3.3 Crankshaft – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116
9.3.4 Crankshaft – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1120
9.3.5 Crankshaft - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1121
9.3.6 Crankshaft – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1122
9.3.7 Crankshaft – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1126
9.3.8 Crankshaft - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1136
9.3.9 Crankshaft – Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1138
M020124/02E 2009-02 © MTU

9.3.10 Crankshaft bearing shells - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1140

9.3.11 Crankshaft bearing bore – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1142
9.3.12 Crankshaft – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1145
9.3.13 PTO flange, driving end, flywheel – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 1153
9.3.14 PTO flange, driving end, flywheel – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1155
9.3.15 Radial-lip shaft seal, driving end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1159
9.3.16 Flywheel on PTO flange, driving end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1160
9.3.17 Flywheel on PTO flange, driving end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1161
9.3.18 Radial-lip shaft seal, driving end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1162
9.3.19 PTO flange, driving end, flywheel – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 1163
9.3.20 Crankshaft PTO, Free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1167
9.3.21 Vibration damper on PTO, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 1169
9.3.22 Vibration damper on PTO, free end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1172
9.3.23 Vibration damper on PTO, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 1173
9.3.24 Vibration damper on PTO, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1174
9.3.25 Vibration damper on PTO, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . 1175
9.3.26 Vibration damper on PTO, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1176
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9.3.27 Piston and conrod – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1180
9.3.28 Piston and conrod – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1182
9.3.29 Piston and conrod – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1185
9.3.30 Piston – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1187
9.3.31 Piston – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1188
9.3.32 Piston – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1191
9.3.33 Conrod – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1197
9.3.34 Conrod – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1198
9.3.35 Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1199
9.3.36 Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1206
9.3.37 Conrod – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1210
9.3.38 Piston – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1213
9.3.39 Piston and conrod – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1216
9.4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1220
9.4.1 Cylinder head and attachments – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1220
9.4.2 Valve-seat turning machine for cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1223
9.4.3 Cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1228
9.4.4 Cylinder head – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1231
9.4.5 Cylinder head – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1233
9.4.6 Cylinder head – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1234
9.4.7 Cylinder head – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1237
9.4.8 Cylinder head – Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1249
9.4.9 Cylinder head – Plug repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1255
9.4.10 Cylinder head – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1257
9.4.11 Cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1262
9.5 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1266
9.5.1 Valve gear – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1266
9.5.2 Camshaft overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1267
9.5.3 Camshaft – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1268
9.5.4 Camshaft – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1270
9.5.5 Camshaft running surfaces and swing followers – Visual inspection . . . . . . . . . . 1271
9.5.6 Camshaft – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1272
M020124/02E 2009-02 © MTU

9.5.7 Camshaft – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1275

9.5.8 Camshaft – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1277
9.5.9 Camshaft drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1284
9.5.10 Camshaft drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1285
9.5.11 Camshaft drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1287
9.5.12 Camshaft drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1288
9.5.13 Camshaft drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1289
9.5.14 Camshaft thrust bearing – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1290
9.5.15 Camshaft thrust bearing – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1291
9.5.16 Camshaft thrust bearing – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1292
9.5.17 Camshaft thrust bearing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1293
9.5.18 Valve drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1294
9.5.19 Valve drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1297
9.5.20 Valve drive – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1299
9.5.21 Valve drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1301
9.5.22 Valve drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1302
9.5.23 Valve drive – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1305
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9.5.24 Valve drive – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1307
9.5.25 Valve drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1310
9.5.26 Cylinder head cover – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1313
9.5.27 Cylinder head cover – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1314
9.5.28 Cylinder head cover – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1315
9.5.29 Cylinder head cover – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1316
9.5.30 Cylinder head cover – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1317
9.6 High Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1318
9.6.1 HP fuel system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1318
9.6.2 HP pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1319
9.6.3 HP pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1321
9.6.4 High-pressure pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1323
9.6.5 High-pressure pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1324
9.6.6 HP pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1325
9.6.7 H.P. fuel pump – Control block replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1327
9.6.8 Injector – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1329
9.6.9 Injector – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1330
9.6.10 Fuel injector disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1333
9.6.11 Injector – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1334
9.6.12 Injector – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1335
9.6.13 Injector – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1336
9.6.14 High-pressure line – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1339
9.6.15 HP fuel line – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1344
9.6.16 HP fuel line – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1348
9.6.17 HP fuel line – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1349
9.6.18 H.P. fuel line – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350
9.6.19 HP fuel line – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1351
9.6.20 HP fuel line – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1354
9.6.21 H.P. fuel system – Leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1359
9.7 Low Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1360
9.7.1 Fuel system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1360
M020124/02E 2009-02 © MTU


9.7.4 Fuel delivery pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1363
9.7.6 Fuel delivery pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1365
9.7.12 Fuel pipework from fuel delivery pump to fuel filter – Overview . . . . . . . . . . . . . . 1371
9.7.13 Fuel lines from fuel delivery pump to fuel filter – Removal . . . . . . . . . . . . . . . . . . 1372
9.7.14 Fuel lines from pump to filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1373
9.7.15 Fuel lines from fuel delivery pump to fuel filter – Check . . . . . . . . . . . . . . . . . . . . 1374
9.7.16 Fuel lines from fuel delivery pump to fuel filter – Installation . . . . . . . . . . . . . . . . . 1375
9.7.17 Fuel duplex filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1376
9.7.18 Fuel duplex filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1377
9.7.19 Fuel duplex filter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1378
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9.7.20 Fuel filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1379
9.7.21 Fuel filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1380
9.7.22 Fuel duplex filter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1381
9.7.23 Fuel duplex filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1382
9.7.24 Fuel pipework from fuel filter to HP pump – Overview . . . . . . . . . . . . . . . . . . . . . 1383
9.7.25 Fuel pipework from fuel filter to HP pump – Removal . . . . . . . . . . . . . . . . . . . . . 1384
9.7.26 Fuel pipework from fuel filter to high-pressure pump – Cleaning . . . . . . . . . . . . . 1385
9.7.27 Fuel pipework from fuel filter to high-pressure pump – Check . . . . . . . . . . . . . . . 1386
9.7.28 Fuel pipework from fuel filter to HP pump – Installation . . . . . . . . . . . . . . . . . . . . 1387
9.7.29 Leak-off fuel pipework – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1388
9.7.30 Leak-off fuel line – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1390
9.7.31 Leak-off fuel pipework – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1391
9.7.32 Leak-off fuel pipework – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1392
9.7.33 Leak-off fuel line – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1393
9.8 Exhaust Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1394
9.8.1 Exhaust turbochargers – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1394
9.8.2 Exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1395
9.8.3 Exhaust turbocharger – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1396
9.8.4 Exhaust turbocharger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400
9.8.5 Exhaust turbocharger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1401
9.8.6 Exhaust turbocharger – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1405
9.8.7 Exhaust turbocharger – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407
9.8.8 Exhaust turbocharger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1413
9.9 Charge-Air Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1414
9.9.1 Intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1414
9.9.2 Intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1416
9.9.3 Intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1417
9.9.4 Intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1418
9.9.5 Intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1420
9.10 Air Intake/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1421
9.10.1 Air intake / air supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1421
M020124/02E 2009-02 © MTU

9.10.2 Intake housing – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1422

9.10.3 Intake housing – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1424
9.10.4 Intake housing – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1425
9.10.5 Intake housing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1426
9.10.6 Intake housing – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1427
9.10.7 Intake air system to cylinders, left – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 1428
9.10.8 Air supply system to cylinders, left-hand side – Removal . . . . . . . . . . . . . . . . . . . 1429
9.10.9 Air supply system to cylinders, left – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 1430
9.10.10 Air supply to cylinders, left side – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1431
9.10.11 Air supply system to cylinders, left-hand side – Installation . . . . . . . . . . . . . . . . . 1432
9.10.12 Air supply system to cylinders, right – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 1433
9.10.13 Air supply system to cylinders, right-hand side – Removal . . . . . . . . . . . . . . . . . . 1434
9.10.14 Air supply system to cylinders, right – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 1435
9.10.15 Air supply to cylinders, RHS – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1436
9.10.16 Air supply system to cylinders, right-hand side – Installation . . . . . . . . . . . . . . . . 1437
9.10.17 Air pipework from turbocharger to intercooler – Overview . . . . . . . . . . . . . . . . . . 1438
9.10.18 Air pipework from exhaust turbocharger to intercooler – Removal . . . . . . . . . . . . 1442
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9.10.19 Air supply from turbocharger to intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . 1443
9.10.20 Air ducts from turbocharger to intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . 1444
9.10.21 Air pipework from turbocharger to intercooler – Installation . . . . . . . . . . . . . . . . . 1445
9.11 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1446
9.11.1 Exhaust system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1446
9.11.2 Exhaust pipework after cylinder head – Overview . . . . . . . . . . . . . . . . . . . . . . . . 1447
9.11.3 Exhaust pipework after cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 1448
9.11.4 Exhaust pipework after cylinder head – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450
9.11.5 Exhaust pipework after cylinder head – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1451
9.11.6 Exhaust pipework after cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . 1452
9.11.7 Exhaust pipework after exhaust turbocharger – Overview . . . . . . . . . . . . . . . . . . 1455
9.11.8 Exhaust pipework after exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . . 1457
9.11.9 Exhaust pipework after turbocharger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1458
9.11.10 Exhaust pipework after exhaust turbocharger – Check . . . . . . . . . . . . . . . . . . . . 1459
9.11.11 Exhaust pipework after exhaust turbocharger – Installation . . . . . . . . . . . . . . . . . 1460
9.11.12 Exhaust pipework after engine – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1461
9.11.13 Exhaust pipework after engine – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1463
9.11.14 Exhaust pipework after engine – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1464
9.11.15 Exhaust pipework after engine – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1465
9.11.16 Exhaust pipework after engine – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1466
9.12 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1467
9.12.1 Electric starter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1467
9.12.2 Starter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1469
9.12.3 Starter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1470
9.12.4 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1471
9.12.5 Starter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1472
9.12.6 Starter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1473
9.12.7 Flame starting system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1474
9.12.8 Flame starting system – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1476
9.12.9 Flame starting system – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1477
9.12.10 Flame starting system – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1478
9.12.11 Flame starting system – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1479
M020124/02E 2009-02 © MTU

9.13 Lube Oil System, Lube Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1480

9.13.1 Lube-oil pump with drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1480
9.13.2 Lube-oil pump with drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1481
9.13.3 Lube-oil pump with drive – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1482
9.13.4 Lube oil pump with drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1483
9.13.5 Lube-oil pump with drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1484
9.13.6 Lube oil pump with drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1486
9.13.7 Oil filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1488
9.13.8 Oil filter with oil filter housing – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1490
9.13.9 Oil filter housing – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1491
9.13.10 Oil filter housing – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1492
9.13.11 Oil filter housing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1493
9.13.12 Oil filter housing – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495
9.13.13 Oil filter with oil filter housing – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1497
9.13.14 Centrifugal oil filter– Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1499
9.13.15 Centrifugal oil filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1502
9.13.16 Centrifugal oil filter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1503
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9.13.17 Centrifugal oil filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1505
9.13.18 Centrifugal oil filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1506
9.13.19 Centrifugal oil filter - Bearing clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1507
9.13.20 Centrifugal oil filter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1508
9.13.21 Centrifugal oil filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1512
9.13.22 Oil heat exchanger – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1513
9.13.23 Oil heat exchanger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1514
9.13.24 Oil heat exchanger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1516
9.13.25 Oil heat exchanger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1517
9.13.26 Oil heat exchanger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1519
9.13.27 Oil system in crankcase – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1522
9.13.28 Oil system in crankcase – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1524
9.13.29 Oil pipework in crankcase – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1526
9.13.30 Oil pipework in crankcase – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1527
9.13.31 Oil system in crankcase – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1529
9.13.32 Turbocharger oil supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1533
9.13.33 Turbocharger oil supply – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1534
9.13.34 Turbocharger oil supply – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1535
9.13.35 Turbocharger oil supply – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1536
9.13.36 Turbocharger oil supply – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1537
9.14 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1538
9.14.1 Coolant system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1538
9.14.2 Engine coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1540
9.14.4 Engine coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1543
9.14.5 Engine coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1548
9.14.6 Engine coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1549
9.14.7 Engine coolant pump – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1551
9.14.8 Engine coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1554
9.14.10 Coolant pipework of engine coolant pump, intake side – Overview . . . . . . . . . . . 1562
9.14.11 Coolant pipework for engine coolant pump, intake side – Removal . . . . . . . . . . . 1565
M020124/02E 2009-02 © MTU

9.14.12 Coolant pipework, engine coolant pump, suction side – Cleaning . . . . . . . . . . . . 1566
9.14.13 Coolant pipework, engine coolant pump, suction side – Check . . . . . . . . . . . . . . 1567
9.14.14 Coolant pipework, engine coolant pump, suction side – Installation .......... 1568
9.14.15 Coolant pipework after cylinder – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1569
9.14.16 Coolant pipework after cylinder – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1570
9.14.17 Coolant pipework after cylinder – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1571
9.14.18 Coolant pipework after cylinder – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1572
9.14.19 Coolant pipework after cylinder – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1573
9.14.20 Engine coolant drain lines – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1574
9.14.21 Engine coolant drain lines – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1575
9.14.22 Engine coolant drain lines – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1576
9.14.23 Engine coolant drain lines – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1577
9.14.24 Engine coolant drain lines – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1578
9.14.25 Engine coolant and charge air coolant ventilation – Overview . . . . . . . . . . . . . . . 1579
9.14.26 Engine coolant and charge-air cooling vent – Removal . . . . . . . . . . . . . . . . . . . . 1581
9.14.27 Ventilation, engine coolant and charge air coolant – Cleaning . . . . . . . . . . . . . . . 1582
9.14.28 Ventilation, engine coolant and charge air coolant – Check ................ 1583
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9.14.29 Engine coolant and charge-air cooling vent – Installation . . . . . . . . . . . . . . . . . . . 1584
9.14.30 Coolant pipework from/to exhaust turbochargers – Overview . . . . . . . . . . . . . . . 1585
9.14.31 Coolant pipework from/to exhaust turbochargers – Removal . . . . . . . . . . . . . . . . 1586
9.14.32 Coolant pipework from/to exhaust turbochargers – Cleaning . . . . . . . . . . . . . . . . 1587
9.14.33 Coolant pipework from/to turbochargers – Check . . . . . . . . . . . . . . . . . . . . . . . . 1588
9.14.34 Coolant pipework from/to exhaust turbochargers – Installation . . . . . . . . . . . . . . 1589
9.14.35 Charge-air coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1590
9.14.36 Charge-air coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1592
9.14.37 Charge-air coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1593
9.14.38 Charge-air coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1598
9.14.39 Charge-air coolant pump – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1599
9.14.40 Charge-air coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1602
9.14.41 Charge-air coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1604
9.14.42 Charge-air coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610
9.14.43 Coolant pipework from/to intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . 1612
9.14.44 Coolant pipework from/to intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 1614
9.14.45 Coolant pipework from/to intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1615
9.14.46 Coolant pipework from/to intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1616
9.14.47 Coolant pipework from/to intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . 1617
9.14.48 Coolant pipework with thermostat – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 1618
9.14.49 Coolant pipework with thermostat – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1619
9.14.50 Coolant pipework with thermostat – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1622
9.14.51 Coolant pipework with thermostat – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1623
9.14.52 Coolant pipework with thermostat – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 1626
9.15 Power Supply, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1629
9.15.1 Battery-charging generator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1629
9.15.2 Battery-charging generator – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1630
9.15.3 Battery-charging generator – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1632
9.15.4 Battery-charging generator – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1633
9.15.5 Battery-charging generator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1634
9.15.6 Battery-charging generator – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1635
9.16 Mounting/Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1638
M020124/02E 2009-02 © MTU

9.16.1 Engine mounting / support – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1638

9.16.2 Engine mounting – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1639
9.16.3 Engine mount – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1641
9.16.4 Engine mount – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1643
9.16.5 Engine mounts – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1644
9.16.6 Engine mount – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1645
9.17 PTO Systems, Driving End and Free End (Coupling) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1649
9.17.1 Geislinger steel-spring coupling – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1649
9.17.2 Geislinger steel-spring coupling – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1651
9.17.3 Steel-spring coupling – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1652
9.17.4 Geislinger steel-spring coupling – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1653
9.17.5 Geislinger steel-spring coupling – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1655
9.17.6 Geislinger steel-spring coupling – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1656
9.17.7 Diaphragm coupling – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1659
9.17.8 Diaphragm coupling – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1660
9.17.9 Diaphragm coupling – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1661
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9.17.10 Diaphragm coupling – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1662
9.17.11 Diaphragm coupling – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1663
9.17.12 Auxiliary PTO, lateral – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1667
9.17.13 Auxiliary PTO – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1670
9.17.14 Auxiliary PTO – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1672
9.17.15 Auxiliary PTO – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1673
9.17.16 Auxiliary PTO – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1674
9.18 Monitoring and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1678
9.18.1 Monitoring, control and regulation devices – Overview . . . . . . . . . . . . . . . . . . . . . 1678
9.18.2 Cabling and engine wiring harnesses – Overview . . . . . . . . . . . . . . . . . . . . . . . . 1679
9.18.3 Engine wiring harnesses – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1683
9.18.4 Engine wiring harness – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1686
9.18.5 Engine wiring harness – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1687
9.18.6 Engine wiring harnesses – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1688
9.18.7 Sensors, actuators and injectors – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1690
9.18.8 Sensors, actuators and injectors – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1694
9.18.9 Sensors, actuators and injectors – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1698
9.18.10 Sensors, actuators and injectors – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1699
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1703
10.1 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1703
10.2 Special tools – Overview .................................................. 1704
10.3 General workshop equipment – Overview .................................... 1829
10.4 Measuring tools – General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1835
10.5 Tools kits – Overview ..................................................... 1840
M020124/02E 2009-02 © MTU

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M020124/02E 2009-02 © MTU

Diesel Engine 12V 4000 R41 / 16V 4000 R41 (2) – Instructions for Major Overhaul 959
Instructions for Major

Overhaul
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M020124/02E 2009-02 © MTU

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M020124/02E 2009-02 © MTU

7 Maintenance Schedule 12V 4000 R41 / 16V 4000 R41
7.1 Maintenance
7.1.1 Preface
MTU maintenance concept

The maintenance system for MTU products is based on a preventive maintenance concept. Preventive maintenance
makes possible advance operational planning and ensures high operational availability.
The maintenance schedule is based on the load profile/load factor specified below. The intervals at
which maintenance work is to be performed and the scope of the inspection and maintenance activities
described are based on experience of average use and serve only as a guide. Additional maintenance
work and/or adaptation of maintenance intervals may prove necessary for special applications and technical
requirements. Maintenance personnel charged with carrying out maintenance work must be appropriately
qualified depending on the complexity of the task concerned. The various stages QL1 to QL4 correspond
to the scope of training offered by MTU and the tools included in the kits:
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QL1: Operational monitoring and maintenance work which may be performed without disas-
sembling the engine when it is out of operation.
QL3: Maintenance work requiring partial disassembly of the engine.
QL4: Maintenance work requiring complete disassembly of the engine.
The maintenance schedule matrix normally finishes with extended component maintenance. The maintenance
services must then be continued in accordance with specified intervals.
The “Task” numbers stated in the action list identify the various maintenance activities. They serve as a reference
for the scope of parts needed and also appear on the labels of the corresponding spare parts.
Notes on maintenance
Fluids and lubricants specifications, maintenance and replacement interval guidelines and the list of recommended
fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications A001061 and in the fluids
and lubricants specifications of the component manufacturers. They are therefore not listed in the maintenance
schedule (exception: deviations from the Fluids and Lubricants Specifications). Use only fluids and lubricants which
conform to MTU specifications or which are approved by the respective component manufacturers.
The user/customer must perform the following maintenance tasks:
• Parts made of rubber or synthetic materials shall be protected from oil, wiped clean with a dry
cloth only, and never cleaned with organic cleaning agents.
• Fuel prefilter:
The maintenance interval depends on the degree of fuel contamination. Paper elements in fuel
prefilters must be replaced every 2 years at the latest (task 9998).
• Battery:
Battery maintenance depends on their use and prevailing ambient conditions. Battery
manufacturer’s specifications shall apply.
Manufacturer’s specifications shall apply to the maintenance of all components not listed in this maintenance schedule.
Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
according to the Fluids and Lubricants Specifications, MTU Publication No. A001061.
TIM ID: 0000009016 – 002
Application group
2A Rail traction
M020124/02E 2009-02 © MTU

Load profile
Load profile table
Power 100% 90% 75% <15%
Corresponding runtime 10% 15% 15% 60%
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TIM ID: 0000009016 – 002
M020124/02E 2009-02 © MTU

7.1.2 Maintenance schedule matrix
0 - 21,000 Operating hours

Limit years
10,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
21,000
11,000
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
Daily
Engine oil filter 2
Engine running - x
Air filter - X X X X X X X X X X X X X X X X X X X X X
Centrifugal oil filter - X X X X X X X X X X X X X X X X X X X X X
Valve gear - X x x x x x x x x x x x x x x x x x x x x
Fuel filter 2 x x x x x x x x x x x x x x x x x x x x x
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Crankcase ventilation - x x x x x x x x x x
Fuel injectors - x x x
Cylinder chambers - X X X
Air filter 2 X X X
Exhaust turbocharger - X X
Component maintenance - X X
Cylinder head - X
Extended component maintenance 18

TIM ID: 0000009017 – 001
M020124/02E 2009-02 © MTU

22,000 - 30,000 Operating hours

Limit years
22,000
23,000
24,000
25,000
26,000
27,000
28,000
29,000
30,000
Engine oil filter 2
Engine running -
Air filter - x x x x x x x x x
Centrifugal oil filter - x x x x x x x x x
Valve gear - x x x x x x x x x
Fuel filter 2 x x x x x x x x x
Crankcase ventilation - x x x x x
Fuel injectors - x x
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Cylinder chambers - x x
Air filter 2 x x
Exhaust turbocharger - x
Component maintenance - x
Cylinder head - x
Extended component maintenance 18 x
TIM ID: 0000009017 – 001
M020124/02E 2009-02 © MTU

7.1.3 Maintenance tasks

Table of maintenance tasks

ifica-
QL1 Engine oil filter Replace engine oil filter during oil change or at latest after Limit W1008
(years) (→Operating Instructions)
.
QL1 Engine operation Check engine oil level (→Operating Instructions ). W0500
Visually check for leaks and general condition of engine. W0501
Check intercooler drain line (if applicable). W0502
Check maintenance indicator of air filter (→Operating Instructions). W0503

m
Check telltale bores of HP fuel pump (→Operating Instructions). W0504
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Check relief bores of coolant pump(s) (→Operating Instructions). W0505
Check for abnormal running noises, exhaust gas color (→Operating W0506
Instructions) and vibrations.
Drain water and contaminants at fuel prefilter drain cock (if applicable) W0507
Check contamination indicator position of fuel prefilter (if applicable) W0508

QL1 Centrifugal oil filter Centrifugal oil filter (if applicable): Check oil residue layer thickness, W1009
clean and replace filter sleeve (→Operating Instructions).
QL1 Fuel filter Replace fuel filter or fuel filter element (→Operating Instructions). W1001
QL1 Valve gear Check valve clearance (→Operating Instructions ). W1002
QL1 Belt Drive Check condition and tension of drive belt, (→Operating Instructions ) W1003
replace if necessary (→Operating Instructions).
QL1 Air filter Replace air filter (→Operating Instructions). W1005
QL1 Fuel injectors Replace fuel injectors (→Operating Instructions ). W1006
QL1 Cylinder chambers Carry out endoscopic inspection on cylinder chambers (→Operating W1011
Instructions ).
QL3 Exhaust turbocharger Overhaul exhaust turbocharger (→ Page 1394). W1038
QL3 Component maintenance Before starting maintenance, drain coolant and flush coolant system W2000
(→ Page 967).
Check rocker arm, valve bridge, swing follower and swing follower W2001
support for wear (→ Page 1294).
Clean air supply pipework (→ Page 1421). W2002
Clean intercooler and check for leaks (→ Page 1414). W2003

TIM ID: 0000009018 – 003
Replace HP fuel sensor (→ Page 1690). W2004
Overhaul engine coolant pump (→Workshop Manual ) and charge-air W2005

coolant pump (→Workshop Manual).
Check engine coolant thermostat and replace thermal actuator W2006

(→ Page 1618).
M020124/02E 2009-02 © MTU


ifica-
Replace charge air coolant thermostat and thermal actuator W2007

(→ Page 1618).
Check centrifugal oil filter (if applicable) for wear (→ Page 1499). W2009
Overhaul starter (→ Page 1467). W2010
Check vibration damper (→ Page 1167). W2011
Replace seals on all disassembled components. W2062
QL3 Crankcase breather Crankcase breather: Replace filter or filter element (→ Page 1071). W1046
QL3 Cylinder head Overhaul cylinder heads, visually check piston crowns and running W1063
pattern of cylinder liners (→ Page 1220).
QL3 Fuel delivery pump Replace fuel delivery pump (→ Page 1361). W1051
QL4 Extended component Perform complete engine disassembly. Inspect engine components W3000
maintenance acc. to assembly instructions, recondition or replace as necessary
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(→ Page 970).
Replace all elastomer components and seals. W3001
Replace piston rings (→ Page 1180). W3002
Replace conrod bearings (→ Page 1180). W3003
Replace crankshaft bearings (→ Page 1113). W3004
Replace cylinder liners (→ Page 1032). W3005
Replace auxiliary PTO antifriction bearing (→ Page 1629). W3006
Replace HP fuel pump (→ Page 1319). W3007
Overhaul generator (→ Page 1629). W3042
TIM ID: 0000009018 – 003
M020124/02E 2009-02 © MTU

Task Schedules 967
8 Task Schedules
8.1 Engine – Checking condition before a major overhaul

Before the engine is removed, a brief test should be conducted to assist in evaluating
its condition and running behaviour.
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TIM ID: 0000000480 – 001
M020124/02E 2009-02 © MTU

Deviations from the Engine Acceptance Test Record Data found during the test run provide
valuable information for subsequent overhaul services.
Preparations for putting into operation. (→Operating Instructions)
Initial operation, start engine. (→Operating Instructions)
Run engine warm. -
Perform operational checks. (→Operating Instructions)
Check operating states with fault code display, assess (→Operating Instructions)
discrepancies.
Check exhaust gas color. (→Operating Instructions)
Operate engine with adjustable zero-power speed. -
Check fuel line connections for leaks. -
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Remove cylinder head cover. (→Operating Instructions)
Check valve gear lubrication. -
Take engine oil sample. (→Operating Instructions)
Install cylinder head cover. (→Operating Instructions)
Check intercooler drain line for leaks. (→Operating Instructions)
Analyze engine oil sample (spot test, water content, MTU test kit
dilution with fuel).
Take engine coolant sample. (→Operating Instructions)
Examine engine coolant sample. MTU test kit
Check monitoring system and ECU. -
Shut down engine. (→Operating instructions)
If installed, lower coolant level in expansion tank and (→Operating instructions)

check level switch response.
Drain engine coolant. (→Operating instructions)
Fill system with cleaning solution. -
Flush cooling system. -
Flush charge air cooling system. -

TIM ID: 0000000480 – 001
Perform endoscopic inspection. (→Operating Instructions)
M020124/02E 2009-02 © MTU

Task Schedules 969
8.2 Engine – Removal
Shut off fuel supply. –
Drain engine oil at operating temperature. (→Operating Instructions)
Examine oil sludge for metallic residues. –
Drain engine coolant. (→Operating Instructions)
Wash machinery plant (as required, without chemical –

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

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

transportation regulations.
TIM ID: 0000002889 – 003
M020124/02E 2009-02 © MTU

8.3 Engine – Disassembly

Before disassembling the engine, it is advisable to take photographs from all sides or to make
a record of all components installed on the engine.
Remove PTO system. –
Remove intake silencer. –
Remove air intake. (→ Page 1424)
Mark and disconnect electric cables. (→ Page 1683)
Remove exhaust system after engine. (→ Page 1463)
Remove exhaust system after exhaust (→ Page 1457)

turbocharger.
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Remove air pipework to intercooler. (→ Page 1442)
Disconnect oil supply to exhaust turbocharger. (→ Page 1534)
Remove exhaust turbocharger. (→ Page 1395)
Disconnect coolant supply to exhaust (→ Page 1586)

turbocharger.
Remove couplings. (→ Page 1660)
Remove MDEC. –
Remove coolant pipework, low-temperature (→ Page 1614)

circuit.
Remove crankcase breather. (→ Page 1074)
Remove charge air pipes. (→ Page 1429)
Remove intercooler. (→ Page 1416)
Remove engine coolant ventilation and (→ Page 1581)

charge-air cooling.
Remove exhaust pipework. (→ Page 1448)
Remove coolant pipework. (→ Page 1570)
Remove centrifugal oil filter. (→ Page 1502)
Remove oil cooler. (→ Page 1514)
Remove thermostat housing. (→ Page 1619)

TIM ID: 0000009008 – 003
Remove coolant pipework, high-temperature DM_410_WM_202050_520A

circuit. (→ Page 1565)
Remove coolant pump, low-temperature circuit. DM_410_WM_203050_520A
Remove coolant pump, high-temperature DM_410_WM_202050_520A

circuit.
M020124/02E 2009-02 © MTU

Task Schedules 971
Remove auxiliary PTO (→ Page 1670)
Remove fuel pipework from fuel filter to HP (→ Page 1384)

pump.
Remove leak-off fuel line. (→ Page 1390)
Remove leak-off fuel monitoring system. (→ Page 1390)
Remove HP fuel pump. (→ Page 1321)
Remove fuel pump, low-temperature circuit. (→ Page 1362)
Remove fuel filter. (→ Page 1377)
Remove starter. (→ Page 1469)
Remove HP fuel lines with HP accumulator. (→ Page 1344)
Remove cylinder head covers. (→ Page 1314)
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Remove valve drive. DM_410_WM_055051_520A
(→ Page 1297)
Remove fuel injector. (→ Page 1330)
Remove cylinder heads. (→ Page 1228)
Remove vibration damper. (→ Page 1169)
Remove coolant distribution housing. (→ Page 1619)
Remove flywheel with timing wheel. (→ Page 1155)
Disassemble crankcase. (→ Page 1002)
Remove engine mounts. (→ Page 1641)
Remove engine lifting attachment. (→ Page 1056)
Remove end housing, driving end. (→ Page 1062)
Remove oil pan. (→ Page 1047)
Remove gearcase, free end. (→ Page 1086)
Remove oil pump with drive and pressure (→ Page 1481)

reducing valve.
Remove piston and conrod. (→ Page 1182)
Remove crankshaft. (→ Page 1116)
Remove cylinder liners. (→ Page 1034)

TIM ID: 0000009008 – 003
Remove oil pipework and oil spray nozzles. (→ Page 1524)

device.
Remove camshaft drive with timing wheel. (→ Page 1285)
M020124/02E 2009-02 © MTU

Replace camshaft axial alignment bearing. (→ Page 1292)
Remove camshaft. (→ Page 1268)
Remove end cover. (→ Page 1002)
Remove studs. (→ Page 1002)
Remove camshaft bearing bush. (→ Page 1002)
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TIM ID: 0000009008 – 003
M020124/02E 2009-02 © MTU

Task Schedules 973
8.4 Engine – Assembly

Clean crankcase. (→ Page 1005)
Check crankcase. (→ Page 1010)
Assemble crankcase. (→ Page 1024)
Install cylinder liners. (→ Page 1042)
Install camshaft. (→ Page 1277)
Install oil system in crankcase. (→ Page 1529)
Install crankshaft. (→ Page 1145)
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Install gearcase, free end. (→ Page 1095)
Install end housing, driving end (→ Page 1069)
Install piston with conrod. (→ Page 1216)
Install lube-oil pump with drive. (→ Page 1486)
Install oil pan. (→ Page 1050)

device.
Install camshaft drive. (→ Page 1289)
Install camshaft thrust bearing. (→ Page 1292)
Install main oil gallery. (→ Page 1024)
Install engine lifting eyes. (→ Page 1645)
Install cylinder heads. (→ Page 1262)
Install coolant distribution housing. (→ Page 1626)
Install leak-off fuel pipework. (→ Page 1393)
Install valve gear. DM_410_WM_055051_720A

(→ Page 1310)
Install vibration damper on PTO, free end. (→ Page 1176)
Install PTO flange, flywheel driving end. (→ Page 1163)

TIM ID: 0000009009 – 003
Install engine lifting attachment. (→ Page 1059)
Install fuel injector. (→ Page 1336)
Install cylinder head cover. (→ Page 1317)
Install thermostat housing. (→ Page 1626)
Install oil cooler. (→ Page 1519)
M020124/02E 2009-02 © MTU

Install HP fuel pump. (→ Page 1325)
Install auxiliary PTO (→ Page 1674)
Install crankcase ventilation. (→ Page 1083)
Install oil filter housing. (→ Page 1519)
Install centrifugal oil filter. (→ Page 1512)
Install HP fuel line. (→ Page 1354)
Install fuel delivery pump. (→ Page 1366)
Install fuel filter. (→ Page 1382)
Install fuel pipework from fuel filter to HP pump. (→ Page 1387)
Install MDEC. –
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Install coolant pump, high-temperature circuit. DM_410_WM_202050_720A
Install coolant pump, low-temperature circuit. DM_410_WM_203050_720A
Install charge air manifolds. (→ Page 1432)
Install starter. (→ Page 1473)
Install intercooler. (→ Page 1420)
Install coolant venting lines (→ Page 1584)
Install coolant pipework, high-temperature circuit. (→ Page 1568)
Install exhaust pipework. (→ Page 1452)
Install coolant pipework after cylinder. (→ Page 1573)
Install coolant pipework from/to intercooler. (→ Page 1617)
Install exhaust turbocharger. (→ Page 1413)
Install engine coolant drain lines. (→ Page 1578)
Install coolant supply to exhaust turbocharger. (→ Page 1589)
Install exhaust turbocharger oil supply. (→ Page 1537)
Install air pipework to intercooler. (→ Page 1445)
Install exhaust system after exhaust turbocharger. (→ Page 1460)
Install air intake. (→ Page 1427)
Install exhaust pipework after engine. (→ Page 1466)

TIM ID: 0000009009 – 003
Install couplings. (→ Page 1663)
Connect electrical lines. (→ Page 1688)
Install intake silencer. –
Install PTO system. –
M020124/02E 2009-02 © MTU

Task Schedules 975
8.5 Engine – Installation
Open all connections, remove caps and rubber plugs. –
Attach engine at lifting eyes only and install as per (→Operating instructions)
transportation instructions.
Connect coolant lines, fuel lines and engine monitoring –

system.
Fill with engine coolant. (→Operating instructions)
Fill with charge-air coolant. (→Operating instructions)
Change/fill with engine oil. (→Operating instructions)
Align engine. –
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TIM ID: 0000002884 – 002
M020124/02E 2009-02 © MTU

8.6 Engine – Run-in procedure

Running in engine after replacing parts
• After replacing pistons, piston rings or cylinder liners, run in the engine according to the respective program.
Correct running in is decisive for the service life and operational reliability of the engine.
• To destroy the braking energy, use the alternator or brake.
• Power must be transmitted from the engine to the brake by means of a resilient coupling.
Adjust engine operational data
• Set temperatures, fuel and intake air in accordance with the temperature values in the
MTU Acceptance Test Record. Note the following:
• The coolant temperature depends on the operating range of the coolant thermostat.
• The fuel temperature depends on the volume of the day tank, as long as there is no
fuel cooling system available at the test bench.
• Note down operational data for power, fuel, oil, coolant, charge air and exhaust gas at every test point (time,
speed and effective power) in the “MTU diesel engine factory test” log under RUN IN ENGINE.
Install engine on test stand. -
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Connect engine to dynamometer or generator. -
Connect exhaust gas, coolant and fuel lines. -
Connect control device to MDEC, DDEC. -
Connect sensors and measuring lines for measuring -

fuel, oil, coolant, charge air and exhaust gas to the
corresponding measuring points.
Connect dialog unit to ECU. (→Acceptance Test Record)
Fill expansion tank with coolant with 2% corrosion (→Operating Instructions)

inhibitor oil up to max. mark.
Fill with charge-air coolant. (→Operating Instructions)
Bleed coolant lines until bubble-free coolant emerges. (→Operating Instructions)
Check that fuel in service or supply tank is to (→Fluids and Lubricants Specification)
specification.
Fill oil system with engine oil. (→Operating Instructions)
Prime valve gear with oil. (→Operating Instructions)
Check emergency shutdown system. -
Preheat coolant. (→Operating Instructions)
Prime engine oil circuit with external pump. -
Start engine using ECU. (→Operating Instructions)
After approx. 1 minute idling operation, switch off (→Operating Instructions)

TIM ID: 0000004051 – 002
engine and:
• Check oil level. If necessary, top up oil.
• Remove valve gear cover and check valve gear
lubrication.
Start engine and check idle speed. -
Check engine running noises. (→Operating Instructions)
M020124/02E 2009-02 © MTU

Task Schedules 977
Warm up engine. (→Operating Instructions)
Check coolant, oil and fuel lines for leaks. (→Operating Instructions)
Run in engine in accordance with run-in program and (→Acceptance Test Record)
record measured values.

Check and enter fuel density and color of exhaust gas. -
Enter barometric pressure and relative air humidity in (→Acceptance Test Record)
Test Record.
Check engine for abnormal running noises and leaks. -
Check engine monitoring. -
Adjust speed-sensitive fuel limiter performance (→Acceptance test record, Control value sheet)
cardiagn.com
according to Acceptance Test Record.
When the run-in program is completed, run down and (→Operating Instructions)
switch off engine.
Cut open one oil filter and check for residues. (→Operating Instructions)
Check oil level and prepare engine for measurement -

of oil consumption.
Carry out acceptance test as per Acceptance Test -

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

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

and switch off.
Carry out measurement of oil consumption. (→Operating Instructions)
Start engine. -
Set engine to operating power in accordance with MTU (→Acceptance Test Record)
Acceptance Test Record.
Switch off engine and carry out six start/stop -

procedures.
Carry out engine preservation run. (→Operating Instructions)
Switch off engine and disable the engine starter. -

TIM ID: 0000004051 – 002
Drain engine oil and coolant. (→Operating Instructions)
Take protective measures for sea transportation. -
Disconnect exhaust gas, coolant, and fuel lines. -
Disconnect control device to MDEC, DDEC. -
M020124/02E 2009-02 © MTU

Remove sensors and measuring lines and seal -

measuring points.
Remove engine from test stand. -
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TIM ID: 0000004051 – 002
M020124/02E 2009-02 © MTU

Task Schedules 979
8.7 Initial engine operation
Carry out services to put the engine into operation. (→Operating Instructions)
Preheat engine (optional). –
Carry out operational checks. (→Operating Instructions)
Check monitoring system and ECU. Contact Service.
Perform test run. (→Acceptance test record)
Measure intake depression (only for initial operation). Contact Service.
Measure exhaust backpressure (only for initial Contact Service.

operation).
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Perform after-shutdown service. (→Operating Instructions)
For extended out-of-service period: (→Fluids and Lubricants Specification)

• Carry out external preservation
• Disable engine start
• Seal air inlet and exhaust outlet
• Carry out internal preservation (air, oil, fuel)
TIM ID: 0000003804 – 001
M020124/02E 2009-02 © MTU

Crankcase



screws
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screws
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 981
Crank drive


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Sequence:
a Short arm
b Long arm

Sequence:
a Short arm
b Long arm

Sequence:
a Short arm
b Long arm
Piston crown screws

±0.1 mm.

0.1 mm.
2 Release screws
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Cylinder head
1 Tighten 25 Nm
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A Exhaust side
B Inlet side
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 983
Valve gear





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seal

high-pressure accumulator
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

specifications
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Exhaust pipework

x 120 P37
Charge air cooling

Starting equipment

TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 985
Lube-oil system

8/12/16 V engines

8/12/16 V engines
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equipment carrier

carrier
Mounting / support



carrier

crankcase

TIM ID: 0000003825 – 005
crankcase
M020124/02E 2009-02 © MTU


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screws 50 Nm

Screw M 20 x 50 500 Nm +50 Nm
Screw M 22 x 55 680 Nm + 68 Nm

TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 987

flange

housing

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

• Lube oil
• Charge air

pressure

pressure

oil
TIM ID: 0000003825 – 005

M020124/02E 2009-02 © MTU

Thread
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
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M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175

TIM ID: 0000003825 – 005
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
M020124/02E 2009-02 © MTU

Task Schedules 989
M6 9 12
M8 21 28
M8 x 1 24 30
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M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230

TIM ID: 0000003825 – 005
M30 1250 1575

M020124/02E 2009-02 © MTU


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TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 991
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TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

inserted in
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
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M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 993
inserted in
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
cardiagn.com
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

cardiagn.com

Thread
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160

TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

Task Schedules 995

Thread
(Nm)
M10 x 1 15
M16 x 1.5 30
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TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU


Thread
(Nm)
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
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M42 x 2 260
M48 x 2 320
1 Union nut
2 Union body
3 O-ring
TIM ID: 0000003825 – 005
M020124/02E 2009-02 © MTU

9 Task Descriptions
9.1 Crankcase and Externally Mounted Components
9.1.1 Engine layout
Illustration applies analogously to 8/12/16 V 4000 G, C and R
010
020
Crankcase and add-on components
Gear train
100
110
Intercooler
210
220
Power supply
Cooling air system
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030 Running gear 120 Air intake / air supply 230 Mounting system/support
040 Cylinder head 140 Exhaust pipework 250 PTO systems, driving and free
050 Valve gear 170 Starting equipment end (couplings)
070 Fuel system (high-pressure) 180 Lube oil system 500 Monitoring, control and regulating
080 Fuel system (low-pressure) 200 Engine cooling system devices, general electr. equipment
TIM ID: 0000008330 – 001
M020124/02E 2009-02 © MTU

9.1.2 Crankcase and attachments – Overview
Overview of crankcase and attachments
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1 Crankcase 8 Block
2 Camshaft bearing 9 Nut for main bearing cap
3 Crankshaft bearings 10 Socket-head screws
TIM ID: 0000000565 – 001
4 Stud 11 Main bearing cap

5 Crankshaft alignment bearing 12 Cylinder liner
6 Crankshaft alignment bearing cap 13 Oil filler neck
7 Oil pan 14 Oil dipstick
M020124/02E 2009-02 © MTU

9.1.3 Crankcase – Overview
Crankcase with cover
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1 Crankcase 9 Sealing ring 17 Washer
2 Block 10 Blanking plug 18 O-ring
4 Drain valve 12 O-ring 20 Inspection port cover
5 Dowel pin 13 Holder 21 Gasket
6 Cover 14 Screw 22 Screw
7 Stud 15 O-ring
8 Plug 16 Screw
TIM ID: 0000000573 – 001
M020124/02E 2009-02 © MTU

Crankcase
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1 Crankcase 4 Stud * 7 Washer
2 Main bearing cap 5 Nut 8 End cover
3 Main bearing cap 6 Screw 9 Camshaft bearing
(*) Newly fitted studs must be elongated before initial tightening
TIM ID: 0000000573 – 001
M020124/02E 2009-02 © MTU

Oil filler neck with oil dipstick
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1 Inspection port cover 5 O-ring
2 Sealing ring 6 Cover for oil filler neck
3 Unions 7 Gasket
4 Oil dipstick 8 Hex screw
TIM ID: 0000000573 – 001
M020124/02E 2009-02 © MTU

9.1.4 Crankcase – Disassembly
Preconditions
Special tools

Camshaft bearing removal device F6783824 1
Suspended load.
Danger to life!
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Risk of injury!
Removing externally mounted components

1. Remove cover (→ Page 999).
2. Remove guide tube (→ Page 999).
3. Remove oil filler neck, (not applicable to gas engines) (→ Page 999).
4. Remove inspection port cover (→ Page 999).
5. Remove all seals and O-rings.
Installing crankcase in crankcase rotation device

1. Attach supports (1) for swivel frame (2) on left
and right sides of crankcase.
2. Lift crankcase with lifting device and ropes.
3. Insert crankcase in swivel frame and secure.
TIM ID: 0000000586 – 009
M020124/02E 2009-02 © MTU

Removing crankshaft bearing cap and studs

Note: Remove studs only if damaged or
over-elongated. When removing, replace
studs in pairs.
2. Place installation/removal tool (arrow) on studs.

3. Remove respective studs using the
installation/removal tool.
Removing camshaft bearings
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2. If only one bearing is replaced, protect the next
bearing (arrow) from damage.
3. Insert jig (6) in camshaft bearing (5).
4. Fit screw (1) and retainer (2) on cylinder (4)
using nut (3).
5. Press camshaft bearing (5) out of crankcase.
6. Follow the same procedure to remove the other
camshaft bearing bushings.
Removing last camshaft bearing with flywheel

housing attached
2. Removal is the same as for removal of the
camshaft bearings, with the difference that jig (1)
is used → 3. .
TIM ID: 0000000586 – 009
M020124/02E 2009-02 © MTU

Removing end cover

Note: Do not drill into end cover. Metal chippings
in the crankcase coolant chamber may
cause local overheating.

2. Use pliers to withdraw plug, taking care that end
cover does not fall into the bore.
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TIM ID: 0000000586 – 009
M020124/02E 2009-02 © MTU

9.1.5 Crankcase – Cleaning
Material

Compressed air.
Risk of injury!
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Crankcase – Cleaning
1. Use cleaner (Hakupur 312) to clean elastomer components.
3. Clean crankcase and all threaded bores and blow clear with compressed air.
Cleaning oil filler neck and oil dipstick

2. Blow oil filler neck and oil dipstick clear with compressed air.
3. Make sure parts are perfectly clean.
Cleaning crankshaft cover

1. Remove sealant from crankcase cover.
2. Clean oil bores thoroughly with a hole brush.
TIM ID: 0000000576 – 004
M020124/02E 2009-02 © MTU

Cleaning oil bores in crankcase

Note: During a major engine overhaul, or if
metal chippings have got into the engine
oil system.
1. Clean oil and coolant bores thoroughly with a

suitable hole brush. Never use a wire brush!
Cleaning crankshaft bearing cap
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2. Clean mating faces on crankshaft bearing cap and
crankcase and blow clear with compressed air.
TIM ID: 0000000576 – 004
M020124/02E 2009-02 © MTU

9.1.6 Crankcase – Checking upper and lower cylinder liner fit
Spare parts

Crankcase
Checking area I of upper and lower fits

1. Check area I of upper and lower fits for corrosive
pitting.
Result: If corrosive pitting is visible in area I,
2. Check area I of upper and lower fit for hollows.
Result: If hollows in area I are larger than
0.500 mm over max. 30° of the circumference,
machine to repair size. To be carried out only in
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3. Check area I of lower fit for recesses.
Result: If recesses are visible in area I, machine to
repair stage. To be carried out only in workshops
authorized by MTU.
a Area I of upper and lower fits
Checking area II of upper and lower fits

1. Check area II of upper fit for corrosive pitting.
Result: If corrosive pitting in area II is larger than
0.600 mm, machine to repair stage. To be carried
out only in workshops authorized by MTU.
2. Check area II of lower fit for corrosive pitting.
Result: If corrosive pitting is visible in area II,
a Area II of upper and lower fits

TIM ID: 0000020077 – 001
M020124/02E 2009-02 © MTU

Exemplary illustrations showing corrosive pitting in

upper and lower fits
1. Upper fit
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2. Upper fit
TIM ID: 0000020077 – 001
M020124/02E 2009-02 © MTU

3. Lower fit
4. Lower fit
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5. Lower fit
6. If the assessment of the findings should be
unclear or extreme corrosive pitting was found,
(→Contact Service.).
TIM ID: 0000020077 – 001
M020124/02E 2009-02 © MTU

9.1.7 Crankcase – Check
Special tools

Bore gauge, 275-300 mm Y20010175 1
Bore gauge, 160-280 mm Y20091483 1
Bore gauge, 18-100 mm Y20091481 1
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Material

Corrosion inhibitor (Pfinder AP 11 F) 40355 1
Spare parts

Crankshaft bearing cap
Studs for main bearing
Socket-head screws for crankshaft bearing cap
Camshaft bearing
Oil filler neck, (not applicable to gas engines)
Oil dipstick
Cover
TIM ID: 0000000579 – 009
Heavy object.
Risk of crushing!
M020124/02E 2009-02 © MTU


Risk of injury!
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TIM ID: 0000000579 – 009
M020124/02E 2009-02 © MTU

Crankcase – Check
Item Findings Task
Check crankcase for cracks using Signs of cracks Contact Service.

surface crack-testing method.
Use magnetic crack-testing method Signs of cracks Replace component.

to check crankshaft bearing caps for
cracks.
Check contact surface and upper and lower cylinder liner fits in crankcase (→ Page 1007).
Check crankcase top for stress • Stress marks To be carried out only in workshops
marks, damage and cavitation. • Damage authorized by MTU. Rework
• Cavitation crankcase top.
visible
Check main bearing studs for Damaged Replace component.

damage.
Check socket-head screws for Damaged Replace component.
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lateral fixation of crankshaft bearing
cap for damage.
Check camshaft bearing and guide Damaged Replace component (→ Page 1024).
bushings for wear and damage.
Check all mating and sealing faces Stress marks • Corrective work: Smooth with
and fits. oilstone or emery cloth.
• Replace
Check all threads for damage. Damaged Recut threads.
Check oil filler neck for damage (not Damaged • Corrective work
applicable to gas engine). • Replace
Check that oil dipstick fits correctly Damaged Replace component. Make sure
in guide tube and check for damage. that replacement oil dipstick is the
correct version.
Check cover for stress marks and • Stress marks • Corrective work
damage. • Damage • Replace
visible • Use a plastic plug to prevent
each bore from being soiled
until the crankcase has been
assembled.
Use a C-frame micrometer to Values exceeded. Replace cap.

measure width of crankshaft bearing
cap at upper and lower fits. Values
(→ Page 1016)
Check stud for damage; • Damaged Replace (→ Page 1024)

measure length of stud. Values • Values exceeded
(→ Page 1016)
TIM ID: 0000000579 – 009
M020124/02E 2009-02 © MTU

Checking oil bores in crankcase

Note: As part of every major overhaul or if metal
chips penetrate the engine oil system, all
oil and coolant bores must be checked
for particular cleanness using a cold light
source or endoscope.
1. Check oil supply bores for valve drive at

crankcase, sides A and B.
2. Check main oil supply bores for camshaft and
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main bearing in crankcase V.
3. Check oil bores (arrow) in camshaft chamber.

TIM ID: 0000000579 – 009
M020124/02E 2009-02 © MTU

4. Check oil bores in crankshaft bearing pedestal

(rear arrow) and in main bearings (front arrow).
5. Check all coolant and oil bores for contamination
in the same manner.
6. If the crankcase is then not immediately
reassembled or put back into service:
6.1. Dry oil bores.
6.2. Preserve oil bores.
6.3. Seal oil bores air-tight with suitable plugs.
Measuring bearing cap guides
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Note: Bearing cap guides not in swivel
frame (results in measuring errors).
1. Remove crankcase from swivel frame and place

on a flat surface.
2. Using a bore gauge (1), measure bearing
cap guides at upper and lower fits. Values
(→ Page 1016).
authorized by MTU.

bearing cap guide to next repair size using
a boring mill.
4. Install crankcase in swivel frame.
Measuring crankshaft bearing bore

1. Install and tighten crankshaft bearing cap
according to specifications (→ Page 1024).
2. Adjust bore gauge.
3. Using a bore gauge (2), measure the crankshaft
bearing bore (1).
4. Record measured values in data sheet. Measuring
planes as well as values (→ Page 1016).
authorized by MTU.
TIM ID: 0000000579 – 009
5. If values are exceeded: Machine respective bore

to next repair size using a boring mill.
6. Mark repair stages of a crankcase main bore
with numeral punches.
7. When installing a new crankshaft bearing cap:
mark position of new crankshaft bearing cap
accordingly.
M020124/02E 2009-02 © MTU

Measuring camshaft bearing bushing bore.

1. Measure diameter of camshaft bearing
bushing bore (Ø B) with bore gauge. Values
(→ Page 1016).
2. If values are exceeded: Remove camshaft bearing
bushing (2) (→ Page 1002).
3. After removal of camshaft bearing bushing:
Measure diameter (dia. A) of the main camshaft
bearing bore in the crankcase (1). Record
measured values in data sheet. Values
(→ Page 1016).
authorized by MTU.

main camshaft bearing bore to next repair size
using a boring mill.
6. Install camshaft bearing bushing (→ Page 1024).
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Measuring crankcase bores for cylinder liners
1. Measure crankcase bore for cylinder liner in upper
and lower fits with bore gauge.
2. Record measured values in data sheet. Values
(→ Page 1016).
authorized by MTU.

crankcase bore to next repair size using a
boring mill.
TIM ID: 0000000579 – 009
M020124/02E 2009-02 © MTU

9.1.8 Crankcase – Tolerances
Crankcase bore for crankshaft
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size Basic
size
1 Crankcase bore 0 171.000 H6 0 +0.025 171.035

bearing verse
ovality
max. 0.050
1 171.500 H6 171.535
Trans-
verse
TIM ID: 0000004151 – 008
ovality
max. 0.050
2 172.000 H6
a After the crankcase bore has been newly produced, it can be exceeded by 0.015 mm in the a-direction
when reinstalled.
M020124/02E 2009-02 © MTU

Crankcase bore for camshaft
cardiagn.com
size Basic
size
1 Crankcase bore 0 97.000 H6 0 +0.022 0.058 0.130

for camshaft
bearing 1 97.500 H6
2 98.000 H6
Camshaft 0 97.080 0 +0.050

bearing, outer
Ø 1 97.580
removed
2 Camshaft 92.012 0 +0.052 0.084 0.171

bearing bush
bore
installed
Camshaft outer 92.000 e7 –0.107 –0.072

Ø
a Coaxiality of left and right bearing
TIM ID: 0000004151 – 008
b Between camshaft bearing bores 1 and 2
M020124/02E 2009-02 © MTU

Top deck and cylinder liner mating face
cardiagn.com
size Basic
size
1 Cylinder liner 0 562.000 −0.150 +0.050

mating face
1 561.700
2 561.400
2 Top deck 0 562.500 −0.200 +0.200
1 562.200 −0.100 +0.100
2
TIM ID: 0000004151 – 008
M020124/02E 2009-02 © MTU

Crankcase bore for cylinder liner
cardiagn.com
size Basic
size
1 Crankcase bore 0 196.000 0 +0.046 0.059 0.016 +0.060

H7
upper fit
1 196.500
H7
2 197.000
H7
Cylinder liner 0 196.000j6 -0.013 +0.016

upper fit
1 196.500 j6
2 197.000 j6
2 Crankcase bore 0 189.000 0 +0.046 0.050 0.125 +0.060

H7
lower fit
1 189.500
H7
TIM ID: 0000004151 – 008
2 190.000
H7
Cylinder liner 0 189.000 f6 -0.079 -0.050

lower fit
1 189.500 f6
2 190.000 f6
M020124/02E 2009-02 © MTU

size Basic
size
Stage marking see reconditioning drawing
Machine all crankcase bores to the same repair size.
Main bearing cap
cardiagn.com
size Basic
size
1 Bearing cap bed 0 298.000 +0.110 +0.240 0.022 0.184

E9
lower fit
1 298.500
E9
2 299.000
E9
Main bearing 0 298.000 p6 +0.056 +0.088

TIM ID: 0000004151 – 008
caps
lower fit 1 298.500 p6
2 299.000 p6
M020124/02E 2009-02 © MTU

size Basic
size
2 Bearing cap bed 0 298.000 0 +0.052 0.004 0.088

H7
upper fit
1 298.500
H7
2 299.000
H7
Main bearing 0 298.000 p6 +0.056 +0.088

caps
upper fit 1 298.500 p6
2 299.000 p6
3 Screw length 348.000 –0.500 +0.500
cardiagn.com
Main bearing bore
Install main bearing cap in crankcase according to installation instructions.

Measure main bearing bores:
TIM ID: 0000004151 – 008
• Determine diameters a, b1 and b2 in two measuring planes and calculate the averages for a, b1 and b2.
Check bore roundness:
b2 according to the formula: (b1+b2) /2 −a
Vertical ovality greater than (b1+b2) /2 is not permissible.
M020124/02E 2009-02 © MTU

Crankcase crankshaft bore coaxiality
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b 8V: from main bearing 1 to 5 Ø 0.060 Ø 0.100

c 12V: from main bearing 1 to 7 Ø 0.080 Ø 0.120
d 16V: from main bearing 1 to 9 Ø 0.120 Ø 0.140

e 20V: from main bearing 1 to 11 Ø 0.160 Ø 0.180
f applies to collar bearing mating faces 0.100 0.120

g applies to all bearings 0.010 0.035
h applies to all bearings, non-concave –0.010 –0.012
k applies to all bearings // 0.015 // 0.018

TIM ID: 0000004151 – 008
M020124/02E 2009-02 © MTU

Crankcase camshaft bore coaxiality
cardiagn.com
b 8V: from camshaft bearing 1 to 5 Ø 0.060 Ø 0.100

c 12V: from camshaft bearing 1 to 7 Ø 0.080 Ø 0.120
d 16V: from camshaft bearing 1 to 9 Ø 0.120 Ø 0.140

e 20V: from camshaft bearing 1 to 11 Ø 0.160 Ø 0.200
TIM ID: 0000004151 – 008
M020124/02E 2009-02 © MTU

9.1.9 Crankcase – Assembly
Special tools

Installation/removal tool for main bearing stud F6553646 1
Stop device for plug (main oil gallery) F6555771 1
Assembly jig for camshaft bearing F6555738 1
Assembly mandrel for end cover F30378754 1
Camshaft bearing shrink-on tool F30450446 1
Guide bushing for camshaft bearing shrink-on tool F6555763 1
cardiagn.com
Material

Sealing paste (Elastosil N189) 50546 1
Screw locking compound Loctite No. 270 40083 1
Engine oil
Dry compressed air
Liquid nitrogen
Spare parts

Gasket
O-ring
O-ring
End cover
Camshaft bearing
Stud
Suspended load.
TIM ID: 0000000590 – 010
Danger to life!

M020124/02E 2009-02 © MTU


Risk of injury!

Installing end cover

1. End cover and crankcase bore must be free
of grease and dry.
2. Coat end cover seat with Loctite screw locking
compound.
3. Using a mandrel, drive end cover into the
crankcase bore.
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4. In case of leaks or sealing surface damage, the
end cover can be swaged in after it has been
driven in with a mandrel.
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

Installing camshaft bearings

1. Screw camshaft bearing stop and alignment
device (1) on to locating bore of swing-follower
shafts. Installation sequence: Start at driving end
and continue in succession towards free end.
2. Fit plastic installation mandrel (1) on assembly tool.
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3. Chill camshaft bearing bushing in liquid nitrogen.
4. Fit chilled camshaft bearing bushing on assembly
tool so that the spring-loaded locating mandrel
(3) of the assembly tool engages in the oil bore
(arrow) of the camshaft bearing bushing.
5. Withdraw installation mandrel from camshaft

bearing assembly tool.
6. Check position of camshaft bearing oil bore in
assembly tool (arrowed). TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU


bushing (2) from outside in main bore as far as
it will go. At the same time, the assembly tool
is positioned by the centering and positioning
mandrel.
8. Check that oil bores in bearing bushing and
Installing last camshaft bearing
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1. Install camshaft bearing stop and alignment device
from outside on free end of crankcase (2) when
installing last camshaft bearing.

bushing in main camshaft bore up to stop. At the
same time, the assembly tool is positioned by the
centering and positioning mandrel.
3. Check that the oil bores in bearing bushing and
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

Inserting studs for crankshaft bearing caps

1. Coat thread of stud (1) on shoulder side with
engine oil.
2. Insert stud (1) with the journal side in the threaded
bore.
3. Insert stud (1) up to stop with installation/removal
device (2) and torque wrench. Tightening torque,
see (→ Page 980).
Note: Replace studs only in pairs.
4. For initial fitting of studs, carry out the following

steps:
4.1. Tighten nut up to contact.
Tightening method: elongation.
4.4. Release studs.
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4.5. Tighten studs again with hydraulic tensioner.
4.6. Release studs.

1. Install bearing cap (→ Page 1145).
2. Crankcase mating face (1) for strip (driving end)
must be dry and free of grease.
3. Coat contact surface with sealing paste (arrows)
and do not forget the end sides.
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

4. Align strip (1) on securing screw bores (arrows) in

crankcase (2).
5. Place strip (1) on surface coated with sealing
paste on crankcase.
6. Use socket-head screws (2) to fasten strip (1) on
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crankcase (3).
7. Using a straightedge, check the alignment of the
strip to the crankcase. The strip surface must form
a single plane with the crankcase joint so that the
oil pan will fit perfectly.
Installing cover
1. Mating faces on crankcase and cover (2) must be
dry and free of grease.
2. Coat new O-ring (1) with grease and insert
in groove.
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

3. Mount assembly jig for cover stop on driving end.

4. Coat mating surface (1) on crankcase with surface
sealant.
5. Coat new O-rings (arrowed) with grease and insert
in oil transfer bores.
6. Insert assembly pins (2) in the crankcase at two
diagonally opposite corner points.
7. Use lifting device to connect cover to assembly
pins and lower.
8. Align cover to assembly jig stop.
9. Tighten screws in accordance with tightening
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sequence.
• 8V 1-18
• 12V 1-26
• 16V 1-34
• 20V 1-42
10. Remove assembly device.
11. Coat O-ring with grease and fit on plug (1).

12. Insert plug in oil gallery and secure with lug (2).
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

Removing crankcase form swivel frame

1. Attach lifting appliance and lifting ropes to
crankcase. Make sure that lifting ropes are
tensioned evenly.
2. Release crankcase from swivel frame and lift out.
cardiagn.com
TIM ID: 0000000590 – 010
M020124/02E 2009-02 © MTU

9.1.10 Cylinder liner – Overview
Overview of cylinder liner with scraper ring
cardiagn.com
1 Cylinder liner 2 Carbon scraper ring 3 Sealing ring
TIM ID: 0000000601 – 001
M020124/02E 2009-02 © MTU

Cylinder liner with scraper ring in crankcase
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1 Carbon scraper ring
2 Cylinder liner
3 Crankcase
4 Sealing ring
5 Sealing ring
TIM ID: 0000000601 – 001
M020124/02E 2009-02 © MTU

9.1.11 Cylinder liner – Removal
Special tools

Removal tool for carbon scraper ring F6782566 1
Removal tool for cylinder liner F6557114 1
Heavy object.
Risk of crushing!

Risk of injury!
Removing carbon scraper ring
cardiagn.com
1. Mount removal tool (3) on cylinder liner (1).
2. Remove carbon scraper ring (2) with removal tool
(3) from cylinder liner fit (1).
3. Remove removal tool (3).
4. Remove piston and conrod (→ Page 1182).
TIM ID: 0000000614 – 008
M020124/02E 2009-02 © MTU

Cylinder liner – Removal

1. Mark installation position of cylinder liner to
crankcase with a marker pen (arrowed).
2. Insert removal tool into cylinder liner.
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3. Position removal tool at lower collar of cylinder
liner. Take care not to damage the oil spray nozzle.
4. To avoid tensioning the liner, only place fork in
position lightly.
5. Rotate the removal tool spindle until the cylinder
liner is released from the crankcase bore.
6. Remove removal tool.
7. Remove cylinder liner from crankcase.
8. Remove sealing rings from cylinder liner.
TIM ID: 0000000614 – 008
M020124/02E 2009-02 © MTU

9.1.12 Cylinder liner – Cleaning
Material


Compressed air.
Risk of injury!
WARNING
cardiagn.com

Cylinder liner – Cleaning

TIM ID: 0000000606 – 002
M020124/02E 2009-02 © MTU

9.1.13 Cylinder liner – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Material

cardiagn.com
Spare parts

Cylinder liner
Carbon scraper ring
Heavy object.
Risk of crushing!
TIM ID: 0000004047 – 005
M020124/02E 2009-02 © MTU

Cylinder liner – Check
Item Findings Task
Check cylinder liner with magnetic Signs of cracks Replace

crack testing method.
Check outer wall for corrosive Pitting visible. Replace

pitting.
Check sealing and mating faces for • Stress marks • Corrective work: Smooth with
wear and damage. • Damage oilstone.
visible • Replace
Check carbon scraper ring for • Scores Replace

scoring and pitting. • Pitting
visible
Check floating mount of the carbon Signs of jamming • Measure cylinder liner.
scraper ring in the cylinder liner. • Replace carbon scraper ring.
Check cylinder liner running surface • Scores Replace
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for scores and pitting. • Pitting
visible
Check reversal point of first piston Wear visible. Replace cylinder liner.
ring for wear.
Measure cylinder liner bore with Values exceeded. Replace

bore gauge and dial gauge.
Measurement plane and values
(→ Page 1039)
TIM ID: 0000004047 – 005
M020124/02E 2009-02 © MTU

9.1.14 Cylinder liner – Tolerances
cardiagn.com
anced
Basic
size
1 Crankcase bore 0 196.000 0 +0.046 0.059 0.016 +0.060

H7
upper fit
1 196.500
H7
2 197.000
H7
Cylinder liner 0 196.000j6 -0.013 +0.016

upper fit
1 196.500 j6
2 197.000j6
TIM ID: 0000004152 – 004
M020124/02E 2009-02 © MTU


anced
Basic
size
2 Crankcase bore 0 189.000 0 +0.046 0.050 0.125 +0.060

H7
lower fit
1 189.500
H7
2 190.000
H7
Cylinder liner 0 189.000 f6 -0.079 -0.050

lower fit
1 189.500 f6
2 190.000 f6
3 Cylinder liner ID 170.000 0 +0.040 0.014 0.094
cardiagn.com
H7
Scraper ring 170.000 g7 -0.054 -0.014

OD
4 Scraper ring ID 164.000 0 +0.063

H8
5 Cylinder liner ID 165.000 0 +0.040

H7
- installed
TIM ID: 0000004152 – 004
M020124/02E 2009-02 © MTU

Cylinder liner
cardiagn.com
anced
Basic
size
1 0 13.800 −0.100 0
1 14.100
2 14.400
Reconditioning instructions:
In case of cavitation at upper and/or lower fit of the crankcase bore:
• Introduce next repair stage and install cylinder liner of corresponding stage.
• Machine cylinder liner mating face on crankcase.
• To be carried out only in workshops authorized by MTU.
Check scraper ring OD and ID when fitted.

TIM ID: 0000004152 – 004
M020124/02E 2009-02 © MTU

9.1.15 Cylinder liner – Installation
Special tools

Press-in tool for cylinder liner F6787880 1
Bore gauge, 160-280 mm Y20091483 1
Micrometer, 150-175 mm Y20000326 1
Material

Engine oil
cardiagn.com
Spare parts

Sealing ring
Heavy object.
Risk of crushing!

Risk of injury!
Installing cylinder liner

1. Clean cylinder liner, ensuring that the lower fit and
chamfer are dry and free of grease.
2. Coat sealing rings (2) with grease.
Note: The flat side of the sealing ring must be in
contact with the cylinder liner.
3. Fit sealing rings (2) in grooves on cylinder liner (1).

Note: Note marking when re-installing used
cylinder liners; the installation position is
irrelevant when installing new cylinder
liners.
4. Insert cylinder in the same installation position as

TIM ID: 0000000619 – 010
prior to removal in accordance with the marking on

liner and crankcase.
M020124/02E 2009-02 © MTU

5. On the opposite side, insert screws (1) of press-in

tool into threaded bores for cylinder head screws.
6. Fit pressure plate (3) on cylinder liner.
7. Rotate spindle (2) clockwise to insert cylinder liner
in crankcase bore.
Measuring cylinder liner ID
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1. Adjust bore gauge and dial gauge with micrometer
to basic cylinder liner bore dimension. Value and
measurement planes (→ Page 1039).
2. Measure cylinder liner bore with bore gauge.
4. If out-of-round is measured:
4.1. Remove cylinder liner.
4.2. Remeasure cylinder liner bore and outer
diameter.
TIM ID: 0000000619 – 010
M020124/02E 2009-02 © MTU


Note: Insert carbon scraper ring after installing
piston (→ Page 1216).
1. Spray cylinder liner and carbon scraper ring

with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
cardiagn.com
TIM ID: 0000000619 – 010
M020124/02E 2009-02 © MTU

9.1.16 Oil pan – Overview
cardiagn.com
1 Oil pan 8 Sealing ring 15 Hex bolt
2 Rubber profile 9 Flange 16 Washer
3 Hex bolt 10 Gasket 17 Plug-in pipe (suction pipe)
4 Washer 11 Hex bolt 18 O-ring
5 Hex bolt 12 Hex bolt 19 Connecting piece
6 Washer 13 Washer 20 Hex bolt
7 Plug 14 Suction basket 21 Washer
TIM ID: 0000008331 – 001
M020124/02E 2009-02 © MTU

View from free end
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1 Hex bolt 2 Washer 3 Oil pan
TIM ID: 0000008331 – 001
M020124/02E 2009-02 © MTU

9.1.17 Oil pan – Removal
Special tools

Eyebolts
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Oil pan – Removal
cardiagn.com
1. Install the engine in the swivel support and
rotate it 180°.
2. Remove hex bolts from oil pan (3).
3. Remove plugs on end faces and install eyebolts
(2).
4. Raise oil pan (3) with hook-ended chain sling (1)
and crane and lower onto suitable support.
5. Remove flanges on end faces.
6. Remove rubber profile.
Removing suction basket

1. Remove hex bolts (5) from connecting piece (2).
2. Remove connecting piece (2) with plug-in pipe (1).
3. Remove plug-in pipe (1) from connecting piece (2).
4. Remove O-rings.
5. Remove hex bolts (4) from suction basket (3).
6. Remove suction basket (3).
TIM ID: 0000008332 – 002
M020124/02E 2009-02 © MTU

9.1.18 Oil pan – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Oil pan – Cleaning
2. Thoroughly blow out oil pan and all threaded bores with compressed air.
TIM ID: 0000004049 – 002
M020124/02E 2009-02 © MTU

9.1.19 Oil pan – Check
Material

Red dye penetrant for surface crack test procedure
Spare parts

Oil pan
Cover
Gasket
Suction basket
Plug-in pipe
cardiagn.com
Connector
Heavy object.
Risk of crushing!
Clean oil pan (→ Page 1048).
Oil pan – Check
Item Findings Task
Cracktest the oil pan using the Crack indication • Recondition: Contact Service.
surface cracktesting method and red • Replace
penetrant dye.
Check mating face of oil pan with Surface irregularity above 0.2 mm Recondition mating face.
crankcase for surface irregularities.
Check sealing surfaces and groove Damaged • Recondition

of rubber profile. • Replace
Check suction basket for damage. Damaged Replace
Check threaded bores for ease of Sluggish Replace thread inserts.

movement.
Check plug-in pipe, connecting Damaged • Recondition

piece and cover for damage. • Replace
TIM ID: 0000004541 – 002
M020124/02E 2009-02 © MTU

9.1.20 Oil pan – Installation
Special tools

Eyebolt T80092075 4
Material

Engine oil
cardiagn.com
Express dry cleaner (Loctite 7061) 50518 1
Silicone rubber (Loctite 5970) 50773 1
Spare parts

Rubber profile
Heavy object.
Risk of crushing!
Heavy object.
Risk of crushing!
Installing suction basket

Note: Minimize contamination!

2. Insert O-rings into groove as shown in overview drawing (→ Page 1045).
3. Install suction basket with screws.
TIM ID: 0000008333 – 008
M020124/02E 2009-02 © MTU

Preparing oil pan for installation

1. Clean flange surfaces of oil pan, equipment
carrier and crankcase.
Note: Use a new rubber profile every time the oil
pan is installed.
2. Place rubber profile in the groove on the oil pan.

3. Coat the rubber profile with grease on the end
face of the free end (arrows).
4. Fit flanges for plug screws at both end faces.
5. Apply surface sealant to fornt cover.
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6. Spray lint-free rag with express dry cleaner and
wipe off excess surface sealant on the exposed
flange faces.
7. Coat slit between equipment carrier/crankcase

with silicone rubber on both sides of the equipment
carrier (arrow), laying down a bead of approx.
5 mm.
TIM ID: 0000008333 – 008
M020124/02E 2009-02 © MTU

8. Coat slit (arrow) between strip/crankcase with

silicone rubber, laying down a bead of approx.
5 mm.
9. Screw eyebolts into bores for plugs on the oil pan.
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10. Lift oil pan with lifting ropes and crane.
11. Lower oil pan onto contact surface of crankcase.
12. Align oil pan to bores in the contact surface
of crankcase.
Note: Washers for screw connections A, B and
C are different.

14. Use torque wrench to tighten oil pan screws
to the specified torque according to tightening
sequence (→ Page 1053).
14.1. Screw ”A”

14.2. Screw "B”

14.3. Screw "C”

TIM ID: 0000008333 – 008
15. Install flanges with new gaskets.
M020124/02E 2009-02 © MTU

9.1.21 Tightening sequence for oil pan made of nodular cast iron (GGG)
cardiagn.com
Number of cylinders Screw joint Number of screws Item
12V to 20V B (driving end side) 8 -
12V to 20V C (free end side) 10 -
Bolt oil pan to crankcase and equipment carrier alternately and in several steps.
Threaded connections for oil pan made of nodular cast iron (GGG)
TIM ID: 0000008334 – 003
A Screw
B Screw
C Screw
M020124/02E 2009-02 © MTU

9.1.22 Engine lifting equipment - Overview
Overview
cardiagn.com
1 Lifting eye 2 Cylinder head screw
TIM ID: 0000000662 – 001
M020124/02E 2009-02 © MTU

Engine lifting equipment
cardiagn.com
1 Lifting eye 2 Thrust washer 3 Cylinder head screw
TIM ID: 0000000662 – 001
M020124/02E 2009-02 © MTU

9.1.23 Engine lifting equipment – Removal
Preconditions
Engine lifting equipment – Removal
1. Remove cylinder head screws (2).
2. Remove cylinder head screws and thrust
washers (1).
3. Remove lifting eye (3).
cardiagn.com
TIM ID: 0000000674 – 005
M020124/02E 2009-02 © MTU

9.1.24 Engine lifting equipment – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Engine lifting equipment – Cleaning
TIM ID: 0000000666 – 002
M020124/02E 2009-02 © MTU

9.1.25 Engine lifting equipment – Check
Material

Spare parts

Lifting eyebolt
Thrust washer
Cylinder head screw
Engine lifting equipment – Check
cardiagn.com
Item Findings Task
Check engine lifting equipment for Damaged Replace

damage.
Check lifting eyebolt with magnetic Signs of cracks Replace the component with an
crack-testing method. original spare part.
Check mating and bolt-on faces for Damaged • Corrective work: Smooth with
damage. oilstone.
• Replace
Check threads in crankcase for ease Sluggish Corrective work: Recut threads
of movement.
Check cylinder head screws for Damaged Replace

damage.
Measure shaft length of the cylinder Value (→ Page 1237) Replace

head screws with depth gauge. exceeded.
TIM ID: 0000000670 – 004
M020124/02E 2009-02 © MTU

9.1.26 Engine lifting equipment – Installation
Special tools

Check engine lifting equipment (→ Page 1058)
Installing engine lifting equipment

1. Place lifting eye (3) on cylinder head and align to
the bores for the cylinder head screws.
Note: If only cylinder head screws at lifting eye
were undone just tighten these two cylinder
head screws to specified tightening torque.
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2. Screw in cylinder head screw (2) with thrust
washer (1) and use torque wrench to tighten to
TIM ID: 0000000678 – 005
M020124/02E 2009-02 © MTU

9.1.27 End housing, driving end – Overview
End housing with attachments
cardiagn.com
1 Flywheel housing 12 Guard plate
2 Deadcenter indicator 13 Guard plate
4 Plug screw 15 Washer
5 Sealing ring 16 Guard plate
6 Sealing ring 17 Hex screw
7 Adapter union 18 Guard plate
10 Conical spring washer 21 Spacer bushing
11 O-ring 22 O-ring
TIM ID: 0000008335 – 002
M020124/02E 2009-02 © MTU

Configuration of guide bush for end housing installation and removal
cardiagn.com
1 Support 5 Nut
2 Guide bush 6 Socket-head screw
3 Guide 7 Flange
4 Washer 8 Flange
TIM ID: 0000008335 – 002
M020124/02E 2009-02 © MTU

9.1.28 End housing, driving end – Removal
Preconditions
Special tools

Bracket T80091102 1
Support F6555724 1
Suspended load.
Danger to life!
cardiagn.com
Risk of injury!
End housing – Removal

Note: The TOP mark (arrow) on the front of the
guide bushing must face up, regardless of
whether the crankcase is in the installation
position or is turned through 180° .
1. Install support (2) on guide bushing (3)

(→ Page 1060).
2. Screw bracket (1) on to end housing and attach to
crane using a slightly tensioned rope.
3. Remove all screws for end housing on crankcase
(→ Page 1060).
4. Remove end housing from crankcase horizontally.
5. Remove O-rings.
TIM ID: 0000000693 – 005
M020124/02E 2009-02 © MTU

9.1.29 End housing, driving end – Disassembly
Special tools

Removal tool for main bearing, driving end F6557190 1
Lukas cylinder B80096717 1

Heavy object.
Risk of crushing!
cardiagn.com
Remove end housing, driving end (→ Page 1062).
Removing main bearing from end housing

1. Cut axial groove in crankshaft bearing, leaving wall
thickness of approx. 1 mm to relieve tension in
bearing.
2. Fit special tool (1), (2) on end housing.
3. Use special tool to press bearing out of end
housing.
4. Remove remaining parts as per overview drawing
(→ Page 1060).
TIM ID: 0000000698 – 005
M020124/02E 2009-02 © MTU

9.1.30 End housing, driving end – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
End housing, driving end – Cleaning
2. Thoroughly blow end housing, driving end, and all threads clear with compressed air.
TIM ID: 0000000686 – 002
M020124/02E 2009-02 © MTU

9.1.31 End housing, driving end – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Retainer 0015890321/00 1
Material

cardiagn.com
Spare parts

Crankshaft bearing
End housing, driving end
End housing, driving end – Check
Item Findings Task
Use the magnetic crack-testing Signs of cracks Replace component.

method to check lifting carrier and
eyebolts for cracks.
Check dead-center indicator for Damaged Replace deadcenter indicator.

damage.
Check mating and bolt-on faces. Stress marks Smooth with oilstone.
Check threads for damage. Damaged Recut threads.
Check crankshaft bearings for • Stress marks Replace crankshaft bearings.

surface condition and wear *. • Damage
visible
Measure bore in end housing, Value exceeded Replace end housing.

driving end. Value (→ Page 1066)
* Replace crankshaft bearings during "Extended component maintenance".

TIM ID: 0000004116 – 004
M020124/02E 2009-02 © MTU

9.1.32 End housing KS – Tolerances
cardiagn.com
Basic limit
size
1 Flywheel housing 223.000H6 0 +0.029 0.234 0.292

bore
Bearing outer Ø, 223.263 0 +0.029

removed
2 Bearing bush 210.142 0 +0.069 0.157 0.272

bore,
bearing pressed
in
Hub outer Ø 210.000 g7 -0.061 -0.015

TIM ID: 0000004153 – 001
M020124/02E 2009-02 © MTU

9.1.33 End housing, driving end – Assembly
Special tools

Installation tool F30378426 1
Material

Liquid nitrogen

cardiagn.com
Suspended load.
Danger to life!

Risk of injury!
Check end housing, driving end (→ Page 1065).
Installing main bearing in end housing

1. Place end housing on suitable surface to allow
installation of the main bearing in the correct
position.
2. Install stop (1) on rear side of end housing (2).
3. Secure stop (1) on front side of end housing
(2) using two nuts.
TIM ID: 0000000701 – 004
M020124/02E 2009-02 © MTU

4. Insert main bearing (3) in locating device (5).

5. Insert main bearing (3) and installation tool (2),
ensuring they are correctly positioned with regard
to each other (position mark/notch mark) (4).
6. Press down pins (1) and lock main bearing by
turning.
7. Chill main bearing (3) with insertion tool (2) in
liquid nitrogen.
8. Place main bearing with insertion tool (2) at end
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housing (1) in 12 o’clock position (arrowed).
9. Insert chilled main bearing with insertion tool (2)
up to stop in end housing (1).
10. After a brief dwell period, unlock and remove
insertion tool (2).
11. Remove stop from rear side of end housing.
12. Install support bracket on end housing.
13. Install remaining parts as per overview drawing
(→ Page 1060).
TIM ID: 0000000701 – 004
M020124/02E 2009-02 © MTU

9.1.34 End housing, driving end – Installation
Special tools

Support F6555724 1
Material

cardiagn.com
Suspended load.
Danger to life!

Risk of injury!
Assemble end housing, driving end (→ Page 1067).
Installing end housing, driving end

1. Using fast cleaner 7061, clean mating face
(arrowed) between end housing and crankcase.
2. Apply a uniform coating of surface sealant 518 to
the sealing surface (arrowed) and smooth.
3. Coat O-rings (1) with petroleum jelly and insert
into bores.
TIM ID: 0000000704 – 004
M020124/02E 2009-02 © MTU

Note: The illustration shows the engine rotated

through 180°, i.e. the oil pan mating face
faces upwards.
4. Using fast cleaner 7061 clean mating face

(arrowed) on crankcase (1).
5. Screw guide sleeve (2) onto crankshaft end flange.
6. Install support bracket (1).
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7. Position support (2) on end housing.
8. Using support bracket (1), attach end housing
to crane.
9. Position end housing on guide sleeve (3) and push
towards crankcase as far as it will go.
10. Install screws into bores, tightening them to
approx. 10 Nm.
11. Tighten two opposite screws in the inner circle of
the end housing to specified tightening torque
(→ Page 980).
12. Remove support (2) from end housing and install
screws. Note that the screws have different
lengths.
13. Install all screws and washers and tighten to
specified tightening torque (→ Page 980). Observe
the following tightening sequence:
13.1. First tighten the screws in the inner circle of
13.2. Then tighten the screws in the outer circle of
14. Remove excess sealant. TIM ID: 0000000704 – 004
M020124/02E 2009-02 © MTU

9.1.35 Crankcase ventilation – Overview
cardiagn.com
1 Vent line 17 Screw 33 Screw
2 Vent line 18 Guide sleeve 34 Pipe half-clamp
3 O-ring 19 Rubber sleeve 35 Pipe
4 Screw 20 Clamp 36 Adapter union
5 Rubber sleeve 21 Pipe 37 Sealing ring
6 Clamp 22 Nut 38 Flange
7 Vent line 23 Pipe 39 Gasket
8 O-ring 24 Nut 40 Screw
9 Screw 25 T-piece 41 Bracket
10 Oil separator 26 Rubber sleeve 42 Washer
11 Clamp 27 Clamp 43 Screw
12 Washer 28 Pipe 44 Screw
13 Spacer bush 29 Bracket 45 Grommet
14 Screw 30 Link 46 Pipe half-clamp
15 Nut 31 Pipe half-clamp 47 Pipe half-clamp
16 Bracket 32 Grommet 48 Washer
TIM ID: 0000008341 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Oil separator 12 Pipe 23 Bracket
2 Screw 13 Nut 24 Screw
3 Clamp 14 Pipe 25 Pipe half-clamp
4 Vent line 15 Nut 26 Grommet
5 O-ring 16 T-piece 27 Screw
6 Screw 17 Rubber sleeve 28 Adapter union
7 Vent line 18 Clamp 29 Sealing ring
8 Rubber sleeve 19 Vent line 30 Flange
9 Clamp 20 Vent line 31 Gasket
10 Vent line 21 Bracket 32 Screw
11 Screw 22 Screw 33 Oil pipe
TIM ID: 0000008341 – 001
M020124/02E 2009-02 © MTU

Crankcase ventilation, free end, 12V, 16V
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1 Oil separator 17 Nut 33 Threaded bush
2 Bracket 18 Oil line 34 Sealing ring
3 Screw 19 Nut 35 Bracket
4 Screw 20 Pipe half-clamp 36 Spacer sleeve
5 Guide sleeve 21 Pipe half-clamp 37 Screw
6 Rubber sleeve 22 Grommet 38 Pipe half-clamp
7 Clamp 23 Screw 39 Grommet
8 Pipe 24 Washer 40 Screw
9 Screw 25 Washer 41 Blanking cone
10 Clamp 26 Rubber sleeve 42 Nut
11 Spacer sleeve 27 Clamp 43 Pipe half-clamp
12 Washer 28 T-piece 44 Grommet
13 Spacer sleeve 29 Oil line 45 Screw
14 Screw 30 Oil line 46 Bracket
15 Nut 31 Banjo screw 47 Screw
16 Oil line 32 Sealing ring
TIM ID: 0000008341 – 001
M020124/02E 2009-02 © MTU

9.1.36 Crankcase ventilation – Removal
Preconditions
Crankcase ventilation – Removal
1. Remove lines and oil separator as per overview drawings (→ Page 1071).
3. Protect oil separator from damage. Even minor damage may cause oil separator failure.
cardiagn.com
TIM ID: 0000005139 – 007
M020124/02E 2009-02 © MTU

9.1.37 Crankcase ventilation – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Crankcase ventilation – Cleaning
Note: Protect rubber and synthetic parts from oil and fuel, rub dry only, never clean with organic cleaning
agents.
TIM ID: 0000005141 – 004
M020124/02E 2009-02 © MTU

9.1.38 Crankcase ventilation – Check
Material

Corrosion inhibitor
Spare parts

Piping
Oil separator
Clamp
Retainer
Guide sleeve
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Spacer bush

Hot testing liquid.
Clean crankcase ventilation (→ Page 1075)
Crankcase ventilation – Check
Item Findings Task

damage and wear.

• Replace

• Replace
Pressure-test piping for leaks with Leaking • Recondition

air and corrosion inhibitor in water • Replace
bath.
• Water temperature min. 30 °C,
max. 40 °C
TIM ID: 0000005142 – 002
Inspect piping visually. • Mechanical damage Replace

• Chafing
• Indentation
Check operation of oil separator. Malfunction Replace
M020124/02E 2009-02 © MTU

9.1.39 Oil separator – Disassembly

Remove oil separator (→ Page 1074).
Oil separator variant A – Disassembly

1. Undo band clamp (1).
3. Remove filter element (2).
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5. Remove O-ring (arrow) from lower part.
TIM ID: 0000008363 – 002
M020124/02E 2009-02 © MTU

Hengst oil separator variant B – Disassembly

1. Remove securing screws (2) for cover (1) with
screwdriver (Torx 30).
3. Remove aerosol element (1) from oil separator
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housing (2).
4. Remove securing screws for cover (1).

5. Remove cover (1), spring (2) and O-ring.
6. Remove diaphragm (3) from oil separator housing.
TIM ID: 0000008363 – 002
M020124/02E 2009-02 © MTU

9.1.40 Oil separator – Check
Spare parts

Oil separator
Clean oil separator (→ Page 1075).
Oil separator variant A – Check
Item Findings Task

damage and wear.

• Replace
cardiagn.com
Hengst oil separator variant B – Check
Item Findings Task

damage and wear.

• Replace

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

with air in water bath.
Oil separator pressure control can only be checked when installed with engine in operation. Vacuum or
overpressure is measured (e.g. with water pressure gauge) over entire engine speed range. Values should lie
between minus 10 mbar and plus 10 mbar (100 mm water column).
TIM ID: 0000008365 – 002
M020124/02E 2009-02 © MTU

9.1.41 Oil separator – Assembly
Material

Spare parts

Filter element with O-ring
O-rings
Check oil separator (→ Page 1079).
Oil separator variant A – Assembly

1. Coat O-ring (3) with petroleum jelly and insert in oil
cardiagn.com
separator housing.
2. Insert filter element (2).
groove provided on oil separator housing.
4. Fit cover (4).
5. Tighten band clamp (1).
6. Insert O-ring (arrow) in lower part.
TIM ID: 0000008364 – 002
M020124/02E 2009-02 © MTU

Hengst oil separator variant B – Assembly

1. Coat O-ring (arrow) with petroleum jelly and insert
in groove provided on oil separator housing (3).
2. Insert diaphragm (2) in oil separator housing (3)
ensuring it is correctly positioned (curvature
facing up).
3. Fit spring (1) on diaphragm (2), ensuring spring (1)
is correctly seated at diaphragm (2).
4. Mount cover (1) on spring (2) in correct position.
cardiagn.com
5. Insert screws with screwdriver and tighten
diagonally and evenly to specified torque
(→ Page 980) .

groove (arrow) provided on oil separator housing
(2).
7. Insert aerosol element (1) in oil separator
housing (2), ensuring it is correctly positioned.
TIM ID: 0000008364 – 002
M020124/02E 2009-02 © MTU

8. Mount cover (1) on oil separator housing and insert

screws (2) with screwdriver and tighten diagonally
and evenly to specified torque (→ Page 980) .
9. Check oil separator for leaks (→ Page 1079).
cardiagn.com
TIM ID: 0000008364 – 002
M020124/02E 2009-02 © MTU

9.1.42 Crankcase ventilation – Installation
Material

Spare parts

Gasket
O-ring
Rubber sleeve
Clamp
Crankcase ventilation – Installation
cardiagn.com
3. Install crankcase ventilation as per overview drawing (→ Page 1071).
TIM ID: 0000005941 – 003
M020124/02E 2009-02 © MTU

9.2 Gear Train
9.2.1 Gearcase, free end – Overview
cardiagn.com
1 Equipment carrier 16 Oil pump 31 Seal carrier (free end)
2 O-ring 17 Threaded bush 32 Radial-lip shaft seal
3 Screw 18 Sealing ring 33 Axle, intermediate gear
4 Sealing ring 19 Plug screw 34 O-ring
5 Plug screw 20 Screw 35 O-ring
6 Main bearing, free end 21 Sealing ring 36 Drain plug
7 Idler gear, right side 22 Plug screw 37 O-ring
8 Idler gear, left side 23 Pipe clamp half/halves 38 Gasket
9 Washer 24 Oil line 39 Cover
10 Washer 25 Gasket 40 O-ring
11 Stud 26 Cover 41 Plug screw
12 Nut 27 Grommet 42 Sealing ring
13 Cover 28 Pressure reduction valve 43 Bearing bush
14 Gasket 29 Sealing ring(s) 44 Sealing ring
15 Stud 30 Banjo screw 45 Plug screw
TIM ID: 0000000778 – 003
M020124/02E 2009-02 © MTU

Arrangement of alignment tool for equipment carrier and equipment carrier cover
cardiagn.com
1 Equipment carrier 3 TOP/OBEN mark 5 Guide bush
2 Alignment tool 4 Screw 6 Screw
TIM ID: 0000000778 – 003
M020124/02E 2009-02 © MTU

9.2.2 Gearcase, free end – Removal
Preconditions
Special tools

Suspended load.
Danger to life!
cardiagn.com
Gearcase – Removal
1. Insert two eyebolts (arrows) in gearcase.
2. Use rope to hook gearcase on to crane with
light initial load.
3. Unscrew screws (1) and (2) and remove with
sealing rings.
4. Unscrew and remove screws through bores in
idlers. If screws are not visible, turn crankshaft
accordingly.
5. Mark all screws on gearcase circumference

(arrows). Note that screws differ in length.
6. Remove all screws. TIM ID: 0000000790 – 008
M020124/02E 2009-02 © MTU

7. Loosen nuts (2) on left and right sides of crankcase

and remove with washers.
8. Carefully force gearcase (1) with rope slightly
pretensioned towards free end until it is released
from crankcase.
9. Remove O-rings.
10. Set gearcase down and protect from damage.
cardiagn.com
TIM ID: 0000000790 – 008
M020124/02E 2009-02 © MTU

9.2.3 Gearcase, free end – Disassembly
Special tools

Adapter B80146411 1
Lucas cylinder B80096717 1
Press-out tool F6557191 1

cardiagn.com
Heavy object.
Risk of crushing!
Removing crankshaft bearing from equipment carrier

1. Replace crankshaft bearing if damaged or during extended component maintenance.
2. Using press-out tool, Lukas cylinder and hand pump, force crankshaft bearing out of equipment carrier.
Removing radial-lip shaft seal from seal carrier (if fitted)

1. Place seal carrier on a suitable surface.
2. Use suitable extractor to pull out radial-lip shaft seal.
TIM ID: 0000000794 – 004
M020124/02E 2009-02 © MTU

9.2.4 Equipment carrier free end – Cleaning
Material


Compressed air.
Risk of injury!
WARNING
cardiagn.com

Cleaning equipment carrier, free end

1. Clean elastomer parts with cleaner (Hakupur 312).
TIM ID: 0000000782 – 002
M020124/02E 2009-02 © MTU

9.2.5 Gearcase, free end – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Material

Spare parts
cardiagn.com
Equipment carrier
Crankshaft bearing
Heavy object.
Risk of crushing!
Gearcase, free end – Check
Item Findings Task
Use magnetic crack-testing method Signs of cracks Replace gearcase.

to check gearcase for cracks.
Check crankshaft bearings for wear, • Scores Replace crankshaft bearings.

scoring and indentation. • Indentations (→ Page 1088)
Visible
Check threads in gearcase for ease Sluggish Recut threads

of movement.
Check thread and shaft of hex bolts Damaged Replace.

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

gearcase. Values (→ Page 1091) (→ Page 1088)
TIM ID: 0000000786 – 004
Measuring crankcase bearing bore Values exceeded. Replace gearcase.

in gearcase. Values (→ Page 1091)
M020124/02E 2009-02 © MTU

9.2.6 Gearcase, free end – Tolerances
cardiagn.com
Basic
size
1 Gearcase bore 193.000 H6 0 +0.029 0.175 0.233 Interfer-

ence min.
Bearing outer 193.204 0 +0.029 0.150
dia.
removed
2 Bearing bush 180.121 0 +0.069 0.321 0.430 Clearance

bore max.
Bearing press- 0.450
fitted
Driver flange 179.800 -0.040 0

outer dia. h7
not press-fitted
TIM ID: 0000004154 – 002
M020124/02E 2009-02 © MTU

9.2.7 Gearcase, free end – Assembly
Special tools

Installation mandrel for radial-lip shaft seal F30377680 1
Material

Denatured ethanol 40250 1
Loctite 7063 50594 1
Liquid nitrogen
cardiagn.com
Spare parts

Crankshaft bearing
Studs

Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
TIM ID: 0000000798 – 003
M020124/02E 2009-02 © MTU

Installing crankshaft bearing in equipment carrier

1. Insert eyebolts in equipment carrier.
with light initial load.
3. Lift equipment carrier and move to installation
position.
4. Place equipment carrier on a firm surface and
secure.
Note: Pay attention to “Oben/Top” (arrow) mark.
5. Install jig (1).
6. Clean crankshaft bearing with Loctite.
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7. Insert crankshaft bearing (1) in locating device (2).
Note: Ensure that position marking on crankshaft
bearing (arrow) and notch mark on
insertion tool are aligned.
8. Insert insertion tool.
9. Lock crankshaft bearing (3) on insertion tool (2)

with tommy bars (1).
10. Chill insertion tool (2) with crankshaft bearing
(3) in liquid nitrogen.
TIM ID: 0000000798 – 003
M020124/02E 2009-02 © MTU

Note: Location specified is by means of an

asymmetrical pin guide.
11. Use insertion tool (2) to install chilled crankshaft

bearing (1) on inner side of equipment carrier
up to stop.
12. After 60 seconds, unlock and remove insertion
tool (2).
13. Check positions of oil bores on crankshaft bearing.
cardiagn.com
Installing radial-lip shaft seal in seal carrier (if
applicable)
1. Push radial-lip shaft seal with sealing lip facing
down on to installation mandrel.
2. Clean and degrease sealing face for radial-lip shaft
seal in seal carrier.
3. Coat sealing face of radial-lip oil seal with ethanol.
4. Press-fit radial-lip shaft seal with drift into seal
carrier.
TIM ID: 0000000798 – 003
M020124/02E 2009-02 © MTU

9.2.8 Gearcase, free end – Installation
Special tools

Alignment tool (free end), equipment carrier F6782344 1
Guide bushing for equipment carrier F6557946 1
Eyebolt 0005800100000 1
Material

cardiagn.com
Spare parts

O-ring
Sealing ring
Suspended load.
Danger to life!

Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
TIM ID: 0000000802 – 005
M020124/02E 2009-02 © MTU

Installing equipment carrier

1. Install idler gears and axles (→ Page 1107).
2. Install delivery valve (→ Page 1522).
3. Install pressure reduction valve (→ Page 1486).
4. Clean alignment tool (2) and guide bushing and
coat with engine oil.
Note: “TOP/BOTTOM” marking must face
upwards, independent of the position of
the crankcase.
5. Use screws (1) to install alignment tool (2) on

equipment carrier.
6. Clean tail shaft, free end.
7. Screw guide bushing with screw on to tail shaft.
8. Screw eyebolts (arrows) into equipment carrier.
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with light initial tension.
10. Clean contact surface (arrowed) with Loctite 7061,

ensuring that its is free of grease and dry.
11. Coat equipment carrier sealing face with Loctite
518.
12. Coat O-rings (1) with petroleum jelly and insert into
groove on equipment carrier.
Note: Woolen thread instructions do not apply to
disassembly if not fitted.
13. Lead woolen thread (2) past and close to O-ring

grooves (1).
TIM ID: 0000000802 – 005
M020124/02E 2009-02 © MTU

14. Using crane, move equipment carrier (3) over

crankshaft guide bushing (1). Always note:
14.1. The studs (2) must be aligned.
14.2. Both idler gears and the crankshaft gear
must be aligned with each other.
14.3. In each case, position one of the round
recesses on the idler gears so that screws
can be retightened. If the holes are not
visible, rotate engine accordingly.
15. Screw in nuts and washers and tighten.
Note: Relieve load on crane ropes before
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tightening nuts and screws.
16. Tighten screws in the sequence 5, 6, 3, 2, 4 and 1.
17. Insert screws (arrows) evenly and tighten.

18. Remove alignment device and guide bushing.
TIM ID: 0000000802 – 005
M020124/02E 2009-02 © MTU

19. Insert screws (1) and (2) with new sealing rings.
20. Remove ropes and eyebolts.
21. Install oil line (→ Page 1486).
cardiagn.com
TIM ID: 0000000802 – 005
M020124/02E 2009-02 © MTU

9.2.9 Gear train, free end – Overview
cardiagn.com
teeth (mm) (mm)

low-temperature circuit

high-temperature circuit
TIM ID: 0000000807 – 002
3 Crankshaft gear 48 — —
4 Camshaft gear 96 0.286 ±0.081 to gear 3 0.1 to 0.18
5 Gear, H.P. fuel pump 32 0.201 ±0.065 to gear 6 —
M020124/02E 2009-02 © MTU


teeth (mm) (mm)
7 Gear, battery-charging generator 19 0.222 ±0.128 to gear 6 —
8 Gear, oil pump 34 0.279 ±0.077 to gear 9 —
10 Gear, hydrostatic pump 34 0.201 ±0.065 to gear 9 —
cardiagn.com
1 Coolant pump drive gear 6 Gearcase, free end
2 Shaft 7 H.P. fuel pump drive gear
3 Idler gear 8 Main bearing, free end
4 Crankshaft 9 Drive flange, free end
5 Crankshaft gear 10 Drive gear
TIM ID: 0000000807 – 002
M020124/02E 2009-02 © MTU

9.2.10 Gear train, free end – Removal
Preconditions
Heavy object.
Risk of crushing!
Removing idler gears

1. Place equipment carrier on a clean and flat
surface.
2. Remove screws (1) and (2).
3. Insert jackscrews M8 with continuous thread in
thread (arrows) of axle (3).
4. Press off axle evenly.
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Removing axles
1. Mark respective axle according to installation
position and remove from equipment carrier.
2. Remove idler gears from fit.
3. Remove bearing bushing of idler gear
(→ Page 1110).
TIM ID: 0000000819 – 003
M020124/02E 2009-02 © MTU

9.2.11 Gear train, free end – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Gear train, free end – Cleaning
1. Clean idler gears and oil bores of axles with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Thoroughly clean gear train, free end, by blowing clear with compressed air.
TIM ID: 0000000811 – 002
M020124/02E 2009-02 © MTU

9.2.12 Gear train, free end – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

cardiagn.com
Spare parts

Idler gears
Axle
TIM ID: 0000000815 – 006
M020124/02E 2009-02 © MTU

Gear train, free end – Check
Item Findings Task
Use magnetic crack-testing method Signs of cracks Replace idler gears.

to check idler gears for cracks.
Check surface quality of idler gear Damaged Replace idler gear.

tooth flanks with magnifying glass.
Check running surface of axles, • Scores • Corrective work: Smooth with

bearing bushes in idler gears and • Stress marks oilstone or emery cloth.
axial friction faces of gears for wear, visible • Replace
scores and stress marks.
Check taper seat and bolt-on • Scores • Corrective work

surface of axles for scoring and • Stress marks • Replace
stress marks. visible
Check screws for damage and • Damaged Replace screws

cardiagn.com
Measure bearing bushing bore in Values exceeded Replace bearing bushing bore
idler gear. Values (→ Page 1105) (→ Page 1110).
Use micrometer to measure outer Values exceeded Replace axle.

diameter of axles at running surface.
Measure equipment carrier bore Values exceeded Replace equipment carrier.

of idler gear axles. Values
(→ Page 1105)
TIM ID: 0000000815 – 006
M020124/02E 2009-02 © MTU

9.2.13 Gear train, free end – Tolerances
cardiagn.com
Basic limit
size
1 Equipment carrier 81.000 H7 0 +0.035 0 0.070 Clear-

bore ance
max.
Axle outer dia. 81.000 H7 –0.035 0 0.080
2 Idler gear bore 80.000 H7 0 +0.030 0.029 0.078
Bush outer dia. 80.000 s6 +0.059 0.078
3 Cylinder liner ID
installed 75.000 H8 0 +0.046 0.060 0.136
removed 75.000 E6 +0.060 +0.079
Axle outer dia. 75.000 e7 –0.090 –0.060
4 Equipment carrier 75.000 P7 –0.051 –0.021 0.009 0.069 Clear-

bore ance
TIM ID: 0000004155 – 001
max.
Axle outer dia. 75.000 e7 –0.090 –0.060 0.080
M020124/02E 2009-02 © MTU


Basic limit
size
5 Equipment carrier 41.200 0 0.200 0.500 0.800 Clear-

width ance
max.
Idler gear width 40.700 –0.100 0 0.900
Measure equipment carrier width unclamped.
6 Crankcase
cardiagn.com
TIM ID: 0000004155 – 001
M020124/02E 2009-02 © MTU

9.2.14 Gear train, free end – Installation
Special tools

Holder 0015890321/00 1
Material

Engine oil
Spare parts
cardiagn.com
O-ring
Suspended load.
Danger to life!
Check gear train, free end (→ Page 1103).
Installing idler gear in equipment carrier

1. Coat bearing bushings in idler gear with engine oil.
2. Insert idler gear (2) through opening (arrow) into
equipment carrier (1), ensuring it is correctly
positioned.
TIM ID: 0000000823 – 003
M020124/02E 2009-02 © MTU

Installing axles
1. Ensure oil bores of axle (3) are perfectly clean.
2. Coat O-ring (1) and (2) with petroleum jelly.
3. Insert O-ring (2) into groove of equipment carrier
(4).
4. Fit O-ring (1) in groove in axle base.
5. Insert axles into equipment carrier. Pay attention
to fit of idler gear.
6. Press axle (3) into equipment carrier.
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7. Install hex screws (1) and tighten evenly.
8. Screw in screw (2).
TIM ID: 0000000823 – 003
M020124/02E 2009-02 © MTU

Checking axial clearance and backlash

1. Install two eyebolts in equipment carrier.
2. Attach equipment carrier to crane with ropes and
tension ropes equally.
3. Position equipment carrier vertically.
4. Mount magnetic dial-gauge holder (3) with dial
gauge (2) in equipment carrier.
5. Measure axial clearance:
5.1. Place dial gauge stylus with preload on
lateral collar of idler gear (1).
5.3. Check axial play by moving idler gear back
and forth in axial direction. Axial clearance
limit values (→ Page 1099).
6. Measure backlash:
6.1. Position dial gauge stylus with preload on
a tooth flank of idler gear.
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6.3. Move idler gear back and forth in radial
direction to check backlash.
6.4. Compare with specified values in table
(→ Page 1099).
7. If limit values are exceeded, replace idler gears.
TIM ID: 0000000823 – 003
M020124/02E 2009-02 © MTU

9.2.15 Bearing bushing of idler gear – Removal and installation
Material

Liquid nitrogen
Spare parts

Bushing

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Component is hot.
Risk of burning!
Bearing bushing – Removal

1. Clean idler gear (→ Page 1102)
2. Using a suitable sleeve and manual press, remove
bearing bushing (1) from idler gear (2).
TIM ID: 0000000827 – 005
M020124/02E 2009-02 © MTU

Bearing bushing – Installation

1. Measure main bore (3) in idler gear (2). Values
(→ Page 1105)
2. Place idler gear on a suitable surface. Ensure that,
when inserting the bearing bushing (1), there is
no lateral projection.
3. Cool bearing bushing in liquid nitrogen and heat
idler gear to 80 °C.
4. Insert chilled bearing bushing in idler gear.
Observe distance (A) 0.35 mm ±0.15 mm.
cardiagn.com
TIM ID: 0000000827 – 005
M020124/02E 2009-02 © MTU

9.3 Crank Drive
9.3.1 Running gear – Overview
Running gear
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1 Flywheel 4 Conrod 7 Vibration damper
2 Ring gear 5 Crankshaft 8 Crankshaft counterweight
3 Piston 6 Crankshaft gear, free end
TIM ID: 0000000835 – 001
M020124/02E 2009-02 © MTU

9.3.2 Crankshaft – Overview
Crankshaft detail
cardiagn.com
1 Vibration damper 9 Crankcase 17 O-ring
2 Crankshaft bearing, free end 10 Conrod screw 18 Crankshaft
3 Gearcase, free end 11 Crankshaft counterweight 19 O-ring
4 Piston 12 Socket-head screw 20 Hex screw
5 Cylinder liner 13 Stud * 21 Seal carrier
6 O-ring 14 Nuts, crankshaft bearing cap 22 Drive flange
7 Oil spray nozzle 15 Crankshaft bearing cap
8 Conrod 16 Crankshaft gear
* New studs must be pretensioned prior to first tightening

TIM ID: 0000029835 – 001
M020124/02E 2009-02 © MTU

Crankshaft
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1 Crankshaft
2 Counterweight
3 Stress bolt
4 Plug
5 Crankshaft gear
TIM ID: 0000029835 – 001
M020124/02E 2009-02 © MTU

Crankshaft with bearings
cardiagn.com
1 Crankshaft bearing, top 3 Upper alignment bearing
2 Crankshaft bearing, bottom 4 Lower alignment bearing
TIM ID: 0000029835 – 001
M020124/02E 2009-02 © MTU

9.3.3 Crankshaft – Removal
Preconditions
Special tools

Crankshaft locating device F6553644 2
Removal tool for crankshaft bearing caps F6783568 1
cardiagn.com
Suspended load.
Danger to life!

Risk of injury!

1. Check marking (1) of the crankshaft bearing caps
in relation to the crankcase.
2. If there is no marking (1): starting at driving
end, emboss main bearing numbers making
sure they can be read from the same direction.
Height of numeral punch: 6 mm.
TIM ID: 0000000859 – 005
M020124/02E 2009-02 © MTU

3. Turn crankcase upside down in swivel frame with

oil pan mating horizontal and facing upwards.
4. Remove socket-head screws (arrows) and remove
strip (1) from crankcase (2).
5. Remove all lateral screws for crankshaft bearing
caps from crankcase.
6. Starting at 1st bearing cap (driving end), position
cardiagn.com
hydraulic pretensioner on bearing cap studs.
7. Insert hydraulic screw pretensioner by hand.
8. Connect high-pressure hoses (1) of hydraulic
pump to hydraulic pretensioner (2).
9. Position magnetic holder and dial gauges on
crankcase mating face.
10. Center both gauge tips on the measuring points.
11. Set preloaded dial gauges to zero.
12. Operate hydraulic pump and simultaneously

elongate studs by a max. 0.25 mm.
13. Use a pin to loosen crankshaft bearing cap nut.
14. Release studs.
15. Position magnetic holder, dial gauges and
hydraulic pretensioner on next bearing cap.
16. Loosen and remove all nuts in the same sequence.
TIM ID: 0000000859 – 005
M020124/02E 2009-02 © MTU


1. Use removal tool to remove crankshaft bearing caps.
2. Remove bearing shell from crankshaft bearing cap and mark.
Crankshaft – Removal
1. To protect the crankshaft, fit sliding protection
sleeves over studs of first and last bearings.
cardiagn.com
2. Using rope (1) and crane, lift crankshaft (2) clear
of crankcase.
3. Ensure horizontal positioning of the crankshaft
when lifting.
4. Lower crankshaft on to firm supports.
TIM ID: 0000000859 – 005
M020124/02E 2009-02 © MTU

5. Use removal jig to remove bearing shells from

bearing pedestals.
6. Mark bearing shells that point towards the driving
end with the number of the corresponding main
bearing (arrow).
7. The marking (arrow) must be made by etching or
with a permanent marker.
cardiagn.com
TIM ID: 0000000859 – 005
M020124/02E 2009-02 © MTU

9.3.4 Crankshaft – Disassembly

Heavy object.
Risk of crushing!

Risk of injury!
Removing counterweights
Note: If counterweights are to be removed, mark
relevant counterweight in its installation
position on the crankshaft prior to removal.
cardiagn.com
1. Determine and record distance A (web to
counterweight).
2. Check that counterweights are consecutively
numbered.
3. If the numbering is not visible, punch in new
numbers.
4. Lower crankshaft onto firm assembly frame.

5. Remove screws (2) and counterweight (1).
TIM ID: 0000000862 – 003
M020124/02E 2009-02 © MTU

9.3.5 Crankshaft - Cleaning
Preconditions
Material

Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!
cardiagn.com

Risk of injury!
Heavy object.


Crankshaft - Cleaning
2. Clean crankshaft and all threads with compressed air.
TIM ID: 0000000847 – 004
M020124/02E 2009-02 © MTU

9.3.6 Crankshaft – Check
Special tools

DynaMIC hardness tester Y20506341 1
Retainer 0015890321/00 1
Bore gauge, 100-160 mm Y20091482 1
Material
cardiagn.com
Spare parts

Crankshaft
Counterweight
Screw
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!
TIM ID: 0000000855 – 008
M020124/02E 2009-02 © MTU

Crankshaft – Check
Item Findings Task
Check mating faces of Wear visible Smooth with oilstone.

counterweights for wear.
Use micrometer to measure Values fallen short of. Corrective work: To be carried out
diameter and roundness of main only in workshops authorized by
bearing journals and crankpins. MTU.
Record measured values in data
sheet. Values (→ Page 1126)
Check crankshaft counterweight Signs of cracks Replace crankshaft counterweight

with magnetic crack-testing method (→ Page 1120).
for cracks.
Check crankshaft gear for stress Stress marks visible • Corrective work
marks. • Replace: To be carried out only
in workshops authorized by
MTU.
cardiagn.com
Using engineer’s blue, check that Unevenly fitted. Level mating face.
screw heads fit correctly.
Measure shaft length of screws with Dimension exceeded Replace screw.

depth gauge. Permissible shaft
length (→ Page 980)
Use magnetic crack-testing method Signs of cracks Replace screw.

with fluorescent magnetic powder to
check screws for cracks.
Make sure that threads are in perfect • Sluggish Replace screw.

condition. • Damaged
Checking crankshaft for cracks

1. Install crankshaft in longitudinal direction between
jaws of test device.
2. The specified magnetic field strength of 20 A/cm
to 60 A/cm must be applied at every part of
the component.
3. Use magnetic crack-testing method to check
crankshaft for longitudinal and transverse cracks.
Also check the oil and journal bores as well as the
mating faces on counterweights and threaded
bores.
Result: If there are signs of cracks, replace
crankshaft.
4. After crack-testing, demagnetize crankshaft. A
residual field strength of 2.5 A/cm to 4 A/cm
must not be exceeded.
TIM ID: 0000000855 – 008
M020124/02E 2009-02 © MTU

Checking crankshaft journal and taper

1. Check taper surfaces (arrows) for scoring and
damage.
2. Remove minor scoring and damage by polishing
with emery cloth.
3. Recondition taper: To be carried out only in
Checking hardness of journals
cardiagn.com
Note: Check hardness of all journals when
not installed.
1. Check hardness of all journals using the DynaMIC

tester or other suitable hardness tester. Required
hardness: 49 HRC to 53 HRC.
Result: If values are fallen short of, contact
Service.
TIM ID: 0000000855 – 008
M020124/02E 2009-02 © MTU

cardiagn.com
Checking concentricity of crankshaft
1. Place crankshaft on rollers in main journals on main bearing.
2. Use adjustable measuring holder and dial gauge to check bearing journals for concentricity.
3. If wear on circumference of journal is irregular, measure at transition from cylindrical section of journal to
radius. Values (→ Page 1126).
Result: If measured values deviate: Recondition crankshaft only in workshops authorized by MTU.
TIM ID: 0000000855 – 008
M020124/02E 2009-02 © MTU

9.3.7 Crankshaft – Tolerances
Crankshaft bearing
cardiagn.com
Basic limit
size
1 Crankcase bore 0 171.000 H6 0 +0.025 171.035

bearing verse
ovality
max. 0.050
1 171.500 H6 171.535
Trans-
verse
ovality
max. 0.050
2 172.000 H6
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU


Basic limit
size
2 Alignment and 0-0 160.120 0 +0.054 0.120 0.199 Trans-

crankshaft verse
bearing Ø 0-1 159.620 ovality
installed 0-2 159.120 max. 0.050
0-3 158.620
1-0 160.120
1-1 159.620
1-2 159.120
1-3 158.620
Main bearing Ø 0-0 160.000 h6 –0.025 0 159.970
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0-1 159.500 h6 159.470
0-2 159.000 h6 158.970
0-3 158.500 h6 158.470
1-0 160.000 h6 159.970
1-1 159.500 h6 159.470
1-2 159.000 h6 158.970
1-3 158.500 h6 158.470

TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Conrod bearings
cardiagn.com
Basic limit
size
1 Conrod bore 126.000 0 +0.025

H6
2 Conrod bearing 0-0 117.082 0 +0.048 0.082 0.152

bore
0-3 116.482
Conrod journal Ø 0-0 117.000 h6 –0.022 0
0-1 116.800 h6
0-2 116.600 h6
0-3 116.400 h6
3 Crankpin length 97.500 −0.100 +0.100 0.200 0.600
−0.100
TIM ID: 0000004156 – 002
Conrod width 48.600 0
4 Expanding 0-0 126.400 0 +1.000

dimension
lower part
0-3 126.400
M020124/02E 2009-02 © MTU

Crankshaft bearing, alignment bearing – expanding dimension
cardiagn.com
Basic limit
size
1 Guide bearing, upper half
2 Guide bearing, lower half
3 Expanding 0-0 171.200 0 +0.500

dimension
Guide bearing, 0-1 171.200
upper and lower 0-2 171.200
part
0-3 171.200
1-0 171.700 0 +0.500
1-1 171.700
1-2 171.700
1-3 171.700
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft bearing – expanding dimension
cardiagn.com
Basic limit
size
1 Crankshaft bearing, upper half
2 Crankshaft bearing, lower half
3 Expanding 0-0 171.400 0 +1.000

dimension
Crankshaft 0-1 171.400
bearing, upper 0-2 171.400
and lower part
0-3 171.400
1-0 171.900 0 +1.000
1-1 171.900
1-2 171.900
1-3 171.900
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft axial play
cardiagn.com
Basic limit
size
1 Crankshaft axial 0.200 0.600 Clear-

play ance
min. 0.100
max. 0.700
2 Drive flange, 156.000 –0.010 +0.010

pressed on
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

cardiagn.com
Bearing shells installed and bearing caps tightened as per specification.
Measure crankshaft bearing bores:
• Determine diameters a, b1 and b2 in the measuring planes 1 and 2 and calculate
the average values for a, b1 and b2.
• Check roundness of crankshaft bearing bores.
b2 in the formula: (b1+b2) /2 −a
Replace bearing shells if:
• roundness deviation >0.040
• b1 : b2 is above/below 0.040
• vertical ovality a > (b1+b2) /2
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft gear, free end
cardiagn.com
Basic limit
size
1 Gear, pressed on 145.500 −0.300 +0.300

Crankshaft front
end to gear front
end
TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Main bearing journal concentricity
cardiagn.com
Crankshaft (8V)
Crankshaft (12V)
Crankshaft (16V)

TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

Crankshaft (20V)
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TIM ID: 0000004156 – 002
M020124/02E 2009-02 © MTU

9.3.8 Crankshaft - Assembly
Special tools

Spare parts

Crankshaft gear
End cover
Heavy object.
Risk of crushing!
cardiagn.com

Risk of injury!
Check crankshaft (→ Page 1122).
Installing counterweights
1. Measure shaft lengths of counterweight screws.
Max. shaft length (→ Page 980).
2. Smooth mating surface for counterweight with
oilstone.
3. The mating faces of crankshaft and counterweight
(2) must be dry and free of grease.
4. Coat threads and screw head mating face of
screws (1) with engine oil.
5. Position counterweight on crankshaft according to
markings and slightly tighten screws.
TIM ID: 0000000865 – 003
M020124/02E 2009-02 © MTU

6. Align counterweight to marking (A) and tighten

screws to specified pretightening torque
(→ Page 980).
7. Check that the installation position of the
counterweight matches the markings or measured
dimensions made before installation.
8. Mark screw heads.
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9. Tighten screws to specified additional angle of
rotation.
10. After installing counterweights, check identification
marks on counterweights and webs.
11. Dynamically balance crankshaft. (→ Page 1138).
12. Starting from driving end, mark counterweights
with number punch.
TIM ID: 0000000865 – 003
M020124/02E 2009-02 © MTU

9.3.9 Crankshaft – Balancing
Special tools

Master weights
Heavy object.
Risk of crushing!

Risk of injury!
Preparatory steps
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1. Prior to balancing, seal all oil bores.
2. Support crankshaft at shaft journals.
3. Depending on stroke position (free residual moment), master weights must be used for dynamic balancing to
simulate the rotating and oscillating mass of conrod and piston.
TIM ID: 0000000851 – 003
M020124/02E 2009-02 © MTU

Dynamic balancing
Crankshaft (8V) Crankshaft (12V) Crankshaft (16V) Crankshaft (20V)
Maximum operating 2100 rpm 1900 rpm 2100 rpm 1900 rpm
speed
Support crankshaft 1 and 5 2 and 6 2 and 8 2 and 10

at shaft journals
Balancing assembly 463 kg 525 kg 775 kg 842 kg

mass
Balancing speed 150 rpm 150 rpm 150 rpm 150 rpm
unbalance per
compensation level
for initial balancing
unbalance per
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compensation level
in other clamp or
balancing machine
(comparison)
Minimum wall 5 mm 5 mm 5 mm 5 mm
thickness around
bore
Bore values at counterweights

1. To balance crankshaft remove material from
counterweights by drilling with twist drill.
2. After balancing, recheck numbers on
counterweights and renumber if necessary.
A 5 ° (min.)
B 10 °
C 32 ° (min.)
D 8V, 12V, 16V: 18 mm (max. bore diameter); 20V:
TIM ID: 0000000851 – 003
20 mm (max. bore diameter)

E 40 mm (max. bore depth)
M020124/02E 2009-02 © MTU

9.3.10 Crankshaft bearing shells - Check

Remove crankshaft (→ Page 1116).
Crankshaft bearing shells - Check

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

non-scheduled removal), check erosion or damage visible
bearing shells for surface wear,
scores, cracks, corrosion, erosion
and damage.
Check bearing shell butt and bearing Fretting corrosion visible Replace and determine cause.
rear side for damage and fretting Possible causes:
corrosion (pitting).
• Insufficient screw pretension
• Assembly error
• Spread dimension of bearing
shell out of tolerance
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• Faulty bearing support bore
Measure spread dimension. Determined value exceeded Replace bearing shell.

(→ Page 1126).
Main bearing shells (grooved bearing), upper half
Running surface has following properties when new:

A approx. 75% slide layer
B approx. 25% intermediate layer
C 5% sputtered blocking layer
TIM ID: 0000000874 – 003
Assessment
Wear of the bearing running surfaces starts at the galvanized slide layer (a). In the event of further wear, the
difference between the intermediate layer (b) and slide layer (a) remains almost constant.
A magnifying glass is required for a more accurate assessment of the running surface
wear condition (magnification min. 5x).
M020124/02E 2009-02 © MTU

In doing so, the slide layer is visible as a dark zone and the intermediate layer as a light zone. The
following is decisive for the wear condition of the grooved bearing:
• Width of intermediate layer
• Width of groove
• Expansion of worn surface
The grooved bearing is still functional if the slide layer is partially missing in the grooves.
During each assessment of the condition of the grooves, the running surface in the area subject to
least load (groove mostly new) should be used for comparison.
The condition of the grooved bearings is assessed in five groups:
1. Continued use
2. Wear
3. Borderline wear and levelling
4. Slide layer fatigue fractures
5. Borderline slide layer continuous fractures and empty grooves
Main bearing shell (sputtered bearing), lower half
cardiagn.com
1 Slide layer
2 Blocking layer
3 Intermediate layer
4 Protective steel shell
Assessment
An important indicator for assessing the extent of wear on the bearing shell is the shape
and extent of the blocking layer areas exposed.
Wear of the bearing running surfaces starts at the galvanized slide layer (1).
The use of the bearing shell is already restricted in friction area once the slide 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.
Renew bearing shells at extended component maintenance.
TIM ID: 0000000874 – 003
Damage to bearing
Damage to bearings occurs mainly through foreign body scoring, impressions and embedding,
cavitation and corrosion, pitting, fatigue and installation faults.
Bearings showing such damage must be replaced.
M020124/02E 2009-02 © MTU

9.3.11 Crankshaft bearing bore – Check
Special tools

Bore gauge, 100-160 mm Y20091482 1
Installation/removal device F6553647 1
Retainer 0015890321/00 1
Material
cardiagn.com
Engine oil
Spare parts

Compressed air.
Risk of injury!

Risk of injury!
Note: The crankshaft bearing bore must first be checked without and subsequently with main bearings installed.
Measure crankshaft bearing bore with main bearings installed

TIM ID: 0000000877 – 005
M020124/02E 2009-02 © MTU

Measuring bearing shells

3. Check codes for repair size and journal diameter
of new shells and bearing number of used
shells. These markings must be on sides facing
the driving end.
4. Compare crankcase data sheet and crankshaft
data sheet.
5. Manually press bearing shells on crankcase side
into crankcase bore to form a positive connection.
Ensure that oil bores (arrows) in bearing shells and
6. Insert bearing shells in crankshaft bearing caps
cardiagn.com
according to markings or bearing number.
7. Position bearing shell so that bearing numbers are
aligned and facing driving end.
8. Position installation tool (1) between bearing
cap stud and rear face of shell on side where
open joint is.
9. Press bearing shell on cap side (2) against guide
bearing shell on crankcase side. Make sure that
the shell joint is closed.
10. Align bearing shells axially.
12. Adjust bore gauge with adjusting ring or

micrometer to reference size of bearing bore.
13. Coat running surfaces of crankshaft bearing
shells with engine oil.
14. Measure crankshaft bearing bore ID with bore
gauge.
16. Compare measured values with specifications
(→ Page 1126).
17. If values are exceeded, recondition bearing shells
to next repair size or replace.
18. After measuring crankshaft bearing bores, if
TIM ID: 0000000877 – 005
necessary mark bearing shells according to

bearing point number.
M020124/02E 2009-02 © MTU

Checking crankshaft bearing bore without main bearing installed

2. Remove bearing shells. Protect against damage.
4. Measure crankshaft bearing bore in same way as with installed bearing shells.
cardiagn.com
TIM ID: 0000000877 – 005
M020124/02E 2009-02 © MTU

9.3.12 Crankshaft – Installation
Special tools

cardiagn.com
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

Installing bearing shells

Note: Top and bottom bearing shells have
different part numbers. First crankshaft
bearing on driving end is designed as an
alignment bearing.
3. Use installation/removal tool to manually insert

the bearing shells on the crankcase side in
accordance with bearing numbers in crankcase
bore to form a positive connection.
4. Check stage of main crankshaft bearing bore and
stage of bearing shells. For data, see crankcase
data sheet and crankshaft data sheet.
5. Align alignment bearing shell and remaining
bearing shells with press-in tool in crankcase
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bores.
Crankshaft – Installation
1. Wipe bearing surfaces on crankshaft with chamois
leather.
2. Spray running faces of bearing shells on crankcase
side with engine oil.
3. To protect crankshaft, slide locating device (1)
over studs of first bearing (2).
4. Slide protective sleeve (2) over studs on last

bearing.
5. Lift crankshaft using rope slings (1) and crane.
6. Align crankshaft horizontally and vertically with
line of bores in crankcase and gradually lower
crankshaft.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

7. Remove protective sleeves and locating device.

Note: Do not rotate the crankshaft until the axial
alignment bearing has been installed.
8. Wipe lower bearing shell and crankshaft bearing

cap with chamois leather, spray running surface
with engine oil and install.
9. Check alignment of upper and lower bearing
shells. Bearing numbers on shells must be aligned
and all numbers must face driving end.
10. Position installation tool (1) between bearing cap
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stud and rear face of shell on side where joint is.
11. Compress bearing shell on cap side and press
against shell on crankcase side.
Result: The joint between the shells must be
closed.
12. Axially align bearing shells.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU


Note: Crankshaft bearing caps must not be
cardiagn.com
interchanged!
2. Assign bearing cap to respective bearing

according to crankcase marking (1). If not present,
stamp numbers of main bearing (1), starting
at driving end.
3. Carefully position assigned bearing cap on

respective bearing.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

4. Tap crankshaft bearing cap lightly to move to

final position.
5. Coat threads and mating faces of studs (1) with
cardiagn.com
engine oil.
6. Turn bearing cap nuts to mating face of bearing
caps.
7. Starting with 1st bearing cap (driving end or free

end), fit support sleeve (2) of hydraulic screw
pretensioner on studs (1) of respective crankshaft
bearing cap.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

8. Turn hydraulic screw pretensioner (1) by hand

until it is in position.
9. Connect high-pressure hose of hydraulic hand
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pump to hydraulic screw pretensioner.
10. Position magnetic holder with dial gauges on
crankcase mating face to measure stud elongation.
11. Position the two dial gauge tips centrally on the

respective measuring core (arrow) on the sleeve
measuring pin.
12. Set preloaded dial gauges to zero. TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

13. Operate hydraulic hand pump and elongate studs

at the same time (max. 1.15 mm +0.05 mm), use a
pin (arrow) to fit nuts on crankshaft bearing cap.
Note: Residual elongation of studs after release:
0.9 mm +0.05 mm
14. Relieve studs, check elongation of studs.

15. If residual elongation of studs is outside tolerance,
loosen nuts, and repeat nut tightening procedure; if
necessary, replace studs.
16. Mount dial gauges with magnetic holders and
hydraulic screw pretensioner on studs of adjacent
bearing cap and follow the same procedure to fit
all remaining nuts.
17. Coat screws (arrow) with engine oil.
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18. Insert screws (arrow) and use torque wrench to
tighten to specified torque (→ Page 980).
19. Install strip (driving end) (→ Page 1024).
20. In order to avoid damage to the

crankshaft bearings, install locating device (1)
before cranking the crankshaft.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

21. Fit barring tool (2) with screws on crankshaft (1)

(free end).
22. Turn crankshaft with barring tool and check for
ease of movement.
Measuring axial play of crankshaft
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Note: Measure axial play only with drive flange or
flywheel mounted.

(1) on crankcase.
2. Position dial gauge tip on face of crankshaft.
3. Use pry bar to press crankshaft axially as far as
it will go.
4. Set preloaded dial gauge to zero.
5. Move crankshaft from stop to stop (arrows) and
enter measured value (axial play) on data sheet.
6. If the determined value is out of tolerance
(→ Page 1126), remove crankshaft and determine
the cause.
TIM ID: 0000000868 – 007
M020124/02E 2009-02 © MTU

9.3.13 PTO flange, driving end, flywheel – Overview
cardiagn.com
1 Flywheel 6 Spring pin 11 Cover
2 Graduated disc 7 Dished washer 12 Conical spring washer
3 Radial-lip shaft seal 8 Screw 13 Screw
4 Screw 9 O-ring 14 Cover
5 Conical spring washer 10 O-ring 15 O-ring
TIM ID: 0000000881 – 002
M020124/02E 2009-02 © MTU

Layout for installation/removal jig for flywheel
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1 Spacer 6 Pressure sleeve 11 Nut
2 Screw 7 Tension spindle A Reference dimension: 363 mm
3 Adjusting mandrel 8 Hydraulic nut B Push-on dimension: 16.7 mm
4 Connection 9 Pressure line to 20 mm
5 Flange 10 Support C Press-fitted flush
TIM ID: 0000000881 – 002
M020124/02E 2009-02 © MTU

9.3.14 PTO flange, driving end, flywheel – Removal
Special tools

Hand pump set 5555890063/00 1
Trestle T80091387 1
Adapter F6555788 1
Impact extractor F30377999 1
Suspended load.
Danger to life!
cardiagn.com

Removing flywheel
1. Remove screws (2) together with washers (3).
2. Remove plug (1) from flywheel.
TIM ID: 0000000890 – 003
M020124/02E 2009-02 © MTU

4. Install adapter (2) for impact extractor (3) with

screws (5).
5. Remove cover (4) from flywheel (4) with impact
extractor (3).
6. Install installation/removal tool on crankcase
journal, driving end, as shown in overview drawing
(→ Page 1153).
7. Turn crankshaft, until fixation (1) on spacer (2)
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engages in flywheel.
8. Insert tension spindle into crankshaft.

9. Measure check dimension ”A” (→ Page 1153).
10. Slide pressure sleeve (2) and hydraulic nut (1) over
tension spindle and screw on nut (3) with support. TIM ID: 0000000890 – 003
M020124/02E 2009-02 © MTU

11. Remove screw for expanding bore in flywheel.

nut (3).
15. Fully tighten hydraulic nut (3) to stop, then back off
nut for a distance equal to push-on dimension
(→ Page 1153).
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19. Actuate hydraulic unit (2) and to bring hydraulic
nut at minimum pressure p2 (start of pressure
increase) to attachment with flywheel.
flywheel.
21. Actuate hand pump (1) for expanding the flywheel,
until half of the maximum expansion pressure
p1 is reached.
23. Increase expansion pressure gradually in steps of
0,1 x pmax with hold times of approx. 2 minutes
until the flywheel comes clear off the crankshaft.
Do not exceed maximum expansion pressure pmax.
pressure.
of the flywheel from the taper seat is indicated by
rising pressure p2 .
26. Gradually drain oil in hydraulic nut, while at the
same time continuing to pump.
27. Relieve pumps (1) and (2).
28. Screw trestle into flywheel and attach flywheel to
crane with rope lightly pretensioned.
29. Remove HP line.
30. Remove nut, support, hydraulic nut and pressure
sleeve.
TIM ID: 0000000890 – 003
M020124/02E 2009-02 © MTU


32. Lift flywheel through assembly sleeve (arrow)
out of end housing.
33. Place flywheel on a clean surface and secure.
34. Remove nut, assembly sleeve, flange and spacer.
35. Clean assembly surfaces on flywheel and
crankshaft.
36. Close openings using suitable covers.
cardiagn.com
TIM ID: 0000000890 – 003
M020124/02E 2009-02 © MTU

9.3.15 Radial-lip shaft seal, driving end – Removal

Removing radial-lip shaft seal from end housing
1. Remove end housing, driving end (→ Page 1062).
2. Use a suitable extractor to extract radial-lip shaft seal from end housing. Do not damage end housing and
crankshaft.
cardiagn.com
TIM ID: 0000000893 – 003
M020124/02E 2009-02 © MTU

9.3.16 Flywheel on PTO flange, driving end – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Flywheel on PTO flange, driving end – Cleaning
2. Remove cleaner.
3. Thoroughly blow all threads clear with compressed air.
TIM ID: 0000000884 – 002
M020124/02E 2009-02 © MTU

9.3.17 Flywheel on PTO flange, driving end – Check
Material

Spare parts

Flywheel
End cover
Coiled spring pin
Heavy object.
cardiagn.com
Risk of crushing!
Flywheel on PTO flange, driving end – Check
Item Findings Task
Use magnetic crack-testing method Signs of cracks Replace.

to check flywheel and ring gear for
cracks.
Check mating faces on flywheel for • Stress marks • Corrective work

evenness, stress marks, scoring • Scores • Replace
and indentations. • Indentations
visible
Check ring gear for wear. Signs of wear • Corrective work

• Replace
Check end cover for wear. Signs of wear • Corrective work

• Replace
Measure outer diameter (hub) of Value fallen short of. Replace flywheel.
flywheel. Value (→ Page 1066)
Check thread of expanding bore. Damaged Recut thread.

TIM ID: 0000000887 – 006
M020124/02E 2009-02 © MTU

9.3.18 Radial-lip shaft seal, driving end – Installation
Special tools

Material

Ethanol 40250 1
Spare parts

cardiagn.com
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Installing radial-lip shaft seal in end housing,

driving end
Note: Install radial-lip shaft seal only in mounted
end housing, driving end.
1. Install flange with spacer on front face of crankshaft

2. Fit radial-lip shaft seal, with sealing lip facing
outwards, on press-in tool.
3. Coat sealing face of radial-lip shaft seal with
ethanol.
4. Clean and degrease locating bore for radial-lip
shaft seal in end housing, driving end.
5. Position press-in tool and secure with hand screw.
6. Use press-in tool to install radial-lip shaft seal flush
in end housing, driving end.
7. Remove press-in tool with flange from crankshaft.
TIM ID: 0000000896 – 004
M020124/02E 2009-02 © MTU

9.3.19 PTO flange, driving end, flywheel – Installation
Special tools

Hand pump set 5555890063/00 1
Trestle T80091387 1
Material

cardiagn.com
Engine oil
Spare parts

O-ring
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!


TIM ID: 0000000899 – 005
Check flywheel on PTO flange, driving end (→ Page 1161).
M020124/02E 2009-02 © MTU

Installing timing wheel

1. Attach timing wheel (2) with screws (1) to flywheel,
do not tighten.
2. Drive spring pins (arrow) into flywheel.
Pressing on flywheel
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1. Prior to installation, remove all covers.
2. Clean and degrease taper surface on crankshaft
with cleaner and dry and degrease with lint-free
cloth.
3. Coat lip of radial-lip oil seal with petroleum jelly.
4. Screw in tension spindle (1) and measure
reference dimension “A” of tension spindle
(→ Page 1153).
5. Install spacer (3) and flange (2) together with
screws on crankshaft face.

7. Use rope to attach flywheel to crane with rope
8. Use crane to insert flywheel through guide sleeve
into end housing,
9. Remove assembly sleeve (arrow).
TIM ID: 0000000899 – 005
M020124/02E 2009-02 © MTU

10. Calculate push-on distance by measuring distance

from end face of crankshaft to end face of flywheel
with depth gauge.
11. If measured value is smaller than push-on distance
“B”, check taper for dimensional accuracy.
12. Slide pressure sleeve and hydraulic nut (3) over
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tension spindle and screw on nut (5) with support.
nut (3).
19. Prior to press-fitting, moisten tapers fit with
expansion fluid. In doing so, actuate hand
pump (1), until expansion fluid emerges at hub
ends.
20. Actuate hydraulic unit (2) for hydraulic nut, and
attach at installation on flywheel using minimal
pressure.
TIM ID: 0000000899 – 005
flywheel.
22. Pump in expansion fluid until expansion
pressure (p1) can no longer be increased (do not
exceed expansion pressure Pmax ), then increase
force-on force by increasing force-on pressure (p2).
23. Select force-on force so that end position
(pressure bush is seated against flywheel) is
achieved in approx. 5 steps.
M020124/02E 2009-02 © MTU


expansion pressure.
26. Unscrew HP lines.
27. Remove nut, support, hydraulic nut, pressure
sleeve and tension spindle after prescribed
soaking time.
28. Coat O-rings (8) with petroleum jelly and insert in
groove on cover (7).
31. Coat O-rings (1) and (3) with petroleum jelly and
insert in groove on plug (2).
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33. Coat screws (4) with Loctite 270 and screw in
together with washers (5).
TIM ID: 0000000899 – 005
M020124/02E 2009-02 © MTU

9.3.20 Crankshaft PTO, Free end – Overview
cardiagn.com
1 Adapter flange 5 O-ring 9 Washer
3 Screw 7 Protective cover 11 Sealing ring
4 Washer 8 Screw
TIM ID: 0000029611 – 001
M020124/02E 2009-02 © MTU

Arrangement of the drive flange installation/removal tool
1
2
3
4
Draw spindle
Nut
Support
Connection
9
10
11
12
Drive flange
Crankshaft
Seal carrier
Screw
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5 Hydraulic nut A Reference dimension: 339 mm
6 Pressure sleeve B Push-on dimension: 76.95 mm
7 Flange to 77.05 mm
8 Spacer bushing a Push-on travel: 15.5 mm
TIM ID: 0000029611 – 001
M020124/02E 2009-02 © MTU

9.3.21 Vibration damper on PTO, free end – Removal
Preconditions
Special tools

Installation/removal tool F0140771 1
cardiagn.com
Material

Engine oil SAE 10 W
Suspended load.
Danger to life!

TIM ID: 0000000912 – 012
M020124/02E 2009-02 © MTU

Removing vibration damper

1. Remove protective cover.
2. Block flywheel by securing with positioning fixture
on end housing.
3. Remove screws (2), one screw is left for securing
purposes.
4. Screw in two adjusting mandrels in opposing
threaded bore of drive flange.
5. Remove remaining screws.
6. Insert two jackscrews with continuous thread
in thread (1).
7. Press off vibration damper.
8. Attach vibration damper (1) with lifting gear (3)
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and support bracket to crane using a lightly
tensioned rope and remove.
9. Remove adjusting mandrels (2).
Pressing off drive flange

1. Screw draw spindle (4) into crankshaft.
2. Check reference dimension “A” (→ Page 1167).
3. Read off push-on dimension at drive flange (1).
4. Mount installation/removal tool as per overview
5. Screw in connecting piece (2) in drive flange (1).
6. Connect HP line for drive flange expansion to
connecting piece.
7. Insert adapter in connection of hydraulic nut (3).
8. Connect HP line (6) to adapter.
TIM ID: 0000000912 – 012

10. Back off nut (5) for a distance equaling push-on
dimension.
M020124/02E 2009-02 © MTU

11. Fill hand pumps (1) and (2) with engine oil SAE 10.
12. Vent hand pumps (1) and (2) and line system until
14. Operate hand pump (2) to bring hydraulic nut at
minimum pressure p2 (start of pressure increase)
to attachment with drive flange.
15. Read off max. expansion pressure pmax at
drive flange.
16. Actuate hand pump (1) to expand the drive flange
until half the maximum expansion pressure p1
has been reached.
18. Increase expansion pressure gradually in
steps of 0.1 x pmax with hold times of approx.
2 minutes until the drive flange comes clear off the
crankshaft. Do not exceed maximum expansion
pressure pmax.
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pressure.
of the drive flange from the taper seat is indicated
by rising pressure p2.
21. Gradually relieve pressure in hydraulic nut while
steadily operating pump for expansion fluid.
22. Relieve hand pumps (1) and (2).
23. Screw eyebolt into drive flange and suspend drive
flange on crane with rope lightly tensioned.
24. Remove installation/removal tool.
25. Remove drive flange (1) from crankshaft (2).
26. Remove screws (4) from adapter flange (3).
27. Remove adapter flange (3).
TIM ID: 0000000912 – 012
M020124/02E 2009-02 © MTU

9.3.22 Vibration damper on PTO, free end – Disassembly
Vibration damper – Disassembly

This component is an exchange component (Reman) and is available via the normal exchange procedure.
cardiagn.com
TIM ID: 0000000915 – 002
M020124/02E 2009-02 © MTU

9.3.23 Vibration damper on PTO, free end – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning vibration damper

2. Remove cleaner.
TIM ID: 0000000906 – 002
M020124/02E 2009-02 © MTU

9.3.24 Vibration damper on PTO, free end – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Micrometer, 175-200 mm Y20001744 1
Holder 0015890321/00 1
Spare parts

Vibration damper
Drive flange
cardiagn.com
Heavy object.
Risk of crushing!

Risk of injury!
Vibration damper - Check
Item Findings Task
Visually inspect vibration damper for • Damage Replace vibration damper.

damage and wear. • Wear
visible
Using a precision bore gauge, Values exceeded. Replace vibration damper.

measure vibration damper bore.
Measure drive flange OD with Values below specification. Replace drive flange.
micrometer. Values (→ Page 1175)
TIM ID: 0000000909 – 005
M020124/02E 2009-02 © MTU

9.3.25 Vibration damper on PTO, free end – Tolerances
cardiagn.com
Basic limit
size
1 ID of vibration 198.000 0 +0.046 0 0.059 0.016

damper H7
OD of driver 196.00 j6 –0.013 +0.016

flange
TIM ID: 0000004053 – 001
M020124/02E 2009-02 © MTU

9.3.26 Vibration damper on PTO, free end – Installation
Special tools

Removal/installation device F0140771 1
Hook-ended chain sling (quadruple branch) T80090748 1
cardiagn.com
Material

Engine oil
Spare parts

O-ring
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

TIM ID: 0000002645 – 013

M020124/02E 2009-02 © MTU

Installing adapter flange

1. Coat O-rings with grease and insert into groove.
2. Install adapter flange with O-rings as shown in the overview drawing (→ Page 1167).
3. Use torque wrench to tighten screws to specified tightening torque (→ Page 980).
Hydraulic press-fitting drive flange

1. Clean, degrease and dry tapers of crankshaft
and vibration damper.
2. Coat running surfaces of crankshaft bearing and
drive flange with oil.
3. Push drive flange onto crankshaft taper by hand.
4. Measure distance from crankshaft end face to
drive flange end face using depth gauge and
note measured value.
5. Calculate difference (= push-on distance) between
measured dimension and push-on dimension
(→ Page 1167).
6. Push-on dimension B = distance between
crankshaft end face and drive flange end face
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after installation.
7. Read off push-on distance at drive flange.
8. If calculated push-on distance is less than
measured value, check dimensional accuracy
of tapers.
9. Screw puller spindle (4) into crankshaft.
10. Check reference dimension (A) (→ Page 1167).
11. Mount installation/removal device as shown in the
12. Slide thrust sleeve (1) and hydraulic nut (3)
over puller spindle.
13. Set hydraulic nut (3) to initial position at zero
stroke.
14. Install nut (5) and hand-tighten.
15. Screw high-pressure line with connecting piece (2)
into drive flange.
16. Connect high-pressure line (6) of hydraulic unit
to hydraulic nut (3).
TIM ID: 0000002645 – 013
M020124/02E 2009-02 © MTU

17. Fill hand pump (1) and (2) with engine oil acc.
to SAE 10 W.
18. Vent hand pump (1) and (2) and pipework until
19. Tighten high-pressure line.
20. Prior to hydraulic press-fitting, moisten tapers fit
with expansion fluid. For this purpose, actuate
hand pump (1) until expansion fluid emerges
at drive flange end.
21. Operate hydraulic hand pump (2) for hydraulic
nut and, by applying minimum pressure on drive
flange, seat against drive flange.
22. Pump in expansion fluid until expansion pressure
p1 no longer rises. Then increase press-on force
by raising force-on pressure p2.
23. Repeat this process until drive flange is correctly
seated.
24. Select push-on pressure so as to achieve
positioning in approx. 5 steps.
cardiagn.com
25. Read off expansion pressure pmax at drive flange.
Ensure that, during installation, the required
expansion pressure is less than the maximum
expansion pressure pmax.
Result: Hydraulic installation is completed when
thrust sleeve is seated against crankshaft.
expansion pressure.
28. Disconnect high-pressure line.
29. Remove installation/removal device after specified
hold time has elapsed.
30. Check push-on dimension (B) between crankshaft
end face and drive flange end face (→ Page 1167).
31. If push-on dimension is not established,
hydraulically remove drive flange and determine
the cause.
32. Do not subject press fitting to operating load
for at least 8 hours. TIM ID: 0000002645 – 013
M020124/02E 2009-02 © MTU

Installing vibration damper

1. Screw adjusting mandrels (1) into threaded hole
of drive flange.
2. Coat O-rings (2) with grease.
3. Fit O-rings (2) on drive flange.
4. Attach vibration damper (1) with lifting gear (3) and
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support bracket to crane using a lightly tensioned
hook-ended chain sling.
5. Push vibration damper (1) onto adjusting
mandrels (2).
6. Remove lifting gear (3).
7. Coat thread and screw head mating faces with
engine oil and screw in.
8. Remove adjusting mandrels.
9. Install remaining screws and washers and tighten
to specified tightening torque (→ Page 980)
using a torque wrench.
10. Install protective cover.
11. Remove positioning fixture from end housing.
TIM ID: 0000002645 – 013
M020124/02E 2009-02 © MTU

9.3.27 Piston and conrod – Overview
Piston and conrod
cardiagn.com
1 Piston 3 Conrod cap 5 Conrod bearing shell, lower
2 Conrod 4 Conrod bearing shell, upper 6 Conrod screw
TIM ID: 0000029621 – 001
M020124/02E 2009-02 © MTU

Piston details
cardiagn.com
1 Snap ring 5 Oil control ring 9 Conrod
2 Piston pin 6 Piston 10 Conrod cap
3 Rectangular-section ring 7 Pressure plate 11 Conrod screw
4 Taper-face compression ring 8 Piston crown screw
TIM ID: 0000029621 – 001
M020124/02E 2009-02 © MTU

9.3.28 Piston and conrod – Removal
Special tools

Barring tool, 8V-16V F6555766 1
Barring tool, 20V F6783293 1
Barring tool for timing disc F6555791 1
Socket, 22 A/F, conrod screws F30378352 1
Lifting device for piston removal, 8V-16V T80091025 1
Lifting device for piston removal, 20V T80091496 1
cardiagn.com
Heavy object.
Risk of crushing!

Risk of injury!
Removing piston and conrod with oil pan installed

1. Remove combustion residues from cylinder liner.
2. Remove carbon scraper ring (arrowed)
(→ Page 1034).
3. Install barring tool.
4. Remove left and right-side inspection port cover on
TIM ID: 0000005021 – 004
M020124/02E 2009-02 © MTU

6. Working through the inspection port (arrowed),

slacken conrod screws using a socket insert and
large ratchet.
7. For further removal, except for altered removal
position of crankcase: see "Removing piston and
conrod in assembly dolly" in next section.
8. Before removing the conrod from cylinder liner (3),
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attach sliding block (2) to conrod (1).
Removing piston and conrod in assembly dolly

Note: Do not bar crankshaft unless the flywheel
or axial locating device is installed.
1. Turn crankcase in assembly dolly until conrod

bearing cap (1) of the piston to be removed
is horizontal.
2. Using socket (2), extension and ratchet, release
conrod screw (3).
TIM ID: 0000005021 – 004
M020124/02E 2009-02 © MTU

Note: Bearing cap and conrod are a single unit

and must not be interchanged.
3. Check marking (arrowed) of conrod bearing cap

and conrod. If necessary, mark components.
4. Remove conrod screws (arrowed) and take off
cardiagn.com
conrod bearing cap (1).
5. Remove bearing shell from conrod bearing cap.
Ensure that toothing on mating faces of conrod
and conrod bearing cap is not damaged.
6. Protect bearing shell and conrod bearing cap
from damage.
7. Check markings of bearing shell to conrod. If
necessary, mark components.
8. Turn crankcase in assembly dolly until the piston

and conrod to be removed are vertical. Ensure
that the oil spray nozzle is not damaged.
9. Remove bearing shell from conrod and protect
from damage.
10. Attach lifting device (1 ) to piston crown (2).
11. Using a crane, withdraw piston and conrod from
cylinder liner fit.
12. Carefully set down piston and conrod on soft
surface and remove from crane.
13. Remove lifting device from piston crown.
TIM ID: 0000005021 – 004
M020124/02E 2009-02 © MTU

9.3.29 Piston and conrod – Disassembly
Special tools

Heavy object.
Risk of crushing!

Risk of injury!
Removing conrod from piston

1. Place piston and conrod on workbench.
2. Check markings of conrod, piston and piston pin. If
cardiagn.com
necessary, mark components anew.
3. Using snap ring pliers (1), remove snap ring (2).
4. Use a piece of round wood to press out piston pin

(2), holding conrod (1) firmly in position.
5. Remove conrod from piston.
TIM ID: 0000000941 – 007
M020124/02E 2009-02 © MTU

Removing piston rings

1. Stretch piston rings until they can be removed
from the piston.
2. Remove piston rings with piston ring pliers in
sequence from top to bottom.
cardiagn.com
TIM ID: 0000000941 – 007
M020124/02E 2009-02 © MTU

9.3.30 Piston – Cleaning
Material

Cleaner (Sima Solv K6) 50632 1
Cleaner is an explosive and poisonous substance.

Danger to life, major material damage!
DANGER • Avoid open flames, electrical sparks and ignition sources.
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
cardiagn.com
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!

Risk of injury!

Piston cleaning
Note: The graphite layer on the piston skirt must not be mechanically removed or treated with strong cleaners!
1. Clean all metallic parts with the cleaner.

2. Clean area of piston ring grooves with rotating plastic brush.
3. After cleaning, blow out oil chamber and oil bores with compressed air.
TIM ID: 0000000928 – 005
M020124/02E 2009-02 © MTU

9.3.31 Piston – Check
Material

Spare parts

Piston
cardiagn.com
Piston pin
Oil-control ring
Taper-face compression ring
Rectangular-section ring
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000000933 – 003
M020124/02E 2009-02 © MTU

Piston – Check
Item Findings Task
Make sure that oil chamber and oil Not clean Clean
bores are particularly clean.
Check piston with fluorescent Signs of cracks Replace piston.

penetrant.
Check piston for wear • Contact erosion at piston edge Replace piston.
and valve clearance pockets
• Large area of polishing wear
on piston skirt (appears dull)
• Concentrated occurrence of
scoring
• Pitting
Measure piston pin boss. Values Values exceeded Replace piston.

(→ Page 1191)
Check sliding surface of bronze • Stress marks Replace piston.
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bush for stress marks and scoring. • Scores
visible
Check groove width with gauge Values exceeded. Replace piston.

blocks. If no gauge block is
available, alternatively a new piston
ring can be inserted in the groove
and the axial play checked with a
feeler gauge. Values (→ Page 1191)
Check piston pin with magnetic Signs of cracks Replace piston pin.
crack-testing method for cracks.
Check condition of piston. • Traces of wear Replace piston pin.

• Scores
• Impact points
visible
Measure outer piston pin diameter Values exceeded. Replace piston pin.
with C-frame micrometer. Values
(→ Page 1191)
Check piston rings. • Piston ring with burring, Replace

chipping or sharp edges
• If chrome layer has signs
of scoring, cracks or heat
discoloration.
TIM ID: 0000000933 – 003
M020124/02E 2009-02 © MTU

Piston rings – Check

1. Place piston ring (1) in ring gauge (3) to measure
piston ring end clearance. Ensure that piston ring
fits evenly in ring gauge.
2. Check ring end clearance with feeler gauge (2).
3. If values are exceeded (→ Page 1191), replace
piston rings. Replace piston rings only in sets.
4. After installation of new piston rings, replace
cylinder liners (→ Page 1034).
cardiagn.com
TIM ID: 0000000933 – 003
M020124/02E 2009-02 © MTU

9.3.32 Piston – Tolerances
Piston bearing
cardiagn.com
No. Designation Stage Tol. Deviation Clearance Interference Wear limit
size
Basic
size
1 Bush inner 68.000 +0.070 +0.080 0.070 0.085 Clearance max.

dia. 0.090
Piston pin 68.000 –0.005 0

outer dia.
2 Bush inner 68.000 +0.012 +0.022 0,012 0,027 Clearance max.

dia. 0.025
Piston pin 68,000 –0,005 0

outer dia.
3 MTU part number and stage stamped on

TIM ID: 0000004138 – 002
M020124/02E 2009-02 © MTU

Piston rings
cardiagn.com
tion size
Basic
size

width 0.300
Rectan- 4,000 –0,035 0

gular-sec-
tion ring
2 Groove 4,000 0,080 0,100 0,080 0,135 Clearance max.

width 0.200
Taper- 4,000 –0,035 0

face com-
pression
ring

width 0.200
Oil control 5,000 –0,035 0

TIM ID: 0000004138 – 002
ring
M020124/02E 2009-02 © MTU


tion size
Basic
size
4 Joint clearance Clearance max.
Rectan- 0,400 0,700 0,900

gular-sec-
tion ring
Taper- 1,000 1,300 1,500

face com-
pression
ring
Oil control 0,450 0,800 1,000

ring
Measure joint clearance in ring gauge 165.000 H6.
cardiagn.com
TIM ID: 0000004138 – 002
M020124/02E 2009-02 © MTU

Piston clearance in cylinder liner
cardiagn.com
Basic size limit
1 Cylinder liner 165.000 H7 0 +0,040 0,184 0,246

dia.
Piston skirt 164,805 –0,011 +0,011

dia.
2 Cylinder liner 165.000 H7 0 +0,040 0,270 0,330

dia.
Piston skirt 164.720 –0.010 +0.010

dia.
3 Cylinder liner 165.000 H7 0 +0.040 0.400 0.480

dia.
Piston crown 164.580 –0.020 +0.020

dia.
4 Cylinder liner 165.000 H7 0 +0.040 0.455 0.495

dia.
TIM ID: 0000004138 – 002
Piston crown 164.525 –0.020 +0.020

dia.
5 Scraper ring 164.000 H8 0 +0.063 0.585 0.698

dia.
Piston crown 163.390 –0.025 +0.025

dia.
M020124/02E 2009-02 © MTU


Basic size limit
Dimensions 1 to 5 measured vertically in relation to pin axis.
6 Scraper ring 164.000 H8 0 +0.063 0.708 0.821

dia.
Piston crown 163.267 –0.025 +0.025

dia.
7 Piston skirt round falling oval

Skirt graphite-coated with two positions at 1 and 2 respectively free of graphite for measuring the diameter.
cardiagn.com
TIM ID: 0000004138 – 002
M020124/02E 2009-02 © MTU

Piston crown mounting
cardiagn.com
No. Designation Stage Tol. Deviation Clearance Interference Wear
size limit
Basic
upper max. min. max.
size lower min.
1 Screw length 49.000 –0.100 +0.100 max.

removed length
49.800
50.000 –0.100 +0.100 max.

length
50.800
TIM ID: 0000004138 – 002
M020124/02E 2009-02 © MTU

9.3.33 Conrod – Disassembly
Spare parts

Conrod
Conrod – Disassembly
1. Disassembly of conrod is not planned.
2. The conrod is an exchange component (Reman) and is available via the normal exchange procedure.
cardiagn.com
TIM ID: 0000000959 – 002
M020124/02E 2009-02 © MTU

9.3.34 Conrod – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Conrod – Cleaning
2. Clean conrod oil bore with hole brush.
3. Use a brass brush to clean meshing on conrod and conrod bearing cap mating faces.
TIM ID: 0000000953 – 004
M020124/02E 2009-02 © MTU

9.3.35 Conrod – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Bore gauge, 100-160 mm Y20091482 1
Material

cardiagn.com
Spare parts

Conrod
Conrod screw
Compressed air.
Risk of injury!
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Conrod – Check
Item Findings Task
Check conrod main bore for blue Blue discoloration Replace conrod.
discoloration.
Check conrod bushing for scores, Damaged • Corrective work

contamination, stress marks and • To be carried out only in
heat discoloration marks. workshops authorized by MTU.
Replace conrod bush.
Check conrod, conrod bearing cap Signs of cracks Replace

and conrod bearing screws for
cracks using magnetic crack-testing
method.
Check threads of conrod and conrod Damaged • Replace conrod.

screw for damage. • Replace conrod screw.
Check conrod screw length. Values Value exceeded Replace

(→ Page 1206)
cardiagn.com
Check basic bore for stress marks • Stress marks • Corrective work
and scores. • Scores • Replace
visible
Inspect meshing for damage and Damaged Replace

check wear pattern with engineer’s
blue.
Measuring conrod basic bore

1. Assemble conrod (→ Page 1210).
2. Before measuring, rub down basic bore (2) with
emery cloth.
3. Adjust bore gauge (1) and measure main conrod
bore (→ Page 1206).
4. If values are exceeded, replace conrod.
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Measuring conrod main bore with bearing shells

1. Coat sliding surfaces of bearing shells with
engine oil.
2. Measure conrod bearing bore. Values
(→ Page 1206).
3. Enter measured values in data sheet.
4. Replace bearing shells if limit values are fallen
short of or exceeded.
5. Remove conrod screws, conrod cap and bearing
shells.
Measuring conrod bush from piston pin end
cardiagn.com
1. Set bore gauge (1) to zero dimension of conrod
bushing bore and measure conrod bush bore (2).
2. Values exceeded: Replace conrod bush only in
Checking conrod bush axial fit

1. Use test mandrel (1) and hydraulic press to
check conrod bush axial fit. Required test force F
(→ Page 1206).
2. If test force is not reached, replace conrod.
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Checking conrod bore axial parallelism and twist
1 Dial gauge for axial parallelism

2 Test mandrel, small conrod bore
cardiagn.com
3 Dial gauge for conrod twist
4 Conrod
5 Test mandrel, large conrod bore
6 V-block
7 Base plate
8 Resilient stop
9 Adjustable dial gauge holder
1. Before inspection, install conrod bearing cap and

tighten conrod bearing screws.
2. Insert test mandrel (2) in large conrod bore so that
and narrow fit faces conrod bearing cap.
3. Clamp test mandrel (2) firmly with locking screw,
ensuring that test mandrel (2) does not tilt.
4. Insert test mandrel (1) in small conrod bore so that
and narrow fit faces oil bores of small conrod bore.
5. Clamp test mandrel (1) with locking screw.
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Checking axial parallelism

(4) of testing device.
2. Place test mandrel (2) on spring-mounted stop (5).
3. Adjust the rigid stop of adjustable stop so that
axle of test mandrel (2) is approx. 2.0 mm below
dial gauge pointer (1).
4. Adjust dial gauges so that their readings indicate
approx. 2 mm preload at highest point on test
mandrel axis, and set to zero.
5. Turn conrod through 180° and carefully place in
testing device.
6. Move test mandrel (2) through dial gauge pointers
at highest point on mandrel axis.
7. Determine and record deviations from zero on dial
gauges.
Checking axial twist
cardiagn.com
1. Set both dial gauges (1) for axial twist with setting
gauge (2) via dial gauge pointer to zero.
2. Remove setting gauge (2) from testing device (3).

(3) of testing device. Fixed support of adjustable
stop is set so that dial gauge pointer travel is
approx. 2 mm.
4. Press conrod at small conrod bore on fixed
support.
5. Read off and note values on dial gauges (1).
TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Calculating axial parallelism

Note: The testing device is set for measuring
axial parallelism at 200 mm intervals.
1. In order to obtain the correct value to 100 mm

clearance (→ Page 1206), calculate recorded
value on dial gauges as shown in the following
example.
cardiagn.com
Description Value
Left dial gauge A = –0.05 mm
Right dial gauge B = +0.03 mm
Result = 0.08 mm
Result: Axial parallelism: 0.08 mm : 4 = 0.02 mm

TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

Calculating axial twist

1. To determine axial twist of conrod bores, calculate
value measured at 100 mm intervals as shown in
example.
cardiagn.com
Description Value
Left dial gauge A1 = –0.06 mm
Right dial gauge A2 = +0.04 mm
Difference = 0.10 mm
Result: Axial twist A = 0.10 mm : 2 = 0.05 mm

TIM ID: 0000000956 – 005
M020124/02E 2009-02 © MTU

9.3.36 Conrod – Tolerances
Conrod bearings
cardiagn.com
Basic
size
1 Conrod bore 126.000 0 +0.025

H6
2 Conrod bearing 0-0 117.082 0 +0.048 0.082 0.152

bore
0-3 116.482
Crankpin Ø 0-0 117.000 h6 –0.022 0
0-1 116.800 h6
0-2 116.600 h6
0-3 116.400 h6
TIM ID: 0000004157 – 003
3 Crankpin length 97.500 −0.100 +0.100 0.200 0.600
Conrod width 48.600 −0.100 0
M020124/02E 2009-02 © MTU

Basic
size
4 Expanding 0-0 126.400 0 +1.000

dimension
lower part
0-3 126.400
Conrod screw length

Basic
Deviation
lower upper
Clearance
min. max.
Interference
min. max.
Wear limit cardiagn.com
size
1 Screw length 103.000 −0.400 +0.200 104.500

removed
TIM ID: 0000004157 – 003
M020124/02E 2009-02 © MTU

Conrod bore parallelism
cardiagn.com
Basic
size
1 Conrod length 354.000 −0.100 +0.100

8/12/16V
1 Conrod length 364.000 −0.100 +0.100

20V
2 Axial parallelism 0.070 over a distance of 100 mm Inclination

Inclination max. 0.100
3 Axial parallelism 0.250 over a distance of 100 mm Offset

Twist max. 0.350
Conrod weight 9.530 kg -0.060 +0.060

8/12/16V kg kg
Conrod weight 20V 9.580 kg -0.060 +0.060

kg kg
TIM ID: 0000004157 – 003
M020124/02E 2009-02 © MTU

Small conrod bore
cardiagn.com
Basic
size
1 Conrod bore 0 75.000 H6 0 +0.019 0.101 +0.139
1 75.200 H6
2 75.400 H6
Conrod bushing 0 75.000 v6 +0.120 +0.139

outer dia.
1 75.200 v6
2 75.400 v6
2 Conrod bushing 68.000 +0.070 +0.080

inner dia.
F Axial test force for 8/12/16V conrod: 17,000 N (tested conrod bushings are marked "X")
F Axial test force for 20V conrod: 30,000 N (tested conrod bushings are marked "X")
A Edges rounded
TIM ID: 0000004157 – 003
M020124/02E 2009-02 © MTU

9.3.37 Conrod – Assembly
Special tools

Socket, SW 22 – Conrod screws F30378352 1
Material

Engine oil
Compressed air.
cardiagn.com
Risk of injury!

Preparing conrod
1. Blow out mating faces (arrows) on conrod and
conrod bearing cap with compressed air and clean.
conrod bearing cap.
3. Before installing bearing shells, compare repair
stage data on conrod and on crankshaft data
sheet.
4. Mark bearing shells according to cylinder number
on end face.
TIM ID: 0000000962 – 006
M020124/02E 2009-02 © MTU

5. Insert lower conrod bearing shell (2) with securing

lug (arrow) in groove of conrod bearing cap (1).
6. Clamp conrod in assembly trolley or in bench
cardiagn.com
vise with aluminum jaws with mating face in
horizontal position.
7. Insert upper conrod bearing shell (2) with securing
lug (arrow) in groove of conrod (1).
onto conrod.
9. Coat threads of conrod bearing screws and screw
head seating surfaces with engine oil.
TIM ID: 0000000962 – 006
M020124/02E 2009-02 © MTU

Note: Thread must not be recut.
10. Carefully insert conrod bearing screw into bore in

conrod bearing cap by hand until initial contact
with thread flanks is established, then turn first
three turns without a tool.
11. Install conrod bearing screws until screw heads
make contact and use socket wrench to tighten
firmly by hand. Ensure that conrod and conrod cap
serrations is closed at short and long conrod arms.
12. Use torque wrench (1) to tighten conrod bearing
screws to specified tightening torque . Tightening
sequence:
12.1.Short arm
12.2.Long arm
cardiagn.com
Conrod screw M20 x 1.5 Preload torque Engine oil 240 Nm +20 Nm
Conrod screw M20 x 1.5 Residual angle of rotation 90° +10°
Conrod screw M20 x 1.5 Control torque 450 Nm +20 Nm
TIM ID: 0000000962 – 006
M020124/02E 2009-02 © MTU

9.3.38 Piston – Assembly
Special tools

Heavy object.
Risk of crushing!

Risk of injury!
Installing piston rings

1. Turn coiled spring expander (2) in oil control ring
(1) in order to offset ring spring butting face (arrow)
cardiagn.com
to oil control ring butt by 180°.
2. Prepare piston rings as per installation sequence.

Note that new piston rings must be replaced in
sets.
3. After replacing piston rings, replace cylinder
liners (→ Page 1034).
TIM ID: 0000000945 – 005
1 Rectangular-section ring
2 Taper-face compression ring
3 Oil control ring
M020124/02E 2009-02 © MTU

4. Stretch piston rings with pliers so that they can be

fitted over the piston.
5. Insert piston rings in sequence from bottom
upwards (oil control ring first) in the annular
grooves on the piston so that the TOP marking on
the piston rings faces the piston crown.
6. Check that piston rings move freely in their
grooves.
7. Wipe down piston pin, conrod bushing and piston
cardiagn.com
pin bore with chamois leather and coat with
engine oil.
8. Insert conrod (1) according to markings into
relevant piston (2) in such a way that the shorter
end (A) of the angle-split conrod faces piston
cooling oil bore (B).
9. Insert corresponding piston pin (2) in piston and

conrod (1) until it makes contact with installed
snap ring.
TIM ID: 0000000945 – 005
M020124/02E 2009-02 © MTU

10. Use snap ring pliers to insert second snap ring.

11. Ensure snap ring is perfectly seated and correctly
positioned (arrow).
cardiagn.com
TIM ID: 0000000945 – 005
M020124/02E 2009-02 © MTU

9.3.39 Piston and conrod – Installation
Special tools

Lifting tool for piston T80091025 1
Piston/conrod assembly sleeves for carbon scraper ring F6557121 1
Barring device for graduated disc F6555791 1
Pointer for barring device F6555792 1
Measuring equipment for TDC measurement in cylinder head Y4341919 1
cardiagn.com
Socket A/F 22 – conrod screws F30378352 1
Material

Engine oil
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
• Check components for special cleanness. TIM ID: 0000022817 – 003
M020124/02E 2009-02 © MTU

Preparing crankcase
1. Move crankpin of respective cylinder on right
engine side to 40° before TDC and on left engine
side to 40° after TDC.
2. Before installing piston with conrod, fit sliding
block (2) on the conrod (1) to be installed.
3. Wipe crankpin and running surface of cylinder liner
with chamois leather and spray with engine oil.
Preparing piston for installation
cardiagn.com
1. Spray piston and piston rings with engine oil.
2. Ensure that piston ring joints (arrowed) are evenly
arranged at 120° around piston circumference.
3. Center piston rings and oil control ring in grooves.
Preparing conrod bearing for installation

1. Blow joint faces (arrows) on conrod bearing
cap and conrod with compressed air and check
cleanness.
conrod bearing cap with chamois leather.
TIM ID: 0000022817 – 003
M020124/02E 2009-02 © MTU

3. Make sure that the lower conrod bearing shell (2)

with locking lug (arrow) is properly seated in the
conrod bearing groove (1).
4. Coat sliding surfaces of conrod bearing shells
with engine oil.
Note: In order to guide the conrod and avoid damage
cardiagn.com
to the oil spray nozzle, piston installation must
be carried out by two people. Install piston with
carbon scraper ring removed.
Installing piston and conrod in cylinder liner

1. Install lifting tool (1) for piston.
2. Place piston assembly sleeve (2) with chamfered
side up on cylinder liner.
3. Oil assembly sleeve and cylinder liner inside.
4. Install piston in cylinder liner making sure that the
short arm of the conrod points outwards to the
air intake side. Turn piston slightly so that the oil
spray nozzle is not damaged.
onto conrod.
Installing conrod bearing cap

1. Coat thread and screw-head mating face with engine oil.
2. Insert conrod bearing screws into screw bore on conrod cap by hand, then turn first three rotations without
a tool.
3. Fit conrod bearing screws up to screw head and tighten firmly by hand using socket wrench, ensuring that
conrod serrations are closed.
TIM ID: 0000022817 – 003
4. Pretighten conrod screws with torque wrench to specified tightening torque (→ Page 980).
5. Check conrod axial movement.
6. Tighten conrod screws with torque wrench to specified tightening torque (→ Page 980).
7. Check conrod axial clearance.
8. Remove lifting tool and assembly sleeve for piston with conrod and take off.
9. Turn crankshaft and ensure that there is ease of movement between oil spray nozzle, piston and conrod.
10. Remove lifting tool after installation.
M020124/02E 2009-02 © MTU

Checking conrod axial clearance

1. Use feeler gauge to check distance between crankshaft web and conrod and between conrod and conrod,
pressed towards each other.
2. If axial clearance is below the minimum of 0.20 mm or above the maximum of 0.60 mm, measured pressed at
three levels, readjust clearance.
3. Release conrod bearing screws and compensate axial clearance.
4. Using a torque wrench, first pretighten conrod cap screw on short conrod arm and then on long conrod
arm to specified tightening torque (→ Page 980).
5. Re-check axial clearance.
6. Tighten conrod bearing screws with torque wrench to prescribed tightening torque (→ Page 980).

1. Coat edge of cylinder liner and carbon scraper
ring with engine oil.
2. Insert carbon scraper ring.
cardiagn.com
TIM ID: 0000022817 – 003
M020124/02E 2009-02 © MTU

9.4 Cylinder Head
9.4.1 Cylinder head and attachments – Overview
Cylinder head and attachments – Overview
cardiagn.com
1 Cylinder head 6 Spring retainer
2 Inlet valve 7 Valve collet
3 Exhaust valve 8 Valve rotator
4 Valve spring, inner 10 Plug screw
5 Valve spring, outer 11 Sealing ring
TIM ID: 0000000969 – 002
M020124/02E 2009-02 © MTU

cardiagn.com
2 Valve-seat insert, inlet * 6 Valve guide 11 Cylinder head
3 Valve-seat insert, exhaust * 7 Plug * Only on cylinder heads of
4 O-ring 8 Plug corresponding design
5 Sleeve 9 Plug
TIM ID: 0000000969 – 002
M020124/02E 2009-02 © MTU

cardiagn.com
1 Sealing ring 3 Cylinder head screw 5 Cylinder head screw
2 Gasket 4 Thrust washer
TIM ID: 0000000969 – 002
M020124/02E 2009-02 © MTU

9.4.2 Valve-seat turning machine for cylinder head
Working principle of valve-seat turning machine
cardiagn.com
The valve-seat turning machine is an inside turning device. While the cutter (3) rotates around the valve-seat
(5), a feed gear mechanism ensures a continuous outward feed motion (1). The feed motion under the proper
valve-seat angle (4) is defined by an inclined slideway in the exchangeable adapter head.
TIM ID: 0000004274 – 002
M020124/02E 2009-02 © MTU

Installing the solid pilot
cardiagn.com
Precondition:
Valve guide is installed and machined to finished dimension.
Valve guide was cleaned.
Cylinder head is securely clamped and valve guide accessible from both sides.
Mounting the supporting spider

To achieve maximum accuracy, the pilot must be supported by the supporting spider (7) below the valve seat. Slide
the supporting spider (7) over the pilot shaft to such position that the spring-loaded spider elements (1) rest just
below the valve seat level when the pilot is installed in the valve guide (4) and tighten the clamping screw (6).
Inserting the pilot into the valve guide
Remove clamping nut (3) from pilot and insert the threaded end of the pilot into the valve guide (4), until
the tapered portion (5) bears against the conical seating of the valve guide (4). The spring-loaded elements
TIM ID: 0000004274 – 002
(1) of the spider (7) will bear against the exhaust/inlet canal below the valve seat.
Locking the pilot
Screw clamping nut (3) onto the pilot and tighten with moderate force. Tighten the screws (6) on
top of the spider to lock the spring-loaded elements (1) of the spider (7). Apply standard machine
oil to the top and around the periphery of the pilot shaft.
M020124/02E 2009-02 © MTU

Setting up valve turning machine
cardiagn.com
Mounting the cutter
Fit the appropriate tool holder of the cutter (8) with an indexable insert and attach to the tool slide (7).
Placing the valve-turning machine on the pilot
Take care that the cutter (8) does not bump against the cylinder head.
Slide the valve-seat cutting machine over the pilot (10) until either the depth stop (3) rests upon
the pilot (10) or the cutter (8) contacts the cylinder head.
Aligning the cutting edge with the valve-seat center
Turn rapid tool adjuster (11) to position cutting edge of cutter over the valve-seat center (9). Hold
the machine with one hand. Loosen screw (4) of depth stop (3) and allow machine to slide down
until the cutting edge contacts the valve seat (9) lightly. Push depth stop (3) slightly downward
against the pilot (10) and then tighten depth stop locking screw (4).
Connecting the machine to power supply
Insert the round plug of the outlet cable (6) of the power supply unit (5) into the corresponding socket
(1) on the driving assembly (2) and allow the securing latch to engage.
TIM ID: 0000004274 – 002
M020124/02E 2009-02 © MTU

Valve seat turning
cardiagn.com
Positioning the cutter at the inner valve-seat edge
Slightly lift machine with one hand and then turn rapid tool adapter (11) with the other hand until the
cutting edge is just clear of the inner edge of the valve seat (10).
Setting cutting depth
To set the depth of cut, turn depth feed (3) counterclockwise. One notch of the depth-feed scale (4) corresponds
to a depth feed of 0.025 mm. As the valve seat (10) usually shows unequal wear, the depth of the first turning
cycle must be selected (max. 0.2 mm) to ensure that the entire valve-seat surface is undercut.
If the cutting edge is just scraping along the surface instead of undercutting the hard surface zone,
there is a risk of premature wear and chipping of the cutting edge.
Lubricating the valve seat
Apply a few drops of metalworking lubricant on hard valve-seat surfaces before turning.
Valve seat turning
Make sure that the pivoted lever (8) is engaged in the groove of the feed actuator (12). Select proper speed by
shifting the switch (6) at the power supply unit (5). Speed can be increased by changing over from 30 VDC to 42 VDC.
TIM ID: 0000004274 – 002
Hold driving unit (2) with both hands at the motors (1) and press pushbutton switch (7) to start the cutting pass.
Release the pushbutton switch (7) as soon as the cutter has been traversed beyond the top edge of the valve seat (10).
Repeating the cutting pass
Repeat steps with a cutting depth between 0.05 mm and 0.1 mm until the valve seat surface (10) is plane all around.
To ensure a smooth valve-seat surface (10) finish, proceed with a final pass at high speed with 0.025 mm cutting depth.
M020124/02E 2009-02 © MTU

Replacing the adapter head
cardiagn.com
Removing the adapter head
Unscrew the two screws (1) from the adapter head (2).
Turn adapter head (2) in the direction of the arrow until the back of the toothed rack (4) is no longer engaged with
the pinion (4) in the gear housing (6). Now the adapter head can be withdrawn off the gear housing (6).
Mounting the adapter head
Place adapter head (2) onto gear housing (6) so that the pinion (5) projecting from the gear housing (6)
is seated in the corresponding bore of the adapter head (2).
The adapter head (2) must be seated flush with the gear housing (6).
Screw the two screws (1) loosely into the gear housing so that the adapter head (2) can still be moved
to adjust proper clearance between toothed rack (4) and pinion.
Adjust the adapter head so that the gap between the toothed side of the rack (4) and the opposite side of
the recess (3) is approximately 0.3 mm to 0.5 mm. Tighten both screws (1).
Turn the rapid tool adjuster to move the tool slide back and forth. If tool slide does not
move freely, readjust the adapter head.
TIM ID: 0000004274 – 002
M020124/02E 2009-02 © MTU

9.4.3 Cylinder head – Removal
Preconditions
Special tools

Plug B80144872 1
Installation/removal tool for plugs F30378956 1

Risk of injury!
cardiagn.com
Heavy object.
Risk of crushing!
TIM ID: 0000005023 – 010
M020124/02E 2009-02 © MTU

Cylinder head – Removal

1. Release hex bolts (1) on the cylinder head with
power amplifier (2) evenly and unscrew.
2. Screw plug (2) on to installation/removal tool and
cardiagn.com
lock it by turning the handle (1).
3. Screw plugs with installation/removal tool (1) into

oil supply line (arrow) in crankcase and spread.
4. Ensure that the plug is firmly anchored.
5. Release installation/removal tool (1) and remove.
TIM ID: 0000005023 – 010
M020124/02E 2009-02 © MTU

6. Suspend cylinder head (2) with support bracket (1)

on crane with rope lightly tensioned.
7. Lift off cylinder head (2) and lower onto a firm
surface.
8. Remove cylinder head gasket from mating face
of crankcase.
9. Remove plug from oil supply bore and close
with protective plug.
10. Use a screwdriver to remove sealing ring from
cardiagn.com
lower side of cylinder head.
TIM ID: 0000005023 – 010
M020124/02E 2009-02 © MTU

9.4.4 Cylinder head – Disassembly
Special tools

Socket F30377634 1
Heavy object.
Risk of crushing!

Risk of injury!

Risk of injury!
WARNING
cardiagn.com
• Only use specified tool and equipment.
Removing valves
1. Place cylinder head on base plate (3).
2. Mount valve-spring compressor (2).
with valve-spring compressor (2) until the valve
collets (4) can be removed.
4. Remove valve collets (4) with a magnet.
5. Release valve springs and remove valve-spring
compressor (2).
TIM ID: 0000000987 – 005
M020124/02E 2009-02 © MTU

6. Remove valve spring retainer, valve springs

and valve rotators.
8. Mark exhaust and inlet valves so that they can be
reinstalled in their original positions.
9. Place valves in storage rack (1).
cardiagn.com
Removing sleeve
1. Secure cylinder head.
2. Using socket, remove sleeve from cylinder head.
3. Remove O-ring from sleeve.
TIM ID: 0000000987 – 005
M020124/02E 2009-02 © MTU

9.4.5 Cylinder head – Cleaning
Material

Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!
cardiagn.com
Risk of injury!


Cleaning the cylinder head

TIM ID: 0000000979 – 006
M020124/02E 2009-02 © MTU

9.4.6 Cylinder head – Check
Special tools

Check gauge for inlet valve seat Y4340442 1
Check gauge for exhaust valve seat Y4340443 1
Removal tool Y4343688 1
cardiagn.com
Material

Corrosion inhibitor
Spare parts

Cylinder head
Sealing ring
Gasket
Thrust washer
Valve guides
Valves
Sleeve
Valve springs
Sliding pin
Valve rotator
Spring retainer
TIM ID: 0000004276 – 008
Valve collet
Compressed air.
Risk of injury!
M020124/02E 2009-02 © MTU

Heavy object.
Risk of crushing!

Cylinder head check
Item Findings Task
Measure cylinder head height. Minimum height not reached Replace cylinder head.
Check cylinder head mating face Damaged • Recondition

(combustion chamber side) for • Replace cylinder head.
evenness and damage.
Check mating face of sleeve in • Scores • Recondition

cylinder head for scores and wear. • signs of wear • Replace cylinder head.
cardiagn.com
visible.
Measure valve guides with alignment Not dimensionally accurate Replace valve guides.
plug gauge. Values (→ Page 1237)
Check valve springs for damage. • Damaged Replace valve springs

Check spring power and • Values below specification
length of valve springs. Values
(→ Page 1237)
Check thread for ease of movement. Sluggish • Recondition

• Replace cylinder head.
Check valve seats on cylinder head Pitting or wear • Recondition: (→ Page 1223)
for pitting and wear. • Replace cylinder head.
Check cylinder head screw threads, Damaged Replace

screw head mating faces and thrust
washer for damage.
Measure shaft length of the cylinder Values exceeded (→ Page 1237). Replace
head screws with depth gauge.
Check valves for damage. • Chrome layer damaged Replace

Check valves for concentricity and • Valve keyways damaged or
dimensional accuracy. Values burnt
(→ Page 1237) • Out-of-round
Check spring retainer and valve • Scores Replace

collet for scores and wear. • signs of wear
visible.
Replace valve guides and valve rotators during extended component repair.
TIM ID: 0000004276 – 008
Only for cylinder heads with valve bridge guides.
Check sliding pin and valve bridge • Signs of wear Replace sliding pin.
bore for wear and damage. Values • Damage visible
(→ Page 1237) • Not dimensionally accurate
M020124/02E 2009-02 © MTU

Checking cylinder head for leaks

Note: Install sleeve prior to leak test (→ Page 1257).

2. Install pressure testing device.
3. Place cylinder head in a water bath heated to 80 °C until cylinder head has warmed up.
4. Pressure-test cylinder head with 0.5 bar compressed air.
5. Pressure must be maintained with cylinder head in water bath for at least 30 minutes. No air bubbles must
emerge.
6. Remove hydraulic pressure testing device.
7. Replace leaking sealing cover (→ Page 1255).
cardiagn.com
TIM ID: 0000004276 – 008
M020124/02E 2009-02 © MTU

9.4.7 Cylinder head – Tolerances
Cylinder head tolerances for heads with valve seat inserts and
exhaust emission certification
Inlet and exhaust valve guides
cardiagn.com
Basic
size
1 Cylinder head 0 19.000 H7 0 +0.021 +0.007 +0.041

bore
1 19.100 H7
2 19.300 H7
Valve guide 0 19.000 r6 +0.028 +0.041

external
diameter 1 19.100r6
2 19.300 r6
2 Valve guide bore 11.000 H7 0 +0.018 0.055 0.093

installed
TIM ID: 0000004159 – 006
Valve stem 10.935 −0.010 +0.010

diameter
M020124/02E 2009-02 © MTU

Basic
size
2 Finished valve 11.000 H9 0 +0.043 0.055 0.118

guide bore
installed
Valve stem 10.935 −0.010 +0.010

diameter
Valve clearance
cardiagn.com
Basic
size
1 Valve protrusion +0.100 up to max.

Exhaust 1.000
with valve seat
ring
2 Valve clearance 0.000 up to max.

or protrusion 1.100
TIM ID: 0000004159 – 006
Inlet
M020124/02E 2009-02 © MTU

Inlet and exhaust valve seat ring
cardiagn.com
Basic
size
1 Valve seat ring 57.000 H6 0 +0.019

bore, exhaust
2 Valve-seat insert 11.200 −0.050 +0.050

- depth
3 Valve-seat insert 58.000 H6 0 +0.019

bore, inlet
• If a valve-seat insert is replaced before reaching the reconditioning depth of 1.100 mm, it must be machined
to the depth of the contour to avoid that the valve-seat insert protrudes into the combustion chamber.
• Max. corrective machining or equalizing of valve-seat inserts by 0.300 mm in depth, without machining the
contour and the radius.
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Inlet and exhaust valve-seat insert
cardiagn.com
Basic
size
1 Plug gauge 73.200 0 0

diameter
2 Plug gauge 87.130 0 0

diameter
3 Valve seat 4.800 −0.200 +0.200 up to min.

surface 3.700
Reference
dimension
Plug gauge
4 Cylinder head 13.800 0 +0.100

depth
Combustion
chamber sealing
ring surface
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Inlet valve elliptical chamfer
cardiagn.com
Basic
size
1 Distance to valve 2.700 −0.150 +0.150

seat center
2 Chamfer −0.300
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Exhaust valve
cardiagn.com
Basic
size
1 Valve head 56.000 −0.200 +0.200

external
diameter
2 Reference 54.000
dimension
with ring gauge
for
valve seat
diameter

3.480

dimension 3.000
without ring
gauge for
valve seat height
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Inlet valve
cardiagn.com
Basic
size
1 Valve head 57.000 −0.200 +0.200

external
diameter
2 Reference 54.000
dimension
with ring gauge
for
valve seat
diameter

3.350

dimension 3.000
without ring
gauge for
valve seat height
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Valve springs, outer
cardiagn.com
Basic
size

released

compressed

when mod. valve
rotator is used

at compressed
spring length

compressed

when mod. valve
rotator is used
TIM ID: 0000004159 – 006

spring length force
pos. 3 min. 897.000 N

max. 47.700
M020124/02E 2009-02 © MTU

Basic
size
6 Wire dia. 5.300
Valve springs, inner

Basic
size
Deviation
lower upper
Clearance
min. max.
Interference
min. max.
Wear limit
cardiagn.com
released

compressed
TIM ID: 0000004159 – 006

when mod. valve
rotator is used

at compressed
spring length
M020124/02E 2009-02 © MTU

Basic
size

compressed

when mod. valve
rotator is used

spring length force
pos. 3 min. 420.000 N

max. 42.500
cardiagn.com
6 Wire dia. 3.600
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

Cylinder head – mating surface – protective sleeve
cardiagn.com
Basic
size
1 Cylinder head 184.000 −0.100 +0.100 183.600

height
2 Protective sleeve 124.000 0 +0.200

mating surface
3 Protective sleeve 44.200 0 +0.100 0.100 0.300

bore
Protective sleeve 44.100 −0.100 0

external
diameter
4 Cylinder head M 24 x 1.5

and protective
sleeve thread
• Rework only until a satisfactory mating surface has been achieved.
• When reconditioning cylinder head height, reestablish the fire side contour of 13.800 +0.100.
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

cardiagn.com
Basic
size
1 Cylinder head 333.000 −0.300 +0.300

screw with
engine lifting eye
2 Cylinder head 283.000 −0.300 +0.300

screw
TIM ID: 0000004159 – 006
M020124/02E 2009-02 © MTU

9.4.8 Cylinder head – Repair
Special tools

Tool kit without elliptical chamfer reconditioning F6783749 1
Tool kit (accessory equipment) for elliptical chamfer reconditioning F6783751 1
Tool kit for valve-seat insert removal F6784421 1
Indexable insert F30450433 1
Mounting plate for valve guide installation F6554300 1
Valve guide extractor F30450348 1
Valve guide mandrel F6781747 1
Reamer, Ø19.00 mm for stage 0 cylinder head bore F30091631 1
Reamer, Ø19.10 mm for stage I cylinder head bore F30047578 1
Reamer, Ø19.30 mm for stage II cylinder head bore F30028269 1
cardiagn.com
Valve seat contour restoring tool for exhaust valve with valve-seat insert F30450631 1
Valve seat contour restoring tool for inlet valve with elliptical chamfer and F30450632 1
with/without valve-seat insert
Turning handle for valve seat contour restoring tool 8205890451/00 1
Exhaust valve gauge Y4340443 1
Inlet valve gauge Y4340442 1
Valve seat test device Y4341935 1
Countersink reamer tool F30451554 1
Inserting mandrel for valve-seat insert, inlet F30450751 1
Inserting mandrel for valve-seat insert, exhaust F30450750 1
Material

Liquid nitrogen
Corrosion inhibitor
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

Spare parts

Valve guide, inlet
Valve guide, exhaust

Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
cardiagn.com

Removing the valve-seat insert

2. Insert pilot into valve guide of cylinder head
(3) and secure.
3. Install head (2) and lathe tool on valve seat
lathe (1).
steady rest.
6. Machine valve-seat insert so that the seat insert
extractor can be installed.
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

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

insert to be removed (2).
9. Using seat insert extractor (1), remove valve-seat
insert (2).
10. Check bore of valve-seat insert (1) in cylinder
head. Values (→ Page 1237).
is exceeded.
Removing the valve guide
cardiagn.com
1. Place cylinder head on hydraulic press. Ensure
correct positioning of the cylinder head side.
2. Using the extractor and working from the
combustion side, press valve guide out of cylinder
head.
3. Check valve guide bore in cylinder head. Values
(→ Page 1237).
Result: If the value is exceeded, recondition
bore to next stage.
4. Secure cylinder head on boring mill.
5. Ream valve guide bore in cylinder head.
Installing the valve guide

1. Prepare water for water bath with corrosion
inhibitor.
2. Place cylinder head (4) in water bath heated to
80°C until cylinder head (4) has warmed up.
3. Chill valve guide (2) in liquid nitrogen for approx.
20 to 30 mins.
4. Position heated cylinder head (4) on assembly
jig (3).
5. Using mandrel (1), position chilled valve guide
(2) in bore of cylinder head (4) until the stop of
assembly jig (3) is reached.
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

Installing the valve-seat insert

2. Place cylinder head in water bath heated to 80 °C until cylinder head has warmed up.
3. Chill valve-seat insert in liquid nitrogen for approx. 20 to 30 mins.
4. Position heated cylinder head on suitable surface.
5. Using the inserting mandrel, install chilled valve-seat insert into the cylinder head bore until the stop is reached.
Machining the valve seat surface

2. Insert pilot (3) and support (2) into valve guide of
cylinder head (1) and secure.
cardiagn.com
3. Install suitable head (2) and lathe tool to valve
seat lathe (1).
steady rest.
Note: Note recondition dimension, required when
machining elliptical chamfer.
6. Only recondition valve seat surface until a

satisfactory surface has been established. Values
(→ Page 1237).
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

8. Recondition valve seat surface (2) with associated

valve seat contour restoring tool (1).
9. Clean cylinder head after machining.
Checking valve seat concentricity
cardiagn.com
1. Insert pilot into valve guide.
2. Mount clamp ring (2) over inserted pilot and
secure.
3. Mount the tester (1) on clamp ring.
4. Set preloaded feeler of tester on valve seat
center (arrowed).
5. Check concentricity of valve seat in relation to
valve guide, values (→ Page 1237).
Result: In event of deviation from test values,
recondition valve seat again.
6. Remove tester (1), clamp ring (2) and pilot.
Measuring valve seat depth

1. Adjust distance from plug gauge to ring gauge.
2. Set scale on dial gauge to zero.
3. Measure valve seat depth. Values (→ Page 1237).
is exceeded.
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

Regrinding valve seats

1. Mount valve (1) as directly as possible behind
valve head in valve grinder (2).
2. Set valve seat grinding angle on valve seat grinder.
3. Using low feed, grind valve seat only until a
satisfactory surface is achieved.
4. Measure height of outer valve seat edge as well as
valve seat width. Value (→ Page 1237).
Result: If the value is not reached, replace valve.
Reconditioning elliptical chamfer (if required)
cardiagn.com
1. Insert pilot (3) for elliptical chamfer (2) into valve
guide.
2. Mount tester (1) over inserted pilot (3) and secure.
3. Set preloaded tester pointer (1) to elliptical
chamfer (2).
4. Align pilot (3) and elliptical chamfer (2) using
tester (1).
5. Secure pilot (3).
6. Remove tester (1).
7. Install suitable head and lathe tool to valve seat
lathe.
8. Position valve seat lathe on pilot and install
steady rest.
9. Set up valve seat lathe (→ Page 1223).
Note: Use recondition dimension as for
machining valve seat surface.
10. Only recondition elliptical chamfer (2) until a

satisfactory surface has been achieved.
11. Check elliptical chamfer (2). Value (→ Page 1237).
is exceeded.
Reconditioning the protective sleeve mating face.

1. Install countersink reamer tool in bore for protective sleeve.
2. Recondition seating surface for protective sleeve with countersink reamer tool. Value (→ Page 1237).
TIM ID: 0000004367 – 008
M020124/02E 2009-02 © MTU

9.4.9 Cylinder head – Plug repair
Special tools

Mandrel, Ø 20 mm F30378617 1
Guide sleeve for mandrel F30377862 1
Mandrel, Ø 24 mm F30271842 1
Mandrel, Ø 30 mm F30377635 1
Material

cardiagn.com
Cleaner (Loctite 7063) 50594 1
Spare parts

Plug
Plug
Plug
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!

Risk of injury!

TIM ID: 0000004275 – 004
M020124/02E 2009-02 © MTU

Replacing plug
Note: Replace plug only if required.

2. Use pliers to withdraw end cover, taking care that
end cover does not fall into the bore.
3. Clean coolant chambers with cleaner
(Snow-White 11-0), then rinse with cleaner
(Hakupur 312).
4. Blow out coolant chambers with compressed air.
5. Clean mating surface of new plug and cylinder
head bore ensuring they are free of grease and dry.
6. Coat mating surface with screw locking compound.
7. Using a mandrel, knock plug into the cylinder
cardiagn.com
head bore until flush.
8. Check cylinder head for leaks (→ Page 1234).
TIM ID: 0000004275 – 004
M020124/02E 2009-02 © MTU

9.4.10 Cylinder head – Assembly
Special tools

Retainer 0015890321/00 1
Socket F30377634 1
Material
cardiagn.com
Engine oil
Spare parts

O-ring
Sealing ring

Risk of injury!
Heavy object.
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

Installing sleeve
1. Clean sealing surface (arrow).
2. Coat O-ring (2) with grease and insert in groove
of sleeve (1).
3. Clamp cylinder head firmly.
cardiagn.com
4. Clean sealing surface of cylinder head.
5. Use torque wrench to tighten prepared sleeve
to specified tightening torque .

Sleeve Tightening torque 60 Nm +6 Nm
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

Installing valves
2. Wipe valves with chamois leather and coat valve
stems with engine oil.
3. Insert valves in valve guides. Observe correct
valve arrangement. Markings are on the end
of the valve stems.
IN Inlet
EX Exhaust
4. The markings and installation positions of the
cardiagn.com
valves are located on the upper side of the
cylinder head.
IN 2 x inlet (1)
EX 2 x exhaust (2)
5. The marking is visible on the lower side of the

valve in the form of a countersink.
• Inlet (1) = Ø 20 mm
• Exhaust (2) = Ø max. 8 mm
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

6. Mount supporting plate for valve spring

compressor on cylinder head.
7. Set cylinder head upright.
8. Slide valve rotator on to valve guide.
9. Fit outer and inner valve springs.
10. Fit valve spring retainers.
11. Mount valve spring compressor (2).
cardiagn.com
with valve-spring compressor (2).
13. Insert valve collets (4) in spring retainer and center.
14. Make sure that lip of valve collet fits firmly in
groove at end of stem.
15. Release valve springs.
16. After installation of all valve collets, remove valve
spring compressor (2) and mounting plate (3).
17. Place cylinder head in installation position or on

its side.
18. Make sure valves move freely.
19. Using a plastic mallet, lightly tap the valve stem to
ensure that the valve collets contact the valve
stem.
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

Measuring valve clearance to cylinder head

1. Install dial gauge (2) on dial-gauge holder (1).
2. Set dial gauge (2) with preload on to plane face
of cylinder head (4).
4. Position dial-gauge stylus on valve head of
valves (3) and measure valve clearance to plane
surface.
5. If the reading is not within the tolerance
(→ Page 1237), check valve seat at cylinder
head and valve head.
cardiagn.com
TIM ID: 0000004273 – 008
M020124/02E 2009-02 © MTU

9.4.11 Cylinder head – Installation
Special tools

Installation/removal tool for seal plug F30378956 1
Seal plug B80144872 1
Tightening tool (power amplifier) F6553658 1
Measuring tool for angle of rotation Y20044010 1
cardiagn.com
Material

Engine oil
Spare parts

Sealing ring
Gasket

Risk of injury!
Heavy object.
Risk of crushing!
TIM ID: 0000000994 – 010

M020124/02E 2009-02 © MTU

Cylinder head – Installation

1. Insert adjusting mandrels (2) in crankcase upper
deck.
2. Fit gasket (1).
3. Ovalize sealing ring by tapping it lightly.
cardiagn.com
4. Insert sealing ring with groove on combustion
chamber side of cylinder head.
5. When installing sealing ring, ensure position

is correct:
• A = Cylinder head side
• B = Piston side
TIM ID: 0000000994 – 010
M020124/02E 2009-02 © MTU

6. Remove seal plug.

7. Attach cylinder head (2) with carrying bracket (1)
and rope to crane, ensuring that the rope is
8. Place cylinder head (2) onto crankcase.
9. Coat thread, shaft and mating surfaces on heads
cardiagn.com
of cylinder head screws (1) with engine oil.
10. Observe assignment of cylinder head screws (1)
(engine lifting eye). Install cylinder head screws (1)
with thrust washers manually in crankcase.
11. Fit alignment tool (2) on inlet channels of cylinder
heads and tighten.
12. Align cylinder heads.
TIM ID: 0000000994 – 010
M020124/02E 2009-02 © MTU

13. Use power amplifier and torque wrench to tighten

cylinder head screws to specified tightening torque
in accordance with the tightening sequence.
A Exhaust side
B Inlet side
cardiagn.com
Cylinder head screw M22 x 2 Preload torque Engine oil 25 Nm
Cylinder head screw M22 x 2 Residual torque 180 Nm +10 Nm
Cylinder head screw M22 x 2 Residual angle of rotation 180 ° +10 °
Cylinder head screw M22 x 2 Control torque 400 Nm

TIM ID: 0000000994 – 010
M020124/02E 2009-02 © MTU

9.5 Valve Gear
9.5.1 Valve gear – Overview
Valve gear – Overview
cardiagn.com
1 Camshaft gear 5 Camshaft 9 Nut
2 Swing follower shaft 6 Pushrod 10 Adjusting screw
3 Swing follower, inlet 7 Shaft 11 Rocker arm, exhaust
4 Swing follower, exhaust 8 Rocker arm, inlet 12 Rocker-shaft support TIM ID: 0000014949 – 002
M020124/02E 2009-02 © MTU

9.5.2 Camshaft overview
Overview of camshaft
cardiagn.com
2 Spring washer 6 Thrust bearing flange
3 Graduated disc 7 Dowel pin
4 Camshaft gear 8 Camshaft
TIM ID: 0000001007 – 001
M020124/02E 2009-02 © MTU

9.5.3 Camshaft – Removal
Preconditions
Special tools

Guide sleeve for assembly on free end F6780579 1
cardiagn.com
Centering sleeve for assembly on free end F6780582 1
Heavy object.
Risk of crushing!

1. Remove camshaft gear as shown in overview drawing (→ Page 1267).
2. To protect the crankcase from falling objects, cover equipment carrier from below.
Removing camshaft thrust bearing

2. Remove thrust bearing flange (2).
3. Check thrust bearing flange (→ Page 1293).
TIM ID: 0000001016 – 004
M020124/02E 2009-02 © MTU

Camshaft – Removal
1. Install inner guide sleeve (2) on face of camshaft,
free end.
2. Fasten guide flange (1) on crankcase.
3. Fasten outer guide sleeve (3) with screws (1) on
cardiagn.com
crankcase (2), driving end.
4. Screw inner guide sleeve (4), driving end, on to
camshaft.
5. Center guide sleeve to camshaft bearings.
6. Mount installation/removal tool on camshaft (2).

7. Attach camshaft with rope in middle (1) to crane.
8. Tension rope slightly and carefully withdraw
camshaft (2) horizontally from crankcase.
9. Remove guide sleeve.
TIM ID: 0000001016 – 004
M020124/02E 2009-02 © MTU

9.5.4 Camshaft – Cleaning
Material


Camshaft – Cleaning
cardiagn.com
TIM ID: 0000001010 – 002
M020124/02E 2009-02 © MTU

9.5.5 Camshaft running surfaces and swing followers – Visual inspection
Special tools

Spare parts

Camshaft
Roller tappet
Visually inspecting camshaft running surfaces

and swing followers
1. Remove valve drive (swing followers remain
installed) (→ Page 1297).
cardiagn.com
2. Insert endoscope into crank drive through every
pushrod bore.
3. Visually check roller surface of cams, roller running
surfaces on the camshaft as well as swing
followers for damage and wear.
4. Replace swing follower if signs of corrosion are
visible, see illustrations (→ Page 1297).
5. Replace camshaft if signs of corrosion are visible,
see illustrations (→ Page 1285).
Install valve drive (→ Page 1310).

TIM ID: 0000008370 – 005
M020124/02E 2009-02 © MTU

9.5.6 Camshaft – Check
Special tools

Hardness tester DynaMIC Y20506341 1
Measuring stand 0015890321/00 1
Material

cardiagn.com
Spare parts

Camshaft
Camshaft gear
Timing wheel
Hex screw
Spring washer
TIM ID: 0000001013 – 004
M020124/02E 2009-02 © MTU

Camshaft – Check
Using magnetic crack-test Crack indication Replace camshaft.

procedure, check camshaft for
cracks.
Check axial bearing flange with red Crack indication Replace camshaft.
dye penetrant for cracks.
Check mating face of camshaft gear. Stress marks visible • Recondition: Smooth with
• Replace
Check axial sliding surface, journal • Scores Replace camshaft.

faces and roller tracks of cams • Stress marks
for scores, stress marks and • Indentations
indentations. visible
Check tooth flank of camshaft gear Damaged Replace camshaft gear.

with magnifying glass.
cardiagn.com
Checking hardness of cam and journal

1. Use hardness tester to check cam hardness
(inlet/exhaust rocker arms) and journals. Required
hardness: 60 HRC ±2 HRC
3. Replace camshaft if values are fallen short of.
TIM ID: 0000001013 – 004
M020124/02E 2009-02 © MTU

Checking concentricity and cam lift

1. Set camshaft at outer journals on to V-blocks
(2) or roller stands.
2. Place supporting mount (3) on center journal.
3. Measure radial run-out of cam base circle
and bearings with dial gauge (1). Values
(→ Page 1275).
cardiagn.com
TIM ID: 0000001013 – 004
M020124/02E 2009-02 © MTU

9.5.7 Camshaft – Tolerances
Concentricity of bearings
cardiagn.com
Max. permissible deviation of New Wear limit
concentricity
During the concentricity check, provide supports for and align the following bearings.
from bearing 1 to bearing 2 0.050
a from bearing to bearing 0.025
b all cams 0.010

0.010
TIM ID: 0000004158 – 001
M020124/02E 2009-02 © MTU

Axial clearance
cardiagn.com
Basic limit
size
1 Camshaft gear 32.000 H7 0 +0.025 0 0.050

bore
Camshaft outer 32.000 H7 –0.025 0

dia.
2 Axial clearance 0.100 0.178 TIM ID: 0000004158 – 001
M020124/02E 2009-02 © MTU

9.5.8 Camshaft – Installation
Special tools

Guide sleeve for installation/removal from free end F6780579 1
Centering sleeve for installation/removal from free end F6780582 1
cardiagn.com
Holder 0015890321/00 1
Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!
TIM ID: 0000001019 – 008
Check camshaft (→ Page 1272).
M020124/02E 2009-02 © MTU

Camshaft – Installation
1. Attach outer guide sleeve (1) at driving end
of crankcase and center carefully to camshaft
bearings with inner guide sleeve (2).
2. Center guide flange (1) with guide sleeve (2) on
cardiagn.com
crankcase (free end) with regard to camshaft
bearings and secure.
3. Mount inner guide sleeve (2) on front face of

camshaft (1) and tighten.
TIM ID: 0000001019 – 008
M020124/02E 2009-02 © MTU

4. Attach camshaft (arrow) with rope at center

to crane and wipe.
5. Spray camshaft, camshaft bearing, and guide
sleeve with engine oil.
6. Install sliding block at outermost cam on camshaft.
7. Carefully insert camshaft up to second-last
bearing.
8. Position assembly extension (1) on camshaft (2)
cardiagn.com
and insert camshaft up to last bearing.
9. Locate camshaft axially and/or ensure that it
cannot fall out until thrust bearing is installed.
10. Remove inner/outer guide sleeve and assembly
extension.
Installing camshaft thrust bearing

1. Coat axial sliding surfaces with engine oil.
screws can fall into crankcase.
3. Tighten thrust bearing flange (1) with screws (2).
TIM ID: 0000001019 – 008
M020124/02E 2009-02 © MTU


cardiagn.com
swing-follower shaft, driving end.
(arrows).
Installing timing wheel (camshaft gear)

2. Install graduated disc (1) with barring tool on
crankshaft. Set to TDC mark of A1 and tighten.
3. Set piston A1 to firing TDC (→ Page 1216).
TIM ID: 0000001019 – 008
M020124/02E 2009-02 © MTU


objects can fall into crankcase.
5. Insert camshaft gear (1) into camshaft so that
dowel pins (3) engage in camshaft gear bore in
a vertical line.
6. Slide timing wheel (2) over dowel pins (3) and
install.
7. Screw in screws (4) with spring washers and
tighten (→ Page 980). Note position of holes of
dowel pins to screw bores.
Measuring backlash
cardiagn.com
1. Remove camshaft locating device.
3. Mount dial gauge stylus with low preload on one
tooth flank of camshaft gear.
5. Check backlash by moving camshaft gear
back and forth. Circumferential backlash
(→ Page 1099).
Measuring camshaft axial clearance

2. Fit dial gauge stylus on timing wheel.
3. Press camshaft on camshaft gear axially as
far as it will go.
4. Set dial gauge with preload to zero.
5. Move camshaft from stop to stop and record
measurement value (axial clearance). Axial
clearance (→ Page 1275)
6. If axial clearance is out of tolerance, replace thrust
TIM ID: 0000001019 – 008
bearing (→ Page 1292).
M020124/02E 2009-02 © MTU

Installing speed sensor

2. Turn speed sensor (2) slightly to install in
crankcase fit.
3. Screw in screw (1) and tighten.
Checking speed sensor clearance
cardiagn.com
1. Pull camshaft on camshaft gear axially toward free
end (arrow) as far as it will go.
2. Measure distance (X) with feeler gauge (specified
value 0.3 mm to 1 mm).
3. If distance is less than 0.3 mm:
3.1. Fit appropriate number of adjusting shims of
0.3 mm thickness.
3.2. Measure distance.
Checking camshaft timing

1. Determine TDC position of piston in the following
way:
1.1. Install measuring device (2) with dial
gauge (1) at cylinder head A1.
1.2. Fit TDC mark (graduated disc) on crankshaft
journal, free end.
1.3. Install suitable TDC pointer on equipment
carrier or crankcase, driving end.
1.4. Using the barring tool, bar the engine until
the piston of cylinder A1 is in the firing TDC.
The piston is at firing TDC when both rocker
TIM ID: 0000001019 – 008
arms are unloaded, i.e. have clearance.

2. Move piston up and down several times and then
position so that pointer on dial gauge shows its
maximum reading.
4. Rotate crankshaft against normal direction of
rotation by approx. 10°.
M020124/02E 2009-02 © MTU

5. Set crankshaft in direction of rotation to 0.3 mm

(dial gauge indicator) before TDC.
6. Apply exact line marking on graduated disc, driving
end, or crankshaft journal, free end, opposite
TDC pointer tip.
7. Bar crankshaft in direction of rotation approx. 10°
past TDC (to take up bearing clearance).
8. Bar crankshaft in direction opposite to normal
direction of rotation to 0.3 mm after TDC and
make a second mark. To prevent measurement
errors caused by bearing clearance, the piston
must move in direction of TDC.
9. Apply third mark at exact center between marks.
10. Align graduated disc so that mark for cylinder A1
corresponds to pointer.
11. Check TDC position.
12. Remove measuring device with dial gauge.
Measuring valve lift
cardiagn.com
1. Set cylinder A1 to firing TDC.
2. Release locknuts on adjusting screw.
3. Screw in adjusting screws until there is no longer
clearance.
4. Lightly tighten locknuts.
5. Mount magnetic-base indicator holder with dial
gauge on cylinder A1.
6. Place dial gauge stylus with slight preload on valve
bridge of inlet valve. Set scale to zero.
7. Slowly turn crankshaft further in direction of engine
rotation 360°. Set to exactly overlap TDC (line
marking on graduated disc).
in Data Sheet.
9. Mount dial gauge stylus on valve bridge of exhaust
valve and set scale to zero.
10. Further rotate crankshaft slowly in engine direction
of rotation until pointer of dial gauge no longer
moves.
in Data Sheet.
12. Check that specified values are
observed. Specified values, see
DM_410_WM_000001_276A.
13. If the specified value is not attained, contact
Service.
14. Remove magnetic-base indicator holder with dial
gauge and TDC indicator.
15. Valve clearance at cylinder A1 (→Operating
TIM ID: 0000001019 – 008
Instructions).
M020124/02E 2009-02 © MTU

9.5.9 Camshaft drive – Overview
Camshaft drive – Overview
cardiagn.com
1 Hex screw 3 Graduated disc 5 Hex screw
2 Spring washer 4 Camshaft gear 6 Thrust bearing flange
TIM ID: 0000001022 – 001
M020124/02E 2009-02 © MTU

9.5.10 Camshaft drive – Removal
Special tools


1. Turn engine with barring tool in normal direction
of rotation until TDC mark and arrow on end
housing are aligned.
• If rocker arms on cylinder A1 are unloaded, the
piston is in firing TDC.
• If rocker arms on cylinder A1 are loaded, the
piston is in overlap TDC.
2. Remove valve drive (→ Page 1297).
cardiagn.com
3. Disconnect electrical plug-in connection.
4. Remove screw (arrow).
5. Turn speed sensor (1) slightly to remove from
crankcase fit.
TIM ID: 0000001031 – 004
M020124/02E 2009-02 © MTU


cardiagn.com
swing follower shaft, driving end.
(arrows).
Removing timing wheel (camshaft gear)

2. Remove timing wheel (2) and camshaft gear (1)
from camshaft and dowel pins (3).
3. To protect the crankcase from falling objects, cover
equipment carrier from below.
4. Do not remove locating device.
TIM ID: 0000001031 – 004
M020124/02E 2009-02 © MTU

9.5.11 Camshaft drive – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com
Camshaft drive – Cleaning
3. Blow camshaft drive clear with compressed air.
TIM ID: 0000001025 – 002
M020124/02E 2009-02 © MTU

9.5.12 Camshaft drive – Check
Spare parts

Camshaft gear
Timing wheel
Screw
Spring washer
Camshaft drive – Check
Item Findings Task
Check surface condition of tooth • Scores • Corrective work

flanks with magnifying glass. • Stress marks • Replace
• Indentations
visible
cardiagn.com
Check timing wheel and camshaft Damaged • Corrective work
gear for damage. • Replace
Check threads of hex bolts for Damaged Replace

damage.
Check spring washer for damage. Damaged Replace
TIM ID: 0000001028 – 003
M020124/02E 2009-02 © MTU

9.5.13 Camshaft drive – Installation
Special tools

Holder 0015890321/00 1
Material
cardiagn.com
Spare parts

O-ring
Heavy object.
Risk of crushing!
For camshaft drive installation, see section “Installing timing wheel (camshaft gear)” (→ Page 1277).
TIM ID: 0000001034 – 004
M020124/02E 2009-02 © MTU

9.5.14 Camshaft thrust bearing – Overview
Overview of camshaft thrust bearing
cardiagn.com
1 Thrust bearing flange 2 Hex screw
TIM ID: 0000001037 – 001
M020124/02E 2009-02 © MTU

9.5.15 Camshaft thrust bearing – Cleaning
Material


Compressed air.
Risk of injury!
WARNING
cardiagn.com

Camshaft thrust bearing – Cleaning

3. Blow thrust bearing clear with compressed air.
TIM ID: 0000001040 – 003
M020124/02E 2009-02 © MTU

9.5.16 Camshaft thrust bearing – Replacement
Material

Engine oil
Spare parts

Hex screw
Camshaft thrust bearing – Replacement

1. Remove camshaft drive (→ Page 1285).
2. Replace camshaft thrust bearing as shown in overview drawing (→ Page 1290).
cardiagn.com
TIM ID: 0000001046 – 001
M020124/02E 2009-02 © MTU

9.5.17 Camshaft thrust bearing – Check
Material

Spare parts

Hex bolts
Camshaft thrust bearing – Check
cardiagn.com
Item Findings Task
Test trust bearing flange for cracks Signs of cracks Replace

using surface crack-test method.
Check mating faces, fits and sliding Damaged • Corrective work

surfaces for damage. • Replace
Check threads of hex bolts for ease Sluggish Replace

of movement.
TIM ID: 0000001043 – 003
M020124/02E 2009-02 © MTU

9.5.18 Valve drive – Overview
Swing follower, swing follower assembly
cardiagn.com
1 Rocker shaft support 5 Snap ring 9 Swing follower
2 Rocker arm 6 Hex screw 10 Swing follower
3 Rocker arm 7 Washer 11 Swing follower shaft
4 Precision washer 8 Valve bridge 12 Hex screw
TIM ID: 0000001055 – 004
M020124/02E 2009-02 © MTU

Rocker, shaft support
cardiagn.com
1 Snap ring 8 Rocker shaft support
2 Precision washer 9 Spring pin
3 Bushing 10 Spring pin
4 Adjusting screw 11 Sealing plug
5 Rocker arm, inlet valve 12 Shaft
6 Nut 13 Rocker arm, exhaust valve
7 Notched pin 14 Thrust element
TIM ID: 0000001055 – 004
M020124/02E 2009-02 © MTU

Swing follower
cardiagn.com
1 Bushing 4 Swing follower, inlet valve 7 Bolt
2 Ball seat 5 Roller
3 Swing follower, exhaust valve 6 Bushing
TIM ID: 0000001055 – 004
M020124/02E 2009-02 © MTU

9.5.19 Valve drive – Removal
Preconditions
Removing rocker arms
1. Bar crankshaft to bring piston of appropriate
cylinder to firing TDC. The piston is at firing TDC
when both rocker arms are unloaded.
Note: Ensure that no pushrod is removed by the
suction effect on the ball socket.
2. Remove screw (2) and remove rocker shaft

support (1) from cylinder head.
cardiagn.com
3. Remove valve bridges (2).
4. Pull out pushrods (1).
TIM ID: 0000001071 – 009
M020124/02E 2009-02 © MTU

Removing swing followers

2. Remove swing follower shaft with swing followers
(2) from crankcase.
cardiagn.com
TIM ID: 0000001071 – 009
M020124/02E 2009-02 © MTU

9.5.20 Valve drive – Disassembly

Risk of injury!
Disassembling rocker arms

jaws.
2. Use snap ring pliers to remove snap ring (2)
from shaft.
3. Take off washer (1).
4. Remove nut (2) and adjusting screw (3).
cardiagn.com
Removing swing follower bushing
1. Check whether the swing follower bushing must
be removed (→ Page 1302).
2. If so, press out swing follower bushing (2) off swing
follower (1) using mandrel and hydraulic press.
TIM ID: 0000001075 – 004
M020124/02E 2009-02 © MTU

Removing bolt and roller

1. Check whether bolt and roller must be removed
(→ Page 1302).
2. If removal is required:
2.1. Position swing follower between two prisms
ensuring sufficient support at both sides
of the bolt bore.
2.2. Using mandrel and hydraulic press, remove
bolt (1) from swing follower (2).
2.3. Remove roller (3) from installation position.
Removing bushing from exhaust rocker arm
cardiagn.com
2. If so, press out rocker arm bushing (1) off exhaust
rocker arm (2) using mandrel and hydraulic press.
Removing bushing from inlet rocker arm

2. If so, press out rocker arm bushing (1) off inlet
rocker arm (2) using mandrel and hydraulic press.
TIM ID: 0000001075 – 004
M020124/02E 2009-02 © MTU

9.5.21 Valve drive – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning the valve drive

TIM ID: 0000001058 – 006
M020124/02E 2009-02 © MTU

9.5.22 Valve drive – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Holder 0015890321/00 1
Material

Crack testing oil (Nr. 63) 40475 1
cardiagn.com
Spare parts

Snap ring
Lockwasher
Bearing bushing
Swing follower
Swing follower shaft
Valve bridge
Roller
Pushrod
Hex screw
Adjusting screw
TIM ID: 0000004265 – 005
M020124/02E 2009-02 © MTU

Checking valve drive
Item Findings Task
Using the magnetic crack-testing Cracks visible Replace

method, check the following
components for cracks.
• Rocker shaft support and axles
• Rocker arms
• Valve bridges
• Swing followers
• Roller
• Pin
• Swing follower shaft
• Pushrods
• Hex screws
• Adjusting screws
Check running surfaces of axles, • Wear • Recondition

rollers, valve bridges and rocker • Indentations • Replace
arms for wear, indentations and • Scores
cardiagn.com
scoring. visible
Check mating faces on rocker shaft Damaged • Recondition

support. • Replace
Check snap ring grooves of axles Damaged • Recondition

for condition. • Replace
Check ball element. The ball Sluggish Replace

element must not jam within the
swivel angle, on all sides at least
10°, and must move freely.
Check screws, nuts and adjusting Damaged Replace

screws for damage.
Check pushrod concentricity. Out-of-round Replace
Measuring diameter of bushing bore in rocker arm

1. Adjust bore gauge to basic size of bushing
bore and measure diameter of bore. Values
(→ Page 1305).
TIM ID: 0000004265 – 005
M020124/02E 2009-02 © MTU

Measuring diameter of rocker shaft support axles

1. Using outside micrometer, measure outside
diameters of bearings. Values (→ Page 1305).
2. If values are not attained, replace rocker shaft
support.
Measuring swing follower bushing bore
cardiagn.com
1. Adjust bore gauge to basic size of bushing bore
and measure diameter of bore.
3. Replace gaskets and sealing washers.
4. Make sure that oil bores are perfectly clean and
free of obstruction.
TIM ID: 0000004265 – 005
M020124/02E 2009-02 © MTU

9.5.23 Valve drive – Tolerances
Rocker shaft support, inlet and exhaust
cardiagn.com
size Basic
size
1 Rocker arm bore 50.000 H7 0 +0.025 0.018 0.059
Bush OD 50.000 s6 +0.043 +0.059
2 Bush bore

max.
removed 45.000 E6 +0.050 +0.066 0.100
Rocker shaft OD 45.000 f6 –0.041 –0.025
3 Rocker shaft 45.000 U7 –0.086 –0.061 0.020 0.061

support bore
Rocker shaft OD 45.000 f6 –0.041 –0.025

TIM ID: 0000004162 – 003
M020124/02E 2009-02 © MTU

Swing follower support, inlet and exhaust
cardiagn.com
size Basic
size
1 Swing follower 36.000 H7 0 +0.025 0.018 0.059

bore
Bush OD 36.000 s6 +0.043 +0.059
2 Bush bore

max.
removed 32.000 E6 +0.050 +0.066 0.100
Shaft OD 32.000 f6 –0.041 –0.025
3 Roller bore 21.000 E7 +0.040 +0.061 0.040 0.082 Clearance

max.
Bush OD 21.000 H7 –0.021 0 0.090
4 Bush bore 14.000 E7 +0.032 +0.050 0.032 0.058 Clearance

max.
Pin OD 14.000 h5 –0.008 0 0.065
TIM ID: 0000004162 – 003
5 Swing follower 14.000 P6 –0.026 –0.015 0.007 0.026

bore
Bush OD 14.000 h5 –0.008 0
M020124/02E 2009-02 © MTU

9.5.24 Valve drive – Assembly
Material

Liquid nitrogen
Engine oil

Compressed air.
Risk of injury!
cardiagn.com
Component is hot.
Risk of burning!

Risk of injury!
Assembling rocker arm assembly

jaws.
2. Insert adjusting screw (3) into rocker arm (1).
3. Attach nut (2) to adjusting screw, do not tighten.
4. Coat axles on rocker shaft support and bushings
of rocker arms with engine oil.
5. Fit rocker arm on axle.
6. Install second rocker arm similarly.
TIM ID: 0000001079 – 005
M020124/02E 2009-02 © MTU

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

8. Check correct seating of snap ring .
9. Check minimum axial clearance of rocker arm.
Assembling inlet and exhaust swing followers
cardiagn.com
1. Chill bushings (2) in liquid nitrogen and press into
both sides of swing follower (1).
2. Observe bushing retention (A) 0.5 mm ±0.5 mm.
TIM ID: 0000001079 – 005
M020124/02E 2009-02 © MTU

3. Heat swing follower to approx. 130 °C to 150 °C.

4. Insert roller (3) in swing follower.
5. Chill bolt (1) in liquid nitrogen. Fit in swing
follower (2) by applying hand force, ensure flush
seating. Do not press the bolt repeatedly.
Assembling rocker arm assembly
cardiagn.com
1. Chill bushing (1) in liquid nitrogen.
2. Heat exhaust rocker arm (2) to approx. 200° C.
3. Insert bushing, ensure flush seating. Projection is
not acceptable.
TIM ID: 0000001079 – 005
M020124/02E 2009-02 © MTU

9.5.25 Valve drive – Installation
Special tools

Graduation plate, free end Y4341124 1
Material
cardiagn.com
Engine oil
Compressed air.
Risk of injury!
Installing swing followers

1. Coat axle and bushes of swing followers with
engine oil.
2. Fit exhaust and inlet swing follower on
swing-follower shaft, ensuring they are correctly
positioned (arrows).
TIM ID: 0000001082 – 008
M020124/02E 2009-02 © MTU

3. Coat rollers and camshaft bushings with engine oil.

4. Match swing followers to left and right cylinder
banks and carefully insert into camshaft chamber.
5. Install swing-follower shaft (1) with screws.
cardiagn.com
6. Ensure correct position of installation (arrow).
Installing pushrods
1. Coat ball seats and ball sockets of pushrods
(1) with engine oil.
2. Insert pushrods (1) through cylinder head into ball
seat of swing follower.
TIM ID: 0000001082 – 008
M020124/02E 2009-02 © MTU

Installing the rocker arm

1. Release nuts (6) of adjusting screws (1) on rocker
arm (4) and back off adjusting screw (1).
2. Place rocker shaft support (4) onto cylinder head.
Take care not to damage fit of grooved pins.
3. Check position of ball joints in pushrods (5).
4. After initial assembly and after extended
out-of-service period: Fill adjusting screws (1)
with engine oil (arrow).
5. Screw hex bolt (2) with washer (3) into cylinder
head and tighten.
6. Adjust valve clearance (→Operating instructions ).
cardiagn.com
TIM ID: 0000001082 – 008
M020124/02E 2009-02 © MTU

9.5.26 Cylinder head cover – Overview
cardiagn.com
1 Seal 3 Screw
2 Cylinder head cover 4 Washer
TIM ID: 0000001086 – 002
M020124/02E 2009-02 © MTU

9.5.27 Cylinder head cover – Removal

Cylinder head cover – Removal
1. Remove screws.
2. Remove cylinder head cover and seal.
cardiagn.com
TIM ID: 0000001095 – 004
M020124/02E 2009-02 © MTU

9.5.28 Cylinder head cover – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cylinder head cover – Cleaning

1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then flush with cleaning agent (Hakupur 312).
TIM ID: 0000001089 – 004
M020124/02E 2009-02 © MTU

9.5.29 Cylinder head cover – Check
Special tools

Oilstone 8205893261/00 1
Spare parts

Cylinder head cover
Screw
Checking the cylinder head cover
cardiagn.com
Check cylinder head cover for Damaged • Corrective work: Smoothen
damage. with emery cloth or oilstone.
• Replace
Check threads of screws for ease of Sluggish • Corrective work: Recut threads
TIM ID: 0000001092 – 004
M020124/02E 2009-02 © MTU

9.5.30 Cylinder head cover – Installation
Material

Engine oil
Spare parts

Seal
Screw
Washer
cardiagn.com
Cylinder head cover – Installation

1. Install cylinder head cover with seal.
2. Tighten screws.
TIM ID: 0000001098 – 004
M020124/02E 2009-02 © MTU

9.6 High Pressure Fuel System
9.6.1 HP fuel system – Overview
cardiagn.com
1 Injector 4 Pressure-relief valve 7 HP fuel line, right engine side
2 HP fuel line 5 HP fuel line, left engine side
3 HP accumulator 6 HP fuel pump
TIM ID: 0000001113 – 002
M020124/02E 2009-02 © MTU

9.6.2 HP pump – Overview
cardiagn.com
1 HP pump 3 Washer
2 Screw 4 Washer
TIM ID: 0000028951 – 001
M020124/02E 2009-02 © MTU

Front view of HP pump
cardiagn.com
1 HP line to right-hand engine side 3 HP line to left-hand engine side
2 Temperature sensor 4 HP sensor
TIM ID: 0000028951 – 001
M020124/02E 2009-02 © MTU

9.6.3 HP pump – Removal
Special tools

Hot-air gun 0005388520 1

• Do not smoke.
Heavy object.
Risk of crushing!
cardiagn.com
Component is hot.
Risk of burning!
HP pump – Removal
3. Remove HP pump (1).
TIM ID: 0000001136 – 005
M020124/02E 2009-02 © MTU


6. Heat intermediate piece (2) to approx. 130°C to
free up screw locking compound.
7. Remove intermediate piece (2).
cardiagn.com
TIM ID: 0000001136 – 005
M020124/02E 2009-02 © MTU

9.6.4 High-pressure pump – Disassembly

This assembly is a replacement part (Reman). It is available within the scope of the service-exchange scheme.
cardiagn.com
TIM ID: 0000001140 – 002
M020124/02E 2009-02 © MTU

9.6.5 High-pressure pump – Check
Spare parts

High-pressure pump
Screw
High-pressure pump – Check
Item Findings Task
Check connection thread on No ease of movement • Recondition

high-pressure pump for damage. • Replace
Check drive gear for damage. Damaged Replace high-pressure pump.
cardiagn.com
Check wiring for damage. Damaged Replace wiring.
Check sealing faces for damage. Damaged • Recondition

• Replace
TIM ID: 0000001133 – 003
M020124/02E 2009-02 © MTU

9.6.6 HP pump – Installation
Special tools

Material

Engine oil
cardiagn.com
Spare parts

O-ring
Suspended load.
Danger to life!

HP pump – Installation
2. Coat thread of intermediate piece (3) with screw
locking compound.
3. Screw intermediate piece (3) into shaft (2).
TIM ID: 0000001143 – 006
M020124/02E 2009-02 © MTU


6. Insert HP pump (1) into bore.
7. Insert screws (2) and tighten.
cardiagn.com
8. Remove lifting equipment from HP pump.
TIM ID: 0000001143 – 006
M020124/02E 2009-02 © MTU

9.6.7 H.P. fuel pump – Control block replacement
Preconditions
Special tools

Material

Engine oil
cardiagn.com
Spare parts

Control block
O-ring
Connector

• Do not smoke.
Removing control block

1. Remove fuel line (5) from control block (4). Collect
emerging fuel.
connector (6) from magnet.
connector (1) from sensor.
4. Remove sensor (1).
5. Remove screws (3) from control block (4).
6. Remove control block (4) from H.P. fuel pump (7).
TIM ID: 0000004092 – 003
Installing control block

1. Coat O-ring with engine oil and insert into groove.
2. Screw control unit (4) with screws (3) onto H.P. fuel pump (7) and tighten to specified torque (→ Page 980) .
M020124/02E 2009-02 © MTU

3. Connect connector (6) to magnet and tighten bayonet lock using pliers.
5. Screw sensor (1) into bore by hand.
6. Tighten nut (2) with torque wrench to specified tightening torque (→ Page 980) .
7. Connect connector to sensor (1) and tighten bayonet lock using pliers.
8. Attach fuel line (5) to control block (4).
9. Vent fuel lines.
cardiagn.com
TIM ID: 0000004092 – 003
M020124/02E 2009-02 © MTU

9.6.8 Injector – Overview
Injector – Overview
cardiagn.com
1 Hold-down clamp 3 O-ring 5 O-ring
2 Hex screw 4 Injector 6 CE-ring
TIM ID: 0000029847 – 001
M020124/02E 2009-02 © MTU

9.6.9 Injector – Removal
Special tools

Puller F30377769 1
Puller bracket F6557991 1

• Do not smoke.
Remove injector
1. Remove H.P. line (2).
cardiagn.com
2. Remove screw (1) from hold-down clamp (2).
3. Take off hold-down clamp.
TIM ID: 0000001167 – 003
M020124/02E 2009-02 © MTU

4. Place puller (4) on injector (1).
5. Turn locking sleeve (2) of puller (1) from position
cardiagn.com
"a" to position "b".
6. Secure locking sleeve with nut.
7. Place puller bracket (2) on cylinder head.

8. Screw in threaded rod (3) in puller (5).
9. Secure nuts (4).
10. Withdraw fuel injector by turning nut (1) to the right.
11. Remove special tool.
12. Remove puller bracket and locking sleeve.
TIM ID: 0000001167 – 003
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13. Remove fuel injector.

14. Remove O-rings (2) from injector.
15. Remove sealing ring (1) from injector or use wire
hook to remove from cylinder head.
16. Seal all connections and installation bores with
covers or plugs.
cardiagn.com
TIM ID: 0000001167 – 003
M020124/02E 2009-02 © MTU

9.6.10 Fuel injector disassembly

This component is an exchange component (Reman) and is available through the usual exchange procedure.
cardiagn.com
TIM ID: 0000001171 – 001
M020124/02E 2009-02 © MTU

9.6.11 Injector – Cleaning
Material

Compressed air.
Risk of injury!

• Do not smoke.
cardiagn.com

Injector – Cleaning
TIM ID: 0000001158 – 002
M020124/02E 2009-02 © MTU

9.6.12 Injector – Check
Material

Crack testing oil (NR. 63) 40475 1
Spare parts

Fuel injector
Hold-down clamp
Screw
Check injector
cardiagn.com
Inspect fuel injector externally for Damaged Replace

damage.
Check screws and hold-down Indication of cracks Replace

clamp for cracks with magnetic
crack-testing method.
Check contact surfaces of hold-down Damaged • Rework: smooth with oilstone.

clamp. • Replace
Inspect sealing cone of fuel injector Damaged Replace injector.

for damage.
Check cable connections for Damaged Replace wiring harness.

damage.
Check thread on screw and injector Sluggish • Rework

valve for ease of movement. • Replace
TIM ID: 0000001162 – 002
M020124/02E 2009-02 © MTU

9.6.13 Injector – Installation
Special tools

Lever F6555197 1
Force-in lever F6557952 1
Material

Engine oil
Grease (Retinax EP2) 40388 1
cardiagn.com
Spare parts

O-rings
Sealing ring

• Do not smoke.
Check injector (→ Page 1335).
Injector – Installation
2. Fit O-rings on fuel injector.
TIM ID: 0000001175 – 004
M020124/02E 2009-02 © MTU

3. Use Retinax EP2 grease to fit sealing ring on

mating face of injector.
4. Fit sealing ring on injector so that the even contact
surface faces injector.
5. Insert fuel injector (1) in cylinder head. Ensure
cardiagn.com
that injector is correctly aligned with H.P. fuel
line connection.
6. Fit force-in tool (2).
7. Lock force-in lever (1) of forces-in tool between

the pushrods.
8. Release palm grip (3) and move pressure element
(2) to correct position for force-in tool.
9. Secure palm grip and press injector (4) with
force-in lever into cylinder head.
10. Remove force-in tool.
TIM ID: 0000001175 – 004
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11. Fit hold-down clamp (2) in correct position by hand.

Note: Tighten screw of hold-down clamp only
after connecting the H.P. line.
12. Hand-tighten screw (1) so that the injector is

still rotatable.
13. Install H.P. lines between connecting piece and
injector (→ Page 1354).
cardiagn.com
TIM ID: 0000001175 – 004
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9.6.14 High-pressure line – Overview
HP line from HP accumulator to injector
cardiagn.com
1 Hold-down clamp 4 Filter element 7 Fuel collecting line

2 Cable connection 5 Fuel return line 8 Limiting valve
3 Injector 6 HP line 9 HP accumulator
TIM ID: 0000029631 – 001
M020124/02E 2009-02 © MTU

HP line from HP pump to HP accumulator
cardiagn.com
1 HP line, left side 4 Pipe half-clamp 7 Pipe half-clamp
2 HP line, right side 5 Screw 8 Screw
3 Retainer 6 Retainer 9 Grommet
TIM ID: 0000029631 – 001
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HP accumulator and add-on components
cardiagn.com
1 HP accumulator 10 Screw 19 Plug-in pipe
2 Thrust element 11 Limiting valve 20 Plug-in pipe
3 Thrust element 12 HP line 21 Screw
4 Thrust screw 13 O-ring 22 Washer
5 O-ring 14 Plug-in pipe 23 O-ring
6 Pressure-relief valve 15 Sealing ring 24 O-ring
7 Adapter 16 Plug 25 O-ring
8 Thrust screw 17 Plug-in pipe 26 Snap ring
9 Connecting piece 18 Plug-in pipe
TIM ID: 0000029631 – 001
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HP accumulator, left engine side
cardiagn.com
1 O-ring 6 Plug-in pipe 11 Plug screw (telltale bore)
2 Thrust screw 7 Thrust element 12 HP accumulator
3 Thrust element 8 Screw 13 O-ring
4 Adapter for HP line 9 Thrust element 14 Plug-in pipe
5 Telltale bore 10 Plug-in pipe
HP accumulator, right engine side
TIM ID: 0000029631 – 001
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1 Screw 6 Telltale bore 11 Thrust element

2 Pressure-relief valve 7 Plug-in pipe 12 HP accumulator
3 Plug-in pipe 8 HP line 13 Plug screw (telltale bore)
4 Adapter for HP line 9 O-ring 14 Plug-in pipe
5 O-ring 10 Thrust screw 15 Thrust element
cardiagn.com
TIM ID: 0000029631 – 001
M020124/02E 2009-02 © MTU

9.6.15 HP fuel line – Removal
Special tools


• Do not smoke.
Removing HP line between HP pump and HP accumulator

Note: Prior to removing HP lines, it is advisable to take photographs of all fitted lines or to identify lines
with metal tags.
1. Release threaded union on HP lines and catch fuel emerging.
cardiagn.com
2. Remove HP fuel lines as per overview drawings (→ Page 1339).
3. After removal of the lines, seal all connections with suitable plugs.
TIM ID: 0000001204 – 005
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Removing HP fuel lines

accumulator on injector side (arrow).
cardiagn.com
accumulator on HP accumulator side (arrow).
TIM ID: 0000001204 – 005
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Removing HP accumulator
1. Remove fuel return line (1) on HP accumulator of
right engine side, driving end.
2. Remove pressure relief valve.
3. Withdraw plug-in pipe end section (2) and remove
O-ring.
cardiagn.com
4. Remove limiting valves (2) from connecting
pieces (3).
5. Withdraw plug-in pipe end section (1) from left HP
accumulator.
6. Carefully remove HP accumulator from connecting

pieces and plug-in pipes. TIM ID: 0000001204 – 005
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7. Remove screws (4) from connecting piece (2)

and take off together with plug-in pipe (1) from
crankcase.
8. Remove O-ring (3) from connecting pieces.
cardiagn.com
TIM ID: 0000001204 – 005
M020124/02E 2009-02 © MTU

9.6.16 HP fuel line – Disassembly
Special tools

Heavy object.
Risk of crushing!
Remove HP fuel line (→ Page 1344).
Disassembling HP accumulator
1. Use retaining device (arrow) to clamp HP
cardiagn.com
2. Unscrew thrust screw.
3. Remove thrust pad and pressure relief valve.
TIM ID: 0000001207 – 002
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9.6.17 HP fuel line – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

HP fuel line – Cleaning

TIM ID: 0000001198 – 003
M020124/02E 2009-02 © MTU

9.6.18 H.P. fuel line – Check
Material

Fluorescent magnetic powder for magnetic crack-testing procedure
Spare parts

H.P. accumulator
Pressure-relief valve
Plug-in pipe
Thrust pad
Limiting valve
cardiagn.com
Disassemble H.P. fuel line (→ Page 1348).
H.P. fuel line – Check
Item Findings Task
Using the magnetic crack-testing Signs of cracks Replace pressure accumulator.

method, check H.P. accumulator for
cracks.
Check all threads for ease of Sluggish • Recondition: recut threads.

Check sealing tapers on thrust pads Damaged Replace

for damage.
Check sealing cone of pressure • Damage Replace

accumulator for damage and wear. • Wear
visible
Check that H.P. lines, plug-in pipes Damaged • Recondition

and fuel return line are in perfect • Replace
condition.
Check that H.P. lines and H.P. Contaminated Clean (→ Page 1349)
accumulator are perfectly clean.
For checking limiting valves Damaged Contact Service.

and pressure relief valves, see
Manufacturer’s Documentation.
TIM ID: 0000001201 – 001
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9.6.19 HP fuel line – Assembly
Special tools

Material

Molykote G-n plus 40041 1
Engine oil
Spare parts
cardiagn.com
O-ring
Snap ring
Sealing ring
Washer
Thrust element, alternatives A and B
A Thrust element with thrust ring (X = 15.5 mm)

B Thrust element without thrust ring (Y = 23.5 mm)
TIM ID: 0000001210 – 005
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Pressing on thrust ring - Variant A only

1. Degrease and dry thrust element surfaces.
2. Coat surface (arrowed) with oil.
cardiagn.com
3. Press-fit thrust ring (2) with supporting washer (3)
on thrust element (1).
TIM ID: 0000001210 – 005
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Assembling HP fuel line, alternatives A and B

1. Coat mating surfaces between thrust screw and
thrust element as well as between thrust screw
and adapter with Molykote G-n plus.
2. Push thrust screw (1) onto thrust element (2).
3. Coat threads (arrowed) and taper (arrowed)
with engine oil.
cardiagn.com
4. Preassemble HP accumulator:
4.1. Use retaining device to clamp HP
4.2. Insert prepared thrust pieces with thrust
screws as well as adapter and thrust screw
for pressure-relief valve (→ Page 1339)in
seating bore and tighten with torque
wrench to the specified tightening torque
(→ Page 980).
4.3. Install pressure relief valve, and insert but
do not tighten socket-head screws.
TIM ID: 0000001210 – 005
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9.6.20 HP fuel line – Installation
Special tools

Alignment tool for HP accumulator F6557185 2
Slotted nut screwdriver F30379005 1
Material

Engine oil
cardiagn.com
Spare parts

O-ring
Gasket
Compressed air.
Risk of injury!

• Do not smoke.
TIM ID: 0000001213 – 008
M020124/02E 2009-02 © MTU

Preparing connecting pieces

2. Insert O-rings in grooves (arrowed) on connecting
piece.
Installing HP accumulator on crankcase
cardiagn.com
1. Fit connecting pieces and plug-in pipes together in
alternating sequence.
Note: Align plug-in pipes with leak check outlet
facing downwards
2. Fit plug-in pipes over connecting piece O-rings.

3. Insert screws (arrows) for attaching the connecting
piece to the crankcase.
4. Insert HP accumulator in preassembled connecting

piece and plug-in pipe assembly.
TIM ID: 0000001213 – 008
M020124/02E 2009-02 © MTU

5. Insert alignment tools in tightened connecting

pieces (first and last connecting piece of respective
engine side).
6. Align HP accumulator until alignment tool taper is
centered in bore of HP accumulator.
7. Tighten alignment tool to 20 Nm +2 Nm.
8. Insert limiting valve into outlet openings (arrowed)
cardiagn.com
of all connecting pieces.
9. If injectors have been removed, they must be

installed first (→ Page 1336).
10. Using a slotted nut screwdriver, tighten thrust rings
(2) at the thread end to 10 Nm.
Result: Distance of pipe end to thrust ring A =
11.7 mm.
11. Coat O-rings with grease and insert in grooves.
12. Pretighten HP lines between limiting valve and
injector to 5 to 10 Nm.
TIM ID: 0000001213 – 008
M020124/02E 2009-02 © MTU

13. Use torque wrench to fasten HP lines to the limiting

valves (2) and tighten to specified tightening
14. Use torque wrench to fasten HP lines to the
injectors (1) and tighten to specified tightening
16. Insert remaining limiting valves and tighten HP
lines as described.
17. Use torque wrench to tighten hold-down clamp with
cardiagn.com
screw to specified tightening torque (→ Page 980).
18. Use torque wrench to tighten all screws for

attaching connecting pieces to the crankcase to
19. Complete HP accumulator (→ Page 1339).
TIM ID: 0000001213 – 008
M020124/02E 2009-02 © MTU

21. Coat thread and screw heads (3) with oil.

22. Install pressure relief valve (2) and fit screws (3)
evenly by hand.
23. Install return line (1) between fuel collecting line
and pressure relief valve.
24. Pressure relief valve:
• Variant A
Use torque wrench to tighten 3 screws (3) to
• Variant B
Tighten 6 screws (3), spherical washers and
conical sockets crosswise in stages to specified
Installing HP line between HP pump and HP accumulator
cardiagn.com
1. Blow out HP lines with compressed air.
2. Install HP lines and securing hardware as per overview drawing (→ Page 1339) or according to
photos/markings, ensuring that the connections are free of tension.
3. Leak test fuel system (high-pressure) (→ Page 1359).
TIM ID: 0000001213 – 008
M020124/02E 2009-02 © MTU

9.6.21 H.P. fuel system – Leak check

Compressed air.
Risk of injury!
Checking common rail system for leaks

1. Remove pressure sensor (1) from high-pressure
pump (2).
2. Install H.P. inspection line and apply pressure to
system. Test pressure: 3 bar
cardiagn.com
4. Check all threaded connections in system for leaks.
5. Again remove H.P. testing line from high-pressure
pump.
6. Insert pressure sensor on H.P. pump and tighten to
specified torque with torque wrench (→ Page 980) .
TIM ID: 0000001116 – 001
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9.7 Low Pressure Fuel System
9.7.1 Fuel system – Overview
Fuel system
cardiagn.com
1 Fuel service tank 13 Measuring point, fuel pressure 24 Non-return valve after fuel
2 Non-return flap after H.P. pump delivery pump
3 Fuel prefilter 14 Measuring point, fuel temperature 25 Fuel ventilation
4 Fuel delivery pump, electric after fuel H.P. pump 26 Fuel restrictor
motor drive 15 Jacketed pipe 27 Overflow valve, fuel return
5 Non-return flap 16 Connection, leak-off fuel return from engine
6 Fuel filling connection from jacketed fuel line 28 Overflow valve, fuel return
7 Connection, fuel supply to engine 17 H.P. accumulator from engine
8 Fuel hand pump 18 pressure relief valve 29 Connection for leak-off fuel return
9 Fuel delivery pump with pressure 19 Injector 30 Leak-off fuel tank
relief valve 20 H.P. fuel pump
10 Fuel filling connection 21 Connection, return from fuel
11 Connection, fuel return from engine prefilter
12 Measuring point, fuel pressure 22 Connection, supply to fuel prefilter
after filter 23 Fuel filter
TIM ID: 0000003454 – 002
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Fuel delivery pump – Overview
cardiagn.com
1 Fuel delivery pump 3 O-ring 5 Washer
2 Coupling element 4 Hex bolt 6 Hex bolt
TIM ID: 0000029644 – 001
M020124/02E 2009-02 © MTU

Preconditions

• Do not smoke.
Removing fuel delivery pump

1. Remove fuel delivery pump as per overview drawing (→ Page 1361).
2. Remove coupling element from the drive shaft of the fuel delivery pump.
3. Remove O-ring.
cardiagn.com
TIM ID: 0000004057 – 007
M020124/02E 2009-02 © MTU

9.7.4 Fuel delivery pump – Disassembly

Disassembling fuel delivery pump

In the event of wear or a complaint, the fuel delivery pump must be replaced.
cardiagn.com
TIM ID: 0000001242 – 002
M020124/02E 2009-02 © MTU

Material

Compressed air.
Risk of injury!

cardiagn.com


TIM ID: 0000001234 – 002
M020124/02E 2009-02 © MTU

9.7.6 Fuel delivery pump – Check
Spare parts

Fuel delivery pump
Screw
Coupling

• Do not smoke.
Fuel delivery pump – Check
Item Findings Task
cardiagn.com
Perform external check of fuel Damaged Replace fuel delivery pump
delivery pump for perfect condition.
Check coupling for stress marks and Damaged Replace coupling

damage.
Check driver of pump shaft for wear. Damaged • Recondition: Smooth with
• Refer to manufacturer’s
documentation when replacing
the driver.
Check threads of securing screws. Damaged Replace

TIM ID: 0000001237 – 003
M020124/02E 2009-02 © MTU

Material

Engine oil
Spare parts

O-ring

• Do not smoke.
cardiagn.com
2. Mount coupling element (2) on driver.
3. Align fuel delivery pump driver to coupling element.
4. Carefully insert fuel delivery pump in bore
and install as shown in overview drawing
(→ Page 1361).
5. If the pump cannot be inserted up to the stop,
remove the pump again and check the position of
the driver to the coupling element.
TIM ID: 0000004059 – 005
M020124/02E 2009-02 © MTU

cardiagn.com
1 Fuel delivery pump
TIM ID: 0000006055 – 001
M020124/02E 2009-02 © MTU


• Do not smoke.
Fuel delivery pump – Removal

1. Switch off fuel delivery pump and disconnect from power supply.
2. Remove fuel lines.
3. Collect emerging fuel in a suitable container.
4. Remove securing screws from fuel delivery pump.
5. Remove fuel delivery pump.
6. Seal all openings on the engine.
cardiagn.com
TIM ID: 0000006056 – 002
M020124/02E 2009-02 © MTU

Material

Cleaning agent
Compressed air.
Risk of injury!

• Do not smoke.
cardiagn.com

1. Clean all components using cleaning agent.
3. Blow off all parts thoroughly with compressed air.
TIM ID: 0000006057 – 001
M020124/02E 2009-02 © MTU


• Do not smoke.
Clean fuel delivery pump (→ Page 1369).

1. Open connections on engine.
2. Mount fuel delivery pump on foundation with securing screws.
3. Install fuel lines.
4. Connect fuel delivery pump to power supply.
cardiagn.com
TIM ID: 0000006059 – 002
M020124/02E 2009-02 © MTU

9.7.12 Fuel pipework from fuel delivery pump to fuel filter – Overview
cardiagn.com
1 Plug-in pipe 6 O-ring 11 Flange
2 O-ring 7 Screw 12 Flange
3 Flange 8 Washer 13 O-ring
4 Non-return valve 9 Plug-in pipe 14 Screw
5 O-ring 10 O-ring 15 Washer
TIM ID: 0000029119 – 001
M020124/02E 2009-02 © MTU

9.7.13 Fuel lines from fuel delivery pump to fuel filter – Removal
Preconditions

• Do not smoke.
Removing fuel lines from fuel delivery pump to fuel filter

2. Disconnect fuel line and collect escaping fuel.
3. Remove fuel lines from fuel delivery pump to fuel filter as shown in overview drawing (→ Page 1371).
cardiagn.com
TIM ID: 0000003457 – 009
M020124/02E 2009-02 © MTU

9.7.14 Fuel lines from pump to filter – Cleaning
Material

Cleaning agent
Compressed air.
Risk of injury!

Remove fuel lines (→ Page 1372).
cardiagn.com
Cleaning fuel lines
1. Clean fuel lines and non-return valve with cleaning agent.
3. Thoroughly blow out fuel lines and non-return valve with compressed air.
TIM ID: 0000004060 – 003
M020124/02E 2009-02 © MTU

9.7.15 Fuel lines from fuel delivery pump to fuel filter – Check
Spare parts

Non-return valve
Flange
Plug-in pipe

Risk of injury!
Fuel lines from fuel delivery pump to fuel filter – Check
Item Findings Task
cardiagn.com
Visually check plug-in pipes, flanges and Damaged Replace
non-return valve for damage and wear.
Check plug-in pipes for leaks with air Leaking Replace

in water bath as necessary. A water
temperature of min = 30 °C or max = 40 °C
and a test pressure of 0.5 bar must be
maintained.
Check non-return valve for leaks and • Leaking Replace

check opening pressure. • Opening pressure
incorrect.
TIM ID: 0000008427 – 002
M020124/02E 2009-02 © MTU

9.7.16 Fuel lines from fuel delivery pump to fuel filter – Installation
Material

Spare parts

O-ring

• Do not smoke.
cardiagn.com
Fuel lines from fuel delivery pump to fuel filter – Installation

2. Install O-rings on plug-in pipes and coat with grease.
3. Install fuel lines as per overview drawing (→ Page 1371).
TIM ID: 0000008429 – 006
M020124/02E 2009-02 © MTU

9.7.17 Fuel duplex filter – Overview
cardiagn.com
1 Valve (0.5 bar) 11 Fuel hand pump 21 Threaded nipple
2 Plug screw 12 Plug screw 22 Plug screw
3 Plug screw 13 Threaded union 23 Plug screw
4 Valve (1 bar) 14 Blanking cone 24 Filter head
5 Plug screw 15 Nut 25 Threaded union
6 Threaded union 16 O-ring 26 Blanking cone
7 Fuel line 17 Elbow 27 Nut
8 Plug screw 18 Screw 28 Threaded union
9 Screw 19 Threaded nipple 29 Threaded union
10 O-ring 20 Easy-change fuel filter 30 O-ring
TIM ID: 0000008168 – 003
M020124/02E 2009-02 © MTU

9.7.18 Fuel duplex filter – Removal
Preconditions
Special tools


• Do not smoke.
Fuel duplex filter – Removal

1. Remove filter elements using filter wrench (1).
cardiagn.com
3. Remove filter head as shown in overview drawing
(→ Page 1376).
TIM ID: 0000004062 – 006
M020124/02E 2009-02 © MTU

9.7.19 Fuel duplex filter – Disassembly

• Do not smoke.
Fuel duplex filter – Disassembly

1. Remove and disassemble hand pump as shown in overview drawing (→ Page 1376).
2. Disassemble filter head as shown in overview drawing.
cardiagn.com
TIM ID: 0000004063 – 003
M020124/02E 2009-02 © MTU

9.7.20 Fuel filter – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Fuel filter – Cleaning

3. Thoroughly blow out all parts using compressed air.
TIM ID: 0000004064 – 002
M020124/02E 2009-02 © MTU

9.7.21 Fuel filter – Check

Risk of injury!
Checking fuel filter
Visually inspect filter head and hand Damaged Replace

pump for damage and condition
Check sealing and bolt-on faces for Damaged • Smooth with oilstone
damage • Replace
Check all threads and threaded Damaged • Rework: recut thread.

holes. • Replace
Leak-test filter head using air and Leaking • Replace plugs and sealing
cardiagn.com
water bath. Install filter elements rings
before carrying out leak test. Test • Replace filter head
temperature: min. 30 °C, max.
40 °C, if oil filter housing has to be
held in hands. Test pressure: 0.5
bar.
TIM ID: 0000004065 – 003
M020124/02E 2009-02 © MTU

9.7.22 Fuel duplex filter – Assembly
Material

Engine oil
Spare parts

Plug screw
O-ring

cardiagn.com
• Do not smoke.
Fuel duplex filter – Assembly

Note: Coat O-rings with grease.
1. Assemble filter head as shown in overview drawing (→ Page 1376).

2. Assemble hand pump as shown in overview drawing and install on filter head (→ Page 1376).
TIM ID: 0000004066 – 003
M020124/02E 2009-02 © MTU

9.7.23 Fuel duplex filter – Installation
Material


• Do not smoke.
Installing fuel duplex filter

3. Install fuel duplex filter as shown in overview drawing (→ Page 1376).
Installing easy-change fuel filter
cardiagn.com
1. Coat sealing rings (arrow) of filters with fuel.
2. Install filter and tighten by hand.
TIM ID: 0000004067 – 005
M020124/02E 2009-02 © MTU

9.7.24 Fuel pipework from fuel filter to HP pump – Overview
Fuel line
cardiagn.com
1 Fuel line 4 Pipe half-clamp 7 Screw
2 Union 5 Grommet
3 Pipe half-clamp 6 Washer
TIM ID: 0000033769 – 001
M020124/02E 2009-02 © MTU

9.7.25 Fuel pipework from fuel filter to HP pump – Removal
Preconditions

• Do not smoke.
Fuel pipework from fuel filter to HP pump – Removal

2. Remove fuel line with securing hardware as shown in overview drawing (→ Page 1383).
3. After removal of the fuel lines, seal all connections with suitable plugs.
cardiagn.com
TIM ID: 0000004068 – 005
M020124/02E 2009-02 © MTU

9.7.26 Fuel pipework from fuel filter to high-pressure pump – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Fuel pipework from fuel filter to high-pressure pump – Cleaning

TIM ID: 0000004069 – 002
M020124/02E 2009-02 © MTU

9.7.27 Fuel pipework from fuel filter to high-pressure pump – Check
Spare parts

Fuel line
Retainer

Risk of injury!
Fuel pipework from fuel filter to high-pressure pump – Check
Item Findings Task
Visually inspect fuel lines for Damaged • Corrective work
cardiagn.com
damage. • Replace
Pressure-test fuel line with air Leaking Replace

in water bath for leaks. A water
temperature of min. = 30 °C or
max. = 40 °C and a test pressure of
damage. oilstone.
• Replace
Check threads of union nuts Sluggish • Corrective work: Recut threads

and threaded unions for ease of • Replace
movement.
Check securing elements on fuel Damaged Replace

lines for damage.
TIM ID: 0000004070 – 002
M020124/02E 2009-02 © MTU

9.7.28 Fuel pipework from fuel filter to HP pump – Installation
Material

Engine oil
Spare parts

Grommet

• Do not smoke.
cardiagn.com

Fuel pipework from fuel filter to HP pump – Installation

2. Install fuel pipework from fuel filter to HP pump as per overview drawing (→ Page 1383).
TIM ID: 0000004071 – 005
M020124/02E 2009-02 © MTU

9.7.29 Leak-off fuel pipework – Overview
Fuel return lines
cardiagn.com
1 Fuel return line 13 Retainer 25 Sealing ring
2 Union 14 Grommet 26 T adapter
3 Sealing ring 15 Grommet 27 Fuel return line
4 Fuel collecting line 16 Screw 28 Fuel return line
5 Fuel collecting line 17 Screw 29 Grommet
6 Union 18 Pipe half-clamp 30 Grommet
7 Sealing ring 19 Pipe half-clamp 31 Pipe half-clamp
8 Sealing cone 20 Fuel return line 32 Pipe half-clamp
9 Plug nut 21 Fuel return line 33 Screw
10 Pipe half-clamp 22 Fuel return line 34 Pipe half-clamp
11 Screw 23 Fuel return line 35 Union
12 Grommet 24 Banjo screw
TIM ID: 0000033770 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Leak-off fuel housing 10 Threaded adapter 19 Screw
2 Screw 11 Sealing ring 20 Pipe half-clamp
3 Washer 12 Sealing cone 21 Pipe half-clamp
4 Adapter 13 Nut 22 Screw
5 Union 14 Retainer 23 Grommet
6 Sealing ring 15 Retainer 24 Screw
7 Plug screw 16 Grommet 25 Pipe half-clamp
TIM ID: 0000033770 – 001
M020124/02E 2009-02 © MTU

9.7.30 Leak-off fuel line – Removal
Preconditions

• Do not smoke.
Removing leak-off fuel line

1. Prior to removal of the lines take photos or mark add-on components and lines.
3. Remove fuel lines with securing hardware as per overview drawing (→ Page 1388).
cardiagn.com
TIM ID: 0000004072 – 007
M020124/02E 2009-02 © MTU

9.7.31 Leak-off fuel pipework – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Leak-off fuel pipework – Cleaning

TIM ID: 0000004073 – 002
M020124/02E 2009-02 © MTU

9.7.32 Leak-off fuel pipework – Check
Spare parts

Sealing rings

Risk of injury!
Leak-off fuel pipework – Check
Item Findings Task
Visually inspect all leak-off fuel lines Damaged • Corrective work

for damage. • Replace
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Pressure-test leak-off fuel lines with Leaking Replace
air in water bath for leaks. A water
temperature of min = 30°C and
max = 40°C and a test pressure of
Check banjo screws for damage and • Damaged • Corrective work: Recut threads
threads for ease of movement. • Threads sluggish. • Replace
damage oilstone.
• Replace
TIM ID: 0000004074 – 002
M020124/02E 2009-02 © MTU

9.7.33 Leak-off fuel line – Installation
Spare parts

Sealing ring
Grommet

• Do not smoke.
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Installing leak-off fuel line

2. Install leak-off fuel line according to overview drawing (→ Page 1388) or according to photos/markings.
TIM ID: 0000004075 – 007
M020124/02E 2009-02 © MTU

9.8 Exhaust Turbocharger
9.8.1 Exhaust turbochargers – Overview
Exhaust turbochargers – Overview
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10 Exhaust turbocharger, left 14 Adapter 25 Nut
engine side 16 Screw 30 Sealing ring
11 Exhaust turbocharger, right 18 Screw 35 Screw
engine side 19 Washer 40 Spacer sleeve
13 Locking plate
TIM ID: 0000029658 – 001
M020124/02E 2009-02 © MTU

9.8.2 Exhaust turbocharger – Removal
Preconditions
Special tools

Heavy object.
Risk of crushing!
Exhaust turbocharger – Removal

1. Insert eyebolt into bearing housing of exhaust turbocharger.
2. Secure exhaust turbocharger with crane and hook-ended chain sling.
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3. Remove nuts and sleeves for exhaust turbocharger as per overview drawing (→ Page 1394).
4. Remove exhaust turbocharger from exhaust manifold.
6. Remove studs from exhaust manifold.
TIM ID: 0000005962 – 006
M020124/02E 2009-02 © MTU

9.8.3 Exhaust turbocharger – Disassembly
Special tools

Vibe jaw F70144375 2
T torque wrench F30520703 1


Risk of injury!
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Exhaust turbocharger – Disassembly

1. Mark positions of compressor casing (1) and
turbine housing (4) to the bearing housing (2) and
to the back wall of the compressor (arrows).
2. Mount turbine housing (4) on the gas intake
flange with braces.
3. Remove tensioning segments (3) from turbine
housing.
4. Carefully take turbine housing (4) off bearing
housing, in doing so do not tilt housing. Tilting
can cause damage to the blade.
5. If the turbine housing (4) sticks, use rust-removing
agent. If necessary, use copper hammer.
TIM ID: 0000019345 – 001
M020124/02E 2009-02 © MTU

6. Remove nuts (1) and tensioning segments (2) from

compressor casing.
7. Carefully take compressor casing off bearing
housing. Take care that the blade is not damaged.
8. If the turbine housing sticks, use a rubber mallet.
9. Mount impeller on the hub in the vibe jaw (3).
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Note: Left-hand thread
10. Remove self-locking nut (2) with two-armed

wrench (1).
11. The nut is only loosened with the two-armed
wrench so that the impeller shaft is not damaged.
12. Pull compressor wheel (1) off compressor shaft, if

necessary press the impeller out with a handpress
(arrow).
TIM ID: 0000019345 – 001
M020124/02E 2009-02 © MTU

13. Carefully remove impeller shaft (2) from bearing

housing (1).
14. Center heat shield (3) and remove from the
impeller shaft, in doing so observe piston rings.
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impeller shaft.
16. Mount bearing housing between both flange faces

in bench vise (use braces).
17. Remove screws (1), take back wall (2) off bearing
housing and remove O-rings. TIM ID: 0000019345 – 001
M020124/02E 2009-02 © MTU

18. Press sealing bushing (1) out of back wall (3).

sealing bushing (1).
20. Remove oil thrower ring (1), oil retainer (2), bearing
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collar (3), axial bearing washer (6), bushing (5)
and bearing collar (4) from bearing housing.
21. Install snap rings (1) and bearing bushing (2) at

the compressor side and then remove snap rings
(3) and bearing bushing (4) at the turbine side.
TIM ID: 0000019345 – 001
M020124/02E 2009-02 © MTU

9.8.4 Exhaust turbocharger – Cleaning
Material

Cleaning agent
Compressed air.
Risk of injury!

• Do not smoke.
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Disassemble exhaust turbocharger (→ Page 1396).
Exhaust turbocharger – Cleaning

3. Thoroughly blow off all parts with compressed air.
Wet sand blasting

1. Protect bearing bores and piston ring sealing faces on the bearing housing and shaft and piston ring sealing
faces on the back wall from cast-steel shots.
2. Wet sand blast housing, impeller, compressor wheel, back wall and heat shield.
TIM ID: 0000019450 – 001
M020124/02E 2009-02 © MTU

9.8.5 Exhaust turbocharger – Check
Spare parts

Bearing housing
Turbine housing
Compressor housing
Rotor
Compressor wheel
Exhaust turbocharger check
Visually check housing, guide vane • Cracks Replace
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ring, heat shield and impellers for • Foreign objects
cracks, foreign objects and scoring. • Scoring
visible
Check oil supply bores in bearing Foreign objects visible. Replace

housing for foreign objects.
Check piston sealing faces and Damaged Replace

bearing points for damage.
Check turbine housing for scaling. Scale visible on gas inlet land or Replace
circumference.
Check gas inlet flange and gas Flange uneven. • Corrective work: Smooth using
outlet flange for flatness. oilstone.
• Replace
Check impellers for bent or broken Damaged Replace

blades and check impeller shaft for
scored bearings.
Check piston seat in rear wall and • Scores Replace

bearing housing for scoring and • Damage
damage. visible
Self-locking nuts Replace

O-rings
Wear parts and rotating parts that display cracks must be replaced.
Replace clamping segments, nut, shaft nut, piston rings, cylinder head bolts and washers, O-rings, oil deflector,
thrust washer, snap rings, bearing bushings and screws during overhaul.
TIM ID: 0000019347 – 002
Bearing housing
Note: The segment mating faces must not display severe corrosion.
1. Measure max. bore ID at the bearing points using a bore gauge.

• Max. bore ID = 22.272 mm
2. If the limit value is exceeded, replace bearing housing.
M020124/02E 2009-02 © MTU

Turbine housing
1. Radial cracks of up to 10 mm in length in the area
of lug (2) and partition wall (1) are permissible.
2. Complete cracking is not permissible.
3. Slight scoring in the circumferential area is
permissible.
4. Replace component if the gas inlet flange or gas
outlet flange is distorted.
Compressor housing
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1. Check circumferential area (arrowed) for scoring
and deformation. Scoring of up to 0.2 mm
is permissible.
2. Replace compressor housing if deformed.
Rotor
1. Check rotor shaft for roundness:
1.1. Position rotor shaft on two V-blocks at
the bearing points.
1.2. Position measuring sensor on the shaft
at a distance of 5 mm to the end of the
compressor wheel seat.
1.3. Evenly press rotor shaft onto the V-blocks
during testing.
1.4. Maximum permissible radial runout <
0.008 mm.
TIM ID: 0000019347 – 002
1.5. Replace rotor if the permissible radial

runout is exceeded.
2. Measure shaft diameter at the bearing points and
piston ring groove width.
• Min. diameter = 14.25 mm
• Max. groove width = 3.32 mm
3. Replace shaft if limit values are violated.
M020124/02E 2009-02 © MTU

Note: During production, all compressor wheels and

shafts are balanced separately. Deposits and
contamination on the compressor and turbine
wheels can lead to unbalance during operation.
Unless a new rotor assembly is installed,
the entire rotor assembly must be balanced
during each repair.
Balancing rotor assembly

1. Clean all parts of the rotor assembly (rotors,
bearing collar, seal bushing (oil deflector ring),
bush, compressor wheel and shaft nut) prior
to balancing.
2. The position of the parts relative to each other
must be marked.
Note: The rotor assembly must only be balanced
in planes A and B!
3. Support rotor assembly at bearing points (arrowed)
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in balancing device.
4. Impermissible residual unbalance of the rotor
assembly must be reduced by taking off material
(see following paragraphs) in planes A and B to
the max. values stated in the table.
Turbocharger type Balancing plane A (C) in mmg Balancing plane B (T) in mmg
K 36 4.0 3.1
K 37 4.6 3.6
Removing material at compressor wheel

1. During material removal in the area of the blade
base a minimum distance (X) of 2 mm must
be adhered to.
surrounding area.
TIM ID: 0000019347 – 002
M020124/02E 2009-02 © MTU

Removing material at turbine wheel

1. Material removal during balancing in a circle
segment of max. 150°.
surrounding area.
Max. permissible material removal
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Turbocharger Compressor wheel Turbine wheel
type
D R F G H
(mm) (mm) (mm) (mm) (mm)
K 36 4 4 2.5 4.0 1.5
K 37 4 5 2.5 4.0 1.5
TIM ID: 0000019347 – 002
M020124/02E 2009-02 © MTU

9.8.6 Exhaust turbocharger – Tolerances
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B Compressor wheel rear side – –

TIM ID: 0000019348 – 001
bearings
bearings
M020124/02E 2009-02 © MTU


B Compressor wheel rear side 0.8 –

bearings
bearings
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TIM ID: 0000019348 – 001
M020124/02E 2009-02 © MTU

9.8.7 Exhaust turbocharger – Assembly
Special tools

Assembly jaws F70144375 2.
Tee torque wrench, 10-90 Nm F30520703 1
Angle of rotation measuring device Y20044010 1
Dynamometer Y20504961 1
Material

Engine oil 40453 1
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Assembly paste Ultra-Therm MTU 50547 1
Loctite 640 40105 1
Spare parts

O-rings
Spring pins
Piston rings
Bearing bushings
Piston rings
Snap ring
Heavy object.
Risk of crushing!

TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

Exhaust turbocharger – Assembly

1. Check that all parts are perfectly clean, clean if
required.
2. Oil the following bearing components prior
to installation:
• Rotor bearing seats
• Bearing bushings
• Thrust washer
• Sealing bushing
• Oil control ring
• Bearing collar
• Piston rings
• Bushing
3. Install snap rings (1) and bearing bushing (2) from
compressor side, then snap rings (3) and bearing
bushing (4) from turbine side in bearing housing.
4. Insert snap rings with the round edge facing the
bearing bushing. Ensure that the snap ring is
properly seated in the groove!
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5. Clamp rotor shaft in bench vise (use protective
jaws).
6. Carefully fit piston rings (1) on shaft, aligning the
piston ring joints (arrow) arranged with an offset
of 180°.
7. Center piston rings on rotor shaft.
8. Carefully place heat shield (1) over piston rings on

turbine wheel.
9. Insert a sheet strip (2) of 1 mm thickness between
heat shield and rear side of turbine wheel to
ensure that the piston rings are properly guided in
the bearing housing bore.
TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

10. If the rotor assembly has been rebalanced,

observe the associated position markings.
11. Move sleeve onto rotor shaft to protect the thread.
12. Carefully move bearing housing (4) onto rotor
shaft, ensuring that the oil supply bore of the
bearing housing is arranged with an offset of 90°
towards the piston ring joint.
Note: The piston rings are properly seated when
heat shield and bearing housing can
easily be rotated.
13. Move first bearing collar (5) and bushing (2)

onto rotor shaft.
14. Insert thrust washer (3) in bearing housing,
ensuring that the centering pins (arrows) are
properly seated.
15. Move second bearing collar (1) onto rotor shaft.
16. Place oil baffle plate (1) on thrust washer, ensuring
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that the oil baffle plate is properly seated (arrows).
17. Move oil control ring (3) with smaller collar facing
downwards onto rotor shaft.
in groove in bearing housing.
19. Carefully install two piston rings (2) on sealing

bushing (1).
20. Arrange piston ring joints with 180° offset.
21. Install sealing bushing with chamfer (arrow)
facing compressor wheel rear side (upwards) in
rear wall (3).
Note: If necessary, compress piston ring with
screwdriver.
22. Position sealing bushing so that oil supply bore

of bearing housing is arranged at 90° offset
towards piston ring joint.
TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

23. Clean threads of screws (1) and in bearing

housing, ensuring that they are free of grease
and dry.
24. Coat screw threads with Loctite.
25. Place rear wall (2) according to the markings
onto bearing housing.
Note: Loctite curing process is completed after
approx. 24 hours only.
26. Install screws and washers and use torque wrench

to tighten to specified tightening torque. Values
(→ Page 980).
27. Remove sheet strip (3) between heat shield and
turbine wheel rear side.
28. Measuring turbine-side contour clearance:
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28.1. Insert core assembly, without compressor
wheel and shaft nut, in turbine housing and
tighten with screws.
28.2. Position dial-gauge anvil on turbine wheel
hub.
29. Following this measurement, remove turbine
housing.
30. Measuring compressor-side contour clearance:

30.1. Push compressor wheel onto shaft. Insert
core assembly, without shaft nut, in
compressor housing and tighten with nuts.
30.2. Position dial-gauge anvil on compressor
wheel hub and set dial gauge to “0”.
30.3. Lift compressor wheel as far as it will go and
31. Following this measurement, remove compressor
housing.
TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

Note: Do not subject shaft to bending stress.
32. Tighten new shaft nut (2) with Tee torque

wrench (1) to specified pretightening torque and
angle of further rotation. Values (→ Page 980).
Note: The turbine-side piston rings are properly
seated if heat shield and bearing housing
can easily be rotated after the compressor
wheel has been installed.
33. Secure shaft nut and threaded journal of rotor with

screw locking varnish (arrow).
34. Measuring axial clearance:
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34.1. Place dial-gauge anvil under preload on
turbine wheel hub.
note down measured value. Values
(→ Page 1405).
35. Measuring radial clearance:

Note: Radial clearance measurement is
required on turbine side only.
35.1. Place dial gauge stylus in the center of the

seating taper (arrow 1) of the turbine wheel.
35.2. Use dynamometer to pull down turbine
wheel hub at 50 N measurement force
(arrow 2).
35.4. Use dynamometer to pull up turbine wheel
hub at 50 N measurement force (arrow 2).
TIM ID: 0000019346 – 001
35.5. Note the reading at the dial gauge. Values

(→ Page 1405).
35.6. Rotate rotor through 90°.
35.7. Repeat measurement.
M020124/02E 2009-02 © MTU

in groove in rear wall.
37. Place compressor housing (1) onto rear wall,
38. Fit clamping segments (2) and screw on new
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nuts (1).
39. Use torque wrench to tighten nuts (1) to specified
tightening torque. Values (→ Page 980).
40. Place turbine housing (3) onto bearing housing,

41. Coat thread of screws (1) with assembly paste.
42. Fit clamping segments (2) and insert screws (1).
specified tightening torque. Values (→ Page 980).
44. Check rotor shaft for ease of movement.
TIM ID: 0000019346 – 001
M020124/02E 2009-02 © MTU

9.8.8 Exhaust turbocharger – Installation
Special tools

Material

Assembly paste (Ultra Therm) 50547 1
Spare parts

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Sealing ring
Sleeve
Heavy object.
Risk of crushing!
Exhaust turbocharger – Installation

1. Coat studs at threaded end with assembly paste.
2. Install studs and use torque wrench to tighten to specified tightening torque (→ Page 980).
3. Fit new sealing rings in exhaust manifold.
4. Position exhaust turbocharger with crane and hook-ended chain sling.
5. Coat thread and nut contact faces with assembly paste.
6. Screw on nuts with sleeves and use torque wrench to tighten crosswise to specified tightening torque
(→ Page 980).
7. Check-tighten with same tightening torque.
TIM ID: 0000008438 – 003
M020124/02E 2009-02 © MTU

9.9 Charge-Air Cooling
9.9.1 Intercooler – Overview
Intercooler
1
2
3
Elbow, left side
Vent line
End housing, top
6
A
B
Elbow, right side
Air inlet (from turbocharger)
Air outlet (to cylinder)
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4 Intercooler core C Coolant inlet
5 End housing, bottom D Coolant outlet
TIM ID: 0000030093 – 001
M020124/02E 2009-02 © MTU

Intercooler and attachments
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1 Intercooler 8 Mounting bracket 15 Mounting bracket
2 Plug screw 9 Mounting bracket 16 Hex bolt
3 Connection housing, bottom 10 Screw 17 Washer
4 Dowel pin 11 Washer 18 Hex bolt
5 Rubber profile 12 Screw 19 Washer
6 Hex bolt 13 Screw
7 Washer 14 Mounting bracket
TIM ID: 0000030093 – 001
M020124/02E 2009-02 © MTU

9.9.2 Intercooler – Removal
Preconditions
Heavy object.
Risk of crushing!
Intercooler – Removal
1. Remove intercooler and elbow as per overview
2. Attach intercooler to crane with rope and carefully
raise from engine.
3. After removing intercooler, seal all connections on
engine with suitable plugs and covers.
4. Protect intercooler from damage. Cover cooler
meshes.
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TIM ID: 0000003462 – 008
M020124/02E 2009-02 © MTU

9.9.3 Intercooler – Cleaning

Work on the intercooler must always be carried out by qualified personnel.
The following sections contain instructions for the cleaning company.
Air-side cleaning
In the event of grease and oil contamination on the intercooler’s air side, it is to be cleaned in a closed
cleaning unit. The cleaner must circulate in the opposite direction of the cooling air.
It is essential to avoid damaging the cooler, especially the cooling fins.
Water-side cleaning
It is recommended that the water side is cleaned in a closed cleaning unit with forced flushing and filter.
The water side can also be cleaned in an immersion or ultrasonic bath.
Intercooler – Flushing
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After cleaning, flush the intercooler with water until the pH values of the clean water and the flushing
water are the same (permissible difference pH value: 1 pH).
Intercooler – Drying and preservation
If the cooler is not to be put into operation immediately after cleaning, the cooler is to be dried in a
drying oven for approx. 3 hours at a temperature of 110 to 120 °C.
After drying, preserve the cooler with a preservative.
TIM ID: 0000008440 – 003
M020124/02E 2009-02 © MTU

9.9.4 Intercooler – Check
Material

Emery cloth
Spare parts

Intercooler
Elbow
Holder
Plug-in pipe with bell
Plug-in pipe
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Drain valve
Compressed air.
Risk of injury!
Component is hot.
Risk of burning!

Hot testing liquid.
Intercooler – Check
Item Findings Task
Visually inspect all components for Damaged • Recondition

damage. • Replace
Check all sealing, mating and • Damaged • Recondition:

contact faces for damage and • Uneven smooth with oilstone or emery
unevenness. cloth.
• Replace
Intercooler – Leak check

TIM ID: 0000008441 – 002
1. Seal coolant chamber connections on intercooler with suitable sleeves and covers with gaskets and clamps.
2. Connect compressed air line at plug.
4. Immerse intercooler in test bath.
5. Open compressed air supply and set pressure reducer to 0.5 bar.
6. Pressure-test intercoolers with air in water bath for leaks. Verify that no bubbles rise to the surface.
M020124/02E 2009-02 © MTU

7. Replace intercooler if leaks are found.

8. After checking, blow through cooling air ducts with compressed air in vertical direction.
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TIM ID: 0000008441 – 002
M020124/02E 2009-02 © MTU

9.9.5 Intercooler – Installation
Material

Spare parts

O-ring
Heavy object.
Risk of crushing!
Intercooler – Installation
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2. Coat O-ring with petroleum jelly and place on
elbow flange.
3. Use crane to place intercooler on engine.
4. Screw screws (5) into mounting brackets (1).
5. Install elbow (3) to intercooler and secure with
screws (2) and nuts (4).
TIM ID: 0000008445 – 003
M020124/02E 2009-02 © MTU

9.10 Air Intake/Air Supply
9.10.1 Air intake / air supply – Overview
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1 Intercooler 6 Air intake 11 Charge air line
2 Charge air manifold 7 Exhaust turbocharger, left 12 Connecting elbow
3 Connecting elbow 8 Exhaust turbocharger, right 13 Charge air manifold
4 Exhaust turbocharger, left 9 Air intake
5 Charge air line 10 Exhaust turbocharger, right
TIM ID: 0000008446 – 001
M020124/02E 2009-02 © MTU

9.10.2 Intake housing – Overview
Air Intake
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1 Connecting piece
2 Rubber sleeve
3 Clamp
4 Clamp
5 Plug
TIM ID: 0000029662 – 001
M020124/02E 2009-02 © MTU

Air Intake
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1 Elbow 2 Clamp
TIM ID: 0000029662 – 001
M020124/02E 2009-02 © MTU

9.10.3 Intake housing – Removal
Preconditions
Intake housing – Removal
1. Release clamps and remove air intake as shown in overview drawing (→ Page 1422).
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TIM ID: 0000008449 – 005
M020124/02E 2009-02 © MTU

9.10.4 Intake housing – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Remove intake housing (→ Page 1424).
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Intake housing – Cleaning
2. Remove cleaner.
TIM ID: 0000008450 – 001
M020124/02E 2009-02 © MTU

9.10.5 Intake housing – Check
Spare parts

Elbow
Rubber sleeve
Clamp
Plug
Connector
Clean intake housing (→ Page 1425).
Intake housing – Check
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Check connector, elbow and rubber • Wear • Recondition
sleeve for wear, cracks and damage. • Cracks • Replace
• Damage
visible
Check clamps, plug for ease of Sluggish • Recondition

TIM ID: 0000008451 – 001
M020124/02E 2009-02 © MTU

9.10.6 Intake housing – Installation

Intake housing – Installation
1. Remove all seals and plugs.
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TIM ID: 0000008452 – 004
M020124/02E 2009-02 © MTU

9.10.7 Intake air system to cylinders, left – Overview
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1 Charge air manifold 5 Hex screw
2 Charge air manifold 6 Washer
3 O-ring 7 Plug
4 Gasket 8 Sealing ring
TIM ID: 0000004079 – 001
M020124/02E 2009-02 © MTU

9.10.8 Air supply system to cylinders, left-hand side – Removal
Preconditions
Removing charge-air pipe
1. Remove charge-air pipe as shown in overview drawing, starting with the free end (→ Page 1428).
3. After removal, seal all openings with plugs or covers.
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TIM ID: 0000004080 – 006
M020124/02E 2009-02 © MTU

9.10.9 Air supply system to cylinders, left – Cleaning
Material

Compressed air.
Risk of injury!

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Cleaning charge-air manifold

1. Clean left charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
TIM ID: 0000004081 – 002
M020124/02E 2009-02 © MTU

9.10.10 Air supply to cylinders, left side – Check
Material

Spare parts

Charge air manifold
Sealing ring
Screws
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Plug screw
Compressed air.
Risk of injury!
Checking air supply to cylinders, LHS
Item Findings Task


• Replace


TIM ID: 0000004082 – 003
M020124/02E 2009-02 © MTU

9.10.11 Air supply system to cylinders, left-hand side – Installation
Material

Engine oil
Spare parts

O-ring
Gasket
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Installing air supply system to cylinders, left-hand

side
manifold union (2).
faces (arrows).
with driving end.
TIM ID: 0000004083 – 005
M020124/02E 2009-02 © MTU

9.10.12 Air supply system to cylinders, right – Overview
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1 Charge air manifold 5 Hex screw 9 Threaded bush
2 Charge air manifold 6 Washer 10 Sealing ring
3 O-ring 7 Plug 11 Plug
4 Gasket 8 Sealing ring 12 Sealing ring
TIM ID: 0000004084 – 001
M020124/02E 2009-02 © MTU

9.10.13 Air supply system to cylinders, right-hand side – Removal
Preconditions
Removing charge air manifold
1. Remove charge-air manifold as per overview drawing starting from the free end . (→ Page 1433)
3. After removal, seal all openings with suitable plugs or covers.
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TIM ID: 0000004087 – 006
M020124/02E 2009-02 © MTU

9.10.14 Air supply system to cylinders, right – Cleaning
Material

Compressed air.
Risk of injury!

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Cleaning the charge-air manifold

1. Clean right charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
TIM ID: 0000004085 – 002
M020124/02E 2009-02 © MTU

9.10.15 Air supply to cylinders, RHS – Check
Material

Spare parts

Charge air manifold
Sealing ring
Screws
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Plug screw
Compressed air.
Risk of injury!
Checking air supply to cylinders, RHS
Item Findings Task


• Replace


TIM ID: 0000004086 – 003
M020124/02E 2009-02 © MTU

9.10.16 Air supply system to cylinders, right-hand side – Installation
Material

Engine oil
Spare parts

O-ring
Gasket
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Installing charge air manifold

manifold union (2).
faces (arrows).
with driving end.
TIM ID: 0000004088 – 006
M020124/02E 2009-02 © MTU

9.10.17 Air pipework from turbocharger to intercooler – Overview
Air pipework 12V
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1 Connection housing 10 Plug-in pipe 19 O-ring
2 O-ring 11 O-ring 20 Clamp
3 Spacer sleeve 12 O-ring 21 Rubber sleeve
4 Spacer sleeve 13 Elbow 22 Clamp
5 Screw 14 O-ring 23 Elbow
7 Connecting piece 16 Washer 25 Screw
8 O-ring 17 Nut 26 Washer
9 Clamp 18 Connecting piece 27 Nut TIM ID: 0000030095 – 001
M020124/02E 2009-02 © MTU

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1 Connecting piece 11 Pipe half-clamp 21 Retainer
2 O-ring 12 Screw 22 Washer
3 Clamp 13 Washer 23 Screw
4 Charge-air pipe 14 Nut 24 Pipe half-clamp
5 Rubber sleeve 15 Connecting piece 25 Pipe half-clamp
7 Retainer 17 Clamp 27 Washer
8 Washer 18 Charge-air pipe 28 Nut
9 Screw 19 Rubber sleeve
10 Pipe half-clamp 20 Clamp
TIM ID: 0000030095 – 001
M020124/02E 2009-02 © MTU

Air pipework 16V
cardiagn.com
1 Connection housing 19 Washer 37 Connecting piece
2 O-ring 20 Nut 38 O-ring
3 Spacer sleeve 21 Retainer 39 Screw
4 Spacer sleeve 22 Washer 40 Washer
5 Screw 23 Washer 41 Elbow
7 Connecting piece 25 Pipe half-clamp 43 Screw
10 Washer 28 Washer 46 Retainer
11 Charge-air pipe 29 Nut 47 Washer
12 Rubber sleeve 30 Connecting piece 48 Washer
14 Plug-in pipe 32 Screw 50 Pipe half-clamp
15 O-ring 33 Washer 51 Pipe half-clamp
16 Elbow 34 Charge-air pipe 52 Screw
17 O-ring 35 Rubber sleeve 53 Washer
18 Screw 36 Clamp 54 Nut
TIM ID: 0000030095 – 001
M020124/02E 2009-02 © MTU

Intercooler elbow
cardiagn.com
1 Elbow 4 Elbow 7 Screw
2 Plug screw 5 Plug screw 8 Nut
3 Plug screw 6 O-ring 9 O-ring
TIM ID: 0000030095 – 001
M020124/02E 2009-02 © MTU

9.10.18 Air pipework from exhaust turbocharger to intercooler – Removal
Preconditions
Air pipework from exhaust turbochargers to intercooler – Removal
1. Remove air pipework as per overview drawing (→ Page 1438).
cardiagn.com
TIM ID: 0000008455 – 003
M020124/02E 2009-02 © MTU

9.10.19 Air supply from turbocharger to intercooler – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning air pipework

TIM ID: 0000008456 – 002
M020124/02E 2009-02 © MTU

9.10.20 Air ducts from turbocharger to intercooler – Check
Material

Spare parts

Charge air line
Connecting housing
Connecting elbow
Connector
Plug-in pipe
cardiagn.com
Rubber sleeve
Elbow
Spacer sleeve
Screw
Nut
Clamp
Bracket
Clean air ducts from turbocharger to intercooler (→ Page 1443).
Air ducts from turbocharger to intercooler – Check
Using the fluorescent penetrant dye method, check the Crack indication Replace
connecting housing, elbow, bracket and connection
elbow for cracks.
Check elbow and connection elbow with air under Leaking: • Replace blanking
water, max. air pressure 0.5 bar, for leaks. • at blanking plugs plug.
• at elbow • Replace elbow.
Check sealing and bolt-on faces for evenness and • Uneven • Recondition:
damage. • Damaged Smooth with
oilstone.
• Replace
Check all threads for ease of movement. Sluggish • Recut thread.

• Replace thread
inserts.
TIM ID: 0000008457 – 001
Check connector, plug-in pipe, charge air line, screws, Damaged Replace
clamps and plugs for damage and wear.
M020124/02E 2009-02 © MTU

9.10.21 Air pipework from turbocharger to intercooler – Installation
Material

Spare parts

O-rings
cardiagn.com
Air pipework from turbocharger to intercooler – Installation
TIM ID: 0000008458 – 003
M020124/02E 2009-02 © MTU

9.11 Exhaust System
9.11.1 Exhaust system – Overview
Exhaust system
cardiagn.com
1 Exhaust turbocharger, left 4 Exhaust turbocharger, right 7 Exhaust turbocharger, right
2 Exhaust system 5 Exhaust pipework connection
3 Exhaust turbocharger, left 6 Exhaust system
TIM ID: 0000008460 – 001
M020124/02E 2009-02 © MTU

9.11.2 Exhaust pipework after cylinder head – Overview
Exhaust pipework 16V (also applicable to 8V / 12V)
cardiagn.com
1 Exhaust pipe 6 V-band clamp
2 Exhaust pipe 7 Insulation
3 Exhaust pipe 8 Gasket
4 Exhaust pipe 9 Screw
5 Bellows 10 Spacer
TIM ID: 0000029668 – 001
M020124/02E 2009-02 © MTU

9.11.3 Exhaust pipework after cylinder head – Removal
Preconditions

Risk of injury!
Exhaust pipework – Removal

1. Remove gasket (1).
2. Screw nut onto stud (2) and secure with second
nut.
3. Remove stud (2).
cardiagn.com
4. Remove screws (1) from band clamps (2).
5. Take off band clamps carefully.
6. Take off insulation.
7. Remove other insulation parts in the same way.
TIM ID: 0000030002 – 001
M020124/02E 2009-02 © MTU

8. Remove V-band clamps (2) from bellows (1).

9. Remove bellows (1).
10. Remove other bellows in the same way.
11. Remove all screws (1) from exhaust pipes and
cardiagn.com
take off spacers (2).
12. Remove all exhaust pipes.
13. Seal exhaust ports on cylinder head with suitable
plugs.
TIM ID: 0000030002 – 001
M020124/02E 2009-02 © MTU

9.11.4 Exhaust pipework after cylinder head – Clean
Material

Compressed air.
Risk of injury!
Compressed air.
Risk of injury!
cardiagn.com

Cleaning exhaust pipework after exhaust turbocharger

2. Place components with deposits in a container with decarbonizer. Time for cleaning depends on the layer
thickness of the deposits.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
5. Remove cleaner.
TIM ID: 0000029122 – 001
M020124/02E 2009-02 © MTU

9.11.5 Exhaust pipework after cylinder head – Check
Material

Spare parts

Exhaust pipe
Bellows
Hex screw
cardiagn.com
Gasket
Exhaust pipework after cylinder head – Check
Using the surface crack-test Crack indication Replace

method and red penetrant
dye, check exhaust pipe and
bellows for cracks.
Check hex screws for Damaged Replace

damage.
Check parts for stress marks, • Stress marks Replace

wear and distortion. • Wear
• Distortion
visible
Check sealing and mating • Uneven • Recondition: Smooth with oilstone

faces for evenness and • Damaged • Replace
damage.
TIM ID: 0000032573 – 001
M020124/02E 2009-02 © MTU

9.11.6 Exhaust pipework after cylinder head – Installation
Special tools

Material

Engine oil 40453 1
Spare parts
cardiagn.com
Gasket
Heavy object.
Risk of crushing!
Exhaust pipework – Installation

2. Fit gaskets (1) on all cylinder head exhaust flanges.
TIM ID: 0000030005 – 001
M020124/02E 2009-02 © MTU

3. Position exhaust pipe starting from engine free

end.
4. Coat screws (1) with engine oil.
5. Insert screws (1) with spacers (2).
6. Tighten screws crosswise.
7. Fit gaskets (arrow) on both flange faces of the
cardiagn.com
exhaust pipe bellows.
8. Fit two V-band clamps (2) over exhaust pipe

bellows.
9. Position exhaust pipe bellows between exhaust
pipe flanges.
10. Use alignment device (1) to align collar of exhaust
pipe flange and exhaust pipe bellows flush.
TIM ID: 0000030005 – 001
M020124/02E 2009-02 © MTU

11. Push V-band clamp (2) centrally over flange collar

of exhaust pipe flange and exhaust pipe bellows
and secure with screws.
12. Remove alignment device (1).
13. Push second V-band clamp centrally over flange
collar of exhaust pipe flange and exhaust pipe
bellows and secure with screws.
14. Install further exhaust pipe bellows in the same
way.
15. Fit insulation (2) over exhaust pipe bellows and
cardiagn.com
secure with band clamps (1).
16. Position band clamps (1) so that screws are
accessible in horizontal position.
17. Tighten screws.
18. Install further insulation parts in the same way.
19. Fit gaskets (1).

20. Insert studs (2) with the small thread ahead into
the flange for the exhaust turbocharger.
21. Tighten studs with locknuts. TIM ID: 0000030005 – 001
M020124/02E 2009-02 © MTU

9.11.7 Exhaust pipework after exhaust turbocharger – Overview
Exhaust pipework
cardiagn.com
1 Exhaust elbow 2 Screw 3 Washer
TIM ID: 0000029672 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Bellows
2 Sealing ring
3 Clamp
4 Sealing ring
5 Clamp
TIM ID: 0000029672 – 001
M020124/02E 2009-02 © MTU

9.11.8 Exhaust pipework after exhaust turbocharger – Removal
Preconditions
Exhaust pipework after exhaust turbocharger – Removal
1. Remove exhaust pipework as per overview drawing (→ Page 1455).
cardiagn.com
TIM ID: 0000008521 – 009
M020124/02E 2009-02 © MTU

9.11.9 Exhaust pipework after turbocharger – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Remove exhaust pipework after exhaust turbocharger (→ Page 1457).
cardiagn.com
Exhaust pipework after turbocharger – Cleaning
5. Remove cleaner.
6. Blow out exhaust lines thoroughly.
TIM ID: 0000003743 – 001
M020124/02E 2009-02 © MTU

9.11.10 Exhaust pipework after exhaust turbocharger – Check
Material

Spare parts

Exhaust elbow
Washer
Bellows
cardiagn.com
Clamp
Checking exhaust pipework after exhaust turbocharger
Item Findings Task
Check exhaust elbow with red dye Crack indication Replace

Check parts for stress marks, wear • Stress marks Replace

and deformation. • Wear
• Deformation
visible
Check sealing and mating faces for • Uneven • Corrective work: Smoothen
flatness and damage. • Damaged with oilstone
• Replace
TIM ID: 0000008522 – 002
M020124/02E 2009-02 © MTU

9.11.11 Exhaust pipework after exhaust turbocharger – Installation
Material

Spare parts

Sealing ring
Exhaust pipework after exhaust turbocharger – Installation

1. Prior to assembly, coat screw threads with assembly paste.
2. Install exhaust elbow and bellows as per overview drawing (→ Page 1455).
cardiagn.com
TIM ID: 0000008523 – 005
M020124/02E 2009-02 © MTU

9.11.12 Exhaust pipework after engine – Overview
cardiagn.com
1 Bellows 3 Clamp
2 Sealing ring 4 Insulation
TIM ID: 0000008524 – 001
M020124/02E 2009-02 © MTU

Companion flange
cardiagn.com
1 Flange
TIM ID: 0000008524 – 001
M020124/02E 2009-02 © MTU

9.11.13 Exhaust pipework after engine – Removal

Exhaust pipework after engine – Removal
1. Remove exhaust pipework according to overview drawing (→ Page 1461).
2. After removal, seal all openings.
cardiagn.com
TIM ID: 0000008525 – 002
M020124/02E 2009-02 © MTU

9.11.14 Exhaust pipework after engine – Cleaning
Material

Cleaner
Decarbonizer
Compressed air.
Risk of injury!

cardiagn.com
Remove exhaust pipework after engine (→ Page 1463).
Exhaust pipework after engine – Cleaning

5. Remove cleaner.
TIM ID: 0000008526 – 001
M020124/02E 2009-02 © MTU

9.11.15 Exhaust pipework after engine – Check
Spare parts

Flange
Clamp
Insulation
Clean exhaust pipework after engine (→ Page 1464).
IExhaust pipework after engine – Check
Check exhaust pipe bellows and flange for wear • Traces of wear Replace
and distortion. • Wear
cardiagn.com
• Deformation
visible
Check insulation for damage Damaged Replace
Check clamps for ease of movement. Sluggish • Recondition

• Replace
Check sealing and mating faces for evenness and • Uneven • Recondition: smooth
damage. • Damaged with oilstone
• Replace
TIM ID: 0000008527 – 001
M020124/02E 2009-02 © MTU

9.11.16 Exhaust pipework after engine – Installation
Material

Spare parts

Sealing ring
Check exhaust pipework after engine (→ Page 1465).
Exhaust pipework after engine – Installation

2. Install exhaust pipe bellows as shown in overview drawing (→ Page 1461).
cardiagn.com
TIM ID: 0000008528 – 002
M020124/02E 2009-02 © MTU

9.12 Starting Equipment
9.12.1 Electric starter – Overview
cardiagn.com
1 Starter (for 12V/16V on left
engine side)
2 Starter, right engine side
3 Hex screw / Allen screw
4 Gear ring
TIM ID: 0000001747 – 002
M020124/02E 2009-02 © MTU

cardiagn.com
1 Terminal 45 5 Engagement relay 9 Driver housing
2 Terminal 30 6 Commutator cover 10 Terminal 30
3 Terminal 50 7 Terminal 31
4 Housing for engagement lever 8 Starter housing
TIM ID: 0000001747 – 002
M020124/02E 2009-02 © MTU

9.12.2 Starter – Removal
Preconditions
Electrical voltage.
Heavy object.
Risk of crushing!
Disconnecting and removing starter

1. Before disconnecting, mark all cables with writable
adhesive tape for identification.
• Connection terminal 30 = positive cable
• Connection terminal 50 = control cable
cardiagn.com
• Connection terminal 31 = ground cable
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Depending on the version, remove hex screws or
Allen screws (1) from starter.
5. Remove starter.
6. Protect starter from damage.
TIM ID: 0000001758 – 003
M020124/02E 2009-02 © MTU

9.12.3 Starter – Disassembly
Starter – Disassembly
Entrust starter overhaul to an authorized and specialized company only.
cardiagn.com
TIM ID: 0000001761 – 003
M020124/02E 2009-02 © MTU

9.12.4 Starter – Cleaning

Compressed air.
Risk of injury!
Starter – Cleaning
1. Clean starter with compressed air; do not wet-clean.
2. Protect starter against humidity.
cardiagn.com
TIM ID: 0000001751 – 002
M020124/02E 2009-02 © MTU

9.12.5 Starter – Check
Spare parts

Starter
Compressed air.
Risk of injury!
Starter – Check
Item Findings Task
Check tooth flanks of drive gear for • Wear • Recondition

wear, indentations and chipping. • Indentations • Replace
cardiagn.com
• Chipping
visible
Check nuts and studs for condition Sluggish Replace

and check threads for ease of
movement.
Check mating face on end housing Wear traces are found. Recondition: smooth with oilstone
for wear. or emery cloth.
TIM ID: 0000001755 – 002
M020124/02E 2009-02 © MTU

9.12.6 Starter – Installation
Material

Long-life grease (Longtherm 2 Plus) 40336 1
Electrical voltage.
Heavy object.
Risk of crushing!
Installing starter
1. Coat starter pinion with long-life grease.
cardiagn.com
2. Attach starter to crane.
3. Insert starter into opening on end housing.
4. Align bores for securing screws on starter with
those on flange.
5. Secure starter to flange with screws (1).
Connecting starter cables

1. Connect cables as per marking on starter (→ Page 1469).
• (1) = terminal 45 = internal control cable (already connected)
• (2) = terminal 30 = positive cable
• (3) = terminal 50 = control cable
• (4) = terminal 31 = ground cable
2. Check operation of starter.
TIM ID: 0000001764 – 003
M020124/02E 2009-02 © MTU

9.12.7 Flame starting system – Overview
cardiagn.com
1 Flange 11 Fuel line
2 Insulating washer 12 Fuel line
3 Nut 13 T-piece
4 Fuel nipple 14 Fuel line
5 Sealing element 15 Fuel line
6 Protective shroud 16 Fuel line
7 Screw 17 Bracket
9 Fuel line 19 Grommet
10 T-piece 20 Screw
TIM ID: 0000005115 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Bracket 27 Adapter 53 Fuel line
2 Bracket 28 Sealing ring 54 Non-return valve
3 Screw 29 Pipe half-clamp 55 Bracket
4 Screw 30 Grommet 56 Pipe half-clamp
5 Screw 31 Screw 57 Grommet
6 Washer 32 Fuel line 58 Screw
7 Pressure regulator 33 Bracket 59 Fuel line
8 Screw 34 Screw 60 Fuel line
9 Spacer bush 35 Washer 61 Blanking cone
10 Pipe half-clamp 36 Pipe half-clamp 62 Nut
11 Screw 37 Pipe half-clamp 63 Fuel line
12 Union 38 Grommet 64 Non-return valve
13 Sealing ring 39 Screw 65 Fuel line
14 Bracket 40 Fuel line 66 Grommet
15 Screw 41 Bracket 67 Grommet
18 Fuel line 44 Grommet 70 Pipe half-clamp
19 Adapter 45 Screw 71 Pipe half-clamp
20 Sealing ring 46 Fuel line 72 Washer
21 Fuel line 47 Bracket 73 Spacer pipe
22 Adapter 48 Pipe half-clamp 74 Screw
23 Sealing ring 49 Grommet 75 Bracket
24 Adapter 50 Screw 76 Screw
TIM ID: 0000005115 – 001
25 Sealing ring 51 Fuel line 77 Grommet

26 Fuel line 52 Non-return valve 78 Pipe half-clamp
M020124/02E 2009-02 © MTU

9.12.8 Flame starting system – Removal

• Do not smoke.
Removing flame torches

1. Remove screws (arrowed) from protective cover.
2. Hold sealing element (2) securely and carefully
remove protective cover.
cardiagn.com
3. Removing fuel lines (1).
5. Disconnect control cable at connections (arrowed).
6. Remove sealing element (2).
7. Release flange (4).
8. Remove flame torch (3).
9. Remove insulating washer (5).
Removing fuel lines and externally mounted components

1. Before removing the lines, take photos or mark lines and externally mounted components.
TIM ID: 0000005111 – 002
M020124/02E 2009-02 © MTU

9.12.9 Flame starting system – Cleaning
Material

Cleaning agent
Compressed air.
Risk of injury!

Remove flame starting system (→ Page 1476).
cardiagn.com
Flame starting system – Cleaning
3. Blow out all components thoroughly with compressed air.
TIM ID: 0000005114 – 001
M020124/02E 2009-02 © MTU

9.12.10 Flame starting system – Check
Spare parts

Flange
Insulating washer
Nut
Fuel nipple
Sealing element
Protective shroud
Fuel line
T-piece
Bracket
Bracket
cardiagn.com
Pressure regulator
Spacer bush
Union

Risk of injury!
Clean flame starting system (→ Page 1477).
Flame starting system – Check
Visually check all fuel lines and attachments for Damaged • Recondition
damage. • Replace
Check fuel lines with air bottom water for leaks. Leaking Replace
Maintain a coolant temperature of min. = 30 °C or
Check all threads for damage and ease of • Damaged • Recondition:

movement. • Thread sluggish. Recut thread.
• Replace
Check sealing and screw-on surfaces for damage. Damaged • Recondition:

Smooth with
oilstone.
• Replace
TIM ID: 0000005113 – 001
M020124/02E 2009-02 © MTU

9.12.11 Flame starting system – Installation
Spare parts

Sealing ring
Grommet

• Do not smoke.
cardiagn.com
Check flame starting system (→ Page 1478).
Install flame starting system

2. Blow fuel lines clear with compressed air.
3. Install fuel lines without tension as shown in the overview drawing (→ Page 1474) or as per photos/marks
made during removal.
TIM ID: 0000005112 – 003
M020124/02E 2009-02 © MTU

9.13 Lube Oil System, Lube Oil Circuit
9.13.1 Lube-oil pump with drive – Overview
cardiagn.com
1 Oil pump 6 Banjo screw 11 Grommet
2 Screw 7 Sealing ring 12 Screw
3 Washer 8 Oil line 13 Spacer sleeve
4 Screw 9 Retainer
5 Pressure reducing valve 10 Pipe half-clamp
TIM ID: 0000032414 – 001
M020124/02E 2009-02 © MTU

9.13.2 Lube-oil pump with drive – Removal
Special tools

Heavy object.
Risk of crushing!
Removing oil pump with safety valve

Note: The illustration does not show engine in
1. Unscrew all screws (1) on the oil pump (2).

2. Attach support bracket to oil pump and with rope,
cardiagn.com
slightly tensioned, to crane.
3. Remove oil pump from equipment carrier and
place aside.
Removing oil line and pressure reducing valve

1. Remove oil line from equipment carrier as per overview drawing (→ Page 1480).
2. Remove pressure reducing valve from equipment carrier.
4. Seal connections with suitable plug.
5. Protect oil line from damage.
TIM ID: 0000004096 – 005
M020124/02E 2009-02 © MTU

9.13.3 Lube-oil pump with drive – Disassembly

Lube-oil pump – Disassembly
1. Do not disassemble lube oil pump.
2. Contact Service.
cardiagn.com
TIM ID: 0000004097 – 002
M020124/02E 2009-02 © MTU

9.13.4 Lube oil pump with drive – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning oil line

TIM ID: 0000004094 – 003
M020124/02E 2009-02 © MTU

9.13.5 Lube-oil pump with drive – Check
Material

Spare parts

Oil pump
Pressure reduction valve
Oil line
cardiagn.com
Banjo screw
Screw
Pipe half-clamp

TIM ID: 0000004095 – 003
M020124/02E 2009-02 © MTU

Lube-oil pump with drive – Check
Item Findings Task
Visually inspect outside of lube-oil Damaged Have lube-oil pump operation

pump for damage and defects. checked and repaired at
manufacturer.
Visually inspect oil line for damage. Damaged • Corrective work

• Replace
Check sealing faces for irregularities. Uneven • Corrective work and check for
evenness with ink-check plate.
• Replace
Check banjo screws for damage and • Damaged Replace

Check drive gear with dye penetrant Signs of cracks Replace

for cracks.
Check tooth flanks of drive gear • Stress marks • Corrective work
cardiagn.com
for stress marks, indentations and • Indentations • Replace lube-oil pump
chipping. • Chipping
visible
Check breather valve for opening Opening pressure not reached or Replace
pressure of 15 bar. Test medium: exceeded.
Engine oil SAE 30 medium
temperature: from 90 °C to 100 °C.
Disassembly of the pressure Damaged Replace

reduction valve is not planned;
check for damage by visual
inspection only.
Check pressure reduction valve Opening pressure not reached, or Replace

opening pressure. Operation: The exceeded.
valve limits the oil flow so that a
constant pressure of 5.5 +1 bar is
maintained at the last crankshaft
bearing. Medium temperature: from
90 °C to 100 °C, design pressure at
n/min 1.5 bar at n/max 7 bar of oil
pump.
TIM ID: 0000004095 – 003
M020124/02E 2009-02 © MTU

9.13.6 Lube oil pump with drive – Installation
Special tools

Material

Engine oil
cardiagn.com
Spare parts

Sealing ring
Grommet
O-ring
Heavy object.
Risk of crushing!
Heavy object.
Risk of crushing!
Compressed air.
Risk of injury!
TIM ID: 0000004098 – 007
M020124/02E 2009-02 © MTU

Installing lube oil pump on equipment carrier

1. Degrease sealing face on equipment carrier
and lube-oil pump.
2. Apply surface sealant to sealing surface on
equipment carrier.
3. Attach oil pump with carrying bracket to crane.
4. Insert oil pump into equipment carrier, making
sure gears engage correctly.
5. Screw in screws (1) and (2) for oil pump and use
torque wrench to tighten diagonally to specified
tightening torque .
cardiagn.com
Installing pressure reducing valve

1. Coat O-ring with grease and insert in groove of
pressure reducing valve (arrow).
2. Insert pressure reducing valve (1) in equipment
carrier and tighten to specified torque using a
torque wrench .

Pressure reducing Tightening torque Engine oil 60 Nm +20 Nm
valve
Installing oil line

2. Blow out oil line with compressed air.
TIM ID: 0000004098 – 007
3. Install oil line loosely using attaching parts as per overview drawing (→ Page 1480).
M020124/02E 2009-02 © MTU

9.13.7 Oil filter – Overview
Oil filter housing
cardiagn.com
1 Oil filter housing 5 Washer 9 Hex screw
2 O-ring 6 Bracket 10 Hex screw
3 O-ring 7 O-ring 11 Oil Filter
4 Hex screw 8 O-ring
TIM ID: 0000003497 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Sealing ring 4 Connector 7 Differential pressure monitor
2 Washer 5 Pipe
3 Hex nut 6 Adapter
TIM ID: 0000003497 – 001
M020124/02E 2009-02 © MTU

9.13.8 Oil filter with oil filter housing – Removal
Special tools

Removing oil filter

1. Remove oil filter with filter wrench.
2. Drain oil from oil filter into a suitable container.
cardiagn.com
Removing oil filter housing
1. Remove oil filter housing according to overview
2. Seal connections (arrows) with plugs.
TIM ID: 0000003500 – 005
M020124/02E 2009-02 © MTU

9.13.9 Oil filter housing – Disassembly

Remove oil filter housing (→ Page 1490).
Oil filter housing – Disassembly

1. Remove threaded fittings (3) from oil filter housing
(2).
2. Unscrew all plugs.
cardiagn.com
3. Remove O-rings (5).
4. Remove plug (3) and remove valve.
TIM ID: 0000008529 – 001
M020124/02E 2009-02 © MTU

9.13.10 Oil filter housing – Clean
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning oil filter housing

2. Blow out/off all parts with compressed air.
TIM ID: 0000003498 – 005
M020124/02E 2009-02 © MTU

9.13.11 Oil filter housing – Check
Special tools

Test bath
Spare parts

Oil filter housing
Bracket
Connector
Pipe
Adapter
cardiagn.com
Nut
Washer

Hot testing liquid.
Clean oil filter housing (→ Page 1492).

TIM ID: 0000008530 – 001
M020124/02E 2009-02 © MTU

Oil filter housing – Check
Check all sealing, mating and • Wear • Recondition: smooth with oilstone or
sliding surfaces for wear, scoring • Scores emery cloth.
and indentations. • Indentations • Replace
visible.
Check all threads and threaded Damaged • Recondition: recut thread.

bores. • Replace
Pressure-test oil filter housing Leaking • Replace plugs.

with air in water bath for leaks. • Replace valve.
Install filter inserts before carrying • Replace oil filter housing.
out leak check. Test temperature:
min. 30 °C, max. 40 °C, if oil filter
housing has to be held in hands.
Test pressure: 0.5 bar.
Check differential pressure Damaged Replace

monitor, bracket and line for
cardiagn.com
mechanical damage.
Check spring of pressure limiting Wear Replace

valve for wear.
TIM ID: 0000008530 – 001
M020124/02E 2009-02 © MTU

9.13.12 Oil filter housing – Assembly
Material

Spare parts

O-rings
Plugs
cardiagn.com
Check oil filter housing (→ Page 1493).
Oil filter housing – Assembly

1. Screw threaded fittings (3) into oil filter housing (2).
2. Coat O-rings for plugs (4) with petroleum jelly.
3. Screw in plugs.
TIM ID: 0000008531 – 001
M020124/02E 2009-02 © MTU

4. Coat O-rings for grooves with petroleum jelly.

5. Insert valve with spring in bore (3).
6. Insert plug (3).
7. Insert O-rings in grooves.
cardiagn.com
TIM ID: 0000008531 – 001
M020124/02E 2009-02 © MTU

9.13.13 Oil filter with oil filter housing – Installation
Material

Engine oil
Spare parts

O-rings
cardiagn.com
Assemble oil filter housing (→ Page 1495)
TIM ID: 0000008532 – 002
M020124/02E 2009-02 © MTU

Installing oil filter housing

2. Install oil filter housing as shown in overview
cardiagn.com
4. Insert O-ring in groove (1) of oil filter housing (2).
Installing oil filter

1. Coat sealing ring of oil filter with oil.
2. Install oil filter and tighten by hand.
TIM ID: 0000008532 – 002
M020124/02E 2009-02 © MTU

9.13.14 Centrifugal oil filter– Overview
Centrifugal oil filter with attachments
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1 Centrifugal oil filter 6 Adapter
2 Hex screw 7 Sealing ring
3 Washer 8 Oil line
4 Sealing ring 9 Hex nut
5 Sealing ring 10 Screw
TIM ID: 0000008533 – 001
M020124/02E 2009-02 © MTU

Centrifugal oil filter with flange
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1 Centrifugal oil filter 3 O-ring
2 Flange 4 Screw
TIM ID: 0000008533 – 001
M020124/02E 2009-02 © MTU

Centrifugal oil filter assembly
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1 Housing 10 Cover screw 19 Standpipe
2 Valve 11 Screw 20 Snap ring
3 Sealing ring 12 Pin 21 O-ring
4 Valve piston 13 O-ring 22 Pin
5 Plug 14 Drain screw 23 Knurled nut
6 Compression spring 15 Clamp 24 Insertion sleeve
7 O-ring 16 Rotor unit 25 Reinforcing plate
8 Cover 17 Nozzle
9 Cover 18 Substructure with bearing
TIM ID: 0000008533 – 001
M020124/02E 2009-02 © MTU

9.13.15 Centrifugal oil filter – Removal
Preconditions
Centrifugal oil filter – Removal
1. Remove centrifugal oil filter as shown in overview drawing (→ Page 1499).
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TIM ID: 0000001888 – 005
M020124/02E 2009-02 © MTU

9.13.16 Centrifugal oil filter – Disassembly

Disassembling centrifugal oil filter
1. Release nut with toggle (2) and remove V-band
clamp (1).
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2. Release screw from cover (1).
3. Remove cover (1) from housing (2).
4. Drain residual oil from centrifugal oil filter into a

suitable container.
5. Carefully remove rotor unit (1) from
shaft/housing (3). Avoid damaging bearing
or shaft.
7. Remove valve piston, plug and pressure spring as
shown in the overview drawing (→ Page 1499).
TIM ID: 0000001891 – 003
M020124/02E 2009-02 © MTU

Note: Take care not to interchange rotors

belonging to different centrifugal filters
because rotor hood and substructure are
aligned to one another during manufacture.
8. Release knurled nut (1) and remove rotor hood (3)

with cover plate (2) from rotor substructure (4).
9. Remove paper element from rotor hood (3).
10. Remove pipe (1) from rotor (2).
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TIM ID: 0000001891 – 003
M020124/02E 2009-02 © MTU

9.13.17 Centrifugal oil filter – Cleaning
Material

Compressed air.
Risk of injury!

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Cleaning the rotor unit

TIM ID: 0000001872 – 004
M020124/02E 2009-02 © MTU

9.13.18 Centrifugal oil filter – Check
Material

Spare parts

Housing
Rotor
Nozzle
Pipe
Screw
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Compression spring
Valve plunger
Plug
Centrifugal oil filter – Check
Item Findings Task
Check all sealing, mating and sliding • Wear • Recondition: smooth with
surfaces for wear, scoring and • Scores oilstone or emery cloth.
indentations. • Indentations • Replace
visible.
Using red penetrant dye, check the Cracks indicated Replace rotor unit.
housing and substructure for cracks.
Check all threads and threaded Damaged • Recondition: recut threads.

bores. • Replace
Check journals on rotor and bearing Wear visible • Recondition: smooth with
running surfaces on shaft for wear. oilstone or emery cloth.
• Replace
Check valve piston and spring Wear visible • Recondition

(→ Page 1499) for wear traces. • Replace
TIM ID: 0000001885 – 002
M020124/02E 2009-02 © MTU

9.13.19 Centrifugal oil filter - Bearing clearance check
Special tools

Retainer 0015890321/00 1
Spare parts

Rotor
Clean centrifugal oil filter (→ Page 1505).
Checking bearing clearance of rotor

1. Arrange dial gauge with dial gauge stylus opposite rotor.
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2. Align dial gauge stylus to upper rotor edge, set dial gauge to zero.
5. Align dial gauge stylus to lower rotor edge, set dial gauge to zero.
8. Measure bearing diameter:
• Diameter at upper bearing running surface of shaft: 14.98 mm
• Diameter at lower bearing running surface of shaft: 21.63 mm
• Inner diameter of upper bearing: 15.06 mm
• Inner diameter of lower bearing: 21.69 mm
TIM ID: 0000001869 – 003
M020124/02E 2009-02 © MTU

9.13.20 Centrifugal oil filter – Assembly
Special tools

Material

Engine oil
Spare parts
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Paper element
O-ring
Sealing ring
Heavy object.
Risk of crushing!
TIM ID: 0000001894 – 004
M020124/02E 2009-02 © MTU

Assembling rotor unit

1. Fit pipe (1) on rotor (2).
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2. Insert gaiter (2) in cover (1).
3. Coat O-ring (arrowed) with grease and insert
in groove on cover.
4. Fit cover (1) with new paper element (2) on rotor.
5. Turn cover (1) so that chase (3) and pin (4) are
flush with one another.
TIM ID: 0000001894 – 004
M020124/02E 2009-02 © MTU

6. Install cover plate (2) and tighten knurled nut (1)

by hand.
7. Coat shaft with engine oil.
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8. Carefully insert rotor unit in housing (2).
9. Check that rotor rotates freely.
10. Coat O-ring with grease and insert in groove (1)
on housing (2).
11. Place cover (1) on housing (2) and use torque

wrench to tighten cover screw to specified
TIM ID: 0000001894 – 004
M020124/02E 2009-02 © MTU

12. Install V-band clamp (1) and use torque wrench

to tighten nut (2) to specified tightening torque
(→ Page 980).
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TIM ID: 0000001894 – 004
M020124/02E 2009-02 © MTU

9.13.21 Centrifugal oil filter – Installation
Material

Spare parts

O-ring
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Centrifugal oil filter – Installation

2. Coat O-ring with grease and insert.
3. Install centrifugal oil filter as shown in overview drawing (→ Page 1499).
TIM ID: 0000001897 – 004
M020124/02E 2009-02 © MTU

9.13.22 Oil heat exchanger – Overview
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1 Insert 6 Nut 11 Retainer
2 O-ring 7 Screw 12 Nut
3 Housing 8 Screw 13 O-ring
4 O-ring 9 Plug-in pipe
5 Washer 10 O-ring
TIM ID: 0000008538 – 003
M020124/02E 2009-02 © MTU

9.13.23 Oil heat exchanger – Removal
Preconditions
Special tools

Eyebolt B80090843 2
Hot oil.
Heavy object.
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Risk of crushing!
Removing oil heat exchanger

1. Remove screws (3) from oil heat exchanger
housing.
2. Remove nuts (1).
3. Screw eyebolts (2) into the left and right oil heat
exchanger housing.
4. Using crane and rope, remove oil heat exchanger
housing from coolant distribution housing.
TIM ID: 0000003509 – 007
M020124/02E 2009-02 © MTU

5. Remove sealing washers (1).

6. Carefully remove oil heat exchanger (arrowed)
vertically upwards from coolant distribution
housing fit.
7. Seal all openings and connections with suitable
plugs.
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TIM ID: 0000003509 – 007
M020124/02E 2009-02 © MTU

9.13.24 Oil heat exchanger – Cleaning
Material

Cleaning agent

Cleaning oil heat exchanger housing and plug-in pipe
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1. Clean oil heat exchanger housing and plug-in pipe with cleaner.
Cleaning oil heat exchanger on water and oil side.
Note: If swarf has got into the engine oil system, e.g. as a result of piston scuffing or bearing damage, replace oil
heat exchanger.
Cleaning water side

1. Examine the degree of contamination.
2. In event of visible encrustation as a result of hardness structure, contamination and oil deposits, clean with
suitable cleaners, e.g. Porodox (from Henkel) or Porozink (from Parobe-Chemie, Basel). Always follow
manufacturer’s instructions.
3. After cleaning, flush the oil heat exchanger with water until pH values of clean water and flushing liquid are
approximately the same (difference 1 pH).
4. If the oil heat exchanger is not put into operation immediately after cleaning, dry and preserve coolant side.
Cleaning oil side

1. Connect oil heat exchanger (oil side) to a closed flushing system with a filter system of 0.05 mm mesh size.
2. Clean oil heat exchanger with suitable cleaner, e.g. buffered alkaline agents such as 3 to 5% solution
of Henkel P3 FD.
3. Ensure flow direction of cleaner is against normal direction of oil flow during operation.
4. After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are
roughly equal (permissible difference 1pH).
5. If the oil heat exchanger is not put into operation immediately after cleaning, dry and preserve oil side.
Drying and preserving oil heat exchanger

1. Dry oil heat exchanger in oven at 110 °C to 120 °C for approx. 3 hours.
TIM ID: 0000008539 – 003
2. Spray preservative (Branorol 32/10 from Brangs & Heinrich) into the oil heat exchanger. A dosage of max.
2 ml Branorol 32/10 per litter of cooling volume must be observed. The preservative vaporizes and forms a
protective film on all interior surfaces.
3. After preservation, seal all openings airtight with suitable plugs.
M020124/02E 2009-02 © MTU

9.13.25 Oil heat exchanger – Check
Material

Red dye penetrant for surface crack-testing procedure
Spare parts

Oil heat exchanger housing
Heat exchanger core
Retainer
Plug-in pipe
Compressed air.
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Risk of injury!

Hot testing liquid.
Component is hot.
Risk of burning!
Oil heat exchanger check
Visually inspect all components for Damaged • Corrective work

damage. • Replace
Check all sealing, mating and • Damaged • Corrective work:

contact faces for damage and • Uneven Smooth with oilstone or crocus
unevenness. cloth.
• Replace
Check thread for easy movement. Sluggish • Recut

TIM ID: 0000008541 – 005
• Replace
Check oil heat exchanger housing Cracks indicated Replace

for cracks with red dye penetrant.
M020124/02E 2009-02 © MTU

Heat exchanger core leak check

1. Seal oil chamber connections of heat exchanger
core (3) with suitable sleeves, blanking plugs,
plugs (2) and clamps.
2. Connect pressure line (1) at plug (2).
4. Immerse heat exchanger core (3) in test bath.
5. Open compressed air supply and set pressure
reducer (1) to 0.5 bar.
6. Pressuretest heat exchanger core (3) for leaks
with air in water bath; no bubbles should emerge.
7. Replace heat exchanger core (3) if leaky.
8. Remove compressed-air line (1), sleeves and
plug (2).
9. Blow out cooling fins of heat exchanger core (3)
with compressed air in vertical direction.
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TIM ID: 0000008541 – 005
M020124/02E 2009-02 © MTU

9.13.26 Oil heat exchanger – Installation
Special tools

Eyebolt B80090843 2
Material

Engine oil (MZK engine oil HD 10W) 40453 1
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Spare parts

O-ring
O-ring
Heavy object.
Risk of crushing!
Installing oil cooler

1. Remove all plugs from coolant distribution housing.
2. Clean oil chambers and oil galleries (arrowed).
TIM ID: 0000008542 – 005
M020124/02E 2009-02 © MTU

3. Coat O-rings on heat exchanger core with grease.

4. Place heat exchanger core in coolant distribution
housing with label “IN” towards the driving end.
5. Place disks (1) on the threads of the heat
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exchanger cores.
on the elbow (2).
7. Loosen screws on elbow (2).

on the oil heat exchanger housing (2).
TIM ID: 0000008542 – 005
M020124/02E 2009-02 © MTU

9. Coat O-rings on plug-in pipe (2) with grease

before installation.
10. Mount plug-in pipe (2) with retainer (3) on oil heat
exchanger housing (1).
11. Screw eyebolts into the oil heat exchanger
housing (1).
12. Using crane and rope, position oil heat exchanger
housing (1) on coolant distribution housing.
13. Screw oil heat exchanger housing (1) into place
with the screws on the coolant distribution housing.
14. Remove eyebolts (2) from both oil heat exchanger
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housings.
16. Screw on nuts (1) and tighten with torque wrench
to the specified tightening torque (→ Page 980).
17. Tighten the screws (2) on the elbow (1) of the

coolant distribution housing.
TIM ID: 0000008542 – 005
M020124/02E 2009-02 © MTU

9.13.27 Oil system in crankcase – Overview
Oil system
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1 Delivery valve 10 Pipe 19 O-ring
2 O-ring 11 Pipe 20 O-ring
3 O-ring 12 Oil spray nozzle 21 Retainer
4 Circlip 13 Screw 22 Retainer
5 Washer 14 Circlip 23 Pipe
6 O-ring 15 Delivery valve 24 Pipe
7 O-ring 16 O-ring 25 Oil spray nozzle
8 Retainer 17 O-ring 26 Screw
9 Retainer 18 Washer TIM ID: 0000029132 – 001
M020124/02E 2009-02 © MTU

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1 Delivery valve 4 O-ring 7 Retainer
2 O-ring 5 Pipe 8 Retainer
3 Washer 6 Retainer 9 Oil spray nozzle
TIM ID: 0000029132 – 001
M020124/02E 2009-02 © MTU

9.13.28 Oil system in crankcase – Removal
Preconditions
Special tools


Risk of injury!
Removing bracket for oil spray nozzle

1. Install barring device at crankshaft (→ Page 1145).
2. Turn crankshaft with barring device until oil spray
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nozzle (1) to be removed is accessible.
3. Remove screws (arrows).
4. Remove oil spray nozzle (1) from retainer (2).
5. Mark oil spray nozzle (1) with a pen according to
cylinder side and cylinder number.
6. Protect oil spray nozzle (1) against damage.
Removing oil pipe connection

1. Remove screw (arrows).
2. Remove holder (2) from oil pipe fit (3).
3. Remove oil pipe (1) from retainer (2).
4. Remove all other oil spray nozzles in same
manner. TIM ID: 0000004102 – 006
M020124/02E 2009-02 © MTU

Removing washer (sealing fit)

1. Remove washer (2) from crankcase (1).
2. Remove O-rings.
3. Protect washer (2) against damage.
Removing delivery valve
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1. Remove pressure valve as per overview drawing
(→ Page 1522).
2. Unscrew plug screws.
3. Remove snap ring (1) from housing.
4. Remove delivery valve (3) from housing.
5. Remove O-rings (2) and (4)
TIM ID: 0000004102 – 006
M020124/02E 2009-02 © MTU

9.13.29 Oil pipework in crankcase – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning oil spray nozzles and oil pipes

2. Remove cleaner.
3. Blow oil pipes, retainers and oil spray nozzle dry with compressed air.
Cleaning washer (sealing fit)

2. Remove cleaner.
3. Then blow washer dry (sealing fit) with compressed air.
TIM ID: 0000004100 – 002
M020124/02E 2009-02 © MTU

9.13.30 Oil pipework in crankcase – Check
Special tools

Material

Spare parts
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Oil spray nozzle
Pipe
Retainer
Washer (sealing fit)
Delivery valve
Component to be tested is under pressure.

Risk of explosion!
DANGER • Observe test specification.

Risk of injury!
TIM ID: 0000004101 – 004
M020124/02E 2009-02 © MTU

Oil pipework in crankcase – Check
Item Findings Task
Check oil spray nozzles with dye Signs of cracks Replace

Check oil bore of oil spray nozzles Contamination visible. • Corrective work: Clean
for obstruction and ensure it is • Replace
particularly clean.
Check oil spray nozzle with testing Deformation of oil spray nozzle. Replace
device for deformation.
Test oil pipes for leaks with air in Leaking Replace

water bath as necessary. Maintain a
of 0.5 bar.

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Check mating and sealing faces of • Damaged • Corrective work: Smooth with
oil spray nozzle. • Stress marks oilstone or emery cloth.
visible • Replace
Check washer (sealing fit) for wear, • Stress marks Replace

cracks and damage. • Cracks
• Damage
visible
Check bore in crankcase for wear. Visible signs of wear. Smooth with emery cloth.
Do not disassemble delivery valve! Damaged Replace

Visually inspect delivery valve for
damage.
Check delivery valve for read Fallen short of or exceeded Replace delivery valve.
opening pressure ± 0.25 bar.
Check sealing face of delivery valve Uneven • Corrective work: Smooth with
for evenness. oilstone.
• Replace
TIM ID: 0000004101 – 004
M020124/02E 2009-02 © MTU

9.13.31 Oil system in crankcase – Installation
Special tools

Material

Engine oil
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Spare parts

O-rings
Snap ring
Compressed air.
Risk of injury!
Compressed air.
Risk of injury!
Installing oil spray nozzle bracket and oil pipes

2. Install bracket (1) so that dimension "a" points
towards crankcase.
TIM ID: 0000004103 – 005
M020124/02E 2009-02 © MTU

3. Coat O-rings with grease and insert into grooves in

oil pipes (1) and (3).
4. Fit oil pipes (1) and (3) in retainer (2) and secure
with screws (arrow) on crankcase.
5. Install oil spray nozzle (1) on retainer and align
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with alignment device (3).
specified tightening torque.

7. After installing, bar engine and ensure there is

clearance between oil spray nozzle and piston.
TIM ID: 0000004103 – 005
M020124/02E 2009-02 © MTU

Installing washer (sealing fit)

1. Coat O-rings with grease and insert into grooves
(arrows) of washer.
2. Align oil pipe so that inner O-ring is not damaged.
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3. Press-fit washer (2) manually in crankcase (3).
TIM ID: 0000004103 – 005
M020124/02E 2009-02 © MTU

Installing delivery valve

1. Coat O-ring (arrow) with grease and insert in
groove (arrow).
2. Coat O-ring (arrow) with grease and insert into
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groove on delivery valve.
3. Insert delivery valve (3) into bore of housing

4. Secure delivery valve with snap ring (1) and
install plug screw. TIM ID: 0000004103 – 005
M020124/02E 2009-02 © MTU

9.13.32 Turbocharger oil supply – Overview
ETC oil supply
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1 Oil line 19 Washer 37 Grommet
3 Screw 21 Pipe half-clamp 39 Screw
4 O-ring 22 Grommet 40 Retainer
5 Threaded adapter 23 Washer 41 Washer
7 Retainer 25 Oil line 43 Washer
8 Washer 26 O-ring 44 Pipe half-clamp
10 Washer 28 O-ring 46 Grommet
11 Pipe half-clamp 29 Threaded adapter 47 Washer
12 Pipe half-clamp 30 O-ring 48 Screw
13 Grommet 31 Retainer 49 Oil line
14 Washer 32 Washer 50 Oil line
16 Retainer 34 Washer 52 Screw
17 Washer 35 Pipe half-clamp 53 Gasket
18 Screw 36 Pipe half-clamp 54 Nut
TIM ID: 0000029676 – 001
M020124/02E 2009-02 © MTU

9.13.33 Turbocharger oil supply – Removal
Preconditions
Turbocharger oil supply – Removal
1. Remove oil line, unions and fixtures as per overview drawing (→ Page 1533).
2. Remove all sealing elements.
4. Protect oil lines from damage.
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TIM ID: 0000005988 – 004
M020124/02E 2009-02 © MTU

9.13.34 Turbocharger oil supply – Cleaning
Material

Compressed air.
Risk of injury!

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Turbocharger oil supply – Cleaning

2. Remove cleaner.
3. Blow turbocharger oil supply pipework dry with compressed air.
TIM ID: 0000008544 – 002
M020124/02E 2009-02 © MTU

9.13.35 Turbocharger oil supply – Check
Spare parts

Pipe
Flange
Adapter
Strap
Compressed air.
Risk of injury!

Risk of injury!
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Turbocharger oil supply – Check
Item Findings Task
Visually inspect oil return line for Damaged Replace

damage.
Pressure-test oil return line with air Leaking Replace

in water bath for leaks. Maintain a
of 0.5 bar.
Check connection parts and Damaged Replace

securing elements on oil return lines
for damage.
Check sealing and bolt-on faces. Damaged • Corrective work: Smooth with
• Replace

TIM ID: 0000008545 – 002
M020124/02E 2009-02 © MTU

9.13.36 Turbocharger oil supply – Installation
Material

Engine oil
Spare parts

O-rings
Grommet
Sealing ring
Pipe half-clamp
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Compressed air.
Risk of injury!

Turbocharger oil supply – Installation

2. Coat O-rings with grease and insert.
3. Insert sealing rings.
4. Install turbocharger oil supply (→ Page 1533).
5. After starting the engine, visually inspect oil lines for leaks.
TIM ID: 0000008546 – 005
M020124/02E 2009-02 © MTU

9.14 Coolant System
9.14.1 Coolant system – Overview
Coolant circuit with internal thermostat
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2 Connection, engine coolant from cooler (low-temperature 20 Coolant pump for charge air
vent line (low-temperature coolant circuit) cooling circuit
coolant circuit) 12 Connection, engine coolant 21 Engine coolant thermostat
3 Connection, engine coolant expansion line (low-temperature (low-temperature coolant circuit)
vent line (high-temperature coolant circuit) 22 Thermostat, engine coolant
coolant circuit) 13 Connection, engine coolant preheating unit
4 Engine coolant expansion tank outlet to cooler (high-temperature 23 Circulation pump for preheating unit
5 Engine coolant heat exchanger coolant circuit) 24 Coolant preheating unit
(low-temperature coolant circuit) 14 Connection, engine coolant inlet
6 Fan cooler from cooler (high-temperature
7 Thermostat (cooler fan in charge coolant circuit)
air coolant system) 15 Connection, engine coolant
8 Engine coolant heat exchanger expansion line (high-temperature
(high-temperature coolant circuit) coolant circuit)
9 Thermostat for cooler fan 16 Engine coolant thermostat
TIM ID: 0000009007 – 001
10 Connection, engine coolant (high-temperature coolant circuit)

outlet to cooler (low-temperature 17 Lube oil heat exchanger
M020124/02E 2009-02 © MTU

Coolant circuit with external thermostat
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2 Connection, engine coolant from cooler (low-temperature 18 Thermostat, engine coolant
vent line (low-temperature coolant circuit) preheating unit
coolant circuit) 11 Engine coolant thermostat 19 Circulation pump for preheating unit
3 Connection, engine coolant (low-temperature coolant circuit) 20 Coolant preheating unit
vent line (high-temperature 12 Connection, engine coolant 21 Coolant pump for charge air
coolant circuit) expansion line (low-temperature cooling circuit
4 Engine coolant expansion tank coolant circuit) 22 Thermostat (cooler fan in charge
5 Engine coolant heat exchanger 13 Connection, engine coolant air coolant system)
(low-temperature coolant circuit) outlet to cooler (high-temperature 23 Lube oil heat exchanger
6 Fan cooler coolant circuit) 24 Dummy thermostat, open, blocked
7 Engine coolant heat exchanger 14 Connection, engine coolant inlet
(high-temperature coolant circuit) from cooler (high-temperature
8 Engine coolant thermostat coolant circuit)
(high-temperature coolant circuit) 15 Connection, engine coolant
9 Connection, engine coolant expansion line (high-temperature
outlet to cooler (low-temperature coolant circuit)
TIM ID: 0000009007 – 001
M020124/02E 2009-02 © MTU

9.14.2 Engine coolant pump – Overview
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1 Engine coolant pump 4 Screw 7 Washer
2 O-ring 5 Screw
3 Screw 6 Nut
TIM ID: 0000019817 – 001
M020124/02E 2009-02 © MTU

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1 Water pump shaft 8 Angular-contact ball bearing 15 O-ring
2 Impeller 9 Cylindrical roller bearing 16 Screw
3 Bearing housing 10 Snap ring 17 Washer
4 Seal carrier 11 Shaft seal 18 Screw
5 Volute 12 Rotary seal 19 Washer
6 Spacer sleeve 13 O-ring 20 Sealing ring
7 Gear 14 O-ring 21 Plug screw
TIM ID: 0000019817 – 001
M020124/02E 2009-02 © MTU

Special tools

Heavy object.
Risk of crushing!

Risk of injury!

1. Attach engine coolant pump with lifting gear and support bracket to crane using a slightly tensioned rope.
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2. Remove screws for engine coolant pump as per overview drawing DM_410_WM_202050_041A.
3. Use crowbar to separate engine coolant pump from front cover and remove.
4. Remove O-ring.
TIM ID: 0000019837 – 001
M020124/02E 2009-02 © MTU

9.14.4 Engine coolant pump – Disassembly
Special tools

Press fit tool F30379316 1
Heavy object.
Risk of crushing!
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Risk of injury!
Engine coolant pump – Disassembly

2. Remove all screws (2) securing the volute (3) to
the bearing housing (1).
TIM ID: 0000019842 – 001
M020124/02E 2009-02 © MTU


device (1).
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pump shaft.
throughout.
8. Take engine coolant pump out of retaining device.
9. Place bearing housing (3) with pump shaft in vise

with aluminum jaws.
remove gear from water pump shaft. TIM ID: 0000019842 – 001
M020124/02E 2009-02 © MTU

housing (1).
12. Remove all screws (1) for seal carrier using a
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box wrench (2).

TIM ID: 0000019842 – 001
M020124/02E 2009-02 © MTU

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17. Use hydraulic press (1) and mandrel (2) to

press cylindrical roller bearing (3) out of bearing
housing (4).
TIM ID: 0000019842 – 001
M020124/02E 2009-02 © MTU

18. Use screwdriver to press counterring (2) out

of impeller (1).
19. Remove shaft seal, intermediate washer and
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rotary shaft seal (arrow) from seal carrier (3) with
mandrel (2) and hydraulic press (1).
TIM ID: 0000019842 – 001
M020124/02E 2009-02 © MTU

9.14.5 Engine coolant pump – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Engine coolant pump – Cleaning

TIM ID: 0000019822 – 001
M020124/02E 2009-02 © MTU

9.14.6 Engine coolant pump – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

Penetrant remover (Standard-Check) 40002 1
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Spare parts

Engine coolant pump
Water pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000019832 – 001
M020124/02E 2009-02 © MTU

Engine coolant pump – Check
Item Findings Task

cavitation.

for cracks.
Check water pump shaft with Crack indication Replace

fluorescent magnetic powder for
cracks.
Check coolant pump shaft for wear • Wear • Recondition: smooth minor
and damage. • Damage traces of wear with emery cloth.
visible • Replace

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visible
Check gear for indentations, traces • Wear • Recondition: smooth with

visible

diameters on engine coolant
pump, impeller, seal carrier and
bearing housing and gear with
inside and outside micrometer.
Values and measuring points
DM_410_WM_202050_276A
TIM ID: 0000019832 – 001
M020124/02E 2009-02 © MTU

9.14.7 Engine coolant pump – Tolerances
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size Basic
size
1 Seal carrier 90.000 K7 −0.025 +0.010 0.025 0.025

ball bearing
outer diam.

bore

ball bearing
outer diam.
3 Angular contact 40.000 −0.012 0 0.002 0.025

ball bearing bore
4 Spacer sleeve 40.000 N7 −0.033 –0.008 0.010 0.046

bore
TIM ID: 0000019827 – 001

bore
Cylindrical roller 80.000 −0.013 0

bearing
M020124/02E 2009-02 © MTU

size Basic
size
6 Cylindrical roller 40.000 −0.012 0 0.002 0.025

bearing bore
7 Gear bore 39.000 H7 0 +0.025 0.018 0.059
Shaft outer diam. 39.000 s6 +0.043 +0.059
cardiagn.com
TIM ID: 0000019827 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
size Basic
size
Shaft seal outer 72.000 +0.130 +0.230

diam.
2 Shaft outer diam. 48.000 −0.100 0
Rotary seal outer 78.200 −0.030 0

diam.
4 Impeller bore 30.000 H5 0 +0.009 0.032 0.050
Shaft outer diam. 30.000 t5 +0.041 +0.050
5 Rotary seal
Counterring

TIM ID: 0000019827 – 001
M020124/02E 2009-02 © MTU

9.14.8 Engine coolant pump – Assembly
Special tools

Press fit tool for angular-contact ball bearings F30378152 1
Press fit tool for ball bearings F30378153 1
Press fit tool for shaft seal F30378550 1
Press fit tool for rotary seal F30378151 1
Support for bearing housing F6780563 1
Support for shaft with bearing F6781573 1
Material
cardiagn.com
Ethanol 40250 1
Engine oil
Spare parts

Snap ring
Shaft seal
Rotary seal
O-ring
Component is hot.
Risk of burning!
Heavy object.
Risk of crushing!

TIM ID: 0000019847 – 001
Risk of injury!
M020124/02E 2009-02 © MTU


Engine coolant pump – Assembly

Note: Apply pressure to bearing outer race.

cardiagn.com
TIM ID: 0000019847 – 001
M020124/02E 2009-02 © MTU

4. Force angular-contact ball bearing (3) onto pump

shaft (4) with hydraulic press (1) and mandrel (2).
5. Force spacer sleeve (3) onto pump shaft (4) with
cardiagn.com
6. Press inner race (2) of cylindrical roller bearing

onto pump shaft (3) with hydraulic press and
mandrel (1).
TIM ID: 0000019847 – 001
M020124/02E 2009-02 © MTU

Note: Apply pressure to bearing outer race (3).

cardiagn.com
position.

TIM ID: 0000019847 – 001
M020124/02E 2009-02 © MTU

10. Place intermediate washer in seal carrier (4).

11. Coat rotary shaft seal (3) with a soap solution
(water : soap mixture = 2:1).
rotary shaft seal (3) into seal carrier (4).
13. Clean running surface with ethanol after assembly.
14. Coat O-ring with petroleum jelly and place into
cardiagn.com
groove.
housing (1) and tighten them evenly.
17. Heat gear (2) to 200 °C.

TIM ID: 0000019847 – 001
M020124/02E 2009-02 © MTU

Note: Insert counterring (2) only after heating.

counterring (2).
22. Place counterring (2) in heated impeller (1).
23. Clean counterring surface with ethanol.
24. Place engine coolant pump onto hydraulic
cardiagn.com
press (1).
25. Place two feeler gauges (clearance
S1 = 0.7 mm to 1.1 mm), on seal carrier (3)
arranged at 180° towards one another.
26. Push heated impeller (2) with hydraulic press (1)
until it stops at feeler gauges.
27. Measure clearance S1 between impeller (2) and
seal carrier (3) with feeler gauge.

removal.
31. Turn pump shaft to check for easy movement.
32. Measure clearance S2 (0.6 mm to 1.5 mm)
between impeller and volute (3) with feeler gauge.
TIM ID: 0000019847 – 001
M020124/02E 2009-02 © MTU

Special tools

Material

Engine oil
Spare parts
cardiagn.com
O-ring
Heavy object.
Risk of crushing!

Risk of injury!

engine coolant pump.
TIM ID: 0000019852 – 002
M020124/02E 2009-02 © MTU

4. Attach engine coolant pump with lifting gear and

support bracket to crane using a slightly tensioned
rope.
Note: Observe tooth meshing.
5. Install engine coolant pump (1) in bore on

equipment carrier, ensuring correct installation
position.
6. Install screws (2) with washers and tighten
uniformly.
7. Remove lifting gear with support bracket.
cardiagn.com
TIM ID: 0000019852 – 002
M020124/02E 2009-02 © MTU

9.14.10 Coolant pipework of engine coolant pump, intake side – Overview
Elbow with attachments
cardiagn.com
1 Elbow 6 Washer 11 Connector
2 Plug screw 7 Holder 12 Banjo screw
3 Sealing ring 8 Screw 13 Sealing ring
4 O-ring 9 Washer
TIM ID: 0000008551 – 002
M020124/02E 2009-02 © MTU

Plug-in pipe with flange
cardiagn.com
1 Plug-in pipe
2 O-ring
3 Flange
4 Screw
5 O-ring
TIM ID: 0000008551 – 002
M020124/02E 2009-02 © MTU

Coolant pipework
cardiagn.com
1 Plug-in pipe 4 Screw 7 O-ring
2 O-ring 5 O-ring 8 Flange
3 Flange 6 Plug-in pipe 9 Screw
TIM ID: 0000008551 – 002
M020124/02E 2009-02 © MTU

9.14.11 Coolant pipework for engine coolant pump, intake side – Removal
Preconditions
Coolant pipework for engine coolant pump, intake side – Removal
2. Remove all monitoring units installed in coolant lines.
3. Remove coolant pipework for engine coolant pump on intake side as shown in overview drawing
(→ Page 1562).
cardiagn.com
TIM ID: 0000003518 – 005
M020124/02E 2009-02 © MTU

9.14.12 Coolant pipework, engine coolant pump, suction side – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning coolant lines

3. Blow dry coolant lines with compressed air and preserve in oil bath.
TIM ID: 0000028467 – 002
M020124/02E 2009-02 © MTU

9.14.13 Coolant pipework, engine coolant pump, suction side – Check
Spare parts

Elbow
Flange
Plug-in pipe
Retainer
Connecting piece
Drain valve

Risk of injury!
cardiagn.com
Coolant pipework, engine coolant pump, suction side, check
Visually inspect retainers, plug • Wear • Corrective work: smooth with

connections and annular grooves on • Pitting oilstone or crocus cloth.
elbows and connecting lines for wear, • Cavitation • Replace
pitting and cavitation. visible
Check sealing and mating faces for Damaged • Corrective work: smooth with
wear and damage. oilstone or crocus cloth.
• Replace
Pressure-test coolant lines with air Leaking Replace

in water bath for leaks as necessary.
Maintain a coolant temperature of min.
= 30 °C or max. = 40 °C at a test
Check operation of drain valve. Damaged Replace

TIM ID: 0000008552 – 003
M020124/02E 2009-02 © MTU

9.14.14 Coolant pipework, engine coolant pump, suction side – Installation
Material

Engine oil
Spare parts

Sealing rings
O-rings
Compressed air.
Risk of injury!
cardiagn.com
Install coolant lines

2. Blow out coolant lines with compressed air.
3. Coat all O-rings with grease.
4. Install coolant lines without tension using new sealing and O-rings as shown in the overview drawing
(→ Page 1562).
5. Install all monitoring units in coolant lines.
TIM ID: 0000008553 – 003
M020124/02E 2009-02 © MTU

9.14.15 Coolant pipework after cylinder – Overview
Coolant pipework after cylinder – Overview

Also applies analogously to 12 V.
cardiagn.com
1 Connecting piece 7 O-ring 13 O-ring
2 Screw 8 Plug screw 14 O-ring
3 O-ring 9 Engine coolant collecting line 15 O-ring
4 Connecting piece 10 Engine coolant collecting line 16 Screw
5 Screw 11 Engine coolant collecting line 17 Screw
6 Screw 12 Engine coolant collecting line
TIM ID: 0000008554 – 002
M020124/02E 2009-02 © MTU

9.14.16 Coolant pipework after cylinder – Removal
Preconditions
Coolant pipework after cylinder– Removal
1. Remove manifolds as per overview drawing (→ Page 1569).
cardiagn.com
TIM ID: 0000008555 – 005
M020124/02E 2009-02 © MTU

9.14.17 Coolant pipework after cylinder – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning coolant pipework after cylinder

TIM ID: 0000004120 – 004
M020124/02E 2009-02 © MTU

9.14.18 Coolant pipework after cylinder – Check
Spare parts

Manifold
Connecting piece
Compressed air.
Risk of injury!

Hot testing liquid.
cardiagn.com
Checking coolant pipework after cylinder
Visually inspect plug connections and Damaged • Corrective work: smooth with
annular grooves on connecting piece and oilstone or crocus cloth.
manifold for wear, pitting and cavitation. • Replace
Check manifold with air and corrosion Leaking Replace

inhibitor in water bath for leaks. Maintain
a coolant temperature of min. = 30 °C or
TIM ID: 0000008556 – 003
M020124/02E 2009-02 © MTU

9.14.19 Coolant pipework after cylinder – Installation
Material

Engine oil
Spare parts

O-ring
Compressed air.
Risk of injury!
cardiagn.com
Coolant pipework after cylinder – Installation
2. Blow out manifolds with compressed air.
4. Install manifolds free of tension as shown in overview drawing (→ Page 1569).
TIM ID: 0000008557 – 005
M020124/02E 2009-02 © MTU

9.14.20 Engine coolant drain lines – Overview
Coolant lines
cardiagn.com
1 Pipe 10 Sealing cone 19 Spacer bushing
2 Sealing cone 11 Nut 20 Retainer
3 Nut 12 Retainer 21 Hex screw
4 Pipe 13 Pipe half-clamp 22 Spacer bushing
5 Pipe 14 Grommet 23 Pipe half-clamp
6 Sealing cone 15 Hex screw 24 Pipe half-clamp
7 Nut 16 Washer 25 Grommet
8 Pipe 17 Hex nut 26 Hex screw
9 T adapter 18 Hex screw TIM ID: 0000008558 – 002
M020124/02E 2009-02 © MTU

9.14.21 Engine coolant drain lines – Removal

Removing drain lines
1. Before removing the lines it is advisable to take photographs of the fitted lines or to mark lines and externally
mounted components.
cardiagn.com
TIM ID: 0000004121 – 003
M020124/02E 2009-02 © MTU

9.14.22 Engine coolant drain lines – Cleaning
Special tools

Cleaning brush
Material

Cleaning agent
Compressed air.
Risk of injury!
cardiagn.com

Remove engine coolant drain lines (→ Page 1575).
Cleaning engine coolant drain lines

1. Clean coolant drain lines with cleaning agent and cleaning brush.
3. Blow dry coolant drain lines with compressed air and preserve in oil bath.
TIM ID: 0000004122 – 002
M020124/02E 2009-02 © MTU

9.14.23 Engine coolant drain lines – Check
Spare parts

Pipe
Sealing cone
T adapter
Retainer
Spacer bushing

Risk of injury!
Compressed air.
cardiagn.com
Risk of injury!
Checking engine coolant drain lines
Check T piece, retainers and lines for Damaged Replace

damage.
Pressure-test lines with air and Leaking Replace

corrosion inhibitor in water bath for
leaks as necessary. Maintain a coolant
Check thread for damage and easy Damaged or sluggish • Corrective work: recut threads
movement • Replace
TIM ID: 0000008559 – 002
M020124/02E 2009-02 © MTU

9.14.24 Engine coolant drain lines – Installation
Material

Engine oil
Spare parts

Grommet
Compressed air.
Risk of injury!
cardiagn.com
Installing engine coolant drain lines
2. Blow out coolant drain lines with compressed air.
3. Install engine coolant drain lines as shown in the overview drawing (→ Page 1574) without tension and
secure with pipe half-clamps.
TIM ID: 0000004123 – 003
M020124/02E 2009-02 © MTU

9.14.25 Engine coolant and charge air coolant ventilation – Overview
Coolant vent lines (also applies to 16V)
cardiagn.com
25 Union 195 T-piece 505 Bracket
30 Sealing ring 205 Vent line 510 Pipe half-clamp
45 Vent line 210 Union 515 Grommet
55 Bracket 215 Sealing ring 520 Screw
60 Washer 225 Vent line 525 Vent line
65 Screw 235 Adapter 535 Bracket
70 Pipe half-clamp 240 Sealing ring 540 Pipe half-clamp
75 Grommet 260 Vent line 545 Grommet
80 Screw 265 Adapter 550 Screw
90 Union 270 O-ring 553 Vent line
95 Sealing ring 305 Bracket 555 Vent line
100 Vent line 310 Pipe half-clamp 565 Bracket
120 Bracket 325 Grommet 575 Grommet
125 Pipe half-clamp 330 Screw 580 Screw
130 Grommet 340 Spacer bush 585 Spacer bush
135 Screw 460 Adapter 590 Pipe half-clamp
145 T-piece 465 O-ring 595 Grommet
155 Vent line 470 Vent line 600 Screw
165 Vent line 475 Adapter 605 Pipe
TIM ID: 0000008899 – 002
170 Union 480 Sealing ring 610 Adapter

175 Sealing ring 490 Threaded union 615 Sealing ring
185 Vent line 495 Vent line
M020124/02E 2009-02 © MTU

cardiagn.com
250 T-piece 380 Grommet 440 Pipe half-clamp
280 Vent line 390 Distributor 445 Grommet
290 Union 395 Bracket 450 Screw
295 Sealing ring 400 Screw 621 Union
350 Vent line 402 Plug 622 Sealing ring
355 Threaded union 403 Plug 630 Pipe
365 Bracket 410 Threaded union 640 T-piece
366 Screw 415 Pipe 650 Pipe
367 Washer 420 Union 655 Elbow
370 Pipe half-clamp 425 Sealing ring 700 Threaded union
375 Pipe half-clamp 435 Pipe half-clamp
TIM ID: 0000008899 – 002
M020124/02E 2009-02 © MTU

9.14.26 Engine coolant and charge-air cooling vent – Removal
Preconditions
Engine coolant and charge-air cooling vent – Removal
1. Prior to removal of the lines take photos or mark attachments and lines.
2. Remove engine coolant and charge-air cooling vent (→ Page 1579).
cardiagn.com
TIM ID: 0000004125 – 005
M020124/02E 2009-02 © MTU

9.14.27 Ventilation, engine coolant and charge air coolant – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning ventilation, engine coolant and charge air coolant

2. Thoroughly blow out coolant and charge air cooling ventilation with compressed air and preserve in oil bath.
TIM ID: 0000008802 – 004
M020124/02E 2009-02 © MTU

9.14.28 Ventilation, engine coolant and charge air coolant – Check
Spare parts

Pipe
Elbow
Vent line
Distributor piece
T adapter
Retainer
Bracket
Spacer sleeve
cardiagn.com
Risk of injury!
Compressed air.
Risk of injury!
Checking ventilation, engine coolant and charge air coolant
Check lines, elbow, distributor, T piece, retainer, Damaged Replace

bracket and spacer sleeve for damage.
Check coolant lines for leaks in water bath, using Leaking Replace
compressed air and corrosion inhibitor. Maintain a
coolant temperature of min. = 30 °C or max. = 40 °C
at a test pressure of 0.5 bar.
Check thread for damage and easy movement. Damaged or sluggish • Corrective work: recut
threads
• Replace
TIM ID: 0000008803 – 003
M020124/02E 2009-02 © MTU

9.14.29 Engine coolant and charge-air cooling vent – Installation
Material

Engine oil
Spare parts

Grommet
Pipe clamp half
Compressed air.
Risk of injury!
cardiagn.com

Engine coolant and charge-air cooling vent – Installation

2. Install engine coolant and charge-air cooling vent as shown in overview drawing (→ Page 1579).
TIM ID: 0000004963 – 005
M020124/02E 2009-02 © MTU

9.14.30 Coolant pipework from/to exhaust turbochargers – Overview
cardiagn.com
1 Adapter 14 Sealing ring 27 Grommet
2 Sealing ring 15 Coolant line 28 Washer
3 Coolant line 16 Adapter 29 Screw
4 Adapter 17 Sealing ring 30 Adapter
5 Sealing ring 18 Coolant line 31 Sealing ring
6 Coolant line 19 Adapter 32 Coolant line
7 Holder 20 Sealing ring 33 Pipe half-clamp
8 Pipe half-clamp 21 Coolant line 34 Pipe half-clamp
9 Pipe half-clamp 22 Adapter 35 Grommet
10 Grommet 23 Sealing ring 36 Washer
11 Washer 24 Coolant line 37 Screw
13 Adapter 26 Pipe half-clamp
TIM ID: 0000008804 – 002
M020124/02E 2009-02 © MTU

9.14.31 Coolant pipework from/to exhaust turbochargers – Removal
Preconditions
Removing coolant lines
2. Remove coolant pipework from/to exhaust turbochargers as shown in overview drawing (→ Page 1585).
cardiagn.com
TIM ID: 0000008805 – 009
M020124/02E 2009-02 © MTU

9.14.32 Coolant pipework from/to exhaust turbochargers – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com


Coolant pipework from/to exhaust turbochargers – Cleaning

1. Clean parts with cleaning agent and cleaning brush.
TIM ID: 0000003529 – 005
M020124/02E 2009-02 © MTU

9.14.33 Coolant pipework from/to turbochargers – Check
Spare parts

Coolant line
Bracket
Pipe half-clamp
Grommet

Risk of injury!
Compressed air.
Risk of injury!
cardiagn.com
Clean coolant pipework from/to exhaust turbochargers (→ Page 1587).
Coolant pipework from/to turbochargers – Check
Visually check lines, pipe clamp halves, Damaged Replace

grommets and brackets for damage.
Check coolant lines for leaks in water bath, Leaking Replace

using compressed air and corrosion inhibitor.
Maintain a coolant temperature of min. = 30 °C
or max. = 40 °C at a test pressure of 0.5 bar.
TIM ID: 0000008806 – 001
M020124/02E 2009-02 © MTU

9.14.34 Coolant pipework from/to exhaust turbochargers – Installation
Material

Engine oil

Coolant pipework from/to exhaust turbochargers - Installation
cardiagn.com
1. Before installation, remove all covers.
2. Install coolant pipework from/to exhaust turbochargers as shown in the overview drawing (→ Page 1585).
TIM ID: 0000008807 – 009
M020124/02E 2009-02 © MTU

9.14.35 Charge-air coolant pump – Overview
cardiagn.com
1 Charge-air coolant pump 4 Screw 7 Drain valve
2 O-ring 5 Nut
3 Screw 6 Washer
TIM ID: 0000019864 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Water pump shaft 8 Angular-contact ball bearing 15 Screw
2 Impeller 9 Cylindrical roller bearing 16 Washer
3 Bearing housing 10 Snap ring 17 O-ring
4 Seal carrier 11 Shaft seal 18 Screw
5 Volute 12 Rotary seal 19 Washer
7 Gear 14 O-ring
TIM ID: 0000019864 – 001
M020124/02E 2009-02 © MTU

9.14.36 Charge-air coolant pump – Removal

Heavy object.
Risk of crushing!

Risk of injury!
Charge-air coolant pump – Removal

1. Remove screws for charge-air coolant pump according to overview drawing DM_410_WM_203050_041A.
2. Use crowbar to separate charge-air coolant pump from equipment carrier and remove.
3. Mask installation hole for charge-air coolant pump.
4. Remove O-ring from charge-air coolant pump.
cardiagn.com
TIM ID: 0000019871 – 001
M020124/02E 2009-02 © MTU

9.14.37 Charge-air coolant pump – Disassembly
Special tools

Retaining device 5505890531/00 1
Press fit tool F30379316 1
Heavy object.
Risk of crushing!
cardiagn.com

Risk of injury!
Charge-air coolant pump - Disassembly

TIM ID: 0000019872 – 001
M020124/02E 2009-02 © MTU

4. Insert charge-air coolant pump (2) into retaining

device (1).
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pump shaft.
throughout.
7. Remove impeller (3) from charge-air coolant pump.
8. Remove charge-air coolant pump from retaining
device.
9. Place bearing housing (3) with pump shaft in vice

with aluminum jaws.
remove gear from water pump shaft TIM ID: 0000019872 – 001
M020124/02E 2009-02 © MTU

housing (1).
12. Remove all bolts (1) using box wrench (2).
cardiagn.com
TIM ID: 0000019872 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
16. Use hydraulic press (1) to force water pump shaft

cylindrical roller bearing out of bearing housing (4).
TIM ID: 0000019872 – 001
M020124/02E 2009-02 © MTU

18. Use screwdriver to press counterring (2) out

of impeller (1).
19. Use hydraulic press (1) and ejection mandrel (2) to
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press shaft seal and rotary seal (arrow) out of
seal carrier (3).
TIM ID: 0000019872 – 001
M020124/02E 2009-02 © MTU

9.14.38 Charge-air coolant pump – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Charge-air coolant pump – Cleaning

TIM ID: 0000019866 – 001
M020124/02E 2009-02 © MTU

9.14.39 Charge-air coolant pump – Tolerances
cardiagn.com
size Basic
size
1 Seal carrier 90.000 K7 –0.025 +0.010 0.025 0.025
Angular-contact 90.000 –0.015 0

ball bearing
outer Ø

bore
Angular-contact 90.000 –0.015 0

ball bearing
outer Ø
3 Angular-contact 40.000 –0.012 0 0.002 0.025

ball bearing bore
Shaft outer Ø 40.000 k5 +0.002 +0.013
4 Spacer sleeve 40.000 N7 –0.033 –0.008 0.010 0.046

bore
TIM ID: 0000019867 – 001
Shaft outer Ø 40.000 k5 +0.002 +0.013

bore
Cylindrical roller 80.000 –0.013 0

bearing
M020124/02E 2009-02 © MTU

size Basic
size
6 Cylindrical roller 40.000 –0.012 0 0.002 0.025

bearing bore
Shaft outer Ø 40.000 k5 +0.002 +0.013
7 Gear bore 39.000 H7 0 +0.025 0.018 0.059
Shaft outer Ø 39.000 s6 +0.043 +0.059
cardiagn.com
TIM ID: 0000019867 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
size Basic
size
Shaft seal 72.000 +0.130 +0.230

outer Ø
2 Shaft outer Ø 48.000 –0.100 0
Rotary seal 78.200 –0.030 0

outer Ø
4 Impeller bore 30.000 H5 0 +0.009 0.032 0.050
Shaft outer Ø 30.000 t5 +0.041 +0.050
5 Rotary seal
Counterring

TIM ID: 0000019867 – 001
M020124/02E 2009-02 © MTU

9.14.40 Charge-air coolant pump – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

Dye penetrant remover (Standard-Check) 40002
Aqueous developer (Standard-Check) 40004
Dye penetrant (Standard-Check) 40488
cardiagn.com
Spare parts

Charge-air coolant pump
Pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000019868 – 001
M020124/02E 2009-02 © MTU

Charge-air coolant pump – Check
Item Findings Task

cavitation.

for cracks.
Check pump shaft with fluorescent Crack indication Replace

magnetic powder for cracks.
Check pump shaft for wear and • Wear traces • Recondition: smooth minor
damage. • Damage traces of wear with emery cloth.
visible • Replace

visible
cardiagn.com
Check gear for indentations, traces • Wear traces • Recondition: smooth with
visible

diameters on pump shaft, impeller,
seal carrier and bearing housing
and gear with inside and outside
micrometer. Values and measuring
points DM_410_WM_203050_276A
TIM ID: 0000019868 – 001
M020124/02E 2009-02 © MTU

9.14.41 Charge-air coolant pump – Assembly
Special tools

Press fit tool for angular-contact ball bearings F30378152 1
Press fit tool for ball bearings F30378153 1
Press fit tool for shaft seal F30378550 1
Press fit tool for rotary seal F30378151 1
Support for bearing housing F6780563 1
Seat for shaft with bearing F6781573 1
Material
cardiagn.com
Ethanol 40250 1
Corrosion inhibitor oil
Spare parts

Snap ring
Shaft seal
Rotary seal
O-ring
Component is hot.
Risk of burning!
Heavy object.
Risk of crushing!
TIM ID: 0000019874 – 001

Risk of injury!
M020124/02E 2009-02 © MTU

Charge-air coolant pump – Assembly

Note: Apply pressure to bearing outer race.

cardiagn.com
4. Force angular-contact ball bearing (3) onto

water pump shaft (4) with hydraulic press (1)
and mandrel (2).
TIM ID: 0000019874 – 001
M020124/02E 2009-02 © MTU

5. Force spacer sleeve (3) onto pump shaft (4) with

6. Press inner race (2) of cylindrical roller bearing
cardiagn.com
onto pump shaft (3) with hydraulic press and
mandrel (1).
Note: Apply pressure to bearing outer race (3).

pump shaft into bearing housing (4). TIM ID: 0000019874 – 001
M020124/02E 2009-02 © MTU


position.
cardiagn.com
10. Use denatured ethanol to clean sliding and

counterring surfaces of the rotary seal, and the
seal carrier.
11. Coat outer surface of rotary seal (3) with surface
sealant.
rotary shaft seal (3) into seal carrier (4).
13. Clean running surface with ethanol after assembly.
TIM ID: 0000019874 – 001
M020124/02E 2009-02 © MTU


groove.
housing (1) and tighten them evenly.
17. Heat gear (2) to 200 °C.
cardiagn.com
Note: Insert counterring (2) only after heating.

21. Coat O-ring (2) with corrosion inhibitor oil and
place into counterring.
22. Place counterring (2) in heated impeller (1).
23. Clean counterring surface with denatured ethanol.
TIM ID: 0000019874 – 001
M020124/02E 2009-02 © MTU

24. Place charge-air coolant pump on hydraulic

press (1).
25. Use hydraulic press (1) to push heated impeller (2)
onto coolant pump shaft to stop position.
cardiagn.com
removal.
28. Turn pump shaft to check freedom of rotation.
29. Use feeler gauge to check clearance S2 (0.6 mm to
1.52 mm) between impeller and volute (3).
TIM ID: 0000019874 – 001
M020124/02E 2009-02 © MTU

9.14.42 Charge-air coolant pump – Installation
Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!
cardiagn.com
Risk of injury!

Preparing charge-air coolant pump for installation

3. Insert O-ring (1) in groove on the bearing housing
of charge-air coolant pump.
TIM ID: 0000019875 – 001
M020124/02E 2009-02 © MTU

4. Insert charge-air coolant pump (1) into the

bore in the equipment carrier, ensuring correct
5. Screw in screws (2) with washers.
6. Tighten screws (2) evenly.
cardiagn.com
TIM ID: 0000019875 – 001
M020124/02E 2009-02 © MTU

9.14.43 Coolant pipework from/to intercooler – Overview
cardiagn.com
1 Pipe 10 Rubber sleeve 19 Clamp
2 Gasket 11 Clamp 20 Holder
3 Screw 12 Holder 21 Spacer washer
4 Holder 13 Spacer washer 22 Screw
6 Nut 15 Coolant line 24 Screw
7 Coolant line 16 Coolant line 25 Washer
8 Plug screw 17 Coolant line 26 Plug screw
9 Coolant line 18 Rubber sleeve 27 Sealing ring
TIM ID: 0000003533 – 002
M020124/02E 2009-02 © MTU

cardiagn.com
1 Adapter union 11 Drain line
2 Sealing ring 12 Drain valve
3 Drain line 13 Holder
4 Drain valve 14 Screw
5 Holder 15 Washer
6 Screw 16 Spacer bushing
7 Washer 17 Pipe half-clamp
8 Pipe half-clamp 18 Grommet
9 Grommet 19 Screw
TIM ID: 0000003533 – 002
M020124/02E 2009-02 © MTU

9.14.44 Coolant pipework from/to intercooler – Removal
Preconditions
Removing coolant pipework
1. Before removing the lines, it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove lines as per overview drawing (→ Page 1612).
3. Remove sealant.
cardiagn.com
TIM ID: 0000004128 – 006
M020124/02E 2009-02 © MTU

9.14.45 Coolant pipework from/to intercooler – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com


Cleaning coolant pipework from/to intercooler

TIM ID: 0000008808 – 004
M020124/02E 2009-02 © MTU

9.14.46 Coolant pipework from/to intercooler – Check
Spare parts

Coolant line
Pipe
Rubber sleeve
Gasket
Retainer
Drain valve
Screw
Hex nut
Spacer washer
Spacer bushing
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Plug screw

Risk of injury!
Compressed air.
Risk of injury!
Checking coolant pipework from/to intercooler
Check sealing surfaces for flatness. Uneven • Corrective work: smooth

with oilstone or crocus
cloth.
• Replace
Check all components for damage. Damaged Replace
Check thread for easy movement and Damaged or sluggish • Corrective work: recut
damage. threads
• Replace
Pressure-test coolant lines with air and Leaking Replace

corrosion inhibitor in water bath for leaks as
necessary. Maintain a coolant temperature
of min. = 30 °C or max. = 40 °C at a test
TIM ID: 0000008809 – 002
M020124/02E 2009-02 © MTU

9.14.47 Coolant pipework from/to intercooler – Installation
Material

Engine oil
White petroleum jelly 40314 1
Compressed air.
Risk of injury!
Installing coolant pipework from/to intercooler

2. Blow out coolant pipework from/to intercooler with compressed air.
3. Install coolant pipework from/to intercooler as shown in the overview drawing (→ Page 1612) and secure with
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pipe half-clamps, ensuring the installation is free of tension.
TIM ID: 0000008810 – 004
M020124/02E 2009-02 © MTU

9.14.48 Coolant pipework with thermostat – Overview
Coolant pipework with thermostat
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1 Coolant distribution housing 13 O-ring 24 O-ring
2 Cover 14 O-ring 25 Screw
5 Cover 17 Screw 28 Restrictor
6 Screw 18 O-ring 29 Thermostat housing (low-
7 Blind flange 19 Screw temperature circuit)
8 O-ring 20 Screw 30 Thermostat insert
9 Screw 21 Thermostat housing (high- 31 Sealing ring
10 Elbow temperature circuit) 32 Screw
11 Gasket 22 Thermostat insert 33 Screw
12 Screw 23 Sealing ring 34 Washer
TIM ID: 0000003722 – 002
M020124/02E 2009-02 © MTU

9.14.49 Coolant pipework with thermostat – Removal
Preconditions
Suspended load.
Danger to life!
Removing thermostat housing (high temperature

circuit)
1. Remove screws from flanges (1) and (2).
2. Press the flanges off the sealing surfaces.
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3. Remove pipes (3) and (4) as shown in the
4. Remove flange (1).
5. Remove screws (2) from thermostat housing (5).
TIM ID: 0000003725 – 007
M020124/02E 2009-02 © MTU

6. Replace two screws from thermostat housing with

guide pins (arrowed).
7. Remove thermostat housing from coolant
distribution housing.
8. Remove thermostat inserts, sealing rings, and
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O-rings.
Removing coolant distribution housing

1. Screw eyebolts into coolant distribution housing
and suspend the housing using crane and rope.
2. Remove screws and washers for coolant
distribution housing as shown in the overview
3. Using crane and rope, remove coolant distribution
housing from gearcase.
4. Remove O-rings.
TIM ID: 0000003725 – 007
M020124/02E 2009-02 © MTU

Removing thermostat housing (low temperature circuit)

1. Remove screws from thermostat housing.
2. Remove thermostat housing as shown in the overview drawing (→ Page 1618).
cardiagn.com
TIM ID: 0000003725 – 007
M020124/02E 2009-02 © MTU

9.14.50 Coolant pipework with thermostat – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning coolant pipework with thermostat

TIM ID: 0000003723 – 004
M020124/02E 2009-02 © MTU

9.14.51 Coolant pipework with thermostat – Check
Material

Spare parts

Coolant distribution housing
Thermostat housing
Thermostat insert
Cover
Blind flange
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Elbow
Restrictor
Compressed air.
Risk of injury!
Component is hot.
Risk of burning!
TIM ID: 0000003724 – 002
M020124/02E 2009-02 © MTU

Checking coolant pipework with thermostat
Check all components for condition Damaged Replace

and damage.
Using red penetrant dye, check the Cracks indicated Replace

coolant distribution housing and
thermostat housing for cracks.
Check all mating and sealing • Wear • Corrective work: smooth with
surfaces for wear and damage. • Damage oilstone or crocus cloth.
visible • Replace
Check support bores of thermostat Damaged • Corrective work: smooth with

elements for damage. crocus cloth.
• Replace
Check threads in coolant distribution Sluggish Replace thread inserts.

housing for easy movement.
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Gaskets, sealing rings and O-rings – Replace
Check coolant and oil chambers Leaking Replace

of coolant distribution housing for
leaks with air and corrosion inhibitor
under water. Maintain a coolant
TIM ID: 0000003724 – 002
M020124/02E 2009-02 © MTU

Checking thermostat element (high- and

low-temperature circuits)
Technical data, thermostat elements
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Hightemperature circuit Start of Full open-
opening (A) =
ing (B) = 88 °C ± 2 °C
75 °C ± 2 °C
Lowtemperature circuit Start of Full open-

opening (A)
ing (B) = 51
= 38 °C ± 2 °C
°C ± 2 °C
Note: The thermostat element must not be in

contact with the container.
1. Suspend the thermostat element by means of a

wire in a container filled with water.
2. Heat water with suitable heat source.
Note: Start-of-opening temperature is stamped
on thermostat insert.
3. Check thermostat insert for start of opening

with heat supply uniform and water constantly
circulated. At approx. 10°C below opening
temperature (B), the heating speed must not
exceed 1°C per minute.
4. Replace thermostat insert if results of check
are negative.
5. Continue to heat coolant to full-opening
TIM ID: 0000003724 – 002
temperature (A).
Result: Thermostat insert must be completely
open after 6 to 8 minutes.
6. Measure stroke travel of thermostat insert. Stroke
must be min. 9.5 mm.
7. If stroke travel is less than 9.5 mm, replace
thermostat insert.
M020124/02E 2009-02 © MTU

9.14.52 Coolant pipework with thermostat – Installation
Special tools

Eyebolt 000580010000 2
Driving mandrel F30379297 1
Material

Engine oil
cardiagn.com
Spare parts

O-rings
Suspended load.
Danger to life!
Installing coolant distribution housing

1. Coat Orings with petroleum jelly and insert into
grooves (1) in equipment carrier.
2. Insert plug screw (2).
3. Coat mating face of coolant distribution housing on
equipment carrier with Loctite 518 (arrowed). TIM ID: 0000003726 – 004
M020124/02E 2009-02 © MTU

Note: When fitting coolant distribution housing

in position, make sure O-rings are not
damaged.
4. Carefully place coolant distribution housing on

equipment carrier with crane and rope and align.
5. Secure coolant distribution housing as shown in
the overview drawing (→ Page 1618).
Installing thermostat elements
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1. Fit sealing ring (2) with flat side to installation
mandrel (1).
2. Drive sealing rings with installation mandrel flush
into thermostat housing.
3. Coat sealing surfaces (arrowed) of thermostat

elements with petroleum jelly.
4. Insert thermostat elements.
6. Insert O-rings in groove.
TIM ID: 0000003726 – 004
M020124/02E 2009-02 © MTU

Installing thermostat housing (high-temperature

circuit)
1. Insert restrictor (arrowed) into support bore.
2. Install thermostat housing on coolant distribution
housing by means of guide pins.
3. Insert securing screws (2) of thermostat
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housing (5).
4. Install flange (1).
5. Install pipelines (3,4) as shown in the overview
6. Install flange (1,2).
TIM ID: 0000003726 – 004
M020124/02E 2009-02 © MTU

9.15 Power Supply, Engine Side
9.15.1 Battery-charging generator - Overview
cardiagn.com
1 Battery-charging generator 10 Grooved ball bearing 19 Guard plate
2 Coupling 11 Shaft seal 20 Holder
3 Carrier 12 O-ring 21 Screw
4 Shaft 13 Screw 23 Washer
5 Gear 14 Washer 24 Holder
6 Snap ring 15 Screw 25 Screw
7 Cylindrical roller bearing 16 Washer 26 Washer
8 Spacer ring 17 Generator bracket 27 Screw
9 Spacer ring 18 Screw
TIM ID: 0000009066 – 001
M020124/02E 2009-02 © MTU

9.15.2 Battery-charging generator – Removal
Special tools

Heavy object.
Risk of crushing!
Removing battery-charging generator

1. Mark and disconnect battery-charging generator
cables.
3. Remove holder (6) and bracket (3).
4. Remove screws (1) and plate (5).
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5. Withdraw battery-charging generator (4) from
carrier seating and coupling.
Removing coupling from battery-charging generator

1. Install battery-charging generator in support (1).
2. Remove nut (3).
3. Remove battery-charging generator from support.
4. Remove coupling (2) from support.
TIM ID: 0000009069 – 002
M020124/02E 2009-02 © MTU

Removing coupling from shaft

2. Remove coupling (3).
cardiagn.com
TIM ID: 0000009069 – 002
M020124/02E 2009-02 © MTU

9.15.3 Battery-charging generator – Disassembly
Disassembling battery-charging generator

Have battery-charging generator overhauled by an authorized workshop only.
cardiagn.com
TIM ID: 0000009071 – 002
M020124/02E 2009-02 © MTU

9.15.4 Battery-charging generator – Cleaning
Material

Compressed air.
Risk of injury!

cardiagn.com

Cleaning battery-charging generator

1. Clean generator with compressed air only; do not use any liquids in cleaning process.
2. Clean all metal parts using cleaner (Snow-White 11-0) and rinse with cleaner (Hakupur 312).
TIM ID: 0000009067 – 002
M020124/02E 2009-02 © MTU

9.15.5 Battery-charging generator - Check
Spare parts

Coupling
Carrier
Shaft
Gear
Spacer ring
Grooved ball bearing
Gear
Bracket
cardiagn.com
Guard plate
Holder
Clean battery-charging generator (→ Page 1633).
Checking battery-charging generator
Item Findings Task
Inspect battery-charging generator Damaged Replace

externally for damage.
Check all contact and mating Damaged • Recondition: Re-surface with

surfaces for damage. oil stone or crocus cloth.
• Replace
Check thread for ease of movement. No ease of movement • Recondition: Re-cut thread(s).
• Replace
Check battery-charging generator Abnormal running noises Contact Service.

drive for abnormal running noises.
Check gear for indentations, signs • Indentations • Recondition: Re-surface with

of wear and damage. • Signs of wear crocus cloth or oil stone.
visible
Check coupling for cracks and • Swellings Replace

swellings. • Cracks
visible.
TIM ID: 0000009068 – 001
M020124/02E 2009-02 © MTU

9.15.6 Battery-charging generator – Installation
Special tools

Material

Engine oil
cardiagn.com
Spare parts

Shaft seal
Heavy object.
Risk of crushing!
Check battery-charging generator (→ Page 1634).
Installing antifriction bearings and gear on carrier

1. Install antifriction bearings (5-9) on carrier (1).
2. Coat sealing lip of radial-lip shaft seal (10) with
engine oil.
3. Press radial-lip shaft seal into carrier until the
stop is reached.
Note: Heat gear to 180°C +20°C.
4. Install shaft (3) and gear (4) using the press-in

tool and ensuring that an thrust distance of 0.1 to
0.88 mm is achieved.
5. Coat O-ring (2) with petroleum jelly and position
in groove.
TIM ID: 0000009070 – 002
M020124/02E 2009-02 © MTU

Installing coupling on shaft

1. Check screws (1) for correct tightening torque
(→ Page 980).
2. Install coupling (3) ensuring correct positioning.
3. Install positioning fixture to lock the engine.
4. Install screw (2) and tighten to specified tightening
Installing battery-charging generator drive
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1. Install coupling (2) in installation tool (1).
2. Fit generator in installation tool.
3. Position Woodruff key on shaft.
4. Tighten nut to specified tightening torque
(→ Page 980).
TIM ID: 0000009070 – 002
M020124/02E 2009-02 © MTU

Installing battery-charging generator

Note: Ensure correct positioning of pins (1).
1. Install battery-charging generator (4) with

coupling (3) to coupling (2) ensuring there is no gap
between the resilient element and the intermediate
plate. Torsion of max. 1.0 mm is permissible.
2. Install holder (6) with bracket (3), ensuring that
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parts are not placed under tension.
4. Align battery-charging generator (4).
5. Tighten screws (2) to specified tightening torque
using a torque wrench (→ Page 980).
6. Install plate (5) using screws (1).
7. Connect cables as per marking.
TIM ID: 0000009070 – 002
M020124/02E 2009-02 © MTU

9.16 Mounting/Support
9.16.1 Engine mounting / support – Overview
Engine mounting / support
cardiagn.com
1 Engine mounting bracket 2 Engine mount
TIM ID: 0000004112 – 001
M020124/02E 2009-02 © MTU

9.16.2 Engine mounting – Overview
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1 Washer 6 Hex screw
2 Hex screw 7 Washer
3 Nut 8 Engine mounting bracket
4 Washer 9 Dowel pin
5 Resilient mount 10 O-ring
TIM ID: 0000034050 – 001
M020124/02E 2009-02 © MTU

Engine mounting brackets
cardiagn.com
1 Engine mounting bracket 3 Engine mounting bracket 5 Screw
TIM ID: 0000034050 – 001
M020124/02E 2009-02 © MTU

9.16.3 Engine mount – Removal
Special tools


Danger to life!
Suspended load.
Danger to life!
Engine mount – Removal

Note: Replace rubber mounts individually, one
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after the other.
1. Install engine supports with engine installed.

2. Insert engine support jackscrews until they make
contact with the foundation and secure the engine
against damping element static deflection.
3. Unscrew all foundation screw fittings on damping
element to be removed.
4. Use locking screws (5) to pull damping elements
together evenly until engine carrier can be
removed.
5. If the gap between base mount and foundation is
not large enough, proceed as follows:
5.1. Remove protective cap (1) and loosen
nut (3).
5.2. Insert height adjusting screw (4) as far as
possible in bearing cap. Make sure not to
twist central buffer. Hold firmly in position at
hexagon (2) if necessary.
6. Remove screws (1,2,4) with washers (3) from
engine mounting bracket.
7. Remove engine mount from crankcase.
TIM ID: 0000003538 – 005
M020124/02E 2009-02 © MTU

Removing engine support

Note: Remove engine support only if necessary. Make sure that supports are not stressed by engine.
1. Remove screws and washers from engine support (→ Page 1639).

2. Remove engine support from crankcase.
cardiagn.com
TIM ID: 0000003538 – 005
M020124/02E 2009-02 © MTU

9.16.4 Engine mount – Cleaning

Compressed air.
Risk of injury!
Engine mount – Cleaning

Note: Do not allow resilient rubber mounts to come into contact with oil and fuel.
1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Blow out all parts thoroughly with compressed air.
cardiagn.com
TIM ID: 0000003536 – 003
M020124/02E 2009-02 © MTU

9.16.5 Engine mounts – Check
Material

Spare parts

Engine mounting bracket
Damper mount
Dowel pin
cardiagn.com
Checking engine mounts
Check engine mounting bracket for cracks Sign of cracks Replace

with red penetrant dye.
Using the magnetic crack-testing method, Sign of cracks Replace

check central buffer for cracks.
Check central buffer for wear and damage. • Traces of wear Replace
• Damage
Visible
Check resilient rubber mounts for cracks and • Damage Replace

deformation (visual inspection). • Cracks
• Deformation
Visible
Check thread for ease of movement. Sluggish • Rework: recut thread.

• Replace
Check bolt-on faces for flatness. Uneven • Rework: smooth with oilstone.
• Replace
Check grooves for O-rings for damage. Damaged • Rework

• Replace
TIM ID: 0000003537 – 002
M020124/02E 2009-02 © MTU

9.16.6 Engine mount – Installation
Special tools

Material

Engine oil
cardiagn.com
Spare parts

O-ring

Danger to life!
Suspended load.
Danger to life!

Installing engine supports

1. Install engine supports with screws and washers as shown in overview drawing (→ Page 1639).
2. Tighten screws and washers of engine supports.
TIM ID: 0000003539 – 005
M020124/02E 2009-02 © MTU

Installing engine mounting bracket with resilient

mount
Note: The resilient mounts are supplied in
preadjusted and locked condition.
1. Prior to installation, check presettings of resilient

mounts. Readjust if required.
A Marking 30 = 6.0 mm buffer clearanceMarking 40

= 8.0 mm buffer clearance
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B Unloaded 152.5 mm
C Serial number
D Shore hardness
E Type
F Unloaded 50 mm
G Initial dimension 5 mm
2. Degrease engine mounting bracket (3) and flange

mating face (1).
4. Insert O-ring (2) in groove.
5. Chill dowel pins (arrows) in liquid nitrogen.
6. Press dowel pins (arrows) into engine mounting
bracket.
7. Use depth gauge to measure and check blind
hole in crankcase.
Result: Protrusion of dowel pin in engine mounting
bracket must not be greater than depth of blind
hole.
TIM ID: 0000003539 – 005
M020124/02E 2009-02 © MTU

8. Install assembly pins (1).

9. Mount engine mount on engine mounting bracket
(2).
10. Tighten nut manually.
11. Install engine mounting bracket (2) with screws (3)
and washers as shown in overview drawing
(→ Page 1639).
12. Use torque wrench to tighten screws to specified
13. Remove assembly pins (1).
14. Align base mounts of resilient mounts in
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longitudinal direction.
15. Loosen screws on engine supports.
16. Lower engine on to foundation by turning all
jackscrews alternately and evenly.
17. Back off jackscrews.
18. Remove locking screws (6), washers (5) and nuts
(4) or jackscrews and store somewhere safe.
19. Check engine alignment (→Height adjustment ).
20. Screw bearing element on to foundation.
21. Use feeler gauge to measure buffer clearance on
resilient mount through measuring groove (3),
readjust central buffer if required.
23. Prevent central buffer from turning by holding
hexagon (1) firmly in place.
Note: Make sure that no oil drips on to rubber
mount.
24. Coat nut mating face and threads of central

buffer with engine oil.
25. Shut down the engine with the locking screws
released for at least 48 hours.
Result: The rubber mounts are compressed.
26. Measure height and height angle.
Result: The dimensions of the shims required to
be installed under the relevant base mount are
defined.
TIM ID: 0000003539 – 005
27. After flanging the engine with alternator or

gearbox, align the unit in longitudinal and
transverse direction in accordance with the
alignment instructions.
M020124/02E 2009-02 © MTU

Adjusting central buffer

Note: Target measured values with locking
system removed and engine filled with
engine coolant and engine oil.
1. Remove protective cap and loosen nut.

2. Screw central buffer clockwise into upper stop
position.
3. Unscrew central buffer counterclockwise by the
dimension of clearance (A).
4. Check clearance with feeler gauge through
measuring groove in base mount.
5. Use torque wrench to tighten nut to specified
6. Fit protective cap.
A Model RD 314 B 3 mm +0.3 mm

A Model RD 315 HD 4 mm +0.3 mm.
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Height adjustment
1. Remove protective cap (1) and release nut (2).
Note: Make sure not to twist central buffer.
2. Lock bearing cap by fitting a locking screw (4).

3. Using height adjusting nut (3), adjust height by
max. 10 mm.
4. If the required height adjustment is still not
achieved, adjust the height by using shims under
the base mount (5).
5. Tighten nut (2) and protect central buffer from
twisting.
6. Seal protective cap and remove locking screw.
TIM ID: 0000003539 – 005
M020124/02E 2009-02 © MTU

9.17 PTO Systems, Driving End and Free End (Coupling)
9.17.1 Geislinger steel-spring coupling – Removal
Special tools

Adjusting mandrels F30379307 2
Heavy object.
Risk of crushing!
cardiagn.com
Removing steel-spring coupling

1. Mount positioning fixture (1) on flywheel.
2. Depending on the position of the steel-spring
coupling, remove screws (2) for lifting device.
TIM ID: 0000004108 – 003
M020124/02E 2009-02 © MTU

3. Fit lifting device (2) on steel-spring coupling (1)

and attach to crane with a lightly tensioned rope.
4. Remove screws (1) from steel-spring coupling (2)
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to flywheel (3).
5. Screw in adjusting mandrels (1).

6. Remove both screws (2) for forcing thread.
7. Install removal device.
8. Using removal tool, force steel-spring coupling off
flywheel.
9. Place steel-spring coupling on a suitable surface.
10. Remove O-rings.
TIM ID: 0000004108 – 003
M020124/02E 2009-02 © MTU

9.17.2 Geislinger steel-spring coupling – Disassembly

Heavy object.
Risk of crushing!
Remove Geislinger steel-spring coupling (→ Page 1649).
Geislinger steel-spring coupling – Disassembly

1. Place steel-spring coupling (1) on flange of inner
star.
2. Remove sealing ring screws (2).
3. Press sealing ring (3) with two sealing ring screws
(2) off forcing thread (4) and remove.
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4. Turn over steel-spring coupling and place coupling
intermediate section on wooden blocks.
5. Remove hex screws (3).
6. Remove inner star (1) with split bearing and
bearing retainer (4).
7. Raise bearing retainer (4) in direction inner star (1).
8. Remove split bearing by radially withdrawing
the bearing shells.
9. Remove bearing retainer (4) from inner star (1).
10. Remove retaining screws (2) from coupling
intermediate section.
11. Raise side plate from intermediate element spring
unit.
Result: This arrangement permits a complete
inspection of the steel-spring coupling.
Further disassembly is permitted only at the
manufacturer’s or at a Geislinger Service Point.
TIM ID: 0000004109 – 001
M020124/02E 2009-02 © MTU

9.17.3 Steel-spring coupling – Cleaning
Material

Cleaning agent
Diesel fuel

• Do not smoke.
Compressed air.
Risk of injury!
cardiagn.com
Steel-spring coupling – Cleaning

4. Treat parts with diesel fuel to protect against corrosion.
TIM ID: 0000004106 – 002
M020124/02E 2009-02 © MTU

9.17.4 Geislinger steel-spring coupling – Check
Spare parts

Steel-spring coupling
Heavy object.
Risk of crushing!
Clean Geislinger steel-spring coupling (→ Page 1652).
Geislinger steel-spring coupling – Check
Item Findings Task
Check bearing running surfaces for Abrasion visible • Replace damaged parts.
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abrasion. • Contact Geislinger or a
Geislinger Service Point.
Check bearing clearance from inner Sluggish • Recondition: Recut threads.

star to bearing bush and sealing • Replace
ring.
Wear test for spring leaves

Note: Wear or deformation of the bronze packing
pieces located between the spring leaves
is perfectly normal.
1. Check max. permissible wear “X” per side of the

inner end of the centre leaf.
2. If wear exceeds the max. permissible wear
dimension “X”, have all spring packs replaced by
Geislinger or a Geislinger Service Point.
X max. permissible wear = 2.4 mm

TIM ID: 0000004107 – 001
M020124/02E 2009-02 © MTU

Wear test for inner star

1. Check maximum wear of groove flanks.
2. If wear exceeds max. permissible dimension “A”,
replace inner star or recondition groove flank.
Contact Geislinger or a Geislinger Service Point.
cardiagn.com
A max. permissible wear = 1 mm
TIM ID: 0000004107 – 001
M020124/02E 2009-02 © MTU

9.17.5 Geislinger steel-spring coupling – Assembly
Material

Engine oil
Lubricating grease
Spare parts

Dished washer
O-rings
Heavy object.
cardiagn.com
Risk of crushing!
Check Geislinger steel-spring coupling (→ Page 1653).
Geislinger steel-spring coupling – Assembly

1. The procedure is the same disassembly but in reverse sequence.
2. The following additional instructions must be observed.
2.1. Replace all sealing elements.
2.2. Replace all dished washers.
2.3. Coat bearings and bearing running surfaces with lubricating grease.
2.4. Coat O-rings with petroleum jelly.
2.5. Insert O-rings in grooves.
TIM ID: 0000004110 – 001
M020124/02E 2009-02 © MTU

9.17.6 Geislinger steel-spring coupling – Installation
Special tools

Material

cardiagn.com
Spare parts

O-ring
Heavy object.
Risk of crushing!

Assemble Geislinger steel-spring coupling (→ Page 1655).

TIM ID: 0000004111 – 003
M020124/02E 2009-02 © MTU

Installing Geislinger steel-spring coupling

1. Degrease and dry-clean flanging surfaces and
centering devices.
2. Screw adjusting mandrels (1) on to flywheel (2).
4. Insert O-ring (3) in flywheel.
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6. Insert O-ring (1) in groove of steel-spring coupling.
7. Prior to installation, ensure positioning pin (2) is
correctly positioned in relation to flywheel.
8. Install lifting equipment (2) with support bracket on

9. Attach steel-spring coupling (1) and lifting
equipment (2) to crane with a lightly tensioned
rope.
TIM ID: 0000004111 – 003
M020124/02E 2009-02 © MTU

10. Use crane to position steel-spring coupling (3) on

flywheel (1) and slide on to adjusting mandrels (2).
11. Place entire steel-spring coupling (3) on
flywheel (1).
12. Screw in steel-spring coupling (3) diagonally with
4 screws and dish washers without Loctite 270.
13. Tighten screws to specified tightening torque using
a torque wrench (→ Page 980).
14. Remove lifting equipment with support bracket
from steel-spring coupling (3).
15. Install positioning fixture(1) on flywheel (2).
cardiagn.com
16. Apply Loctite 270 to both sides of dish washers
for screws (3).
17. Insert 8 screws (3) with dish washers in
18. Tighten opposing screws (3) to specified tightening
19. Remove the 4 assembly screws.
20. Coat both sides of dish washers for assembly
screws with Loctite 270.
21. Tighten opposing screws to specified tightening
22. Coat both sides of dish washers for slotted

screws (1) with Loctite 270.
23. Insert slotted screws (1) in lifting thread bores
and tighten to specified tightening torque using a
torque wrench (→ Page 980).
24. Remove positioning fixture.
TIM ID: 0000004111 – 003
M020124/02E 2009-02 © MTU

9.17.7 Diaphragm coupling – Overview
Diaphragm coupling
cardiagn.com
1 Diaphragm coupling 5 Washer
2 Screw 6 Screw
3 Washer 7 Screw
4 Washer 8 Washer
TIM ID: 0000008850 – 001
M020124/02E 2009-02 © MTU

9.17.8 Diaphragm coupling – Removal

Electrical voltage.
Suspended load.
Danger to life!
Diaphragm coupling – Removal

1. Secure generator with rope and crane.
2. Remove guard plates from flywheel housing.
3. Remove screws (2) and (7) with washers (8) as per overview drawing (→ Page 1659).
4. Carefully separate generator from engine.
5. Remove screws (6) as per overview drawing (→ Page 1659).
6. Remove diaphragm coupling.
cardiagn.com
TIM ID: 0000008851 – 002
M020124/02E 2009-02 © MTU

9.17.9 Diaphragm coupling – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Remove diaphragm coupling (→ Page 1660).
cardiagn.com
Diaphragm coupling – Cleaning
1. Clean diaphragm coupling with cleaner.
2. Remove cleaner.
3. Rub diaphragm coupling dry with cloth.
TIM ID: 0000008852 – 001
M020124/02E 2009-02 © MTU

9.17.10 Diaphragm coupling – Check
Material

Spare parts

Diaphragm coupling
Washer
Heavy object.
Risk of crushing!
cardiagn.com
Clean diaphragm coupling (→ Page 1661).
Diaphragm coupling – Check
Visually inspect all components for damage Damaged, deformation visible Replace
and deformation.
Check varnish coat of diaphragm coupling for Damaged Replace

damage.
Check thread for ease of movement. Sluggish • Recut

• Replace
Check diaphragm coupling with red penetrant Cracks indicated Replace

dye for cracks.
TIM ID: 0000008853 – 001
M020124/02E 2009-02 © MTU

9.17.11 Diaphragm coupling – Installation

Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
DANGER • Take special care when working on a running engine.
Heavy object.
Risk of crushing!
Check diaphragm coupling (→ Page 1662).
Installing diaphragm coupling on generator shaft
Measurement values table
Σ = (pressed + pulled) / 2
X (engine) Y (generator)
cardiagn.com
No. pressed pulled pressed pulled
Mean value
1. Fit diaphragm coupling on generator shaft.

2. Install 4 screws (M16 x 60) offset 90° and tighten
crosswise and evenly to specified tightening
pressed.
pressed.
position.
TIM ID: 0000008854 – 002
M020124/02E 2009-02 © MTU

12. Measure dimension X with crankshaft pressed.

14. Measure dimension X with crankshaft pulled.
position.
Note: If necessary, disassemble diaphragm
coupling and correct dimension Y by
means of adjusting shims.
21. Check result (specified value Y = X -0.2 to -0.5).
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22. Screw in remaining screws (M16 x 60) and tighten
23. Replace angular plates in generator fan gap with
more easily detachable shims (1).
TIM ID: 0000008854 – 002
M020124/02E 2009-02 © MTU

24. Screw 2 guide pins (1) into diaphragm coupling

and into flywheel housing and tighten.
Installing generator housing on flywheel housing
cardiagn.com
1. Secure generator housing (2) with rope (1) and
crane.
2. Join generator housing to flywheel housing (3) and
diaphragm coupling (4) into flywheel, positioning
by means of guide pins (arrow).
3. Fit generator housing screws (M12 x 40).
4. Tighten 2 screws simultaneously, or, if not possible,
then alternately in stages of 30° angle of rotation,
5. Remove guide pins, replace with screws (M12 x
40) and tighten.
6. Support genset on generator side at bearing points.
7. Detach starter from crane.
8. Remove shims from generator fan gap.
TIM ID: 0000008854 – 002
M020124/02E 2009-02 © MTU

Installing diaphragm coupling with generator shaft

on flywheel
1. Insert screws (1) (M16 x 40) via flywheel housing
openings.
2. Replace guide pins with screws.
3. Tighten 2 opposite screws simultaneously to
4. Use a suitable tool to rotate crankshaft further via
flywheel housing opening until all screws have
been pretightened.
5. Tighten screws, again diagonally and evenly or
alternately in stages of 30° angle of rotation, to
specified tightening torque (→ Page 980) .
cardiagn.com
Concentricity check
Note: If concentricity is above 0.13 mm, remove generator and repeat installation with new installation
position of flywheel and coupling.
1. Measure concentricity of diaphragm coupling (max. permissible 0.13 mm).

2. Note measured values.
TIM ID: 0000008854 – 002
M020124/02E 2009-02 © MTU

9.17.12 Auxiliary PTO, lateral – Overview
Auxiliary PTO, lateral
cardiagn.com
1 Cover 6 Housing 11 Guard plate
5 Gear 10 Flange
TIM ID: 0000030048 – 001
M020124/02E 2009-02 © MTU

Auxiliary PTO externally mounted components
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1 Flange 8 Washer 15 Screw
2 Cover 9 Screw 16 Washer
3 O-ring 10 Washer 17 Screw
4 Washer 11 Plate 18 Washer
5 Screw 12 Retainer 19 Coupling
6 Retainer 13 Screw 20 Screw
TIM ID: 0000030048 – 001
M020124/02E 2009-02 © MTU

Arrangement of installation/removal device for auxiliary PTO flange
1 Connection, SKF oil pressure

hand pump
2 Thrust sleeve
3 Bush
5
6
7
A
Draw spindle
Flange
Housing
Reference dimension = 185 mm
B Push-on dimension = 5.1mm –
7.5mm (measured from inner face
of flange to face of gear shaft).
C Check surface = Press-fitted flush
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4 Removal/installation device
TIM ID: 0000030048 – 001
M020124/02E 2009-02 © MTU

9.17.13 Auxiliary PTO – Removal
Special tools

Installation/removal device, hydraulic pump drive flange F0140044 1
Hydraulic hand pump, 0-3000 bar F6557936 1

Removing auxiliary PTO

1. Remove hydropump and coupling with externally
mounted components as shown in the overview
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2. Screw draw spindle (3) into flange (2).
3. Install installation/removal device.

4. Screw hydraulic HP fuel line (5) into flange.
5. Install nut (4) and fit by hand.
6. Vent oil pressure hand pump and pipework until
bubblefree oil emerges.
7. Connect HP line to oil pressure hand pump.
8. Read off maximum expansion pressure Pmax
at flange.
9. Operate hydraulic hand pump for expanding the
flange taper until expansion pressure is half the
permitted maximum.
10. Maintain this pressure for approx. 5 minutes.
11. Raise expansion pressure in stages of 0.1 x Pmax,
TIM ID: 0000005487 – 004
observing holding times of approx. 2 minutes.

Ensure that Pmax is not exceeded.
12. Slowly back off nut (4) until flange (2) is completely
released from shaft.
13. Release hand pump pressure and unscrew
HP line.
14. Remove installation/removal device and draw
spindle.
M020124/02E 2009-02 © MTU

15. Remove flange from shaft.

16. Remove housing (1 in the overview drawing
(→ Page 1667)).
Removing shaft with gear

1. Press gear shaft (5 in the overview drawing (→ Page 1667)) from fit and remove.
2. Unscrew all screws (3 in the overview drawing) from cover (1 in the overview drawing) and remove cover.
3. Press sealing ring (9 in the overview drawing) from fit and remove.
4. Use a suitable puller to remove cylindrical roller bearing (4 in the overview drawing) from shaft.
cardiagn.com
TIM ID: 0000005487 – 004
M020124/02E 2009-02 © MTU

9.17.14 Auxiliary PTO – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Remove auxiliary PTO (→ Page 1670).
cardiagn.com
Auxiliary PTO – Cleaning
1. Clean all parts with cleaner.
2. Remove cleaner.
3. Blow clean all parts thoroughly with compressed air.
TIM ID: 0000005497 – 001
M020124/02E 2009-02 © MTU

9.17.15 Auxiliary PTO – Check
Material

Fluorescent magnetic powder for magnetic crack-testing method
Spare parts

Cover
Gear
Housing
Flange
cardiagn.com
Guard plate
Bracket
Plate (optional)
Coupling
Clean auxiliary PTO (→ Page 1672).
Checking auxiliary PTO
Item Findings Task
Using the magnetic crack-testing method and Signs of cracks Replace

fluorescent magnetic powder, check housing,
shaft and gear for cracks.
Visually check sealing surfaces, annular Damaged • Reconditioning:

grooves on cover, flange and housing for wear, Smooth with emery
pitting and cavitation. cloth or oilstone.
• Replace
Check shaft with gear for wear and damage. • Slight wear • Reconditioning:
• Damage Smooth with emery
visible cloth or oilstone.
• Replace
Measure bearing seats on shaft with Limit values exceeded Replace

micrometer.
Visually inspect cylindrical roller bearing Damaged Replace

for damage. Always replace during major
overhaul.
TIM ID: 0000005494 – 002
Check thread for ease of movement. Sluggish Recut
Check coupling visually for wear and damage. Heavy wear, damage visible Replace
M020124/02E 2009-02 © MTU

9.17.16 Auxiliary PTO – Installation
Special tools

Installation/removal device assembly, hydraulic pump drive flange F0140044 1
Hydraulic hand pump 0-3000 bar F6557936 1
Draw spindle F6557108 1
Thrust sleeve F6555733 1
Installation tool, radial-lip shaft seal with support F30378655 1
Pressin tool for cylindrical roller bearing 30378656 1
Material
cardiagn.com
Engine oil
Heavy object.
Risk of crushing!

Check auxiliary PTO (→ Page 1673).
Preparing gear shaft

Note: Bearing inner race and outer race are
seen as a single unit and must not be
interchanged.
1. Coat contact surfaces of shaft (4) and track ring (3)

of cylindrical roller bearing with engine oil.
2. Press-fit track ring (3) of cylindrical roller bearing
with jig (1,2) onto gear shaft (4), ensuring it is
gap-free and correctly positioned.
3. Rotate gear shaft and press-fit track ring of
opposite side accordingly.
TIM ID: 0000005503 – 003
M020124/02E 2009-02 © MTU

Preparing housing
1. Coat O-ring (2) with petroleum jelly and insert in
groove of housing (3).
2. Coat housing bearing with engine oil.
3. Press-fit cylindrical roller bearing (1) with suitable
tool into housing (3).
4. Turn housing through 180°.
5. Clean and degrease housing bore for sealing
cardiagn.com
ring (1).
6. Press-fit sealing ring (1) so that it is flush with
housing (2).
Installing flange
1. Coat O-ring of cover with petroleum jelly.
2. Install cover (1 in the overview drawing
(→ Page 1667)) with screws (3 in the overview
drawing).
TIM ID: 0000005503 – 003
M020124/02E 2009-02 © MTU

3. Coat cylindrical roller bearing (2) with engine oil.

4. Drive cylindrical roller bearing (2) with jig (1)
carefully into housing bore (3).
5. Insert gear shaft (2) up to stop into cylindrical
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roller bearing.
6. Position water cock (1) suitably for housing
installation.
7. Screw 2 guide pins (2) into equipment carrier (1).

8. Position housing (3) with small bore (4) down on
guide pins (2).
9. Insert housing (3) via guide pins (2) into equipment
carrier (1).
10. Secure housing with screws.
TIM ID: 0000005503 – 003
M020124/02E 2009-02 © MTU

11. Coat contact surfaces of flange bore (1) with

engine oil.
12. Fit flange (1) on gear shaft (2) by hand up to stop.
Note: Push-on dimension = 5.1mm – 7.5mm,
measured from inner face of flange
(arrowed) to face of gear shaft (arrowed).
13. Push-on dimension check.
14. Install draw spindle (3), thrust sleeve and jig.
cardiagn.com
15. Connect HP fuel line (5) to flange (2).
16. Vent hand pumps and pipework until bubblefree oil
emerges.
17. Tighten nut (4).
18. Using hand pump, generate expansion pressure
until flange (2) with nut (4) can be easily screwed
on.
19. Do not exceed maximum permissible expansion
pressure.
20. Retain expansion pressure and screw on flange
21. Release expansion pressure.
22. Remove HP fuel line (5).
23. Leave jig approx. 60 mins. at rest.
24. Remove jig, thrust sleeve and draw spindle.
Installing Centa coupling and externally mounted components

1. Install Centa coupling – see Special Publication M060715.
2. Install externally mounted components as shown in the overview drawing (→ Page 1667).
TIM ID: 0000005503 – 003
M020124/02E 2009-02 © MTU

9.18 Monitoring and Control System
9.18.1 Monitoring, control and regulation devices – Overview
Engine Control Unit (ECU)
cardiagn.com
TIM ID: 0000004300 – 001
M020124/02E 2009-02 © MTU

9.18.2 Cabling and engine wiring harnesses – Overview
Designation Pin assignment

W2
B1 Camshaft speed
B3 Intake air temperature
B5 Oil pressure
B6 Engine coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
cardiagn.com
B26 Charge-air coolant temperature
B34 Fuel pressure after filter
B50 Crankcase pressure
F25 Lube oil differential pressure
F46 Leak-off fuel

W3
B33 Fuel temperature
B48 Fuel pressure after HP pump
M8 HP fuel pump actuator

W4
For 8V
For 12V
For 16V

TIM ID: 0000034004 – 001

(power supply)

(generator control)
M020124/02E 2009-02 © MTU

cardiagn.com
1 Wiring harness W2 5 O-ring 9 Sealing ring
4 Bush 8 Temperature sensor 12 Temperature sensor
TIM ID: 0000034004 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 Wiring harness W3 2 Pressure sensor 3 HP fuel pump actuator M8
TIM ID: 0000034004 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
A1 Injector Y39.1 A8 Injector Y39.8** B7 Injector Y39.17**
A2 Injector Y39.2 B1 Injector Y39.11 B8 Injector Y39.18**
A3 Injector Y39.3 B2 Injector Y39.12 X4 Connector to ECU 4
A4 Injector Y39.4 B3 Injector Y39.13 * Only for 12V and 16V
A5 Injector Y39.5* B4 Injector Y39.14 ** Only for 16V
A6 Injector Y39.6* B5 Injector Y39.15*
A7 Injector Y39.7** B6 Injector Y39.16*
TIM ID: 0000034004 – 001
M020124/02E 2009-02 © MTU

9.18.3 Engine wiring harnesses – Removal
Preconditions
Special tools

Hot oil.
cardiagn.com
Removing engine wiring harnesses W2 and W3

connector pliers.
sensors/actuators.

TIM ID: 0000034006 – 001
M020124/02E 2009-02 © MTU


retainers.
7. Carefully remove wiring harness.
Removing engine wiring harness W4
cardiagn.com
connector pliers.
sensors/actuators.


retainers.
TIM ID: 0000034006 – 001
M020124/02E 2009-02 © MTU

7. Remove cylinder head covers (→ Page 1314).

8. Unscrew spade lugs (1) on injector (2).
9. Undo cable entry (3) and carefully pull connecting
wires out of the cable entry.
10. Remove wiring harness.
cardiagn.com
TIM ID: 0000034006 – 001
M020124/02E 2009-02 © MTU

9.18.4 Engine wiring harness – Clean
Material

Cleaner (Hakupur 312 at 2% concentration)


Cleaning engine wiring harness
cardiagn.com
1. Clean engine wiring harness with cleaning agent.
2. Remove cleaner.
TIM ID: 0000029141 – 001
M020124/02E 2009-02 © MTU

9.18.5 Engine wiring harness – Check
Material

Cable tie
Insulating tape
Heat-shrinkable hose
Spare parts

Engine wiring harness
Checking engine wiring harness

1. The engine governor continuously monitors all engine wiring harnesses.
cardiagn.com
2. The engine governor detects and reports the following errors to the connected monitoring system:
• Defective electrical assemblies
• Cabling damage
• Short circuits
• Sensor values outside of the plausibility range.
3. Carry out following checks and maintenance:
Check engine wiring harness for • Cracks • Rework: repair using insulating
cracks, kinks and chafing • Kinks tape or heat-shrinkable hose.
• Chafing • Replace engine wiring harness.
visible
Check shrink-formed components Damaged Replace shrink-formed components.

for damage.
Check plug connections for Damaged • Rework: Straighten plug

damages. connections.
• Replace plug connector.
Check engine wiring harness for Loose engine wiring harness Re-fix engine wiring harness with
tight seating. cable tie.
TIM ID: 0000029142 – 001
M020124/02E 2009-02 © MTU

9.18.6 Engine wiring harnesses – Installation
Special tools

Spare parts

Cable clamps/ties
Installing engine wiring harnesses W2 and W3

connected sensors/actuators without tension.
cardiagn.com
3. Engage and tighten connectors to
sensors/actuators.
4. Press wiring harness into cable retainers.
5. Press locking clips (1) firmly onto cable retainers
until they are fully engaged.

when installing.
6. Secure cables/wiring harnesses (2) with cable

clamps/ties (1).
TIM ID: 0000034068 – 001
M020124/02E 2009-02 © MTU

Installing engine wiring harness W4

connected injectors without tension.
3. Press wiring harness into cable retainers. Finally
press the locking clips (1) firmly onto the cable
retainers until they engage audibly.
cardiagn.com
when installing.
4. Secure cables/wiring harnesses with cable

clamps/ties (1).
7. Insert connecting wires in cable entries (3).

8. Twist the wires four times to a suitable length
before connecting them to the injector.
9. Connect spade lugs (1) on injector (2).
10. Install cylinder head cover (→ Page 1317).
TIM ID: 0000034068 – 001
M020124/02E 2009-02 © MTU

9.18.7 Sensors, actuators and injectors – Overview
cardiagn.com
1 F46 (leak-off fuel level) 2 F25 (lube oil differential pressure)
TIM ID: 0000034106 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 B6 (coolant temperature) 3 B34 (fuel pressure after filter) 5 B1 (camshaft speed)
2 B5 (lube oil pressure) 4 B33 (fuel temperature) 6 B48 (fuel high pressure)
TIM ID: 0000034106 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 B13 (crankshaft speed) 2 B9 (charge-air temperature) 3 B10 (charge-air pressure)
TIM ID: 0000034106 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
1 B50 (crankcase pressure)
2 B7 (lube oil temperature)
3 B26 (charge-air coolant
temperature)
4 B3 (intake air temperature)
The injectors are located below the cylinder head covers. Injector replacement and
necessary activities (→ Page 1330).
TIM ID: 0000034106 – 001
M020124/02E 2009-02 © MTU

9.18.8 Sensors, actuators and injectors – Removal

• Do not smoke.
Hot oil.

Removing temperature sensors (B3, B6, B7, B9,
cardiagn.com
B26, B33)
1. Always note:
also identical.
(→ Page 1690).
2. Observe the following prior to removal:
B6 (coolant temperature) Task description and safety instructions (→Operating Instructions)
B7 (oil temperature) During removal, small amounts of engine oil may emerge. Catch engine
oil in a suitable container.
B33 (fuel temperature) During removal, small amounts of fuel may emerge. Catch fuel in a
suitable container.

(2).
TIM ID: 0000029692 – 002
M020124/02E 2009-02 © MTU

Removing pressure sensors (B5, B10)

1. Always note:
also identical.
(→ Page 1690).
• During removal of sensor B5 (oil pressure),
small amounts of engine oil may emerge. Catch
engine oil in a suitable container.
(2).
cardiagn.com
1. Always note:
(→ Page 1690).
• During removal of sensor B34 (fuel pressure
after filter), small amounts of fuel may emerge.
(2).

1. Always note:
(→ Page 1690).
• During removal of sensor B48 (fuel high
pressure), small amounts of fuel may emerge.
(2).
TIM ID: 0000029692 – 002
M020124/02E 2009-02 © MTU


1. Always note:
(→ Page 1690).
(2).
Removing speed sensors (B1, B13)
cardiagn.com
1. Always note:
also identical.
(→ Page 1690).
2. Release bayonet lock (1) of speed sensor (2) and
remove connector (3) from engine wiring system.
4. Remove speed sensor (2).
Removing differential pressure monitor (F25)

1. Always note:
(→ Page 1690).
• During removal of sensor F25, small amounts of
engine oil may emerge. Catch engine oil in a
suitable container.
2. Release screw (1) of connector and remove
connector (2).
3. Release nut (3) and screw out sensor (4) from
measuring block (6).
4. Remove copper sealing ring (5).
TIM ID: 0000029692 – 002
M020124/02E 2009-02 © MTU

Removing level probe (F46)

1. Always note:
(→ Page 1690).
cardiagn.com
TIM ID: 0000029692 – 002
M020124/02E 2009-02 © MTU

9.18.9 Sensors, actuators and injectors – Check
Material

Isopropyl alcohol
Spare parts

Pressure sensor
Pressure monitor
Speed sensor
Temperature sensor
Level monitor
cardiagn.com
Sensors, actuators and injectors – Check
1. Always note:
• The governor is able to detect defective electric assemblies, wire breaks, short circuits and deviating
sensor values.
2. Carry out the following checks:
Item Findings Task
Check sensors and actuators for Loose sensors or actuators. Retighten securing screws.
secure seating.
Check security of plug connections. Loose plug connections. Connect plug connections properly
and tighten.
Check sensors, actuators and Damaged Replace

plug connections for mechanical
damage.
Check sensors, actuators and plug Contamination visible. Clean relevant assembly with
connections for contamination (e.g. isopropyl alcohol.
oil sludge).
TIM ID: 0000028437 – 001
M020124/02E 2009-02 © MTU

9.18.10 Sensors, actuators and injectors – Installation
Material

Spare parts

O-ring
Sealing ring
Adjusting washer
Check sensors, actuators and injectors (→ Page 1698).
Installing temperature sensors (B3, B6, B7, B9,
cardiagn.com
B26, B33)
1. Always note:
(→ Page 1690).
Installing pressure sensors (B5, B10)

1. Always note:
(→ Page 1690).
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU


1. Always note:
(→ Page 1690).
cardiagn.com
1. Always note:
(→ Page 1690).

1. Always note:
(→ Page 1690).
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU


1. Always note:
(→ Page 1690).
3. Determine clearance “A” see table below. Fit
adjusting washer at installation bore if required.
cardiagn.com
Clearance “A” (between sensor and timing wheel)
MDEC 1 mm to 1.3 mm
DDEC 0.5 mm to 1 mm


1. Always note:
(→ Page 1690).
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU

Installing differential pressure monitor (F25)

1. Always note:
(→ Page 1690).
2. Fit new sealing ring (5).
3. Screw in sensor (4) in bore of measurement
block (6) by hand.
5. Fit connector (2) and tighten screw (1).
Level probe (F46)
cardiagn.com
1. Always note:
(→ Page 1690).
3. Screw in sensor and tighten nut (1).
TIM ID: 0000029694 – 002
M020124/02E 2009-02 © MTU

Special Tools 1703
10 Special Tools
10.1 Standard tools – Overview

Use tity
8205891159/00 General tool kit 1
cardiagn.com
TIM ID: 0000009214 – 003
M020124/02E 2009-02 © MTU

10.2 Special tools – Overview
cardiagn.com
Y20010175 Bore gauge, 275-300 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1705

mm
cardiagn.com
Y20091483 Bore gauge, 160-280 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


mm
cardiagn.com
mm
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1707
Y20091481 Bore gauge, 18-100 mm 1
cardiagn.com
mm
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20011268 Dial gauge 1
cardiagn.com
Y20002779 Depth gauge, 500 mm 1

TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1709
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6783824 Camshaft bearing removal 1

device
cardiagn.com
B80146893 Hand pump kit 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1711
cardiagn.com
F6557186 Hydraulic screw pretensioner 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


main bearing stud
cardiagn.com
F6555771 Stop device for plug (main oil 1
gallery)
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1713
F6555738 Assembly jig for camshaft 1

bearing
cardiagn.com
F30378754 Assembly mandrel for end 1
cover
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30450446 Camshaft bearing shrink-on 1

tool
cardiagn.com
F6555763 Guide bushing for camshaft 1
bearing shrink-on tool
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1715
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6782566 Removal tool for carbon 1

scraper ring
cardiagn.com
F6557114 Removal tool for cylinder liner 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1717
F6787880 Press-in tool for cylinder liner 1
cardiagn.com
Y20000326 Micrometer, 150-175 mm 1
Eyebolts

TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

T80092075 Eyebolt 4
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1719
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


mm
cardiagn.com
0015890321/00 Retainer 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1721
T80091102 Bracket 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6555724 Support 1
cardiagn.com
F6557190 Removal tool for main 1
bearing, driving end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1723
B80096717 Lukas cylinder 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378426 Installation tool 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1725
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1727
cardiagn.com
B80146411 Adapter 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

B80096717 Lucas cylinder 1
cardiagn.com
F6557191 Press-out tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1729
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30377680 Installation mandrel for 1

radial-lip shaft seal
cardiagn.com
F6782344 Alignment tool (free end), 1
equipment carrier
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1731
F6557946 Guide bushing for equipment 1

carrier
cardiagn.com
0005800100000 Eyebolt 1

mm
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


mm
cardiagn.com
0015890321/00 Holder 1
Master weights
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1733

mm
cardiagn.com
Y20506341 DynaMIC hardness tester 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20091482 Bore gauge, 100-160 mm 1
cardiagn.com
F6553644 Crankshaft locating device 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1735
F6783568 Removal tool for crankshaft 1

bearing caps
cardiagn.com
F6557936 Hydraulic set 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

B80144827 High-pressure hose 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1737
cardiagn.com
F6553645 Slide protection 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1739
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6553649 Installation aid 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1741
cardiagn.com
F0140440 ZB Installation/removal tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

5505890163/00 SKF hydraulic unit 1
cardiagn.com
5555890063/00 Hand pump set 1
T80091387 Trestle 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1743
F6555788 Adapter 1
cardiagn.com
F30377999 Impact extractor 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6557134 Assembly sleeve 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1745
Y20001744 Micrometer, 175-200 mm 1
cardiagn.com
F0140771 Installation/removal tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1747
cardiagn.com
F6557187 Flywheel positioning fixture 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1749
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

T80090748 Hook-ended chain sling (4 off) 1
cardiagn.com
F0140771 Removal/installation device 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1751
T80090748 Hook-ended chain sling 1

(quadruple branch)
cardiagn.com
F6555766 Barring tool, 8V-16V 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6783293 Barring tool, 20V 1
cardiagn.com
F6555791 Barring tool for timing disc 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1753
F6555792 Pointer for barring tool 1
cardiagn.com
Y4341124 Timing disc, free end 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378352 Socket, 22 A/F, conrod screws 1
cardiagn.com
removal, 8V-16V
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1755

removal, 20V
cardiagn.com
F6559604 Sliding block 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378003 Piston-ring pliers 1
cardiagn.com
T80091025 Lifting tool for piston 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1757
F6557121 Piston/conrod assembly 1

sleeves for carbon scraper
ring
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6555791 Barring device for graduated 1

disc
cardiagn.com
F6555792 Pointer for barring device 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1759
Y4341124 Graduated disc, free end 1
cardiagn.com
Y4341919 Measuring equipment for 1
TDC measurement in cylinder
head
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378352 Socket A/F 22 – conrod 1

screws
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1761
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378352 Socket, SW 22 – Conrod 1

screws
cardiagn.com
mm H7
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1763

mm H9
cardiagn.com
mm H7
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


mm H7
cardiagn.com
mm H7
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1765
Y4340442 Check gauge for inlet valve 1

seat
cardiagn.com
Y4340443 Check gauge for exhaust 1
valve seat
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y4343688 Removal tool 1
cardiagn.com
Y20000083 C-frame micrometer, 0-25 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1767
cardiagn.com
B80144872 Plug 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


plugs
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1769
F6783833 Valve spring compressor 1
cardiagn.com
F30377634 Socket 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6783749 Tool kit without elliptical 1

cardiagn.com
F6783751 Tool kit (accessory 1
equipment) for elliptical
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1771
F6784421 Tool kit for valve-seat insert 1

removal
cardiagn.com
F30450433 Indexable insert 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6554300 Mounting plate for valve guide 1

installation
cardiagn.com
F30450348 Valve guide extractor 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1773
F6781747 Valve guide mandrel 1
cardiagn.com
0 cylinder head bore
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


I cylinder head bore
cardiagn.com
II cylinder head bore
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1775

tool for exhaust valve with
valve-seatinsert
cardiagn.com
tool for inlet valve with
ellipticalchamfer and
with/without valve-seat
insert
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

8205890451/00 Turning handle for valve seat 1

contour restoring tool
cardiagn.com
Y4340443 Exhaust valve gauge 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1777
Y4340442 Inlet valve gauge 1
cardiagn.com
Y4341935 Valve seat test device 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30451554 Countersink reamer tool 1
cardiagn.com
valve-seat insert, inlet
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1779

valve-seat insert, exhaust
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
seal plug
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1781
B80144872 Seal plug 1
cardiagn.com
F6553658 Tightening tool (power 1
amplifier)
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6558582 Alignment tool for 8V and 12V 1

cylinder heads
cardiagn.com
F6553648 Alignment tool for 16V and 1
20V cylinder heads
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1783
cardiagn.com
Y20044010 Measuring tool for angle of 1
rotation
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
F30378617 Mandrel, Ø 20 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1785
F30377862 Guide sleeve for mandrel 1
cardiagn.com
F30271842 Mandrel, Ø 24 mm 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30377635 Mandrel, Ø 30 mm 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1787
Y20506341 Hardness tester DynaMIC 1
cardiagn.com
0015890321/00 Measuring stand 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6553642 Camshaft locating device 1
cardiagn.com
F30450435 Camshaft installation/removal 1
tool
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1789

8V-16V
cardiagn.com
20V
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


driving end
cardiagn.com
driving end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1791

free end
cardiagn.com
F6780582 Centering sleeve for assembly 1
on free end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU


driving end
cardiagn.com
driving end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1793

free end
cardiagn.com
F6780582 Centering sleeve for 1
free end
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1795
Y20010128 Feeler gauge 1
cardiagn.com
Y4341124 Graduation plate, free end 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1797
cardiagn.com
8205893261/00 Oilstone 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

T80091799 Lifting equipment for HP 1

pump
cardiagn.com
0005388520 Hot-air gun 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1799
0135315483 Connector pliers 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30377769 Puller 1
cardiagn.com
F6557991 Puller bracket 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1801
cardiagn.com
F6555197 Lever 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6557952 Force-in lever 1
cardiagn.com
F30373588 Crowfoot box wrench for HP 1
lines
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1803
F6553674 Retaining device for HP 1

accumulator installation
cardiagn.com
F6557185 Alignment tool for HP 2
accumulator
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30379005 Slotted nut screwdriver 1
cardiagn.com
F30379104 Filter wrench 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1805
F70144375 Vibe jaw 2
cardiagn.com
F30520703 T torque wrench 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
F70144375 Assembly jaws 2.
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1807
F30520703 Tee torque wrench, 10-90 Nm 1
cardiagn.com
Y20044010 Angle of rotation measuring 1
device
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Y20504961 Dynamometer 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1809
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
Test bath
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1811
B80090843 Eyebolt 2
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1813
F6781539 Hydraulic spindle 1
cardiagn.com
F6780562 Puller tool for impeller 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6780561 Puller tool for gear 1
cardiagn.com
F6781573 Holding fixture 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1815
F30275611 Carrier for several mandrels 1
cardiagn.com
F30379316 Press fit tool 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F30378152 Press fit tool for 1

angular-contact ball bearings
cardiagn.com
F30378153 Press fit tool for ball bearings 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1817
F30378550 Press fit tool for shaft seal 1
cardiagn.com
F30378151 Press fit tool for rotary seal 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6780563 Support for bearing housing 1
cardiagn.com
F6781573 Support for shaft with bearing 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1819
F6780561 Retaining device 1
cardiagn.com
Cleaning brush
5505890531/00 Retaining device 1

TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6781573 Seat for shaft with bearing 1
cardiagn.com
000580010000 Eyebolt 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1821
F30379297 Driving mandrel 1
cardiagn.com
F6782572 Retaining jig 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
F6557187 Positioning fixture 1
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1823
F30379609 Box wrench 1
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

cardiagn.com
F30379307 Adjusting mandrels 2
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1825
cardiagn.com
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F0140044 Installation/removal device, 1

hydraulic pump drive flange
cardiagn.com
F6557936 Hydraulic hand pump, 1
0-3000 bar
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1827

assembly, hydraulic pump
driveflange
cardiagn.com
F6557936 Hydraulic hand pump 1
0-3000 bar
F6557108 Draw spindle 1

TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

F6555733 Thrust sleeve 1
cardiagn.com
F30378655 Installation tool, radial-lip 1
shaft seal with support
30378656 Pressin tool for cylindrical 1

roller bearing
TIM ID: 0000009600 – 001
M020124/02E 2009-02 © MTU

Special Tools 1829
10.3 General workshop equipment – Overview

Use tity
F30004455 Open-end wrench 1
cardiagn.com
F30006068 Double open-end 1
wrench
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU


Use tity

bit
cardiagn.com
bit
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU

Special Tools 1831

Use tity

bit
cardiagn.com
bit
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU


Use tity
F30047446 Torque wrench 1
cardiagn.com
F30450902 Ratchet bit 1
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU

Special Tools 1833

Use tity
F30501631 Starter wrench 1
cardiagn.com
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU


Use tity
5505890921/00 Compression 1
pressure recorder
cardiagn.com
5505890921/06 Diagram sheets 1
TIM ID: 0000009216 – 002
M020124/02E 2009-02 © MTU

Special Tools 1835
10.4 Measuring tools – General overview

Use tity
cardiagn.com
TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU


Use tity
Y20000665 Adjusting ring 1

(9 mm)
cardiagn.com
Y20000918 Depth gauge 1
TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU

Special Tools 1837

Use tity
Y20001743 Caliper gauge 1
cardiagn.com
TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU


Use tity
cardiagn.com
TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU

Special Tools 1839

Use tity
cardiagn.com
TIM ID: 0000009215 – 002
M020124/02E 2009-02 © MTU

10.5 Tools kits – Overview
Part No. Designation Qty.

Use
F30378882 W4 tool kit for Series 1

4000
cardiagn.com
TIM ID: 0000019250 – 001
M020124/02E 2009-02 © MTU

Annex 1841
Annex
11 MTU Contact/Service Partners ................................................... 1843
cardiagn.com
TIM ID: 0000007624 – 003
M020124/02E 2009-02 © MTU

1842
M020124/02E
2009-02
© MTU
Annex
TIM ID: 0000007624 – 003

cardiagn.com
MTU Contact/Service Partners 1843
11 MTU Contact/Service Partners
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/worl/
24h Hotline
With our 24h hotline and flexibility, we’re your contact around the clock: during the 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.
cardiagn.com
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
TIM ID: 0000007624 – 003
M020124/02E 2009-02 © MTU

cardiagn.com

Diesel Engine MTU4000R41 Workshop Manual

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Diesel Engine MTU4000R41 Workshop Manual

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M020124/02E 2009-02 © MTU

M020124/02E 2009-02 © MTU

M020124/02E 2009-02 © MTU

M020124/02E 2009-02 © MTU

1.1 Prerequisites for maintenance work and general

Prerequisites for maintenance work

General assembly instructions

M020124/02E 2009-02 © MTU

M020124/02E 2009-02 © MTU

1.2 Reman assemblies

Series 2000 Series 4000

HP fuel pump HP fuel pump

Cylinder head Cylinder head

Exhaust turbocharger Exhaust turbocharger

M020124/02E 2009-02 © MTU

M020124/02E 2009-02 © MTU

2.1 General Instructions

M020124/02E 2009-02 © MTU

2.2 Personnel and organizational requirements

TIM ID: 0000000509 – 001

M020124/02E 2009-02 © MTU

2.3 Safety precautions when working on the engine

Always seal connections with caps or covers if a line is removed or opened.

M020124/02E 2009-02 © MTU

into shaft end until correct sealing is achieved.

M020124/02E 2009-02 © MTU

Working on electrical/electronic assemblies

M020124/02E 2009-02 © MTU

2.4 Auxiliary materials, fire prevention and environmental

M020124/02E 2009-02 © MTU

M020124/02E 2009-02 © MTU

2.5 Standards for warning notices in the publication

TIM ID: 0000002862 – 001

M020124/02E 2009-02 © MTU

2.6 General information regarding the Tolerances

Explanation of terms for dimensions of new components

Toleranced size Designed size followed by a fit symbol (e.g. 24 H6) or by

Basic size Designed size without fit symbol or permissible

Deviation Permissible tolerance of toleranced/basic size.

Clearance Difference between bore and shaft diameter when bore

Explanation of terms for reconditioning of components

Reworking instructions If wear limits are exceeded or values are below

M020124/02E 2009-02 © MTU

2.7 Engine side and cylinder designations

TIM ID: 0000000415 – 002

M020124/02E 2009-02 © MTU

2.8 Tightening specifications for screws, nuts and bolts

Stud for crankshaft bearing cap in crankcase 80 Nm Engine oil

Stud (nominal length: 347.5 mm to 348.5 mm):

Stud elongation for crankshaft bearing cap ΔI = 1.15 mm +0.05 mm

Residual screw elongation ΔI = 0.9 mm +0.05 mm

Newly fitted studs must be elongated before initial tightening.

1 Starting, driving end: Left side, all 80 Nm

3 Final tightening torque, left side 280 Nm +20 Nm

4 Final tightening torque, right side 280 Nm +20 Nm

Screws for oil pan made of extruded and cast aluminum.

Stress bolt “C” 27 Nm +3 Nm

Stress bolt “D” 27 Nm +3 Nm

Screws for spherical-graphite cast iron oil pan

M020124/02E 2009-02 © MTU

Screws for counterweight Engine oil

1 Pretightening torque 320 Nm +30 Nm

2 Additional angle of rotation 120° + 10°