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Service Publication

Diesel Engine
16V 4000 G

Maintenance Manual
MR20108/00E

DaimlerChrysler Powersystems Off-Highway


Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
Diese Verffentlichung einschlielich aller seiner Teile ist urheberrechtlich geschtzt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere fr Vervielfltigung, Verbreitung, Bearbeitung,
bersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschlielich Datenbanken
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Das Handbuch ist zur Vermeidung von Strungen oder Schden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfgung zu stellen.
nderungen bleiben vorbehalten.

Printed in Germany
E 2002 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.

Imprim en Allemagne
E 2002 Copyright MTU Friedrichshafen GmbH
Tout droit rserv pour cet ouvrage dans son intgralit. Toute utilisation ou exploitation requiert au pralable laccord crit de MTU
Friedrichshafen GmbH. Ceci sapplique notamment la reproduction, la diffusion, la modification, la traduction, larchivage sur microfiches,
la mmorisation et / ou le traitement sur des systmes lectroniques, y compris les bases de donnes et les services en ligne.
Le manuel devra tre observ en vue dviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous
lexploitant de le mettre la disposition du personnel charg de lentretien et de la conduite.
Modifications rserves.

Impreso en Alemania
E 2002 Copyright MTU Friedrichshafen GmbH
Esta publicacin se encuentra protegida, en toda su extensin, por los derechos de autor. Cualquier utilizacin de la misma, as como su
reproduccin, difusin, transformacin, traduccin, microfilmacin, grabacin y/o procesamiento en sistemas electrnicos, entre los que se
incluyen bancos de datos y servicios en lnea, precisa de la autorizacin previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daos durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposicin del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania
E 2002 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione protetta dal diritto dautore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla
riproduzione, alla diffusione, alla modifica, alla traduzione, allarchiviazione in microfilm ed alla memorizzazione od allelaborazione in
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GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.
Amendment Service!
Any changes in contents will be sent to you in the form of an amendment,
provided you complete the reverse of this receipt card and return it to us.

MR20108/00E
Maintenance
Manual

Postcard

MTU Friedrichshafen GmbH

16V 4000 G
Department SCT
88040 Friedrichshafen
GERMANY
No. Date Name
Please mark all filed amendments here.
1.
2.
3.
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Please use block capitals!

Receipt Amendment No. 1.


2.
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Publication number:
4.
MR20108/00E
5.
6.
Name 7.

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Country 16.
Contents Repair Manual

A General
Important information
Designation of engine sides
Tightening specifications
Settings
Dangers in the work place
Data sheets
Conversion tables
Publication summary
Threaded bore repair
Abbreviations
Keyword index

B Work schedules
Engine condition check
W5 Maintenance operations
Engine removal
Engine disassembly
Engine assembly
Engine run-in
Engine installation
Engine drawings

C Task description
Group summary
Materials and consumables
Tools
Component removal
Component disassembly
Inspection and repair
Component assembly
Component installation
.
General Section A

Page 1

Contents

A001 Important Information

A002 Designation of engine sides and cylinders

A003 Torque specification for screws and nuts

A004 Settings

A005 Hazards in the work area

A006 Data sheets

A007 Conversion tables

A008 Publication summary

A009 Repairing threaded bores

A080 Abbreviations

A090 Keyword index

MR20108/00E 01.12 MTU


Section A General

Page 2

MTU 01.12 MR20108/00E


General Section A
Important Information Group 001
Page 1

A 001 Important Information

This manual is intended for use by technical personnel responsible for the maintenance of the MTU 4000 series
diesel engine.
This manual describes
D scheduled service operations from maintenance echelons W6 and
D non-scheduled service operations on the individual assemblies.

Structure of this manual


This manual is divided into 3 main sections:
Section A General
Section B Work schedules
Section C Task description

Section C is further subdivided into main function groups (MFG) and function groups (FG). The structure is oriented
toward the logical structure of the parts list and Spare Parts Catalogues.

Each function group (FG) consists of no more than nine parts:

e.g. C.011.05.01 Overview drawing


C.011.05.02 Special tool
C.011.05.04 Before-removal operations
C.011.05.05 Removal
C.011.05.06 Disassembly
C.011.05.08 Inspection and repair
C.011.05.10 Assembly
C.011.05.11 Installation
C.011.05.12 After-installation operations

Systematic searches for specific information and rapid orientation in the manual are supported by:
The contents sheet cross-references the tables of contents of the individual groups.
An alphabetical subject index in Section A provides direct access to the individual Groups.
The Group Summary at the start of Section C lists the individual main function groups.

Requirements for maintenance tasks


Customers performing their own maintenance must ensure that the following conditions and basic requirements are
satisfied:
all safety regulations are observed
good general-purpose tools are provided
cleaning and testing equipment is provided
work is performed by trained personnel
special tools are provided
service area is adequately equipped

MTU 01.12 MR20108/00E


Section A General
Group 001 Important Information
Page 2

General Assembly Instructions


D Component cleanness:
Areas of all components that come in contact with oil, fuel, engine coolant and combustion air must be kept
clean.
D Components requiring special cleanness (e.g. oil and fuel-carrying parts) must be cleaned with suitable clean-
ing procedures before assembly, checked for particular cleanness and treated accordingly.
D Component packaging must only be removed immediately before installation.
D Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners.
Parts dirtied with oil and fuel must be cleaned immediately. The parts should be wiped with a dry cloth.
Elastomer components such as engine mounts, damping elements, couplings and V-belts must not be painted.
They can only be installed after painting the engine or must be covered before painting work is carried out.
D Radial-lip shaft seals treated by the manufacturer with oil show as a result definite signs of swelling when deliv-
ered. They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.
D The surfaces of parts that slide against each other must be lubricated with SAE30 engine oil when installed, un-
less otherwise specified.
D O-rings and surfaces moving against them during installation (bores and shafts) must be coated with petroleum
jelly, unless otherwise specified.
When installing O-rings with counterrings in coolant pumps, always follow the installation instructions.
D After installing O-rings in shaft grooves, in order to remedy twists caused by installation, pass a rounded mark-
ing 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.
D Before installing 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 SAE30 engine oil.
In the support bore, the outer surface of metal outer jackets unless otherwise specified in the drawing must
be coated with surface sealant. For elastomer outer jackets or combined metal/elastomer outer jackets, the
outer surface must be coated with denaturated ethanol.

This symbol applies to radial-lip shaft seals and its significance depends on its position.
The arrow indicates the position of the sealing lip.

D 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.
Oil, multi-purpose grease or other materials must not be used to fix the position.
D Before installing antifriction bearings, lightly lubricate the bearing seats.
Only remove the bearings from their original packaging immediately before installation so they do not get dirty.
Do not remove the corrosion inhibitor from the bearings in original packaging.
Use petroleum spirit or acid-free kerosene to clean the antifriction bearings.
After cleaning, relubricate the bearings with engine oil.
During assembly, do not apply (axial) forces to antifriction elements and do not hit the bearing rings with a
hammer (use assembly aids).
Do not use an open flame to heat bearing inner races.
The temperature should be between 80 _C and 100 _C and must never exceed 120 _C.
Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
D Dry bearings must not be oiled.
D When installing gears, the splines must be lubricated with SAE30 engine oil.

MTU 01.12 MR20108/00E


General Section A
Important Information Group 001
Page 3

D Before installation, all contact and support surfaces of components (e.g. mating faces for centrings, flange and
sealing surfaces, butting faces of press-fits) must be clean and the metal bare, or provided with the specified
surface protection, and free from warping and damage. Corrosion inhibitors (e.g. oil, grease) must be removed
from support and mating surfaces.
D After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate must be re-
moved and the parts coated with SAE30 engine oil.
D Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
D Cable connections with cutting ring threaded connections must be installed in a vice and tightened, the thread
first being coated with thin-film lubricant.
D If components are to be marked by etching, after the etching is completed the solution must be removed by
means of neutralization agent. The affected parts must then be preserved with SAE30 engine oil.
D Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes) must be coated at the support and
mating surfaces with assembly paste, unless otherwise specified.
D The assembly surfaces of screws, nuts, washers and of parts to be tensioned must be clean and polished or
provided with the specified surface protection and free from warping and damage. Corrosion inhibitors (e.g. oil,
grease) must be removed. Threads and screw heads must be coated with lubricant before assembly as per
tightening specifications.
Unless otherwise specified, the following lubricants should be used:
SAE30 engine oil for general application
Assembly paste in hot part areas.

a) Threaded connections without tightening specifications


For threaded connections without tightening specifications, the tightening procedure can be selected as re-
quired, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end wrench or box
wrench is possible. In the event of mechanical tightening, the tightening torque must be taken from the general
tightening specifications according to thread size and property class.

b) Threaded connections with tightening specifications


Torque tightening
The screw connections must be tightened by hand with a torque wrench or angle-of-rotation torque wrench.
The specified tightening torques must be set at the torque wrench without consideration of the specified toler-
ance. When using an angle-of-rotation torque wrench, the torque indicated must be within the torque specifi-
cation limit value. Proceed in a similar manner with torsionally protected threaded connections. These instruc-
tions apply also to testing torque.
Note: If no tolerance for tightening torque is stated, the tightening tolerance is +10% of specified torque.

Note: Angle of rotation tightening:


The additional angles of rotation specified in the tightening specifications must be achieved and
may be exceeded within the specified tolerance.
If no tightening tolerance is specified, the following tolerances must be observed:
+ 5_ for additional angle of rotation less than or equal to 90_
+ 10_ for additional angle of rotation greater than 90_
Before angle-of-rotation tightening, each screw head must be colour-marked so that after tightening it is poss-
ible to check that the angle of rotation is correct (exception: colour-marking is not necessary in the case of a
self-monitoring NC screwdriver).
Elongation tightening
Tightening must be carried out in accordance with tightening specifications taking the tightening tolerance into
consideration.

MTU 01.12 MR20108/00E


Section A General
Group 001 Important Information
Page 4

Information on installation of Flexmaster pipe connection


To improve adhesion between the sealing ring and pipe, as well as prevent loosening of the sealing ring, both
pipe ends are to be thoroughly degreased to at least the insertion depth. Remove paint from the area near the
sealing ring. Otherwise, paint particles loosened during installation or operation result in leakage.
Deburr sharp edges on the pipe resulting from cutting.
Push seal carriers and sealing rings onto both ends of the pipe.
To facilitate installation, the sealing rings can first be immersed in water.
Note: Oil, grease, graphite or other lubricants must not be used for sealing rings.

1 Sleeve
2 Sealing ring
3 Seal carrier
4 Clamps
5 Screw
6 Self-locking nut

In event of alignment offset (v) of pipes to be con-


nected, pipe ends of the sleeve must not touch.
The permissible non-alignment is determined by the
immersion depth of the pipe ends (g) and the per-
missible angle of  2_.
The depth of insertion (g) must be marked before-
hand for a well centred fit.

MTU 01.12 MR20108/00E


General Section A
Important Information Group 001
Page 5

The clamp halves are placed over seal carrier and


sleeve and tightened with screws and self-locking
nuts until dimension a is achieved.

Note: Replace deformed clamping-ring


halves.
Clamps must not be fully tightened.
Replace self-locking nuts after loosen-
ing and retightening several times.
Dimension a for pipe outer diameters:
from 12 mm to 26.9 mm min. 2 mm max. 5 mm
from 28 mm to 60.3 mm min. 4 mm max. 8 mm
from 63.5 mm to 127 mm min. 8 mm max. 12 mm

MTU 01.12 MR20108/00E


Section A General
Group 001 Important Information
Page 6

MTU 01.12 MR20108/00E


General Section A
Designation of Group 002
Engine Sides and Cylinder Designations Page 1

A 002 Engine Side and Cylinder Designations

Engine sides are always designated as viewed from the driving end.
Cylinders are designated (to DIN ISO 1204) A on the left engine side and B on the right engine side.
The cylinders of each bank are numbered in consecutive order, beginning at No. 1 at the driving end.
The consecutive numbering of other components, too, always begins with No. 1 at the driving end of the engine.

Designations and Abbreviations


Driving end = KS
Free end = KGS
Left side
Right side
Top end
Bottom end

MR20108/00E 01.12 MTU


Section A General
Group 002 Designation of
Page 2 Engine Sides and Cylinder Designations

MTU 01.12 MR20108/00E


General Section A
Tightening Specifications for Group 003
Screws, bolts and Nuts Page 1

A 003 Tightening Specifications for Screws, Bolts and Nuts

Designation Tightening Lubricant See


Specification

Crankcase
Stud for main bearing cap in 80 Nm Engine oil C 031.05
crankcase (against bottom of blind hole)
Stud
Nominal length: 347.5 mm to 348.5 mm
Elongation, stud, crankshaft bearing cap l 1.15 mm
+ 0.05 mm
Remaining screw elongation l 0.9 mm
+ 0.05 mm
Newly installed studs must be pre-stretched prior to initial C 011.05
tightening C 031.05
Side socket-head screws
Starting driving end: Left side, all screws 80 Nm Engine oil C 031.05
Starting driving end: Right side, all screws 80 Nm
Final tightening torque 280 Nm + 20 Nm
Final tightening torque 280 Nm + 20 Nm
Running Gear
Screws for counterweight
Nominal length: 129.6 to 130 mm Engine oil C 031.05
Maximum length: 132 mm
Pretightening torque: 320 Nm + 30 Nm
Additional angle of rotation: 120 + 10
Checking torque: 800 Nm + 50 Nm
Hex screws on vibration damper flange 500 Nm + 50 Nm Engine oil C 035.05
Hex screws on side plate of vibration 400 Nm Engine oil only on C 035.05
damper thread
Conrod screws
Nominal length: 102.6 mm to 103.2 mm Engine oil C 037.05
Maximum elongation 104.5 mm
Initial tightening
Sequence: 1 short arm
2 long arm
Pretightening torque: 240 Nm + 20 Nm
Additional angle of rotation: 90 + 10
Checking torque: 450 Nm + 20 Nm
Notch mark:
Hex screws on seal carrier, free end 74 Nm + 7 Nm Engine oil C 035.05
Hex screws on graduated disc 21 Nm + 2 Nm Engine oil C 032.20
Piston crown screws C 037.05
Rated length: Manufactured dimension 48.9 mm to
49.1 mm *
Maximum length after reassembly: 49.8 mm *
Rated length: Manufactured dimension 49.9 mm to
50.1 mm ** Molykote G n plus
Maximum length after reassembly: 50.8 mm ** 17 Nm
Lubricant:
Screws tightened diagonally and evenly: 10 Nm + 3 Nm
Screws again released 60 + 5
Pretightening torque 20 Nm + 3 Nm
Additional angle of rotation:
Checking torque:

* Piston E=13.2 mm
** Piston E=13.7 mm

MR20108/00E 01.12 MTU


Section A General
Group 003 Tightening Specifications for
Page 2 Screws, Bolts and Nuts

Designation Tightening Lubricant See


Specification

Cylinder Head
Sleeve for injector 60 Nm + 6 Nm Engine oil C 041.05
Plug 60 Nm + 6 Nm Engine oil C 041.05
Hex screws for cylinder head
Nominal length: 283.3 mm Engine oil C 042.05
Nominal length: 333.3 mm engine lifting eye
Tightening sequence of screws: 1, 2, 3, 4 ,5 ,6
Fit: approx. 25 Nm
Pretightening torque: 180 Nm + 10 Nm
Additional angle of rotation: 180+ 10
Checking torque: 450 Nmfg
Cylinder head tightening diagram

Valve Gear
Hex screw for camshaft gear 100 Nm + 10 Nm Engine oil C 052.05
Version I: Locknut 24 A/F of valve bridge for exhaust 90 Nm + 9 Nm Engine oil C 055.05
valve clearance adjusting screw
Version I: Locknut 24 A/F of valve bridge for inlet valve 90 Nm + 9 Nm Engine oil C 055.05
clearance adjusting screw
Version II: Locknut 19 A/F of valve bridge for exhaust 35 Nm + 5 Nm Engine oil C 055.05
valve clearance adjusting screw
Version II: Locknut 19 A/F of valve bridge for inlet valve 35 Nm + 5 Nm Engine oil C 055.05
clearance adjusting screw
Hex screws for rocker shaft support
Max. shaft length: 180.8 mm
Tightening torque: 250 Nm + 25 Nm Engine oil C 055.05

Fuel System - High-Pressure


Nut on H.P. line at limiting valve 100 Nm + 10 Nm Engine oil C 077.05
Nut on H.P. line at injector 100 Nm + 10 Nm Engine oil C 075.05
H.P. accumulator on crankcase 57 Nm + 6 Nm Engine oil C 086.05

MTU 01.12 MR20108/00E


General Section A
Tightening Specifications for Group 003
Screws, bolts and Nuts Page 3

Designation Tightening Lubricant See


Specification

H.P. sensor for H.P. pump 30 Nm to 40 Nm Engine oil C 073.05


Thrust screw for H.P. accumulator seal 550 Nm + 55 Nm Engine oil C 077.05
Hex screw for hold-down clamp at injector 100 Nm + 10 Nm Engine oil C 075.05
Temperature transmitter on H.P. pump 30 Nm to 40 Nm Engine oil C 075.05
Exhaust Turbocharger
Hex screw on compressor housing/bearing housing 21 Nm + 2 Nm Engine oil C 101.01
Nut with dished washer, turbine housing/bearing hous- 21 Nm + 2 Nm Engine oil C 101.01
ing
Nut without dished washer, turbine housing/bearing 42 Nm + 4 Nm Engine oil C 101.01
housing
Hex screw on housing cover/bearing housing 9 Nm + 1 Nm Engine oil C 101.01
Magnetic nut on turbine wheel
Pretightening torque: (left-hand thread) 50 Nm + 5 Nm Hot lubricating C 101.01
Additional angle of rotation: 60_ + 5 _ paste
Ultra-Therm MTU
Generator
Hex screws, mounting bracket 74 Nm + 7 Nm Engine oil C 213.05
Nut, alternator shaft 200 Nm + 20 Nm Engine oil C 213.05
Hex socket screw, coupling 21 Nm + 2 Nm Engine oil C 213.05

Exhaust System
Hex screws, exhaust distribution housing/exhaust line 70 Nm + 7 Nm Ultra-Therm MTU C 143.05
M12 X 60 or Molykote P37

Lube Oil System


Nut for cooler insert 100 Nm Engine oil C 183.15
Lube oil pressure transmitter 24 to 27 Nm Engine oil C 183.05
Lube oil temperature transmitter 24 to 27 Nm Engine oil C 183.05
Crankcase pressure transmitter 24 to 27 Nm Engine oil C 183.05
Oil spray nozzle 21 Nm + 2 Nm Engine oil C 184.10

MR20108/00E 01.12 MTU


Section A General
Group 003 Tightening Specifications for
Page 4 Screws, Bolts and Nuts

Tightening specification for set screw and stud connections to works standard MTN 5008
This works standard applies to set screws subjected to little dynamic load as per MMN 384, DIN 912, EN 24014
(DIN 9311), 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.
Tightening torques MA are for screws of strength class 8.8 (bright surface, phosphate coating or galvanised) and
10.9 (bright surface or with phosphate coating).
The values in the table are based on a friction coefficient tot = 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 per-
mitted 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 %.
Tightening torques = MA

Thread








8.8
Manual-tightened
10.9 8.8
Machine-tightened
10.9

MA (Nm) MA (Nm) MA (Nm) MA (Nm)

M6 9 12 8 11

M8 21 31 20 28

M 8x1 23 32 21 30

M 10 42 60 40 57

M 10 x 1.25 45 63 42 60

M 12 74 100 70 92

M 12 x 1.25 80 110 75 105

M 12 x 1.5 76 105 72 100

M 14 115 160 110 150

M14 x 1.5 125 180 120 170

M 16 180 250 170 235

M16 x 1.5 190 270 180 255

M 18 250 350 240 330

M18 x 1.5 280 400 270 380

M 20 350 500 330 475

M 20 x 1.5 390 550 350 520

M 22 480 680 450 650

M 22 x 1.5 520 730 490 700

M 24 600 850 570 810

M 24 x 1.5 680 950 640 900

M 24 x 2 660 900 620 850

M 27 900 1250 850 1175

M 27 x 2 960 1350 900 1275

M 30 1200 1700 1100 1600

M 30 x 2 1350 1900 1250 1800

MTU 01.12 MR20108/00E


General Section A
Tightening Specifications for Group 003
Screws, bolts and Nuts Page 5

Tightening torques for stress bolt connections prescribed in standard MTN 5007
This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic 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).
The values in the table are based on a friction coefficient tot = 0.125. Precondition: Thread and mating faces of
screws and nuts must be coated in engine oil prior to assembly.
When tightening manually (defined tightening), an assembly tolerance of + 10 % of the table values is permitted for
unavoidable deviations of the tightening torque from the table value during the tightening process e.g. resulting
from inaccurate readings and overtightening during assembly.
The values in the tables are for manual tightening with torque wrench.
Tightening torques = MA

thread Without torsion protection With torsion protection*


MA (Nm) MA (Nm)
M6 9 12
M8 21 28
M8x1 24 30
M10 42 55
M 10 x 1.25 46 60
M12 75 93
M 12 x 1.5 78 99
M 14 120 150
M 14 x 1.5 135 160
M 16 180 225
M 16 x 1.5 200 245
M 18 250 315
M 18 x1.5 300 360
M 20 350 450
M 20 x 1.5 430 495
M 22 500 620
M 22 x 1.5 560 675
M 24 640 790
M 24 x 2 700 850
M 27 900 1170
M 27 x 2 1000 1230
M 30 1250 1575

*Protect shank against torsion when tightening.

MR20108/00E 01.12 MTU


Section A General
Group 003 Tightening Specifications for
Page 6 Screws, Bolts and Nuts

Tightening torques for plugs prescribed in standard MTN 51831

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 7603Cu).

DIN 908 DIN 910 DIN 7604A/C

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

Tightening torques for plugs DIN 908, DIN 910 and DIN 7604A
(with short screwed plug)

thread inserted in
steel /gray cast iron Al-alloy
MA (Nm) MA (Nm)
M 10 x 1 15 15
M 12 x 1.5 35 25
M 14 x 1.5 35 25
M 16 x 1.5 40 30
M 18 x1.5 50 35
M 20 x 1.5 55 45
M 22 x 1.5 60 50
M 24 x 1.5 70 60
M 26 x 1.5 80 70
M 27 x 2 80 70
M 30 x 1.5 100 90
M 30 x 2 95 85
M 33 x 2 120 110
M 36 x 1.5 130 115
M 38 x 1.5 140 120
M 42 x 1.5 150 130
M 45 x 1.5 160 140
M 48 x 1.5 170 145
M 52 x 1.5 180 150
M 56 x 2 190 160
M 64 x 2 205 175

MTU 01.12 MR20108/00E


General Section A
Tightening Specifications for Group 003
Screws, bolts and Nuts Page 7

Tightening torques for plugs as per DIN 7604C (with long screwed plug)

thread inserted in
steel /gray cast iron Al-alloy
MA (Nm) MA (Nm)
M8x1 10 10
M 22 x 1.5 80 65
M 26 x 1.5 105 90
M 30 x 1.5 130 130
M 38 x 1.5 140 120
M 45 x 1.5 160 140

MR20108/00E 01.12 MTU


Section A General
Group 003 Tightening Specifications for
Page 8 Screws, Bolts and Nuts

Tightening torques for banjo screws as per MTN 51832 standard

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

MMN 223 (4 flow holes) N 15011 (3 flow holes)

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

Tightening torques for banjo screws made of steel

thread inserted in
steel/gray cast iron/Al-alloy
MA (Nm)
M8x1 10
M 10 x 1 15
M 12 x 1.5 20
M 14 x 1.5 25
M 16 x 1.5 25
M 18 x 1.5 30
M 22 x 1.5 60
M 26 x 1.5 90
M 30 x 1.5 130
M 38 x 1.5 140
M 45 x 1.5 160

Tightening torques for banjo screws made of copper-alluminium alloys

thread inserted in
steel/gray cast iron/Al-alloy
MA (Nm)
M 10 x 1 15
M 16 x 1.5 30

MTU 01.12 MR20108/00E


General Section A
Tightening Specifications for Group 003
Screws, bolts and Nuts Page 9

Tightening torques for male connector as per MTN 51833 standard

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

DIN 2353, model C

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

thread inserted in
steel /gray cast iron
MA (Nm)
M 10 x 1 10
M 12 x 1.5 20
M 14 x 1.5 40
M 16 x 1.5 50
M 18 x 1.5 60
M 22 x 1.5 70
M 26 x 1.5 100
M 32 x 2 160
M 42 x 2 260
M 48 x 2 320

MR20108/00E 01.12 MTU


Section A General
Group 003 Tightening Specifications for
Page 10 Screws, Bolts and Nuts

MTU 01.12 MR20108/00E


General Section A
Settings Group 004
Page 1

A 004 Settings

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

Direction of rotation as viewed from driving end

Crankshaft counterclockwise
Camshaft clockwise
H.P. fuel pump counterclockwise
Oil pump counterclockwise
Engine coolant pump counterclockwise
Charge air coolant pump counterclockwise
Generator counterclockwise
Hydrostatic pump counterclockwise

Valve clearance, engine cold (20 _C)

Inlet 0.20 mm
Outlet 0.50 mm

Valve timing, valve clearance adjusted

Crank angle
1 Inlet valve opens . . . . . . . . . . . . . 42.6 before TDC
2 Inlet valve closes . . . . . . . . . . . . . . 66.6 after BDC
3 Exhaust valve opens . . . . . . . . . 57.6 before BDC
4 Exhaust valve closes . . . . . . . . . . . 30.4 after TDC
5 Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6 Start of delivery . . . . . . . . . . . . . . . . . . . . Map based

I . . . . . . . . . . . . . . . . . . . . . . . . Top dead centre (TDC)


II . . . . . . . . . . . . . . . . . . . . Bottom dead centre (BDC)

Cam and valve lift for camshaft adjustment

Inlet Outlet
Cam lift at TDC 1.43 mm 1.43 mm
Valve lift at TDC (zero valve clearance) 2.00 mm 2.00 mm

MR20108/00E 01.12 MTU


Section A General
Group 004 Settings
Page 2

MTU 01.12 MR20108/00E


General Section A
Hazards in the Work Area Group 005
Page 1

A 005 Hazards in the Work Area

These Safety Instructions must be read and followed by any persons operating, carrying

out maintenance or repairs on the machinery plant.

General safety and accident prevention regulations


D In addition to the instructions given in this publication, general safety and accident prevention regulations and
laws must be taken into consideration; these may vary from country to country.
D This MTU engine is a state-of-the-art product and conforms with all the applicable specifications and regula-
tions. Nevertheless, persons and property may be at risk in the event of:
Incorrect use
Operation, maintenance and repair carried out by untrained personnel
Modifications or conversions
Noncompliance with the Safety Instructions
Correct use
D The engine is to be used solely for the purpose stated in the contract. 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.
D Correct use also includes observation of the Operating Instructions and Maintenance Manual and compliance
with maintenance and repair instructions.
Personnel requirements
D Work on the engine must be carried out only by reliable personnel. The specified legal minimum age must be
respected.
D Only fully-trained or qualified personnel must be employed. Responsibilities of the operating, maintenance and
repair personnel must be specified.
Modifications or conversions
D Modifications made by the customer to the engine may affect safety. No modifications or conversions must be
implemented without prior consent from DDC or MTU.
D No liability will be accepted for damage resulting from unauthorised modifications.
Organisational measures
D This manual must be made available to maintenance and repair personnel.
D The personnel must be instructed on engine operation and repair by means of the Maintenance Manual, 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.

Note: This copy is only subject to the Amendment Service if the acknowledgement of receipt card has
been returned to MTU.This also applies to in-house use by MTU personnel.
Spare parts
D Spare parts must at least satisfy the requirements specified by the manufacturer. This is guaranteed when orig-
inal components are used.
Working clothes and protective equipment
D Always wear protective shoes when working on plant.
D Select appropriate protective goggles for the work to be carried out. Always wear protective goggles when work-
ing with mallets, cutting tools, drift punches and associated tools.
D Work clothing must be tight-fitting so that it does not catch on rotating or projecting components. Do not wear
jewellery (e.g. rings, chains, etc.).

MR20108/00E 01.12 MTU


Section A General
Group 005 Hazards in the Work Area
Page 2

Welding operations
D Never use the engine as a ground terminal! (This prevents the welding current passing through the engine and
causing scorching or burning at bearings, sliding surfaces and tooth flanks, which can lead to pitting or other
material damage)
D Welding operations on the engine or mounted plants are not permitted.
D Never lay the welding cable over or near the cable harnesses of the DDC/MTU plants. (The welding current
could be induced in the cable harnesses which could possibly damage the electrical plant)
D The ground terminal of the welding unit must be connected to the welding point at a distance no greater than
60 cm.
D If welding must be carried out on components (e.g. exhaust pipe), these components must be removed from the
engine beforehand.
D On the DDC/MTU electronics system, it is not necessary to remove the connector and connections to carry out
welding operations if the master switch of the power supply is switched from On to Off and the cable has
been disconnected from the negative and positive poles on the battery.
D During welding operations, always wear welding gloves, headgear/goggles, protective aprons and other suitable
protective clothing.
Transport
D Lift the engine only with the lifting eyes provided.
D Use only the transport and lifting equipment approved by DDC/MTU.
D Take into consideration engine centre of gravity.
D The engine must only be transported in installation position.
D In event of special packaging with aluminium foil, attach engine to lifting eyes of bearing pedestal or transport
with forklift truck.
D Before transporting the engine, the crankshaft transportation locking device and engine mount locking device
must be installed.
Engine operation
D When the engine is running, ear protectors must always be worn in the engine room.
D The engine room must be well ventilated.
D To avoid injuries caused by falling, leaked or spilt engine oil and coolant must be cleaned up immediately or ab-
sorbed with appropriate bonding agents.
D Exhaust gases from combustion engines are poisonous and injurious to health if inhaled. The exhaust pipework
must be leak-free and discharge exhaust gases to atmosphere.
D 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.
D If engine is running, never release coolant, oil, fuel, compressed air or hydraulic lines.
Maintenance and repair
D Compliance with maintenance specifications is an important safety factor.
D Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. The
engine must be secured against inadvertent starting and the battery disconnected. Attach sign Do not operate
in operating area or to control equipment. Persons not involved must keep clear.
D Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance work must only be carried out by authorised, qualified personnel.
D Use only tools in perfect condition.
D Do not work on engines or components which are only held by lifting equipment or crane. Always support these
components on suitable frames or stands before beginning any maintenance or repair work.

MTU 01.12 MR20108/00E


General Section A
Hazards in the Work Area Group 005
Page 3

D Before barring the engine, ensure that nobody is within the danger area. After working on the engine, check that
all guards have been reinstalled and that all tools and loose components have been removed from the engine.
D Fluids emerging under high-pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
D Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal
connections with caps or covers if a line is removed or opened.
D During maintenance or repair work, do not hit fuel lines with wrenches or other tools. To tighten connections
when installing lines, use the correct tightening torque and ensure that all retainers and dampers are installed
correctly.
D Ensure that all fuel injection lines and compressed oil lines have sufficient play to avoid contact with other com-
ponents. Do not place fuel or oil lines near hot components.
D The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
D Do not attempt to bend or apply force to lines.
D In order to avoid burning, take special care when handling hot components on products just taken out of use
and when working with hot liquids in pipelines, pipes and chambers.
D Until the engine has cooled, the breather cap must not be opened. Release the breather cap and allow pressure
to escape before cap removal.
D Take special care when removing ventilation or plugs from engine. In order to avoid being sprayed with highly-
pressurised liquids, hold a cloth over the screw or plug. There is increased danger if the engine has only re-
cently been shut down as the liquids can still be hot.
D Take special care when draining hot fluids Risk of injury! Drain the fluids into a suitable container and wipe up
any spillages.
D When changing engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
D When working high on the engine, always use suitable ladders and work platforms. Make sure components are
placed on stable surfaces.
D To avoid damaging your back when lifting components weighing 25 kg (50 lb.) or more, use lifting gear or re-
quest aid from other workers. Ensure that all chains, hooks, slings, etc. are in good condition, are sufficiently
strong and that hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
D When operating electrical equipment, certain components of this equipment are live.
D Noncompliance with warning notices could result in serious physical injury or damage to property.
D Work must be carried out only by qualified personnel. Prior to working on electrical equipment, switch off live
units.
D Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to
come into contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before con-
necting 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.
D 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 another component or by a hot surface. Never
connect wiring to a line which carries liquid.
D On completion of the maintenance and repair work, any cables which have become loose must be correctly se-
cured.
D Always tighten connectors with connector pliers.
D If cables are present at mechanical components and there is a risk of wear, the cables must be retained in cable
clamps.
D For this purpose, no cable straps must be used as, during maintenance and/or repair work, the straps can be
removed but not installed a second time.
D Check security of all plug-in connections.

MR20108/00E 01.12 MTU


Section A General
Group 005 Hazards in the Work Area
Page 4

D It is not sufficient to tighten the connections by hand with a bayonet union. There is the risk of the lock not en-
gaging properly and the connector coming loose during engine operation. Therefore pliers must be used for
turning the bayonet union nut in clockwise direction.
Fire prevention
D Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires there-
fore always keep the engine in a clean condition. Do not leave oil-soaked cloths on the engine. Do not store
combustible fluids near the engine. Do not allow dirt or foreign matter to accumulate near the engine, as this
constitutes a fire hazard.
D Welding work must not be carried out on pipes and components containing oil. Before welding, clean with a non-
combustible fluid.
D Never mix petrol/gasoline with diesel fuel. If petrol/gasoline is added to diesel fuel, there is increased risk of fire.
D 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.
D Always keep a fire extinguisher at hand and learn how to operate it.
Noise
D Hearing may be impaired at workplaces where the sound pressure level is in excess of 85 dB(A).
D Wear earplugs or earmuffs!
Environmental protection
D Dispose of used fluids and lubricants and filters in accordance with local regulations.
D Manipulation of the injection or control system can influence the engine performance and exhaust emissions. As
a result, compliance with environmental regulations may no longer be guaranteed.
Skin complaints
D Barrier creams issued for prophylactic use are not suitable for treatment of skin complaints. Seek medical ad-
vice on skin rashes of any type, even if symptoms are very slight.
Warning signs
D Before putting the engine into service and before working on the engine, read and follow all warning signs. Do
not paint on warning signs. Replace illegible signs.
Auxiliary materials
D Use only fluids and lubricants that have been tested and approved by MTU or DDC.
D Fluids and lubricants must be kept in properly designated containers. When using fluids, lubricants and other
chemical substances, follow the safety instructions applicable to the product. Take special care when using hot
and caustic materials. When using inflammable materials, avoid all sparks and do not smoke.
Lead
D When working with lead or pastes that contain lead, take care that the body does not absorb even tiny amounts
of lead (from air-borne lead dust, smoke, dirty hands).
Adopt suitable measures to avoid the formation of lead dust!
Switch on extraction system!
Wash hands before consuming food or beverages!
Chlorinated hydrocarbons
D When working with chlorinated hydrocarbons (e.g. perchlorethylene, trichlorethane) or other cold cleaners which
contain declared hazardous substances, health-endangering substances may be inhaled.
Switch on ventilation and extraction systems!
Observe fire-prevention regulations!
No smoking and no consumption of alcoholic beverages!
Do not permit substances to enter the waste-water system!

MTU 01.12 MR20108/00E


General Section A
Hazards in the Work Area Group 005
Page 5

Acids and alkalis


D 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 clean water!
Rinse eyes immediately with water from rinsing bottle or clean mains water!
Painting
D When painting in other than spray booths equipped with extractors, ensure good ventilation. Ensure that neigh-
bouring workplaces suffer no detrimental effects.
Always wear a mask providing protection against paint and solvent vapours!
Observe all fire-prevention regulations!
No smoking!
No naked flame!
Liquid oxygen
D Liquid oxygen is highly flammable.
D Store liquid oxygen only in small quantities and always in regulation containers (without fixed seal)! Do not bring
into contact with parts of the body (hands); causes cold burns and severe frostbite.
No smoking, no naked flame (risk of explosion)! Oxygen enrichment in the air causes flash combustion.
Do not store combustible substances (e.g. oils and greases) within 5 m of the working area!
Under no circumstances wear oily or greasy clothing!
Do not allow vapours to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignite
suddenly!
After working with liquid oxygen, do not smoke until clothing is free of vapours!
Take great care to avoid impact and shock when working with liquid oxygen!
Liquid nitrogen
D Store liquid nitrogen only in small quantities and always in regulation containers (without fixed seal)!
D Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands). Liquid nitrogen causes cold
burns and severe frostbite.
Wear protective clothing (including gloves and closed shoes) and protective goggles!
Ensure good ventilation (suffocation if nitrogen enrichment in inhaled air reaches 88%)
Do not subject containers, fittings and tools to impact or shock!
Compressed air
D Compressed air is compressed, pressurised air and is stored in pressure vessels from which the compressed air
is then extracted.
D The compressed air pressure can be read off at the pressure indicator (pressure gauge); the pressure vessels
and compressed air lines must also be at this pressure.
D High pressure is harmful to the human body, especially if applied suddenly.
D 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 per-
mitted 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 damage to the 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!

MR20108/00E 01.12 MTU


Section A General
Group 005 Hazards in the Work Area
Page 6

Unauthorised use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers,
results in a Risk of explosion!
Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying pur-
poses or to check for leaks results in a Risk of explosion.
Removing dirt on soiled clothes while still worn can result in a Risk of injury.
Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back, the air can enter the
anal cavity and fatally rupture the intestines!
Used oil
D Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Clean hands thoroughly after contact with used oil!

Warning notices
D Section C of this Publication contains especially emphasised safety instructions in accordance with the Ameri-
can standard ANSI Z535, which begin with one of the following signal words according to the degree of danger:
Take extreme care in these situations!
Read and become acquainted with all warning notices and symbols before operating or repairing this product!
Inform operating and maintenance personnel on all Safety Instructions!

DANGER
An instruction of this type draws attention to an
impending danger which, if ignored, may lead to
serious injury.

WARNING
An instruction of this type draws attention to a
possible danger which, if ignored, may lead to
serious injury or death.

CAUTION
An instruction of this type draws attention to a
danger which, if ignored, may lead to slight in-
jury.

MTU 01.12 MR20108/00E


General Section A
Data Sheets Group 006
Page 1

A 006 Data Sheets


To ensure that unusable components are not installed or components which can still be used are not discarded all
inspection work should only be carried out by qualified personnel using the necessary measuring instruments.
All measuring and testing equipment is naturally subject to wear.
To determine resulting tolerance deviations in good time, the measuring and test equipment must be inspected an-
nually at a location equipped with appropriate technical facilities.
Alternatively, equipment can be inspected by our Product Support service and MTU, Friedrichshafen, or DDC, or
by an external product support service.
Values must not exceed or fall below the limit values listed in the Tolerances and Wear Limits List M0700....
The following data sheets should be used to record the individual examination results:
Inspection sheet, crankcase (4X)
Inspection sheet explanation, crankcase (2X)
Assembly data sheet, crankshaft bearing
Cylinder liner (installed)
Crankshaft data sheet
Crankshaft bearing
Gear train, edges and axial clearance
Conrod bearing (shells installed)
Injection timing

MR20108/00E 01.12 MTU


Section A General
Group 006 Data Sheets
Page 2

MTU 01.12 MR20108/00E


Housing No.: Inhouse order No.:
Findings Data Sheet
Crankcase repair Casting date: Date:
Series 4000 Engine No.: Name:

Bearing cap fit


For dimension limits, see Tolerances and Wear Limits List.
Bearing (CB) CB1 CB2 CB3 CB4 CB5 CB6 CB7 CB8 CB9
298 H7 (+ 0.052)
(No. 2)
298 E9 (+ 0.110 +0.240)
(No. 1)
Remarks:

Bearing cap width


For dimension limits, see Tolerance and Wear Limits List.
Bearing (CB) CB1 CB2 CB3 CB4 CB5 CB6 CB7 CB8 CB9
298 p6 (+ 0.056 +0.088)
(No. 2)
298 p6 (+ 0.056 +0.088)
(No. 1)
Remarks:

Crankshaft bearing bores 170.985 H6 (+0.025)


For dimension limits, see Tolerances and Wear Limits List.
Bearing bore CB1 CB2 CB3 CB4 CB5 CB6 CB7 CB8 CB9
a

b1

b2

Remarks:
Housing No.: Inhouse order No.:
Findings Data Sheet
Crankcase repair Casting date: Date:
Series 4000 Engine No.: Name:

upper fit specified dimension: 196 H7 (+ 0.046)


lower fit specified dimension: 189 H7 (+ 0.046)
bush contact surface specified dimension: 562 (+0.05 0.15)
For dimension limits, see Tolerances and Wear Limits List.
Cylinder bank A 1 2 3 4 5 6 7 8
top

bottom

Bush contact
surface

Remarks:

upper fit specified dimension: 196 H7 (+ 0.046)


lower fit specified dimension: 189 H7 (+ 0.046)
bush contact surface specified dimension: 562 (+0.05 0.15)
For dimension limits, see Tolerances and Wear Limits List.
Cylinder bank B 1 2 3 4 5 6 7 8
top

bottom

Bush contact
surface

Remarks:
Housing No.: OHAU No.:
Data Sheet
Crankcase repair Casting date: Date:
Series 4000 Engine No.: Name:

Characteristic Deviation Remarks


For dimension limits, see Tolerance and Wear Limits List.

Roof surfaces

Bush contact surface

Coolant transfers

Cover surface

Camshaft bearing

Coolant chambers
Housing No.: OHAU No.:
Findings Data Sheet
Crankcase repair Casting date: Date:
Series 4000 Engine No.: Name:

Characteristic Deviation Remarks


For dimension limits, see Tolerance and Wear Limits List.

Outer wall A side


Outer wall B side

Driving end end face


Free end end face

Bearing cap fits

Bearing cap widths

Studs for bearing cap


Lmax = 348.5

Nuts for bearing cap

Crankcase bottom

Other
D a t a S h e e t explanation
Dimension/visible inspection
Crankcase repair series 4000

Characteristic Remarks
For dimension limits, see Tolerance and Wear Limits List.
in event of cracks (chipping) at edges of cylinder surface to bores remove material
Roof surfaces
in event of traces of rust/cavitation near cylinder head screws mill cut roof surface
Endoscopic examination of cylinder head screw bores.
check with bridge meter with surface irregularities over 0.02, perform hardness test ring solution
Bush contact surface

all with pitting, and too deep mill cut roof surface
Coolant transfers

Damage smooth with whetstone or mill cut surface


Cover surface
Coolant transfer bores in event of pitting redo countersink or provide with bushes

Camshaft bearing

Visual inspection rust or minor pitting remove


Coolant chambers
D a t a S h e e t explanation
Dimension/visible inspection
Crankcase repair series 4000

Characteristic Deviation
For dimension limits, see Tolerance and Wear Limits List
Visual inspection torn screws drill
Outer wall A side all sealing surfaces smooth with whetstone
Outer wall B side
Visual inspection in event of localised galling hone or recut via AE
Driving end end face
Free end end face
Dimension/visual inspection
Bearing cap fits in event of localised galling smooth with whetstone or recut to next repair stage
in event of serious warping recut with mill cutter to next repair stage
Dimension/visual inspection
Bearing cap width in event of serious warping replace

Visual inspection
Studs for bearing cap in event of damage/rust replace
Lmax = 348.5 Check length only with screws removed
Visual inspection
Nuts for bearing cap in event of damage/rust replace

Visual inspection of all functional surfaces smooth with whetstone mill cut via AE
Crankcase bottom

Other
Assembly Data Sheet
One-Part Crankshaft Bearing

Engine type Note:


................................................. Measuring point a for bearing
Engine No. clearance
.................................................
Crankcase No.
.................... ...........................
Operating hours
................................................
Item
...............................................
Specified dia.
...............................................

Measuring points
Component Crankshaft main a b c1 c2 d Mean
bearing dimen-
sion
Driving end

Free end

Remarks:

Specified values from the Tolerance and Wear Limits List

Date: Inspected by:

60594
Engine Model
Assembly Data Sheet
Cylinder Liners (installed)
Engine No.

Crankcase No.:
2
Cyl. bush part No.:

Specified dimension, bore: 3

To measure: In measuring direction a (direction of travel)


4
and b (transverse)
Measuring levels 1 2 3 4
Measur- Basic Actual dimensions Cylinder Measur- Basic Actual dimensions
Cylinder ing dimen- No. ing dimen-
No. direction sion Measuring levels direction sion Measuring levels
1 2 3 4 1 2 3 4
A1 a B1 a
b b
A2 a B2 a
b b
A3 a B3 a
b b
A4 a B4 a
b b
A5 a B5 a
b b
A6 a B6 a
b b
A7 a B7 a
b b
A8 a B8 a
b b
A9 a B9 a
b b
A10 a B10 a
b b

Remarks:

Specified dimensions from Tolerance and Wear Limits List

Date: Inspected by:

D2447
KURBELWELLEN-KENNBLATT Typ
CRANKSHAFT DATA SHEET Model

Sach-Nr. Wellen-Nr.
Item No. Shaft No.

Zeichnungs-Nr. Abnahme
Drawing No. Classification

Mestelle / Measuring Point 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Hublager
Crankpin dia.

Grundlager
Main journal dia.

Anlaufbund lbohrungen einwandfrei gereinigt und verrundet.


Thrust collar Oil ducts thoroughly cleaned and edges smoothed.
Rundlauf Smtliche Hohlkehlen und Ansenkungen nach Zeichnung.
Concentricity All fillets and countersinks as per drawing.
Hrte Hublager Gegengewichtsauflageflchen Rt und Ebenheit nach Zeichnung.
Crankpin hardness Roughness height and flatness of counterweight seating surface as per drawing.
Hrte Grundlager Winkligkeit der Gegengewichtbefestigungsgewinde nach Zeichnung.
Journal hardness Angularity of counterweight securing thread as per drawing.
Riprfung Prfmoment der Gegengewichtbefestigung nach Zeichnung.
Crack test Test torque of counterweight screwed joint as per drawing.

Bemerkungen / Remarks:

, den /date Prfer / Checked by: Freigabe / Approved by:

D2437
Engine Model
Assembly Data Sheet
Crankshaft Main Bearing Engine No.

Engine Order No.:

Crankcase No.:

Crankshaft No.:

Specified dimensions:

Main bearings dia.:

Crankshaft dia.:

Radial clearance:

Crankshaft axial
clearance: Actual dimension:

Measuring and entry: Smallest dimension, diameter a, b and b, measuring level 1 and 2
Determining bearing clearance: Smallest dimension a
Bearing No. Actual dimensions
Basic dimension 1 2 3 4 5 6
Bearing dia. b
Bearing dia. c
Bearing dia. a
Crankshaft dia.
(actual dimension)
Bearing clear-
ance, rad.

Bearing No. Actual dimensions


Basic dimension 7 8 9 10 11 12
Bearing dia. b
Bearing dia. c
Bearing dia. a
Crankshaft dia.
(actual dimension)
Bearing clear-
ance, rad.
Remarks:

Specified dimensions from Tolerance and Wear Limits List

Date: Inspected by:

D2448
Engine model: BR 4000
Backlash and axial clearance
Equipment carrier Symmetrical gear train

Item Designation Specified Actual Specified Actual


dimension dimension dimension dimension
Backlash Backlash Axial Axial
clearance clearance
(mm) (mm) (mm) (mm)
1 Crankshaft gear
2 Camshaft gear, Pos. 1 0.286 0.081
3 Idler gear, Pos. 1 0.285 0.080 0.201.10
4 Gear, coolant pump, rear, Pos. 3 0.201 0.065
5 Gear, coolant pump, front, Pos. 3 0.201 0.065
See coolant pump, from, Pos. 3
6 Gear, oil pump, Pos. 3 0.279 0.077
7 Gear, fuel H.P. pump, Pos. 3 0.201 0.065
8 Gear, compr. (MTU), front, Pos. 3 0.201 0.065
9 Gear, hydrostatic pump, Pos. 3 0.201 0.065
10 Gear, generator, Pos. 3 0.222 0.128
11 Gear, compr. (DDC), rear, Pos. 3 0.201 0.070

D2753
Engine Model
Assembly Data Sheet
Conrod bearing
(Shells installed) Engine No.

Crankcase No.: Specified dimensions:

Crankshaft No.: Conrod bearing bore

Radial clearance
To measure: Diameter a, b, c
To determine clearance, min. dimension a, b or c
Conrod, A bank
Dia. actual dimensions
Cyl. Rod Basic a b c Crank- Radial
No. No. Dimen- Dimen- Dimen- Dimen- shaft clear-
sion sion sion sion ance
1
2
3
4
5
6
7
8
9
10
Conrod, B bank
Dia. actual dimensions
Cyl. Rod Basic a b c Crank- Radial
No. No. Dimen- Dimen- Dimen- Dimen- shaft clear-
sion sion sion sion ance
1
2
3
4
5
6
7
8
9
10

Remarks:

Date: Inspected by:

D2798
Engine Model
Assembly Data Sheet
Timing and injection timing Engine No.

1. Control diagram
Speci- Actual
fied
Cylinder No.

Exhaust valve opens before BDC

Inlet valve opens before TDC

Exhaust valve closes after TDC

Inlet valve closes after BDC

Settings for valve timing correspond to the adjustment diagram

2. Cam lift
Speci- Actual
fied
Cylinder No.

Inlet

Exhaust

3. Injection timing

For start of delivery, see engine master card

Remarks:

Date: Inspected by:

D2440
Task Description Section A
Conversion Tables Group 007
Page 1

A 007 Conversion Tables

Length SI unit: m
Other permitted units: m, mm, km
Unit A multiplied by factor = Unit B
in 25.40 = mm
ft 0.3048 = m
yd 0.9144 = m
stat. mile 1.609 = km
yd 3 = ft
yd 36 = in

Unit B multiplied by factor = Unit A


mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile

Area SI unit: m2
Other permitted units: mm2, a (Ar) = 100 m2, ha
Unit A multiplied by factor = Unit B
in2 (sq in) 645.16 = 2mm
ft2 (sq ft) 0.0929 = m2
yd2 (sq yd) 0.8361 = m2
stat. mile2 2.5889 = km2

Unit B multiplied by factor = Unit A


2mm 0.00155 = in2 (sq in)
m2 10.7643 = ft2 (sq in)
m2 1.1960 = yd2 (sq yd)
km2 0.3863 = stat. mile2

Volume SI unit: m3
Other permitted units: l, mm3, cm3, dm3
Unit A multiplied by factor = Unit B
in3 (cu in) 16387 = 3mm
ft3 (cu ft) 0.02832 = m3
yd3 (cu yd) 0.7646 = m3
gallon (US) 3.787 = dm3
gallon (brit.) 4.546 = dm3

Unit B multiplied by factor = Unit A


cm3 0.06102 = in3 (cu in)
m3 35.31 = ft3 (cu ft)
dm3 0.2642 = gallon (US)
dm3 0.22 = gallon (brit.)

MR20108/00E 01.12 MTU


Section A Task Description
Group 007 Conversion Tables
Page 2

Speed SI unit: m/s


Other permitted units: km/h
Unit A multiplied by factor = Unit B
ft/s 0.3048 = m/s
stat. mile/h 1.609 = km/h
(mph)
knot (brit.) 1.852 = km/h

Unit B multiplied by factor = Unit A


m/s 3.281 = ft/s
km/h 0.6215 = stat. mile/h
(mph)
km/h 0.54 = knot (brit.)

Density SI unit: kg
Other permitted units: mg, g, t
Unit A multiplied by factor = Unit B
lb 0.4536 = kg
oz 28.35 = g
ton 1.016 = t

Unit B multiplied by factor = Unit A


g 0.03527 = oz
kg 2.205 = lb
t 0.9843 = ton

Force SI unit: N
Other permitted units: mN, kN, MN
Unit A multiplied by factor = Unit B
lb 0.4536 = kp
lb 4.4483 = N

Unit B multiplied by factor = Unit A


kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 = N

MTU 01.12 MR20108/00E


Task Description Section A
Conversion Tables Group 007
Page 3

Pressure SI unit: Pa
Other permitted units: bar, mbar, bar; 1 bar = 105 Pa
Unit A multiplied by factor = Unit B
lb/sq in (psi) 703.1 = kp/m2
(mm WS)
lb/sq in (psi) 0.06895 = bar
lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m2

Unit B multiplied by factor = Unit A


atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m2
(mm WS)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lb/sq in
bar 14.503 = lb/sq in

Density SI unit: kg/m3


Other permitted units: g/cm3, kg/dm3, kg/l
Unit A multiplied by factor = Unit B
lb s2/ft4 515.4 = kg/m3

Unit B multiplied by factor = Unit A


kg/m3 0.00194 = lb s2/ft 4

Torque SI unit: Nm
Unit A multiplied by factor = Unit B
ft lb 1.3563 = Nm

Unit B multiplied by factor = Unit A


Nm 0.7373 = ft lb

Mass moment, 2nd grade SI unit: kg m2


Unit A multiplied by factor = Unit B
ft lb s2 1.3563 = kg m2

Unit B multiplied by factor = Unit A


kg m2 0.7373 = ft lb s2

MR20108/00E 01.12 MTU


Section A Task Description
Group 007 Conversion Tables
Page 4

Energy SI unit: J
Other permitted units: kJ, kWh
Unit A multiplied by factor = Unit B
ft lb 1.356 = J
kcal 4186.8 = J
BTU 1055 = J
CHU 1899 = J

Unit B multiplied by factor = Unit A


J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU

Power SI unit: W; 1 W = 1 J/s = 1 Nm/s


Other permitted units: kW, kJ/h
Unit A multiplied by factor = Unit B
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 = W
HP 550 = ft lb/s

Unit B multiplied by factor = Unit A


kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP

Temperature SI unit: K
Other permitted units: C; 1 C = 273.15 K, F = 9/5 C + 32
Celsius Kelvin Fahrenheit Raumur
xC = x + 273.15 K = 9/
5 x + 32 F = (4/ 5 x) R
xK = x 273.15 C = 9/5 (x 273.15) + 32 F = 4/5 (x 273.15) R
xF = 5/9 (x 32) C = 5/9 (x 32) + 273.15 K = 4/9 (x 32) R
xR = 5/4 x C = (5/4 x) + 273.15 K = (9/4 x) + 32 F

Specific fuel consumption


Unit A multiplied by factor = Unit B
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km

Unit B multiplied by factor = Unit A


km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)

MTU 01.12 MR20108/00E


Task Description Section A
Publication Summary Group 008
Page 1

A 008 Publication Summary

Other applicable Customer Service documents:

Operating Instructions M0 15 ...


Fluids and Lubricants Specification A00 1061
Tools List M0 04 029
Tolerance and Wear Limits List M0 70 040
Test Procedure A 060 643
Instructions for use for auxiliary materials,
protective measures

Further data, in particular operational data, can be obtained from the MTU Engine Acceptance Test Record for the
individual engine concerned.

MR20108/00E 01.12 MTU


Section A Task Description
Group 008 Publication Summary
Page 2

MTU 01.12 MR20108/00E


General Section A
Repairing Group 009
Threaded Bores Page 1

A 009 Repairing Threaded Bores with Threaded Inserts (Heli-Coil)

Data

Thread Core hole bore-dia. (max./min.) Twist drill-dia.


M6 6.31 6.16.26.25
6.04
M8 8.35 8.18.28.258.3
8.04
M8x1 8.32 8.18.28.258.3
8.04
M 10 10.40 10.25
10.05
M 12 12.50 12.2512.5
12.05
M 12 x 1.5 12.43 12.25
12.05
M 14 14.53 14.2514.5
14.06
M 14 x 1.5 14.43 14.25
14.05
M 15 x 2 15.30 15.25
15.20
M 16 16.53 16.2516.5
16.06
M 16 x 1.5 16.43 16.25
16.05
M 24 x 1.5 24.43 24.25
24.05
M 26 x 1.5 26.43 26.25
26.05
M 30 x 1.5 30.43 30.25
30.05

Repairing
If necessary, remove thread insert with suitable re-
moval tool from bore (left).
Bore core hole with suitable twist drill see table.
Cut thread with special tapped bore.
Note: Do not countersink bore!
Mount spindle (2) and snout (1) corresponding with
thread.
Groove on snout must be aligned with markings on
installation tool (arrows).

L92_23443

MR20108/00E 01.12 MTU


Section A General
Group 009 Repairing
Page 2 Threaded Bores

Insert thread insert (2) into spindle (1) in installation


tool.
Driver journal of thread insert must be in groove
(arrow).
2

L92_23443

Use spindle to turn thread insert through snout until


it is flush at front (arrow).

L92_23443

Mount installation tool on threaded hole and install


thread insert without applying pressure to spindle.
Note: Insert thread insert 1/2 to 1 1/2 turns
deeper than threaded bore surface.
Use bolt shearer to remove driver journal to M 14.
In event of threaded inserts over M 14, move driver
journal up and down with pointed pliers and remove.

L92_23443

MTU 01.12 MR20108/00E


Task Description Section A
Abbreviations Group 080
Page 1

A080 Abbreviations
ATL Abgasturbolader (Exhaust turbocharger)
brit. britisch (British)
bzw. beziehungsweise (and/or)
DBR Drehzahlbegrenzungsregler (Speed-sensitive fuel limiter)
DDC Detroit Diesel Corporation
d. h. das heit
DIN Deutsche IndustrieNorm (German Industrial Standard)
ECS Engine Control System
ECU Engine Control Unit
ISO International Organization for Standardisation
KGS Freie Seite (Kraftgegenseite) (Free end)
KS Antriebsseite (Kraftseite) (Driving end)
KW Kurbelwelle (Crankshaft)
LLK Ladeluftkhler (Intercooler)
MTU Motoren und Turbinen Union
NW Nockenwelle (Camshaft)
OT Oberer Totpunkt
SSK Schnellschluklappe (Emergency air shutoff flap)
usw. und so weiter (etc.)
UT Unterer Totpunkt (Bottom dead centre)
WP Wasserpumpe (Coolant pump)

MR20108/00E 01.12 MTU


Section A Task Description
Group 080 Abbreviations
Page 2

MTU 01.12 MR20108/00E


General Section A
Keyword Index Group 090
Page 1

A090 Keyword Index

Cooler, charge air C 110


A
Cooler, charge air C 110
Acceptance test record B 006 Counterweight, crankshaft C 031.05
Adjusting valve clearance C 055.05.11 Crankcase C 011.05
Air intake C 123.05 Crankcase and externally mounted components C 010
Air intake/air supply C 120 Crankcase ventilation C 018.12
Alternator C 344.05 Crankcase ventilation, driving end/free end C 018.10
Assembly instructions, general A Crankshaft C 031.05
Assembly, engine B 005 Crankshaft gear, free end C 031.05
Attachments, crankcase C 010 Crankshaft, free end, with PTO and vibration damper C 035.05
Auxiliary PTO, side (free end) C 259.05 Cutaway drawings, engine B 008
Axial mounting of crankshaft C 031.05 Cylinder head C 041.05
Cylinder head cover C 055.10
B
Cylinder head with fixtures C 040
Bearing bush, camshaft C 011
Cylinder liner C 013.05
Bearing cap (see crankshaft bearing cap)
Cylinder, designation 002 A
Bearing pedestal, rocker arm C 055.05
D
C
Dangers in the work place, brief information 005 A
Camshaft C 051.05
Data sheets 006 A
Camshaft axial alignment bearing C 053 05
Defining piston TDC C 037.05
Camshaft bearing bush C 011.05
Designation of engine sides and cylinders 002 A
Camshaft drive C 052.05
Disassembly, engine B 004
Carrier housing C143.05
Drive, lube oil pump C 181.05
Centrifugal oil filter C 183.10
Driver flange, driving end C 032.10
Charge air coolant line (low-temperature) C 203.25
Driver flange, free end C 035.05
Charge air coolant pump (low-temperature) C 203.05
Charge air manifold C 124.01 E
Checking camshaft timing C 051.05.11 ECU box C 507.05
Connecting rod and piston C 037.05 Electric cable C 500
Conrod bearing shell C 037.05 Electric starting C 172.05
Control block for air and exhaust flow control flaps C 128.05 End housing C 016.30
Coolant lines (high-temperature) C 202.10 Engine assembly B 004
Coolant lines after cylinder head (high temperature) C 202.20 Engine carrier (free end) C 231.05
Coolant pipework with thermostat C 206 Engine coolant lines C 202.15
Coolant pump (see engine coolant pump or charge air Engine coolant lines, engine coolant pump C 202.05
coolant pump)
Engine coolant pump (high-temperature) C 202.05
Coolant system C 200
Engine coolant system pipework C 202.10
Coolant system (high-temperature) C 202
Engine disassembly B 005
Coolant system (low-temperature) C 203
Engine drawings B 008
Coolant thermostat (see thermostat)
Engine installation B 007
Coolant vent lines C 202.65
Engine installation and operation B 007
Coolant vent lines (high temperature) C 202.65
Engine layout B 008
Coolants route from/to intercooler (low temperature) C 203.25
Engine mount C 231.05
Coolants route from/to intercooler (low temperature) C 203.25
Engine oil heat exchanger and lube oil filter C 183.05
Coolants route with thermostat (low temperature) C 206.05
Engine operation B 007

MR20108/00E 01.12 MTU


Section A General
Group 090 Keyword Index
Page 2

Engine operation B 007 Intercooler C 110


Engine removal B 003 Intercooler, intake air system C 125.05
Engine removal B 003 Intercooler, left side C 111.07
Engine run-in B 006 Intercooler, right side C 113.07
Engine sides, designation 002 A
L
Equipment carrier C 024.05
Exhaust distribution housing C 142.05 Lifting attachments for engine and running gear C 015.05

Exhaust distribution housing (constant-pressure mani- C 142.05 Lifting attachments for engine and running gear C 015.05
fold) Lines, lube oil pump C 181.05
Exhaust flap with actuator C 144.05 Longitudinal section, engine B 008
Exhaust pipework after cylinder head C 141.10 Lube oil pump with drive C 181.05
Exhaust system C 140 Lube oil system C 180
Exhaust transverse connection C 142.05
Exhaust turbocharger C 100 M
Main bearing cap C 011.05
F
Main oil gallery C 011.05
Filter element (see fuel filter) C 083.05 Monitoring, control system C 500
Flywheel housing C 016.30 Mounting C 230
Fuel filter C 083.05
Fuel injector (see injector) O
Fuel line, pump filter C 082.15 Oil bores C 011.05
Fuel lines before fuel pump C 084.05 Oil conditioning system C 183.15
Fuel pump (low-pressure) C 081.10 Oil conditioning system (plate-type oil heat exchanger) C 183.17
Fuel system (high-pressure) C 070 Oil dipstick C 011.05
Fuel system (low-pressure) C 080 Oil filler neck C 011.05
Oil filter, suspended C 183.05
G
Oil heat exchanger C 183.17
Gear case (equipment carrier) free end C 024.05 Oil pan C 014.05
Gear Train C 020 Oil pressure relief valve C 181.05
Gear train, free end C 025.05 Oil pump (see lube oil pump)
General A Oil return lines for exhaust turbocharger C 185.25
Generator C 213.05 Oil separator C 018.10
Graduated disc, camshaft C 052.05 Oil supply lines for turbocharger C 185.10
Graduated disc, driving end C 032.10 Oil supply/return lines for turbocharger ZR C185.12
Group summary C Oil system in crankcase C 184.10
-off fuel line C 086.05
H
Operation schedules B 004/005
High-pressure pump C 073.05
Overview, groups C1

I P
Idler gear, free end C 025.05
Piston cooling C 184.10
Important information 001 A
Pistons and conrods C 037.05
Injection line (high-pressure) C 077.05
Power supply, engine side C 210
Injector (high pressure) C 075.05
Pressure reduction valve C 181.05
Intake air system to cylinders, left engine side C 124.05
Pressure relief valve (see oil pressure relief valve)
Intake air system to cylinders, right engine side C 124.10
Pressure testing coolant chambers C 200.08
Intake housing C 123.05
PTO (free end), vibration damper C 035.05
Intake pipe, lube oil pump C 181.05
PTO systems, driving and free ends C 250

MTU 01.12 MR20108/00E


General Section A
Keyword Index Group 090
Page 3

PTO, driving end C 032.10


Pushrods C 054.10

R
Resilient coupling C 255.05
Rocker arm C 055.05
Rocker arm assembly C 055.05
Rotating trestle C 011.05
Run-in program B 006
Running gear C 030
Running gear (see running gear)
Running gear and engine lifting attachments C 015.05

S
Seal carrier (driving end) C 032.10
Seal carrier (free end) C 035.05
Sectional drawings B 008
Settings 004 A
Starter C 172.05
Starter C 172.05
Starting system C 170
Suction basket C 181.05

T
TDC disc C 037.05
Thermostat (see coolant thermostat) C 206.05
Thermostat and coolant distribution housing C 206.05
Torque specification for screws and nuts 003 A
Transverse sectional view, engine B 008
Turbocharger oil supply C 185.20

V
Valve bridge C 055.05
Valve drive C 055.05
Valve gear C 050
Valve gear (see valve gear)
Vibration damper C 035.05

Y
Y-pipe, exhaust outlet housing C 141.10

MR20108/00E 01.12 MTU


Section A General
Group 090 Keyword Index
Page 4

MTU 01.12 MR20108/00E


Task Schedules Section B

Page 1

Contents

B 001 Checking engine condition before a major overhaul

B 002 W5 Maintenance operations

B 003 Engine removal

B 004 Engine disassembly

B 005 Engine assembly

B 006 Engine running-in

B 007 Engine installation and operation

B 008 Engine drawings

MR20108/00E 01.12 MTU


Section B Task Schedules

Page 2

MTU 01.12 MR20108/00E


Operation Schedules Section B
Checking Engine Condition before W5 Group 001
and W6 Page 1

B 001 Checking Engine Condition before a Major Overhaul


Before the engine is removed, a brief test should be conducted to assist in evaluating its condition and running behav-
iour. 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


Perform operations preparatory to starting the engine Operating Instructions
Start engine Operating Instructions
Carry out engine warm-up procedure Operating Instructions
Test engine at highest possible power
Check engine speed, temperatures and pressures where gauges are installed
Check operating states with fault recorder, assess discrepancies Operating Instructions
Check running noises; these should be restricted to normal operating sounds
During test run, visually inspect engine and external lines for leaks Operating Instructions
Check for water emerging from intercooler drain lines and check for obstructions Operating Instructions
Check exhaust gas colour Operating Instructions
Operate engine with adjustable zero-power speed
Connect fuel line connections for leaks
Remove cylinder head cover C 055.10
Check valve gear lubrication (visual inspection)
Extract engine oil sample Operating Instructions
Analyze engine oil sample (spot test, water content, dilution with fuel) MTU Test Kit
Extract coolant sample Operating Instructions
Analyze coolant sample MTU Test Kit
Check function of monitoring system and ECU. Operating Instructions
Shut down engine Operating Instructions
Only if installed: Reduce the coolant level in the expansion tank and check the level Operating Instructions
switch response (coolant level monitoring)
Drain coolant Operating Instructions
Drain charge air coolant Operating Instructions
Fill system with cleaning solution Special Publication
Start engine Operating Instructions
Flush cooling system
Flush charge air cooling system
Shut down engine Operating Instructions
Check engine (endoscopic examination) Operating Instructions

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 001 Checking Engine Condition before W5
Page 2 and W6

MTU 01.12 MR20108/00E


Operation Schedules Section B
W5 Maintenance Operations Group 002
Page 1

B 002 W5 Maintenance Operations

Note: The following table is based on maintenance schedule MO...../.


When carrying out maintenance work, always use the valid maintenance schedule corresponding to the
affected engine.

Operations to be performed See


Disable engine start Operating Instructions
Wash plant, without using chemical cleaning agents Operating Instructions
Drain engine coolant and flush coolant systems Operating Instructions
Drain engine oil Operating Instructions
Replace engine oil filter Operating Instructions
Replace fuel duplex filter easy-change filter Operating Instructions
Replace filter elements of fuel prefilter Operating Instructions
Clean air filter, replace if necessary. Empty dust collection box Operating Instructions
Check function of contamination indicator and reset if necessary Operating Instructions
Overhaul engine coolant preheating system
Replace exhaust turbocharger C 101.01
Intake air system, remove lines, clean, replace gaskets
Drain exhaust system, check security of securing screws Operating Instructions
Remove intercooler (low-temperature circuit), clean and check for leaks C 111.05
C 113.07
Engine coolant cooler (high-temperature circuit), clean and check for leaks
Clean charge air coolant cooler (low-temperature circuit), check for leaks
Check coolant thermostat (high-temperature circuit), replace if necessary C 206.05.08
Check coolant thermostat (low-temperature circuit), replace if necessary C 206.05.08
Disassemble engine coolant pump (high-temperature circuit), check parts, replace C 202.05.06
bearing and gaskets
Charge air coolant pump, check parts, replace bearings and gaskets C 203.05.08
Check condition of engine control system and wiring and check for security
Check starter, wiring and connections for corrosion and loose connections, check wir-
ing
Check generator and contacts for corrosion and loose connections, check wiring
Generator drive, check tension and condition of drive belt Operating Instructions
Replace H.P. fuel pump and H.P. sensor C 073.05.05
Remove and check valve gear, rocker arms and valve bridges C 055.05.05
Check rocker arms, rollers, pushrod seat and rocker arm bearings for wear
Replace fuel injectors Operating Instructions
Remove cylinder heads, check valve guides, recondition valve seats and valves C 041.05.05
replace gaskets
Check wear pattern of cylinder liners C 013.05.05
Check piston crowns (visual inspection) C 037.05.05
Valve gear, prelubricate
Remove, clean and check exhaust flap with actuator for flap, drive shaft and flap bear- C 144.05.05
ings

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 002 W5 Maintenance Operations
Page 2

Operations to be performed See


Check air flow control flap stop, bearing and gasket C 123.05.05
Remove and examine vibration damper, repair if necessary C 035.05.05
Clean centrifugal oil filter Operating Instructions
Check bearing, replace if necessary C 183.10.05
Replace sealing sleeve Operating Instructions
Remove engine oil heat exchanger, clean and check for leaks, replace O-rings C 183.15.05
Remove, disassemble and clean plate-core heat exchanger, replace gaskets and C 183.17.05
check for leaks (engine test run)
Crankcase breather, replace oil separator Operating Instructions
Check generator C 213.05.08
Check starter C 172.05.08
Engine mount, check security Operating Instructions
Check condition of resilient mounts Operating Instructions
Check buffer clearance C 231.05.11
ECU, wiring, check security and condition Operating Instructions
Check function of monitoring units Operating Instructions
Check battery charge state, electrolyte specific gravity and level Operating Instructions
Reinstall/mount parts that were removed after they have been assembled according to B 005
the engine assembly sequence
Fill oil system with engine oil Operating Instructions
Fill engine coolant, vent coolant system Operating Instructions
Carry out before-operation services Operating Instructions
Switch on monitoring system Operating Instructions
Carry out lamp test
Open fuel supply Operating Instructions
Preheat engine Operating Instructions
Start engine Operating Instructions
Perform checks with engine running as for initial operation Operating Instructions
Engine test run, check speed, pressures, and temperatures Operating Instructions
Check running noises
Check engine and external pipework for leaks Operating Instructions
Check turbocharger and exhaust connections for leaks; check oil supply and return Operating Instructions
lines for leaks
Check exhaust gas colour Operating Instructions
Check intake air system for leaks Operating Instructions
Shut down engine Operating Instructions
Check engine oil level Operating Instructions
Check engine coolant level Operating Instructions
Charge air coolant, check level Operating Instructions

MTU 01.12 MR20108/00E


Maintenance Schedules Section B
Engine Removal Group 003
Page 1

B 003 Engine Removal


Operations See
Shut off fuel supply Operating Instructions
Drain engine oil, if possible while engine is warm Operating Instructions
Examine oil sludge for metallic residues Operating Instructions
Drain engine coolant when temperature of coolant is below 60 C Operating Instructions
Drain charge air coolant Operating Instructions
Wash plant, without using chemical cleaning agents
Disconnect all connections
Install non-fibrous plugs and blanking plates to seal all open connections
Release engine securing screws
Remove engine and place on stands
Using a lifting device, attach engine only on suspension brackets provided as shown in Operating Instructions
installation drawing, taking centre of gravity and transportation specifications into con-
sideration.

Engine weight

(dry weight)


16 V 4000 approx. 6950 kg

Note: Raise engine only by means of the lifting


eyes shown (arrows).


Illustration also applies to 16V


Lower the engine onto the floor, placing a wooden


block on a level, firm surface below the oil pan at the
driving and free ends.


F000 0117a0

MR20108/00E 01.12 MTU


Section B Maintenance Schedules
Group 003 Engine Removal
Page 2

MTU 01.12 MR20108/00E


Operation Schedules Section B
Engine Assembly Group 004
Page 1

B 004 Engine Disassembly


Before beginning complete engine disassembly, it is advisable to take photographs of the engine from all sides or
to record all components installed on the engine in writing.
The sequence of the required operations in the following list corresponds to the order in which actual disassembly
is to be carried out.
The individual tasks are described in detail in the Groups listed in the right-hand column.

Operations to be performed See


Remove coupling see Special Publication
Mark and disconnect electric cables C 500.00
Remove generator C 213.05
Remove control block for air and exhaust flow control flaps C 128.05
Remove exhaust flap with actuators C 144.05
Remove air intake C 123.05/123.20
Remove oil supply lines for turbochargers C 185.10
Remove oil return lines for turbochargers C 185.25
Remove exhaust turbocharger with carrier housing C 143.05/101.01
Remove intercooler, left side C 111.07
Remove intercooler, right side C 113.07
Remove coolant vent lines (high temperature and low temperature) C 202.65
Remove charge air coolant lines (low temperature) * C 203.25
Remove coolant lines (high temperature) C 202.10
Remove crankcase breather C 018.12
Remove coolant distribution housing and thermostat C 206.05
Remove charge air coolant pump (low temperature) * C 203.05
Remove coolant pump (high temperature) C 202.10
Remove exhaust distribution housing (constant-pressure manifolds) C 142.05
Remove centrifugal oil filter if installed C 183.10
Remove oil filter C 183.05
Remove oil treatment system if installed C 183.15
Remove oil treatment system (plate-core heat exchanger) if installed C 183.17
Remove charge air manifolds C 124.05
Remove leak-off fuel pipework C 086.05
Remove fuel pipework from fuel filter to high-pressure pump C 084.05
Remove fuel filter C 083.05
Remove injection lines with H.P. accumulator C 077.05
Remove fuel pump (low pressure) C 083.10
Remove fuel injector C 075.05
Remove H.P. pump C 073.05
Remove starter, left and right side C 172.05
Remove main oil gallery C 011.05
Remove engine mounts, free and driving ends C 231.10

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 004 Engine Assembly
Page 2

Operations to be performed See


Remove cylinder head covers C 055.10
Remove valve drive C 055.05
Remove pushrods C 054.10
Remove cylinder heads C 041.05
Remove vibration damper C 035.05
Remove drive flange (free end) from crankshaft C 035 05
Remove seal carrier (free end) C 035.05
Remove charge air coolant pump (low temperature) * C 203.05
Remove coolant pump (high temperature) C 202.05
Remove starter, left and right side C 172.05
Remove flywheel with graduated disc C 032.20
Remove graduated disc, seal carrier (driving end) C 032.10
Remove auxiliary PTO C 259.05
Install crankcase in assembly dolly C 011.05.11
Remove oil dipstick and oil filler neck C 011.05
Remove oil pan C 014.05
Remove suction basket and oil drain valve from the oil pan C 014.05
Remove camshaft drive with measuring wheel C 052.05
Remove camshaft axial alignment bearing C 053.05
Remove flywheel housing C 016.30
Remove gear case (equipment carrier), free end C 024.05
Remove gear case (equipment carrier), lube oil pump with drive C 181.05
Remove gear case (equipment carrier), pressure reduction valve C 181.05
Remove gear case (equipment carrier), gear train, free end C 025.05
Remove piston with connecting rod C 037.05
Remove oil supply and oil spray nozzles C 184.10
Remove crankshaft C 031.05
Remove main bearing C 013.05/024.04
Remove cylinder liners C 013.05
Remove crankcase from assembly dolly C 011.05.11
Remove camshaft C 053.05/C 051.05
Remove camshaft bearing bush after examination C 011.05

* TB version

MTU 01.12 MR20108/00E


Operation Schedules Section B
Engine Disassembly Group 005
Page 1

B 005 Engine Assembly


The sequence in which the following required procedures are listed corresponds to the order in which actual as-
sembly is performed.
The individual tasks are described in detail in the Groups listed in the right-hand column.

Operations to be performed See


Check and repair crankcase C 011.05
Make sure that oilways are perfectly clean C 011.05
Install plugs and covers C 011.05
Install plugs for oil and coolant bores C 011.05
Measure crankcase bores C 011.05
Install camshaft bearing bushes C 011.05
Install camshaft C 051.05/C 053.05
Install crankcase in assembly dolly C 011.05.05
Install cylinder liner C 013.05
Measure cylinder liner bore C 013.05
Install oil pipework and oil spray nozzle C 184.10
Store crankshaft C 031.05
Install crankshaft C 031.05
Install piston with connecting rod C 037.05
Install flywheel housing C 016.30
Install idler gears in gear case (equipment carrier), free end C 025.05
Install gear case (equipment carrier), pressure reduction valve C 181.05
Install gear case (equipment carrier), lube oil pump with drive C 181.05
Install equipment carrier C 024.05
Install camshaft drive with graduated disc C 052.05
Install camshaft thrust bearing C 053.05
Install flange on oil pan C 014.05
Install suction basket in oil pan C 014.05
Install oil pan C 014.05
Remove crankcase from assembly dolly C 011.05
Install seal carrier (free end) C 024.05
Install drive flange (free end) on crankshaft C 035.05
Install vibration damper C 035.05
Install auxiliary PTO C 259.05
Install graduated disc, seal carrier (driving end) C 032.10
Install flywheel with graduated disc C 032.20
Install oil dipstick and oil filler neck C 011.05
Install cylinder heads C 041.05
Install pushrods C 054.10
Install valve drive C 055.05
Install cylinder covers C 055.10

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 005 Engine Disassembly
Page 2

Operations to be performed See


Install main oil gallery C 011.05
Install starter, left and right side C 172.05
Install H.P. pump C 073.05
Install fuel injector C 075.05
Install fuel pump (low pressure) C 081.10
Install injection lines with H.P. accumulator C 077.05
Install fuel filter C 083.05
Install fuel pipework from fuel filter to high-pressure pump C 084.05
Install leak-off pipework C 086.05
Install charge air manifolds C 124.05
Install oil treatment system if installed C 183.15
Install oil treatment system (plate-core heat exchanger) if applicable C 183.17
Oil treatment, install oil filter C 183.07
Install centrifugal oil filter, if installed C 183.10
Install oil filter C 183.05
Install charge air coolant pump (low temperature) * C 203.05
Install coolant pump (high temperature) C 202.10
Install coolant distribution housing and thermostat C 206.05
Install coolant lines (high temperature) C 202.10
Install coolant vent lines (high temperature and low temperature) C 202.65
Install exhaust distribution housing (constant-pressure manifolds) C 142.05
Install crankcase breather C 018.12
Install exhaust turbocharger with carrier housing C 143.05
Install air intake C 123.05
Install exhaust flow control flap with actuator C 144.05
Install control block for air and exhaust flow control flaps C 128.05
Install intercooler, left side C 111.07
Install intercooler, right side C 113.07
Install oil supply lines for turbochargers C 185.10
Install oil return lines for turbochargers C 185.25
Install charge air coolant pump (low temperature) * C 203.05
Install charge air coolant lines (low temperature) * C 203.25
Install electric cables C 507.00
Install generator C 213.05
Install engine mounts, free and driving ends C 231.10
Install ECU BOX C 507.05
Install coupling see Special Publication

* TB version

MTU 01.12 MR20108/00E


Operation Schedules Section B
Engine Running-In Group 006
Page 1

B 006 Engine Running-In


If pistons, piston rings or cylinder liners have been replaced, the engine must be run in as per the appropriate
run-in schedule.
Conscientious running in is of critical importance as regards the durability and operational reliability of the engine.
Use a brake or alternator to absorb the power generated in the braking run.
Power must be transmitted from the engine to the brake by means of a resilient coupling.

Settings
Set fuel and intake air temperatures before engine in accordance with the temperatures stated for the engine in the
MTU Engine Acceptance Test Record.
The engine coolant temperature depends on the operating range of the coolant thermostat.
Fuel temperature depends on the volume of the service tank insofar as there is no fuel-cooling device on the test
stand.
Record readings for power, fuel, lube oil, coolant, charge air and exhaust gas at each test point (time, speed and
effective power) of the run-in schedule and enter readings under Engine Running-In in MTU Diesel Engine Fac-
tory Test record.

Operations to be performed See


Install engine on test stand
Connect engine to brake or alternator
Connect exhaust, engine coolant and fuel lines
Connect valve gear to DDEC
Connect measuring sensor and measuring lines to the corresponding measuring MTU Engine Accept-
points to record the measured values for fuel, lube oil, engine coolant, supercharging ance Test Record
and exhaust which were noted in the MTU Engine Acceptance Test Record.
Connect dialogue unit to ECU
Fill expansion tank with coolant and 2% corrosion inhibitor oil up to max. mark Operating Instructions
Vent coolant lines until bubble-free coolant emerges Operating Instructions
Check that fuel in service or supply tank is to specification MTU Fluid and Lubric-
ants Specification
Fill oil system up to max. mark with fresh oil Operating Instructions
Prelubricate valve gear with oil Operating Instructions
Check operation of emergency shutdown system
Preheat engine coolant Operating Instructions
Prelubricate engine oil system (external pump)
Start engine via ECU Operating Instructions
Shut down engine after approx. 1 min no-load operation and carry out following oper-
ations: Operating Instructions
Check oil level, top up with oil if necessary. Operating Instructions
Remove valve gear cover, check valve gear lubrication.
Start engine, check idling speed
Check engine running noises Operating Instructions
Carry out engine warm-up procedure Operating Instructions
Check for leaks at coolant, oil and fuel lines, crankcase seals, air system and exhaust Operating Instructions
lines
Run in engine and record measurements in accordance with running-in schedule B 006
Compare test data with those recorded in MTU Acceptance Test Record MTU Engine Accept-
Check and make a note of fuel density ance Test Record
Check colour of exhaust gas

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 006 Engine Running-In
Page 2

Operations to be performed See


Enter barometric reading and relative humidity in record MTU Engine Accept-
ance Test Record
Check engine for abnormal noises and for leaks
Check function of monitoring units
After running in, run down engine and switch off Operating Instructions
Oil filter cut open one filter and check residues Operating Instructions
Check oil level and prepare engine for oil-consumption measurement
Carry out acceptance test in accordance with MTU Engine Acceptance Test Record B 006
Enter operational data in engine acceptance test record provided MTU Engine Accept-
ance Test Record
Compare test data with those recorded in MTU Engine Acceptance Test Record MTU Engine Accept-
ance Test Record
Carry out governor test
After completing acceptance test, run down engine and switch off Operating Instructions
Carry out oil-consumption test Operating Instructions
Start engine
Go through the governor curve (DBR) in accordance with the MTU Engine Acceptance MTU Engine Accept-
Test Record ance Test Record
Set the specified service power rating as per MTU Engine Acceptance Test Record MTU Engine Accept-
ance Test Record
Shut down engine and carry out six start attempts
Carry out engine preservation run Operating Instructions
Shut down engine and disable engine start
Drain engine oil and coolant Operating Instructions
Adopt suitable protective measures if engine is scheduled for marine transport
Disconnect exhaust, engine coolant and fuel lines
Disconnect valve gear from DDEC
Remove measuring sensors and measuring lines from engine and seal measuring
points
Remove engine from test stand
Prepare engine for paint spraying and spray with protective paint

See next section for run-in program.

MTU 01.12 MR20108/00E


Run-In Program (Test Stand) 12V 4000
Intake air temperature t0 = 25 _C; Fuel temperature tKR = 25 _C

Engine
speed 1423 3252 4060 5081 6300 7520 8740 9714 FBR [N]
[rpm1] 3.5 8.0 10.0 12.5 15.5 18.5 21.5 23.9 Pe [bar]
1000 142
1500 488 609 762 945 1128 1311 1457
1650 670
1800 915 1134 1354 1573 1748 Peff
1900 1197 1429 1661 1845 [kW]
2000 1504 1748 1942
2100 1835 2040

Engine wash- Full measure-


ing ment

Running period 10 20 15 15 15 15 15 20 [min]

Note: Engine speed and power are increased as per above-stated running period specification.
After rated speed is reached, power must only be increased until contractually specified power is reached.
Engine is run up to contractually specified power not stated in the run-in program until speed and power are reached which correspond closest to
the contractually specified value. Then run up to contractually specified power.
Engine data are recorded only at n = 1000 rpmand at final power (full measurement).
The respective final power must be maintained for 20 minutes.
.
.
.
Operation Schedules Section B
Engine Installation and Operation of the Engine Group 007
Page 1

B 007 Engine Installation and Operation of the Engine


Operations to be performed See
Open all connections, remove cover and rubber plugs
Attach engine only on suspension brackets provided as shown in installation drawing,
taking centre of gravity and transportation specifications into consideration, and install
in plant.
Join connections for engine coolant, fuel, engine monitoring as appropriate
Fill engine coolant system Operating Instructions
Fill charge air coolant system Operating Instructions
Fill oil system with engine oil Operating Instructions
Align engine
Prepare engine for operation Operating Instructions
Preheat engine Operating Instructions
Start engine Operating Instructions
Perform checks while engine is running Operating Instructions
Measure intake air depression Operating Instructions
Measure exhaust backpressure Operating Instructions
Shut down engine Operating Instructions
Perform after-shutdown services Operating Instructions
If the plant is to be taken out of service for an extended period, carry out external pres- Operating Instructions
ervation, disable engine start, seal air inlet and exhaust outlet.
(Note: An engine preservation run was carried out after the test stand run.)

* TB version

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 007 Engine Installation and Operation of the Engine
Page 2

MTU 01.12 MR20108/00E


Operation Schedules Section B
Engine Drawings Group 008
Page 1

B 008 Engine Drawings


Engine cross-section R 40
Engine longitudinal section R 40
Engine view, left R 10/20
Engine view, right R 10/20
Engine overhead view R 10/20
Engine view, free end R10/20

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 008 Engine Drawings
Page 2

Engine cross-section

MTU 01.12 MR20108/00E


Operation Schedules Section B
Engine Drawings Group 008
Page 3

Engine longitudinal section

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 008 Engine Drawings
Page 4

Engine view, left

MTU 01.12 MR20108/00E


Operation Schedules Section B
Engine Drawings Group 008
Page 5

Engine view, right

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 008 Engine Drawings
Page 6

Engine overhead view

MTU 01.12 MR20108/00E


Operation Schedules Section B
Engine Drawings Group 008
Page 7

Engine layout, free end

MR20108/00E 01.12 MTU


Section B Operation Schedules
Group 008 Engine Drawings
Page 8

MTU 01.12 MR20108/00E


Task Description Section C
Group Summary Page 1

C Group Summary

010 Crankcase and externally mounted components


020 Gear train
030 Running gear
040 Cylinder head
050 Valve gear
060 Governor actuator*
070 Fuel system (high-pressure)
080 Fuel system (low-pressure)
090 Regulation*
100 Exhaust turbocharger
110 Intercooler
120 Air intake / air supply
130 not assigned
140 Exhaust system
150 not assigned
160 not assigned
170 Starting system
180 Lube oil system
190 not assigned
200 Coolant system
210 Power supply, engine side
220 Cooling air system
230 Mounting/support
240 Engine-gearbox connection*
250 PTO Systems, driving end and free end (coupling)
290 Pumps driven separately*
Blank register
360 Auxiliary systems, supplementary units*
Blank register
500 Monitoring, control and regulation devices

* not mounted on this engine

MR20108/00E 01.12 MTU


Section C Task Description
Page 2 Group Summary

C Group Overview as for 16V

010 Crankcase and externally mounted 120 Air intake / air supply
components 140 Exhaust system
020 Gear train 170 Starting system
030 Running gear 180 Lube oil system
040 Cylinder head 200 Coolant system
050 Valve gear 210 Power supply, engine side*
070 Fuel injection system (high-pressure) 220 Mechanical fan drive *
080 Fuel system (low-pressure) 230 Mounting/support *
100 Exhaust turbocharger 250 PTO systems, driving and free end
110 Intercooler (couplings)*
* not shown 500 Electrical equipment

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase and Externally Mounted Components Group 010
Page 1

Contents

C 010 Crankcase and Externally Mounted Components

C 011.05 Crankcase
C 011.05.01 Overview drawing
C 011.05.02 Special tools
C 011.05.04 Before-removal operations
C 011.05.05 Removal
C 011.05.06 Disassembly
C 011.05.08 Inspection and repair
C 011.05.10 Assembly
C 011.05.11 Installation
C 011.05.12 Afterinstallation operations

C 013.05 Cylinder liner


C 013.05.01 Overview drawing
C 013.05.02 Special tools
C 013.05.04 Before-removal operations
C 013.05.05 Removal
C 013.05.08 Inspection and repair
C 013.05.11 Installation
C 013.05.12 Afterinstallation operations

C 014.05 Oil pan


C 014.05.01 Overview drawing
C 014.05.02 Special tools
C 014.05.04 Before-removal operations
C 014.05.05 Removal
C 014.05.08 Inspection and repair
C 014.05.11 Installation
C 014.05.12 Afterinstallation operations

C 015.05 Lifting attachments for engine and running gear


C 015.05.01 Overview drawing
C 015.05.04 Before-removal operations
C 015.05.05 Removal
C 015.05.08 Inspection and repair
C 015.05.11 Installation
C 015.05.12 Afterinstallation operations

C 016.30 End housing, driving end


C 016.05.01 Overview drawing
C 016.05.02 Special tools
C 016.05.04 Before-removal operations
C 016.05.05 Removal
C 016.05.08 Inspection and repair
C 016.05.11 Installation

MR20108/00E 01.12 MTU


Section C Task Description
Group 010 Crankcase and Externally Mounted Components
Page 2

C 016.05.12 Afterinstallation operations

C 018.10 Crankcase ventilation, driving end


C 018.10.01 Overview drawing
C 018.10.04 Before-removal operations
C 018.10.05 Removal
C 018.10.06 Disassembly
C 018.10.08 Inspection and repair
C 018.10.10 Assembly
C 018.10.11 Installation
C 018.10.12 Afterinstallation operations

C 018.10 a Crankcase ventilation, free end


C 018.10.01 a Overview drawing
C 018.10.04a Before-removal operations
C 018.10.05 a Removal
C 018.10.06 a Disassembly
C 018.10.08 a Inspection and repair
C 018.10.10 a Assembly
C 018.10.11a Installation
C 018.10.12 a After-installation operations

C 018.12 Crankcase ventilation


C 018.12.01 Overview drawing
C 018.12.04 Before-removal operations
C 018.12.05 Removal
C 018.12.06 Disassembly
C 018.12.08 Inspection and repair
C 018.12.10 Assembly
C 018.12.11 Installation
C 018.12.12 Afterinstallation operations

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase and Externally Mounted Components Group 010
Page 3

C 010 Crankcase and Externally Mounted Components

1 Crankcase 6 Crankshaft alignment bearing cover 11 Main bearing cap


2 Camshaft bearing 7 Oil pan 12 Cylinder liner
3 Crankshaft bearing 8 Block 13 Oil filler neck
4 Stud 9 Nut for crankshaft bearing cap 14 Oil dipstick
5 Crankshaft alignment bearing 10 Socket-head screws

MR20108/00E 01.12 MTU


Section C Task Description
Group 010 Crankcase and Externally Mounted Components
Page 4

The following is a list of auxiliary equipment and materials needed for the assembly operations:

CAUTION
When using these chemical substances, it is essential to observe the manufacturers instructions for
use, safety instructions and waste disposal specifications.

Materials and consumables Designation MTU Order No. Remarks


Emery cloth
Wire brush
Bottle brush
Magnifying glass
Spray gun
Inspection lamp
Endoscope with cold light
Liquid nitrogen
Activator Loctite No. 7649 50548
Vaseline Petroleum jelly, white 40317
Thread-locking compound Loctite No. 270 40083 Final strength at 20 C  12 h
Cleaner Loctite No. 7061 50518
Surface sealant Loctite No. 518 50592 Final strength  24 h
Surface sealant Loctite No. 573 40031 Final strength  48 h
Surface sealant Loctite No. 5910 50570 Final strength  48 h
Thread-sealing compound Loctite No. 586 40033 Final strength at 20 C 12 h
Engine oil
Multipurpose grease Shell Retinax 40333
Hydrochloric acid
Corrosion inhibitor Pfinder AP 11 F 40355
Cleaning agent Solvclean KW 40022
Cleaning agent (carbon-deposit remover) Meister Proper 40377
Kerosene or diesel fuel
Sealing paste Elastosil N 189 50545
Denaturated ethanol 40250
Engineers blue blue 40641
Dry compressed air
Corrosion inhibitor Caramba Express 40008
Magnetic crack-testing equipment with fluor-
escent magnetic powder
Surface crack-testing equipment with red
penetrant dye

Surface crack-testing equipment with fluor-


escent penetrant dye

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 1

C 011.05 Crankcase
C 011.05.01 Overview Drawing

Cover, guide tube, oil filler neck

1 Crankcase 18 O ring
2 Block 19 Hex screw
3 Socket-head screw 20 Washer
4 Drain valve 21 O ring
5 Hex screw 22 O ring
6 Plug 23 Inspection port cover
7 Sealing ring 24 Gasket
8 Dowel pin 25 Hex screw
9 Cover 26 Guide tube
10 Stud 27 Sealing ring
11 Blanking plug 28 Union
12 Sealing ring 29 Oil dipstick
13 Blanking plug 30 O ring
14 Hex screw 31 Oil filler neck
15 O ring 32 Cover
16 Link 33 Gasket
17 Hex screw

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 2

Crankcase

1 Crankcase 6 Socket-head screw


2 Main bearing cap * Pretightening torque: 80 Nm
* Tightening torque: 280 Nm + 20 Nm
3 Main bearing cap Lubricant: Engine oil
4 Stud ** 7 Washer
Tightening torque: 80 Nm 8 End cover
(to blind hole) Securing agent: Thread-locking compound
Lubricant: Engine oil
9 Camshaft bearing
5 Nut, main bearing cap
Screw elongation: l = 1.15 mm + 0.05 mm
Remaining screw elongation: l = 0.9 mm + 0.05 mm
Lubricant: Engine oil

* Tightening sequence, starting from driving end:


1. Pretighten all socket-head screws on left side and then on right side
2. Fully tighten all socket-head screws on left side and then on right side
** Newly installed studs must be pre-stretched prior to initial tightening

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 3

C 011.05.02 Special Tool


Designation Application Number

Crankcase barring tool 1


Stop device for assembly of camshaft bearing 1
Stop device for assembly of camshaft bearing, free end 1
Removal pipe for camshaft bearing 1
Removal tool 1
Shrink-on tool, camshaft bearing 1
Installation tool, camshaft bearing 1
Holder for shrink-on tool 1
Guide bush for shrink-on tool 1
Mandrel for end cover 1
Hydraulic clamping device for main bearing stud 1
Installation/removal tool for stud, main bearing 1

C 011.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations to be performed See


x Remove engine B 003
x Perform operations as per Disassembly Plan B 004

C 011.05.05 Removal
Removing cover, guide tube, oil filler neck, inspection port cover
Remove cover, guide tube, oil filler neck and inspection port cover as shown in the overview drawing, see
C 011.05.01.
Remove gaskets and O-rings.
Installing crankcase in assembly dolly


Install supports (1) for assembly dolly at left and right
side of the crankcase.


1
WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.


Raise crankcase with lifting appliance and lifting


ropes, place in assembly dolly (2) and secure.
2

FG010002a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 4

C 011.05.06 Disassembly

Checking marking on main bearing cap


Check marking on main bearing cap to crankshaft,
and if necessary mark according to sequence.
To do this, punch the main bearing serial
number on crankcase and main bearing cap on
left side of engine (A side).
Numeral punch 6 mm high.
Number sequence: Beginning at driving end
side with main bearing no. 1.
Note: In the diagram opposite, the crankcase is
rotated 180 . Viewed from this angle the
A side is on the right.

Removing main bearing caps


Note: Crankcase has been turned round, main
bearing cap faces upwards.
Remove block, see overview drawing C011.05.01.


Using a ratchet and socket wrench, remove all side
socket-head screws (arrow) for crankshaft bearing

cap from the crankcase.

F0310020a0

Beginning with the first bearing cap (driving end),


place support sleeve (2) of hydraulic screw preten-
sioner on studs (1) of respective main bearing cap.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 5

Turn hydraulic pretensioner by hand until it is in posi-


tion.

Connect high-pressure hose of the hydraulic hand


pump to hydraulic pretensioner.
Position magnetic-base indicator holder with dial
gauges on the crankcase support surface for exten-
sion measurement of the studs.

Position the two dial gauge styluses centrally on the


respective measuring point (arrow) on the face of the
sleeve measuring pin.
Set dial gauges with preload to zero.

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 6

Operate the hydraulic hand pump and, at the same


time, elongate studs (each by a max. 0.25 mm).
Using a pin (arrow), release the nuts at the main
bearing cap.
Release studs, mount magnetic-base indicator
holder with dial gauges and hydraulic pretensioner
on adjacent bearing cap respectively and release all
nuts in the same sequence.
Remove loose nuts from the studs.

CAUTION
Components have sharp edges.
Risk of injury!
Handle components only when wearing protec-
tive gloves.

Screw lifting eye into bearing cap.


Move lifting appliance into position.
Carefully raise all bearing caps vertically until clear
of crankcase (arrow).

Removing stud(s) for main bearing cap


Note: Only remove studs if necessary.
Remove appropriate stud(s) using an installation/re-
moval tool (arrow).

F0110007

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 7

Removing camshaft bearing bush


Note: Remove camshaft bearing bushes only
when wear limits are reached or when
they are damaged.
Measure camshaft bearing bush (B) see Section
C 011.05.08.
Replace camshaft bearing bush(es) if limit values
are exceeded.

Removing first bearing bush, driving or free end

If only one bearing is being replaced, ensure that the


following bearings are protected against damage,
1 see following illustration.
Important: Cover the bottom of the camshaft
chamber so that no bearing bush falls
into the running gear.
Insert thrust pad (1) into appropriate bearing.

F0110008a0

Protect bearing (arrow) against damage, e.g. with


use of a rag.



F0110010a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 8

Place removal tool (1) in support of thrust pad (2)


2
and move camshaft bearing into position.
Using a copper hammer, carefully drive camshaft


1 bearing out of crankcase.

F0110009a0



1 Removing following camshaft bearing bush.
Insert thrust pad (arrow) into next bearing bush
which is still installed.


Insert removal tool (2) with guide washers (1) into


camshaft bearing bore on crankcase.
1
Drive out camshaft bearing bush

Follow same procedure to remove other bearing

2 bushes.


F0110011a0

Removing end cover


Note: Remove end cover only if necessary (e.g.
in event of leakages).
Using a mandrel and hammer, carefully knock the
edge of one side of the end cover inwards until it tilts
in the bore. Then withdraw the cover with pliers.
When removing, take care that the cover does not
fall into the bore and that the sealing face of the bore
is not damaged.
Never attempt to drill a hole in cover, as chips of
metal in engine cooling jacket can cause localized
overheating.

ZV011 0001a

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 9

Removing plug
Release hex screws (2) and link (1).
Using a hex screw, carefully withdraw plug from oil
bore.
Remove O-ring from blanking plug.

FG010008 a0

C 011.05.08 Inspection and Repair

Clean all components.


Using the surface crack-testing method with red penetrant dye, check crankcase for cracks.
Using the magnetic crack-testing method with fluorescent powder, check the crankshaft bearing cap and screws
for main bearing cap for cracks; replace part if cracks are detected.
Check mating faces, upper and lower fits of the cylinder liners in the crankcase for wear, damage and cavitation,
machine if necessary.
Check thread and shaft of main bearing studs for damage; replace studs if necessary.
Check that thread, shaft and screw head surface of the socket-head screws, which are used to secure crankshaft
main bearing cap at the side, are in perfect condition; replace socket-head screw as required.
Check camshaft bearings and guide bushes on wear and damage;
replace if necessary.
Check all mating faces, sealing faces and fits; rub down with an oilstone or emery cloth as necessary.

CAUTION
Compressed air is highly pressurized. Risk of injury!
If compressed air is used for blowing out or blow-drying components, always wear protective goggles
or safety mask. Pressure must not exceed 3.0 bar.

Thoroughly blow clear all threads; check for ease of movement; machine if necessary.
Note: Any inquiries concerning machining work at the crankcase should be directed to DCC or MTU.

Oil filler neck


Clean all components.
Clean oil filler neck with cold cleaner and blow clear with compressed air.
Visually inspect component for damage and defects; replace if necessary.
Check condition of threads; machine or replace components as necessary.
Replace sealing rings.
Note: Ensure oil filler neck is perfectly clean!

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 10

Oil dipstick
Visually inspect for damage and defects; replace if necessary.
Check that the oil dipstick is secure in the guide tube.
When replacing dipstick, make sure you use correct version. Part number is stamped on grip.
Replace O-ring.
Note: Make sure parts are perfectly clean.

Cover
Remove old sealant from mating surfaces and check
for wear and damage; machine if necessary.
Thoroughly clean oil bores, use a bristle brush if
necessary.
Important: Never use a wire brush!

CAUTION
Compressed air is highly pressurized.
Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Pressure must not exceed 3.0 bar.

After cleaning, flush oilways (under pressure if poss-


ible) and blow clear with dry compressed air.
Use a plastic plug or suitable adhesive tape to pre-
vent each bore from getting dirty until the crankcase
has been assembled.

Check oil bores in crankcase

Note: During a major engine overhaul or when there are metal chips in the engine oil system, all oil bores
must be thoroughly cleaned and checked for particular cleanness.
The oil bores in the following pictures should be lit up with an endoscope and cold light and checked for particular
cleanness.

Oil supply bores to valve gear at crankcase, sides


A and B.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 11

Main oil supply bores to camshaft and main bearing


in crankcase V.

FG010027 a0

Oil bores (arrow) in camshaft chamber.

FG010013a0

Oil bores (arrow) to the main bearings (arrow).

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 12

Check all other coolant and oil bores in same way for
contamination.
If necessary, clean bores with bristle brush (1).
Important: Never use a wire brush!

FG010014a0

CAUTION
Compressed air is highly pressurized.
Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Pressure must not exceed 3.0 bar.
After cleaning, flush bores (under pressure if poss-
ible) and blow clear with compressed air.
Note: If the crankcase is not assembled or put
into operation immediately, dry oil bores,
preserve and seal air-tight with suitable
plugs.

FG010015a0

Measuring bearing cap width


Using an outside micrometer (1), measure the bear-
ing cap width at the bottom and top fits of the bear-
ing cap (2).
For limit values see Tolerances and Wear Limits
List.

L92_23432

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 13

Installing main bearing cap


Wipe bearing shell mating faces on main bearing
cap.

CAUTION
Compressed air is highly pressurized.
Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Pressure must not exceed 3.0 bar.
Check mating faces on crankshaft bearing cap and
crankcase for cleanness; blow out with compressed
air if necessary.

Checking stud for main bearing cap.


Note: Remove stud only if loose or damaged.
Check removed studs only if they are to
be re-used.
Measure length L of the stud.
Lmax = from 347.5 mm to 348.5 mm, corresponds to
new manufacture.
Check that thread and shaft are in perfect
condition, replace stud if necessary, see also
Section C 011.05.10, Tightening process for
elongation of stud.

Measuring bearing cap guides


Note: Do not measure bearing cap guides with
crankcase installed in assembly dolly
(falsified values).
Using bore gauge (1), measure bearing cap guides
at upper and lower fits.
For permissible values, see Tolerances and Wear
Limits List.

L92_23435

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 14

Setting bore gauge


Adjust bore gauge (1) and dial gauge with adjusting
ring or micrometer to basic size of respective bore to
be measured.
Note: All dimensions and tolerances apply to
the crankcase with crankshaft bearing
caps fitted and tightened to specified
torque.

Measuring main bearing bore


Install main bearing cap as per instructions and
tighten, see C011.05.11.
Using a bore gauge (2), measure the main bearing
bore (1).
Enter measurement values in data sheet.
For measurement planes and limit values, see Toler-
ances and Wear Limits List.
If reconditioning is necessary, recondition only the
respective bearing in the crankcase to the next re-
pair stage.
Marking repair stage work on a main bearing bore
with numeral punches, at least 6 mm high;
at stage 1: + 0.5
at stage 2: +1.0
Marking location: At bottom of crankcase, respective
L92_23430
main bearing see Section C 011.05.06.
Note: If a new bearing cap is to be installed, its
position must be marked accordingly.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 15

Measuring camshaft bearing bush bore


Measure camshaft bearing bush bore (diameter B)
with bore gauge.
For limit values, see Tolerances and Wear Limits
List.
Replace camshaft bearing bush (2) if limit values are
exceeded.
After removing camshaft bearing bush, measure
main bore (diameter A) in crankcase (1).
If limit values are exceeded, recondition main bore to
next repair size.
Enter measurement values in data sheet.

Measuring crankcase bores for cylinder liners


Using bore gauge, measure upper and lower fits of
cylinder liner locating bores.
Enter measurement values in data sheet.
For limit values, see Tolerances and Wear Limits
List.
If limit values are exceeded, recondition bores to
next repair size.
Note: If reconditioning is necessary, only re-
condition the respective cylinder liner
bush bore in crankcase top and bottom
fits to next repair stage.
Marking repair stage work with numeral
punches, at least 6 mm high:
at stage 1: + 0.5
at stage 2: + 1.0
Marking location: at the top edge of the
crankcase side surface below the roof
surface, beside the affected cylinder.

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 16

C 011.05.10 Assembly

Installing end cover


Clean and degrease seating face on end cover and
bore in crankcase.
Coat seating face of cover with thread locking com-
pound.

L92_23421

Installing end cover


Coat seating surface of end cover with high-strength
thread-locking liquid Loctite 7061.
Using a mandrel, knock end cover into the crank-
case bore.
Note: If necessary (leaks, sealing surface dam-
age), the cover can be swaged in after it
has been knocked with a mandrel.


Installing camshaft bearing


Note: Make sure parts are perfectly clean. In-
1 stallation sequence of camshaft bearing,
starting from driving end, continuing in
direction of free end.
For installing the camshaft bearing bushes, the oil
pan mounting surface on the crankcase must be
horizontal and face upwards.
Check lube oil bores and ensure they are perfectly
clean and unobstructed, clean if necessary.
Beginning with the first camshaft bearing, screw the
stop and camshaft bearing alignment device (1) onto
the locating bore of the rocker shafts.

FG010019 a0

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 17

Fit plastic mandrel (2) on installation tool (1).

CAUTION
Nitrogen is liquid at 200 C.


1 Danger of freezing and suffocation!


2 Do not allow liquid nitrogen to come into contact
with parts of body (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ventilate working area well.


Fit chilled camshaft bearing bush so that spring-
loaded locating mandrel (3) of installation tool en-

3 gages in oil bore (arrow) of camshaft bearing bush.

FG010020 a0

Remove insertion mandrel from assembly tool.


Check position of crankshaft bearing oil bore in as-
sembly tool (arrow).

FG010021a0

Using the assembly tool (1), insert camshaft bearing


bush (2) from the outside into the camshaft basic
bore as far as it will go.
At the same time, the assembly tool is positioned by
the centring and positioning mandrel which are in-
serted as the camshaft bearing bush is fitted in the
stop (arrow).
Check that lube-oil bores in bearing bush and crank-
case are aligned.

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 18

Installing camshaft bearing No. 7


To install the last camshaft bearing (free end), install
stop and alignment device (1) from the outside on

the free end of the crankcase (2).

FG010023a0

Using the assembly tool (1), insert camshaft bearing


bush in the camshaft locating bore as far as it will
go.
At the same time, the assembly tool is positioned by
the centring and positioning mandrel which are in-

serted as the camshaft bearing bush is inserted in


1 the stop.
Check that lube-oil bores in bearing bush and crank-


case are aligned.



FG010022a0

Installing studs for crankshaft bearing cap


Clean threaded bore in crankcase and blow clear
with compressed air.
Check threaded bore with a new stud (1) for ease of
movement up to the thread end in the crankcase.
Coat stud thread on the journal side (arrow) with en-
gine oil.

L92_22980

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 19

Insert stud (3) with the journal side in the threaded


bore.
Screw in stud with installation tool (2) and torque
wrench (1) as far as it will go see overview drawing
C 010.

Installing main bearing cap


Note: Crankcase is upside down, with oil pan
mating face horizontal.

CAUTION
Components have sharp edges.
Risk of injury!
Handle components only when wearing protec-
tive gloves.
Allocate bearing cap according to crankcase marking
to respective bearing.
Note: Main bearing caps must not be inter-
changed!
Insert bearing cap into crankcase so that the mark-
ings on bearing cap and crankcase are on the same
2 side. If bearing cap movement is sluggish, knock it
with a copper hammer as necessary.

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 20

Install and loosely tighten all side socket-head


1 screws (2).
Fit all nuts (1) for main bearing cap and tighten by
hand.

FG030002a0

Beginning with the first bearing cap (driving end),


place support sleeve (2) of hydraulic screw preten-
sioner on studs (1) of respective main bearing cap.

Install hydraulic pretensioner (1) by hand until it is in


position.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 21

Connect high-pressure hose of the hydraulic hand


pump to hydraulic pretensioner.
Position magnetic-base indicator holder with dial
gauges on the crankcase support surface for exten-
sion measurement of the studs.

Position the two dial gauge styluses centrally on the


respective measuring point (arrow) on the face of the
sleeve measuring pin.
Set dial gauges with preload to zero.
Important: Initial assembly of studs.
Replace studs only in pairs.
Fit nuts but do not tighten, tighten studs
with hydraulic tensioning device:
Tightening process: Elongation
Pre-stretching of studs at 1500 bar hy-
draulic pressure(with hydraulic tensio-
ning device F6 557 186)
Detension studs
Pre-stretch as described above at 1500
bar
Detension studs
Further procedure described in following
text.

Operate hydraulic hand pump and elongate studs at


same time (max. 1.15 + 0.05 mm), use pin (arrow) to
fit nuts on crankshaft bearing cap (arrow).
Relieve tension on studs, mount dial gauges with
magnetic holders and hydraulic pretensioner on
studs of next adjacent bearing cap and install all nuts
in same order.
Note: Remaining elongation of studs after re-
lease: 0.9 mm + 0.05 mm
If remaining elongation of studs is outside tolerance,
release nuts, see C 031.05 .05 and repeat nut
tightening procedure; if necessary, replace studs.

FG010005 a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 22

Tighten side socket-head screws as per tightening


specifications, see overview drawing C 010.

FG030002a0
L92_22985

Clean and degrease crankcase mating face (1) for


block (driving end).
Coat mating face with surface sealant 5910 (arrows),
making sure that end faces are also coated.

L92_22985

Align block (1) on bores of securing screws (arrows)


in crankcase (2) and fit on crankcase surface coated
with surface sealant 5910.

L92_22985

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 23

Using socket-head screws (2), secure the block (1)


to the crankcase (3).
Using a straightedge, check the alignment of the
block to the crankcase.
The block surface must form a single plane with the
crankcase parting line so that the oil pan sits per-
fectly.

L92_22985

C 011.05.11 Installation
Installing oil filler neck, guide tube with oil dipstick
Note: Before installation, remove the plugs and adhesive tape strips that were fitted as a protection against
contamination.
Make sure parts are perfectly clean.

Installing oil filler neck, guide tube with oil dipstick


Note: Use new gaskets!
Install oil filler neck and guide tube tension-free as shown in the overview drawing, see C 011.05.01, and tighten.
Installing inspection port cover
Install oil filler neck and guide tube tension-free as shown in the overview drawing, see C 011.05.01, and tighten.
Note: Use new gaskets!



1
Installing cap
Make sure that oil chambers and oilways are per-

fectly clean.


Clean and degrease mating faces on crankcase and


cover (2) (arrows).
Coat O-ring (1) with petroleum jelly and insert into
groove in cover.



F011 0012a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 24

Coat mating face (2) on crankcase with surface seal-


ant (Loctite 5910).
Insert new O-rings (arrows) in oil transfer bores on
crankcase.
Insert assembly pins in the crankcase at two diag-
onally opposite corner points.
Screw in suitable lifting eyes.
Using the lifting appliance, fit the cap onto the as-
sembly pins and slowly lower onto the crankcase
support surface.
Install stop plate on face (1) of crankcase.
Align cover with stop plate.

Tighten the two hex screws which are opposite each


other in the middle of the cap.
Unscrew assembly pins.
Tighten all other hex screws, starting in the middle of
the cap and working spirally towards the outside in a
clockwise direction. (see tightening diagram oppo-
site).

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Group 011.05
Page 25

Coat O-ring with petroleum jelly and fit on end cover


(1).
Install end cover in oil gallery and secure with link
(2).
Note: Make sure parts are perfectly clean.

FG010008 a0

Removing crankcase from assembly dolly


Move lifting appliance and lifting ropes into position
at the crankcase. Ensure lifting ropes are equally
tensioned.

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

Release crankcase from assembly dolly and raise it


out.

C 011.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007

MR20108/00E 01.12 MTU


Section C Task Description
Group 011.05 Crankcase
Page 26

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Liner Group 013.05
Page 1

C 013.05 Cylinder Liner


C 013.05.01 Overview Drawing without Scraper Ring

1 Cylinder liner
2 Sealing ring (2), black

MR20108/00E 01.12 MTU


Section C Task Description
Group 013.05 Cylinder Liner
Page 2

Overview drawing with scraper ring

1 Cylinder liner
2 Scraper ring
3 Sealing ring (2), black

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Liner Group 013.05
Page 3

Cylinder liner (without scraper ring) in crankcase

1 Cylinder liner
2 Crankcase
3 Sealing ring
4 Sealing ring

Cylinder liner (with scraper ring) in crankcase

1 Scraper ring
2 Cylinder liner
3 Crankcase
4 Sealing ring
5 Sealing ring

MR20108/00E 01.12 MTU


Section C Task Description
Group 013.05 Cylinder Liner
Page 4

C 013.05.02 Special Tool


Designation Application Number

Removal tool for liner 1


Installation tool for liner 1
Removal tool for carbon scraper ring 1

C 013.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Remove engine B 003


x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions
x Drain engine coolant Operating Instructions
x Drain charge air coolant ** Operating Instructions
x Drain or draw off engine oil Operating Instructions
x x Remove air filter (if necessary) Operating Instructions
x x Remove exhaust crossover (if required) C 142.05.05
x x Remove exhaust turbochargers * C 101.05.05
x x Remove charge air manifold C 124.10.05
x x Remove cylinder head cover C 055.05.05
x x Remove charge air coolant lines (if required) C 203.25.05
x x Remove H.P. line C 073.05.05
x x Disconnect fuel return lines C 086.05.05
x x Remove exhaust manifold (if required) * C 142.05.05
x x Remove crankcase ventilation (if necessary) C 018.12.05
x x Remove exhaust distribution housing (constant-pressure manifolds) C 142.05.05
x x Remove valve drive C 055.05.05
x x Remove pushrods C 054.05.05
x x Remove H.P. line C 077.05.05
x x Remove cable connection (injector) C 077.05.05
x x Disconnect electric cables C 500.00.00
x x Remove cylinder head C 041.05.05
x x Remove cylinder head gasket C 041.05.05
x x Open inspection port cover, lower or remove oil pan as required C 014.05.05
x x Remove piston and conrod C 037.05.05
* Track dry (with uncooled exhaust manifold)
** TB version

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Liner Group 013.05
Page 5

C 013.05.05 Removal

Removing carbon scraper ring


Using removal tool (3), withdraw carbon-deposit
scraper ring (2) from fit of cylinder liner (1).

Removing cylinder liner


Mark installation position of cylinder liner in crank-
case (arrow).

F013 0027a0

Insert removal tool into cylinder liner and fit on bot-


tom collar of cylinder liner.
Take care that the oil spray nozzle is not damaged.
Position the fork of the removal tool only lightly so
that the liner is not displaced.
Rotate the removal tool spindle until the cylinder liner
is released from the crankcase bore.
Remove removal tool.
Remove cylinder liner from crankcase.
Remove sealing rings from cylinder liner.

F013 0023a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 013.05 Cylinder Liner
Page 6

C 013.05.08 Inspection and Repair

Clean cylinder liner and, using the magnetic crack-testing method with fluorescent magnetic powder, check for
cracks; replace component as necessary.
Check outer wall for pitting; replace cylinder liner if necessary .
If minor pitting is found, install cylinder liner rotated by 90.
If cylinder liner has to be turned for reinstallation, rehone liner bore.
Note: If cylinder liner is rehoned, install new piston rings. Similarly, rehone liner if new piston rings are in-
stalled.
Check sealing and mating faces for wear and damage; replace cylinder liner if necessary.
Replace sealing rings.
With cylinder liners with carbon scraper ring: Check carbon scraper ring for scores and pitting, replace if necessary.
Check floating mount of the carbon scraper ring in the cylinder liner. If the carbon scraper ring appears to jam,
measure the fit in the cylinder liner, replace carbon scraper ring if necessary.

Checking wear pattern of cylinder liners


Check wear face for flats, scores, cracks and pitting;
rehone or replace cylinder liner as necessary.
Check the reversing point of the first piston ring for
wear, replace cylinder liner if necessary.

Note: When cylinder liners have scraper rings,


honing is carried out with the scraper ring
removed. After honing, carefully clean the
transition from the honing pattern to the
mating face of the scraper ring.

F037 0012a0

When reusing cylinder liners which have not been


rehoned, the honing must be more or less clearly
recognisible over entire running surface.
There must be no signs of wear at reversing point of
initial piston ring.

F037 0011a0

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Liner Group 013.05
Page 7

Measure cylinder liner ID


Adjust bore gauge (1) and dial gauge with micro-
meter or gauge ring (2) to basic size for cylinder liner
as per Tolerances and Wear Limits List.

Measure cylinder liner I.D. with bore gauge.


For measuring points and limit values, see Toler-
ances and Wear Limits List.
Replace cylinder liner if measured values are ex-
ceeded.

FG 01 0030 a0

C 013.05.11 Installation

Check cylinder liner repair stage as per Tolerances


and Wear Limits List and assign according to crank-
case data sheet.
Wipe cylinder liner at lower fit (arrow) and at chamfer
inclination; then lightly coat with petroleum jelly.

MR20108/00E 01.12 MTU


Section C Task Description
Group 013.05 Cylinder Liner
Page 8

Fit sealing rings (2), bottom, on grooves on cylinder


liner (1).
Note: Fit the sealing rings so that the flat side
lies against the cylinder liner and the
rounded side lies against the crankcase.

Insert cylinder liner in the crankcase


Note: If there is minor cavitation on the outer
wall of the cylinder liner, rotate the cylin-
der liner 90 (arrows) to the old installa-
tion position before installing (for this, see
markings made during disassembly).

On the opposite side, insert screws (1) of insertion


1 tool into threaded bores for cylinder head screws.
Fit pressure plate (3) on cylinder liner.
2 Turn spindle (2) in clockwise direction to press cylin-
der liner into crankcase bore.

1
3

F013 0024a0

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Liner Group 013.05
Page 9

Measuring cylinder liner ID


Adjust bore gauge and dial gauge with micrometer or
gauge ring to basic size for cylinder liner as per Tol-
erances and Wear Limits List.
Using a bore gauge, measure cylinder liner ID at 4
points offset at 90 with respect to each other.
For measuring points and limit values, see Toler-
ances and Wear Limits List.
Note: When cylinder liners have carbon scraper
rings, make sure that the measurement
planes are below the fit for the carbon
scraper ring.
The carbon scraper ring is not inserted in
the cylinder liner until the pistons have
been installed, see C 037.05.
Enter measurement values in data sheet.
If an out-of-round is measured, remove cylinder liner
and measure cylinder liner ID and OD

Installing carbon scraper ring


Spray cylinder liner and carbon scraper ring with en-
gine oil.
Insert carbon scraper ring into fit of cylinder liner.

MR20108/00E 01.12 MTU


Section C Task Description
Group 013.05 Cylinder Liner
Page 10

C 013.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Perform operations as per Assembly Plan B 005


x Install engine B 007
x x Install piston and conrod C 037.05.11
x x Install oil pan (if necessary) or close inspection port cover C 014.05.11
x x Install cylinder head C 041.05.11
x x Install pushrods C 054.05.11
x x Install valve drive C 055.05.11
x x Install cable connection (injector) C 077.05.11
x x Adjust valve clearance C 055.05.11
x x Install fuel return lines (if necessary) C 086.05.11
x x Install H.P. line C 077.05.11
x x Connect electric cables C 075.05.11
x x Install cylinder head cover C 055.05.11
x x Install charge air manifolds C 124.05.11
x x Install exhaust manifold (if required) * C 142.05.11
x x Install turbocharger * C 101.05.11
x x Install exhaust distribution housing (constant-pressure manifolds) C 142.05.11
x x Install exhaust crossover C 142.05.11
x x Install crankcase ventilation (if necessary) C 018.12.11
x x Connect electric cables
x x Install air filter (if necessary) Operating Instructions
x Fill oil system with engine oil Operating Instructions
x Fill engine coolant system Operating Instructions
x Fill charge air coolant system ** Operating Instructions
x Release engine start Operating Instructions
* Track dry (with uncooled exhaust manifold)
** TB version

MTU 01.12 MR20108/00E


Task Description Section C
Oil Pan Group 014.05
Page 1

C 014.05 Oil Pan


C 014.05.01 Overview Drawing, Grey Cast Iron

1 Oil pan 11 Suction basket


2 Rubber profile 12 Hex screw
3 Hex screw 13 Washer
4 Washer 14 Plug-in pipe (intake pipe)
5 Hex screw 15 O-ring
6 Flange
16 Connector
7 Gasket
17 Hex screw
8 Socket-head screw
18 Washer
9 Plug
19 Taper pin
10 Sealing ring

MR20108/00E 01.12 MTU


Section C Task Description
Group 014.05 Oil Pan
Page 2

Tightening diagram, oil pan (cast steel)

Tighten four hex screws by hand at the corner points of the oil pan (11, 24) diagonally and evenly so that the
rubber profile settles.
Insert two securing screws (1 to 10) in the equipment carrier and pretighten to 60 Nm.
Release two securing screws (1 to 10) and tighten to torque of 30 Nm.
Tighten four hex screws at the corner points (11, 24) of the oil pan to respective specified final torques diagonally
and evenly, hex screws (11, 24) to 42 + 5 Nm.
Tighten eight hex screws at the front face of the oil pan, driving end, (25 to 32) to 42 Nm + 5 Nm.
Tighten hex screws (11 to 24) to respective specified final tightening torque 45 Nm + 5 Nm.

MTU 01.12 MR20108/00E


Task Description Section C
Oil Pan Group 014.05
Page 3

C 014.05.02 Special Tool


Designation Application Number

Taper reamer for taper pin 10 x 65 in accordance with


1
DIN 258

C 014.05.02 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions
x Drain engine coolant (as required) Operating Instructions
x Drain or draw off engine oil Operating Instructions
x x Remove gear case C 024.05.05
x x Remove fuel delivery pump (as required) C 081.05.05
x x Release or remove oil filler neck C 011.05.05
x x Remove engine mounts, free and driving ends C 231.05.05

MR20108/00E 01.12 MTU


Section C Task Description
Group 014.05 Oil Pan
Page 4

C 014.05.05 Removal

Removing oil pan



Install engine in assembly dolly and turn by 180 .
Remove taper pin see following illustration.



1
Remove all hex screws for oil pan (1).


Unscrew plugs at the drain points of the oil pan and
insert two suitable eyebolts (arrow) in the oil pan.

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

F0140012b1 Carefully raise oil pan with lifting ropes (1) and crane
and lower onto suitable support.
Remove eyebolts and remove flange from the front
face.
Remove rubber profile.

Removing taper pins, engine A and B sides.


Remove tapered pin (arrow).

MTU 01.12 MR20108/00E


Task Description Section C
Oil Pan Group 014.05
Page 5

Remove suction basket


1
Unscrew and remove hex screws (3) with washers,
remove suction basket (4) with connector (2) and
intake pipe (1) from oil pan.
Remove O-rings.
Remove connector see overview drawing


C 014.05.01, cast aluminium or cast steel oil pan.

3

3


4
F0140003a0

C 014.05.08 Inspection and Repair


Note: Make sure parts are perfectly clean.
Clean oil pan and carefully remove any remaining detergent.
Check oil pan and attachments for cracks using surface crack-testing method with red penetrant dye and repair as
necessary.
Replace component if cracks are found.
If oil pan must be reconditioned, contact MTU or DDC.
Check mating face of oil pan with crankcase for surface irregularities.
In event of irregularities over 0.2 mm, recondition mating face.
Check all mating and sealing faces and the rubber profile support groove; rub down with emery cloth or an oilstone
as necessary.
Check all parts for wear and damage; replace components as necessary.
Check condition of threads in tapped bores; replace threaded inserts if necessary.
Check suction basket for contamination and damage; replace the suction basket if the mesh grill is found to be
damaged (pierced).
Replace gaskets, sealing rings and rubber profile.

MR20108/00E 01.12 MTU


Section C Task Description
Group 014.05 Oil Pan
Page 6

C 014.05.11 Installation
Note: Always make sure that all components are perfectly clean.
Cast aluminium and cast steel oil pan, see also overview drawing C 014.05.01 for definition of differ-
ences.



2 Installing suction basket


1 Coat O-ring (3) with petroleum jelly and insert into
3 groove of connector (2).
Clean suction basket (1), mating face (arrow), and
install suction basket with mating face on connector
see next illustration.

F0140004a0

Screw on suction basket (1) with connector (2), hex

2
screws (4) and washers.

3
Fit intake pipe (3), O-rings and coat with petroleum
jelly.

Fit intake pipe in connector, hold suction basket and


1 spacer firmly and secure with hex screws (1) and
bracket (2).

F0140005a0

MTU 01.12 MR20108/00E


Task Description Section C
Oil Pan Group 014.05
Page 7

Press suction basket with connector and intake pipe



into oil pan (arrow).
Install hex screws (1) with washers and tighten.



1 F0140006a0






Installing oil pan
Clean and degrease mating faces of oil pan upper


section and crankcase.
Fit rubber profile carefully in groove provided (see


arrow) on oil pan see next illustration.






F0140006a0

Note: Description applies to cast aluminium


and steel oil pan.
(1), (3) Flange surface
(2) Contact area, rubber profile
(4) Oil pan

MR20108/00E 01.12 MTU


Section C Task Description
Group 014.05 Oil Pan
Page 8

Note: Description applies to cast aluminium and


steel oil pan.
Spray flange surface with Loctite cleaner and clean.
Engine sides A and B, woollen thread only when in-

stalled.



Move the woollen thread, which protrudes on both
sides of the equipment carrier (arrow), to along the
parting line of crankcase/equipment carrier.

FG01 0044 a0

Note: Description applies to cast aluminium and


steel oil pan.
Embed the woollen-thread ends that have been
moved to both sides of the equipment carrier in sur-
face sealant 5910; apply a bead of approx. 5 mm.
Note: Apply surface sealant 5910 (black) di-


rectly before assembly to the oil pan. Sur-
face sealant must not be allowed to dry.





FG01 0043 a0

Note: Description applies to cast aluminium and


steel oil pan.
Coat parting line/crankcase with surface sealant


5910 (arrow); apply a bead of approx. 5 mm.


Note: Apply surface sealant 5910 (black) di-


rectly before assembly to the oil pan. Sur-
face sealant must not be allowed to dry.

F0140008a0

MTU 01.12 MR20108/00E


Task Description Section C
Oil Pan Group 014.05
Page 9

Note: Description applies to cast aluminium oil


pan.
Leave the crankcase/oil pan parting line blank,
viewed from equipment carrier, until after the sixth
bore (see double arrow, corresponds to a length of
approx. 360 mm) see next illustration.
Note: The bore for the taper pin was included
when bores were counted.

Note: Description applies to cast aluminium oil


pan.
Coat flange surface on equipment carrier (3) with
Loctite 518 (red).
Wipe off excess Loctite 518 (red) from free flange
surfaces with lint-free cloth, or clean with Loctite
cleaner.
Coat rotating contact area (5) of rubber profile to
crankcase with Loctite 5910, as described above.
Flange surface of free end, dimension A equals
360 mm length, must be smooth.
Coat remaining oil pan flange surfaces (5).
Note: Apply surface sealant 5910 (black) di-
rectly before assembly to the oil pan. Sur-
face sealant must not be allowed to dry.

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

MR20108/00E 01.12 MTU


Section C Task Description
Group 014.05 Oil Pan
Page 10

Insert two suitable eyebolts into oil pan bores for


blanking plugs.
Using the lifting ropes and crane, lift the oil pan and
carefully place on the mating face of the crankcase.
At the same time, align the oil pan to the bores in the
mating face of the crankcase.
Tighten cast aluminium oil pan as per tightening
diagram see respective overview drawing
C 014.05.01.
Note: After installing the oil pan and shutting
down the engine in installation position, it
is advisable to secure the engine on a
firm surface horizontal surface against
toppling.
Follow instructions in engine installation
drawing.




Note: Description applies to cast steel oil
pan.


Coat flange surface on equipment carrier with
Loctite 518 (red).


Wipe off excess Loctite (red) from free flange
surfaces with lint-free cloth, or clean with Loctite

cleaner.
*Fit rubber profile (arrow) carefully in oil pan
groove.

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

Insert two suitable eyebolts into oil pan bores for


blanking plugs.
Using the lifting ropes and crane, lift the oil pan
and carefully place on the mating face of the
crankcase. At the same time, align the oil pan to
the bores in the mating face of the crankcase.
Secure cast steel oil pan as per respective
tightening diagram see C14.05.01.
Note: After installing the oil pan and shut-
ting down the engine in installation
position, it is advisable to secure the
engine on a
firm surface
horizontal surface
against toppling.
Follow instructions in engine installa-
tion drawing.

MTU 01.12 MR20108/00E


Task Description Section C
Oil Pan Group 014.05
Page 11

Note: Description applies to cast aluminium


and steel oil pan.
(1), (3) Flange surface
(2) Contact area, rubber profile
(4) Oil pan

Screw in hex screw with appropriated washers


(arrow) and tighten as per following instructions
see overview drawing C 014.05.01.
Note: Washers differ in thickness (cast alumin-


ium or cast steel oil pan).

F0140009a0

Installing taper pins in oil pan


Note: During initial assembly, the oil pan is se-
cured to the crankcase on the A and B
side with one taper pin respectively (for
the position of taper pins, see picture op-
posite).
With new oil pans from the spare parts
store, there is not yet a bore for the taper
pins.

MR20108/00E 01.12 MTU


Section C Task Description
Group 014.05 Oil Pan
Page 12

Mount taper pin 10 x 65 with standardised taper-


ing C = 1:50 based on DIN 258 as follows:
Predrill taper pin (2) locating bore in the oil pan
(3) to a diameter of 10 mm (corresponds to the
smallest taper pin diameter). At the same time,
position the drill in the locating bore for the taper
pin in the crankcase (1). Drilling depth as per
illustration opposite.
Note: Make sure parts are perfectly clean.
All inlets and oil-carrying components
must be sealed.

CAUTION
Compressed air is highly pressurized.
Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Pressure must not exceed 3.0 bar.
Clean locating bore and ream with a suitable
taper reamer. Clean locating bore once again
carefully.
Drive taper pin in with gentle knocks of a
hammer until the specified alignment between
taper pin thread and locating bore has been re-
ached.
Shorten the fitted taper pin at thread end so that
the thread projection is A = 8 mm + 1 mm.

MTU 01.12 MR20108/00E


Task Description Section C
Oil Pan Group 014.05
Page 13

C 014.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007
x x Install gear case C 024.05.11
x x Install fuel delivery pump (as required) C 081.05.11
x x Install oil filler neck C 011.05.11
x x Install engine mounts, free and driving ends C 231.05.11
x Fill oil system with engine oil Operating Instructions
x Fill engine coolant (as required) Operating Instructions
x Release engine start Operating Instructions
x Vent fuel system Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 014.05 Oil Pan
Page 14

MTU 01.12 MR20108/00E


Task Description Section C
Lifting Attachments for Engine and Running Gear Group 015.05
Page 1

C 015.05 Lifting Attachments for Engine and Running Gear


C 015.05.01 Overview Drawing

1 Cylinder head screw


2 Lifting eye

MR20108/00E 01.12 MTU


Section C Task Description
Group 015.05 Lifting Attachments for Engine and Running Gear
Page 2

Engine lifting attachments, driving end

1 Lifting eye
2 Thrust washer
3 Cylinder head screw

MTU 01.12 MR20108/00E


Task Description Section C
Lifting Attachments for Engine and Running Gear Group 015.05
Page 3

Engine lifting attachments, free end

1 Lifting eye
2 Thrust washer
3 Cylinder head screw

MR20108/00E 01.12 MTU


Section C Task Description
Group 015.05 Lifting Attachments for Engine and Running Gear
Page 4

C 015.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Remove engine B 003


x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions

C 015.05.05 Removal

Removing engine lifting attachment


Release cylinder head screws (2) that connect lifting
eye (3) to the cylinder heads.
Remove cylinder head screws and thrust washers
(1).
Remove lifting eye.

C 015.05.08 Inspection and Repair

Clean all components and visually inspect for damage and defects; repair as necessary.
Using the magnetic crack-testing method with fluorescent powder, check lifting eye for cracks; replace with original
spare part if cracks are detected.
Note: Alignment work or repair welding is not permitted at the lifting eye!
Check condition of mating faces and/or screw-down surfaces; rub down with oilstone if necessary.
Check thread in cylinder head for ease of movement; rechase as necessary.

MTU 01.12 MR20108/00E


Task Description Section C
Lifting Attachments for Engine and Running Gear Group 015.05
Page 5

Checking cylinder head screws


Check that thread and screw head mating face are
in perfect condition; replace screw if necessary.
Measure shaft length L of the cylinder head screws
with depth gauge.
For max. permissible shaft length see
C 041.05.01.

C 015.05.011 Installation

Installing engine lifting attachment


Place lifting eye (3) on cylinder head edges and align
to the bores for the cylinder head screws.
Screw in cylinder head screw (2) with thrust washer
(1) and tighten in accordance with Tightening Spec-
ification, see C 041.05.01.
Note: If, at both of the cylinder heads that carry
the lifting eye, only the cylinder head
screws at the lifting eye itself were re-
leased, then it is sufficient to tighten both
of these cylinder head screws to torque /
additional angle of rotation in accordance
with C 41.05.01.
If, at both of the cylinder heads that carry
the lifting eye further cylinder head
screws were released, the cylinder head
gasket must be replaced, C 041.05.11.

C 015.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Perform operations as per Assembly Plan B 005


x Install engine B 007
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 015.05 Lifting Attachments for Engine and Running Gear
Page 6

MTU 01.12 MR20108/00E


Task Description Section C
Connecting Housing, Driving End Group 016.30
Page 1

C 016.30 Connecting Housing, Driving End


C 016.30.01 Overview Drawing

1 Flywheel housing
2 Hex screw
Lubricant: Engine oil
Tightening torque: as per Table A 003.
3 Hex screw
Lubricant: Engine oil
Tightening torque: as per Table A 003.
4 Hex screw
Lubricant: Engine oil
Tightening torque: as per Table A 003.
5 Hex screw
Lubricant: Engine oil
Tightening torque: as per Table A 003.
6 Plug

MR20108/00E 01.12 MTU


Section C Task Description
Group 016.30 Connecting Housing, Driving End
Page 2

Flywheel housing with attachments

1 Flywheel housing 11 End cover


2 Dead-centre indicator 12 End cover
3 Hex screw 13 Hex screw
4 Washer 14 Washer
5 Hex screw 15 Spacer bush
6 Spring washer 16 Hex screw
7 Hex screw 17 Spring washer
8 Hex screw
9 O-ring
10 End cover

MTU 01.12 MR20108/00E


Task Description Section C
Connecting Housing, Driving End Group 016.30
Page 3

Guide bush layout for installation / removal of flywheel housing

1 Support 5 Nut
2 Guide bush 6 Hex socket screw
3 Guide 7 Flange
4 Washer 8 Flange

MR20108/00E 01.12 MTU


Section C Task Description
Group 016.30 Connecting Housing, Driving End
Page 4

C 016.30.02 Special Tool


Designation Application Number

Guide bush, flywheel housing 1

Support 1
Socket-head screws 6

Press-fitting tool, radial-lip shaft seal 1

Flange 1
Flange 1

C 016.30.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Remove engine B 003


x Perform operations as per Disassembly Plan B 004
x x Remove flywheel C 032.05.05

C 016.30.05 Removal


1 Removing radial-lip shaft seal

Note: The engine is turned 180_, i.e. oil pan


2 side is at the top.
Using a suitable mandrel and hammer, knock shaft


seal (2) out of the flywheel housing (1).
3


Mount flanges (3 and 4) on crankshaft end.
Unscrew the two hex screws marked with an arrow



4 in the flywheel housing inner circle.

FG030032aO

MTU 01.12 MR20108/00E


Task Description Section C
Connecting Housing, Driving End Group 016.30
Page 5

Push support (1) onto guide bush (2).


1
Insert the positioning mandrels (3) of the support in


2 the bores of the hex screws that were previously re-
leased and press the support against the flywheel
housing as far as it will go.
Note: The TOP mark at the front side of the
support must face upwards, i.e. in the
direction of the oil pan (see double ar-
rows).
If the guide bush jams and does not align


in the flywheel housing bore, two long
guide pins can also be inserted in the

3 screw bores in order to remove the fly-


wheel housing.

FG 01 0052 a0

1
Suspended load.
WARNING
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.


Never stand beneath a suspended load.

Screw lifting appliance (1) to flywheel housing and,


using a lightly tensioned rope, hang onto crane.
Unscrew all of the hex screws that secure the fly-
wheel housing to the crankcase (see overview draw-
ing C 016.30.01).
Remove flywheel housing (in direction of arrow) from
crankcase.

FG 01 0075 a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 016.30 Connecting Housing, Driving End
Page 6

C 016.30.06 Disassembly

Remove end cover and plugs (see overview draw-


ing)
Remove dead-centre indicator (1) from flywheel
housing (2).

C 016.30.08 Inspection and Repair

Clean all components and visually inspect damage and defects; repair as necessary.
Using the magnetic crack-testing method with fluorescent powder, check lifting carrier and eyebolts for cracks; re-
place components if cracks are detected.
Check dead-centre indicator for damage. Do not straighten dead-centre indicator if it is damaged or bent but re-
place with a new part.
Check condition of mating faces and/or screw-down surfaces; rub down with oilstone if necessary.
Check condition of threads; rechase threads or replace component if necessary.

Measuring crankshaft bore in flywheel housing


Adjust bore gauge (1) and dial gauge with micro-
meter or gauge ring (2) to basic size for crankshaft
bearing bore as per Tolerance and Wear Limits List.
Using a bore gauge, measure diameter of crankshaft
bore at flywheel housing.
Enter measurement values in data sheet.
For measuring points and limit values, see Tolerance
and Wear Limits List.
Replace equipment carrier if limit values are ex-
ceeded.

MTU 01.12 MR20108/00E


Task Description Section C
Connecting Housing, Driving End Group 016.30
Page 7

C 016.30.10 Assembly

Fit dead-centre indicator (1) to flywheel housing (2).

Screw on cover (2).


Preclean sealing surface between flywheel housing
and crankcase with Loctite cleaner.
Coat sealing surface evenly with surface sealant 518
(1).

Spread surface sealant 518 evenly on sealing sur-


face (arrows).
Coat O-rings (1) with petroleum jelly and insert into
bores.

MR20108/00E 01.12 MTU


Section C Task Description
Group 016.30 Connecting Housing, Driving End
Page 8

C 016.30.11 Installation

Clean sealing surface (arrows) on crankcase (1) with


Loctite cleaner.
Screw guide bush (2) onto flange at crankshaft end.

WARNING

1 Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.

Never stand beneath a suspended load.

2
Place support (2) on the flywheel housing.

Suspend flywheel housing from crane with lifting


gear (1).


Install flywheel housing with support on guide bush
3 (3) and push in direction of crankcase up to stop.
Screw hex screws into designated bores hand-tight
(see overview drawing, C 016.30.01).
FG01 0075 a0
Tighten two opposing hex screws in the inner circle
(arrow) of the flywheel housing to specified torque.
Remove support from flywheel housing and screw
the hex screws in the bores as they become visible.
Tighten all hex screws for securing flywheel housing
and crankcase (see overview drawing, C 016.30.01)
to specified torque.

MTU 01.12 MR20108/00E


Task Description Section C
Connecting Housing, Driving End Group 016.30
Page 9

Note: Firstly, tighten hex screws (item 2 in over-


view drawing C 016.30.01) in the inner
circle of flywheel, then tighten all hex
screws in interior of flywheel housing
(item 3 in overview drawing); finally,
tighten the screws at the outer rim of the
flywheel housing (item 4 in overview
drawing). Tighten all hex screws clock-
wise.

Carefully remove excessive surface sealant from the

parting line between flywheel housing (1) and oil pan


mating face at the crankcase (2) (arrow).

FG 01 0053 a0

C 016.30.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Perform operations as per Assembly Plan B 005


x Install engine B 007
x Release engine start Operating Instructions
x x Install flywheel C 032.05.11

MR20108/00E 01.12 MTU


Section C Task Description
Group 016.30 Connecting Housing, Driving End
Page 10

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10
Page 1

C 018.10 Crankcase Ventilation


C 018.10.01 Overview Drawing, Driving End

1 Pipe 11 Clamp 21 Pipe 31 Pipe clamp half


2 Pipe 12 Washer 22 Nut 32 Pipe clamp half
3 Gasket 13 Spacer bushing 23 Pipe 33 Grommet
4 Socket-head screw 14 Hex screw 24 Nut 34 Hex screw
5 Rubber sleeve 15 Hex nut 25 T-piece 35 Pipe
6 Clamp 16 Bracket 26 Rubber sleeve 36 Reduction union
7 Pipe 17 Hex screw 27 Clamp 37 Sealing ring
8 Gasket 18 Guide sleeve 28 Pipe 38 Flange
9 Hex socket screw 19 Rubber sleeve 29 Bracket 39 Gasket
10 Oil separator 20 Clamp 30 Bracket 40 Hex screw

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 Crankcase Ventilation
Page 2

C 018.10.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Remove engine B 003


x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions

C 018.10.05 Removal



1 2
Release clamps (1) and fit rubber sleeve (3 ) over
remaining pipe end (2).
Note: Dismantling refers to engine side, left and
right.


F0180015b1

1 Release clamps (2) and fit rubber sleeve (1 ) over


remaining pipe end (3).
Remove piping system.
Note: Dismantling refers to engine side, left and
right.

F0180016b1

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10
Page 3

1 Release clamps (arrow) and fit rubber sleeves over re-


maining pipe.
Unscrew hex screws (2), remove clamps with oil sep-
arator (1) and spacer sleeves.
2
2

F0180017b1

Unscrew hex sockets (1) and remove piping system


(2), left engine side.

F0180018b1

Unscrew hex sockets (1) and remove piping system,


right engine side.

F0180019b1

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 Crankcase Ventilation
Page 4

Disconnect piping system (2) at T-piece.


2
Remove pipe clamp halves (1), disconnect line (3) at


1
partition area (4) and remove.

F0180034b1




1
2
Remove pipe clamp halves (2), disconnect line (1) at
partition area to oil pan and remove.

F0180035a0



Unscrew hex screw (1), withdraw sleeve (2) from oil
2


1 separator and remove.
Note: Sleeve is not included in scope of delivery
of new oil separator.

F0180060a0

Note: After removal, seal all connections with suitable plugs.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10
Page 5

C 018.10.08 Inspection and Repair


Note: Make sure that air-carrying components are perfectly clean.
Clean all components.
Replace oil separator.
Dispose of parts in accordance with local regulations.
Visually inspect components for damage and wear; replace components as necessary.
Check sealing and mating faces for damage and defects; rub down with an oilstone or replace parts if necessary.
Check pipes for damage, repair if necessary. Check for leaks in water bath, using compressed air which contains
corrosion inhibitor.

WARNING
Compressed air is highly pressurized.
Risk of injury! Pressure must not exceed 0.5 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.

Air test pressure: 0.5 bar


Water temperature min. 30 C, max. 40 C.

WARNING
Hydrochloric acid is extremely caustic. Risk of injury and suffocation!
Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Ventilate working area well.

After welding or hot-bending pipework, allow pipework to cool slowly and then pickle with a hydrochloric acid sol-
ution (9 parts water and 1 part hydrochloric).
Pickling period up to 2 hours depending on layer of scale or rust.

CAUTION
Compressed air is highly pressurized. Risk of injury!
If compressed air is used for blowing out or blow-drying components, always wear protective goggles
or safety mask. Pressure must not exceed 3.0 bar.

After pickling, wash lines with hot water and blow dry with compressed air.
Preserve lines in oil bath and allow to drip dry.
Check condition of threads; rechase threads if necessary or replace threaded inserts if necessary.
Replace gaskets and O-rings.

C 018.10.11 Installation
Note: Prior to installation, remove all blanking plugs and ensure oil-carrying components are perfectly clean.
Install all pipes tension-free.

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 Crankcase Ventilation
Page 6

Engine side, right


Fit pipe (arrow) with new gasket, see overview drawing
C 018.05.01.

Slide rubber sleeves over pipe end and loosely fit


clamps over rubber sleeve.

F0180020b0

Ensure pipes (1) and (2) are free of tension when in-
stalled. Mount pipe clamp halves with rubber grommet
and hex screw. Tighten nuts on piping system.

F0180036b0

Ensure pipework (1) is free of tension when installed.


Mount pipe clamp halves with rubber grommet and hex
screw. Tighten nuts on piping system.


1 Hold reduction union firmly in position.

F0180037b1

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10
Page 7

Engine side, left


Fit pipe (arrow) with new gasket, see overview drawing
C 018.05.01.
Slide rubber sleeves over pipe end and loosely fit
clamps over rubber sleeve.

F0180021bo

Coat O-ring (arrow) with denaturated ethanol. Insert


sleeve, see next illustration.
Note: Denaturated ethanol acts as an anti-fric-
tion coating during fitting.

Insert sleeve (1) and tighten with hex screw (2).

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 Crankcase Ventilation
Page 8

Mount clamps (3) with spacer sleeves (1) and hex


1 2
screws (2) on intercooler retainer but do not fully

3 tighten.
Mount oil separator (4) and align, see overview draw-
ing C 018.05.01.

F0180022b1



1
Fit rubber sleeves (2) and (3) over the pipe ends and
tighten using suitable pipe clamps, see overview draw-


ing C 018.05.01.


2 Tighten hex screws (1) with clamps and spacer
sleeves, see overview drawing C 018.05.01.

F0180023b1



Mount rubber sleeve (3) with clamps (1).
1


2 Note: Installation refers to engine side, left and
right.
Ensure that pipe (2) is installed free of
tension.

F0180015b1

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10
Page 9


Mount rubber sleeve (1) with clamps (2).


1
Note: Installation refers to engine side, left and
right.
Ensure that pipe (3) is installed free of
tension.

F0180016b1

C 018.10.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Perform operations as per Assembly Plan B 005


x Install engine B 007
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 Crankcase Ventilation
Page 10

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10a
Page 1

C 018.10 a Crankcase Ventilation


C 018.10.01 a Overview Drawing, Free End

1 Oil separator 10 Clamp 19 Pipe clamp half 28 Nut


2 Bracket 11 Spacer sleeve 20 Hex nut 29 Reduction union
3 Hex screw 12 Spacer sleeve 21 Grommet 30 Sealing ring
4 Hex screw 13 Hex screw 22 Hex screw 31 Pipe clamp half
5 Guide sleeve 14 Hex nut 23 Rubber sleeve 32 Grommet
6 Rubber sleeve 15 Oil line 24 Clamp 33 Hex screw
7 Clamp 16 Nut 25 T-piece 34 Bracket
8 Pipe 17 Oil line 26 Oil line
9 Hex screw 18 Nut 27 Sealing cone

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 a Crankcase Ventilation
Page 2

C 018.10.04 a Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Remove engine B 003


x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions

C 018.10.05 a Before-Removal Operations


1
1
Release clamps (1) and fit rubber sleeves (2 ) over
remaining pipe end.



2 2

F0180024b1

Unscrew hex screws (1), remove pipe clamp halves,



1
2 release clamps (3) and fit rubber sleeve (4) over the

3 remaining pipe end.


Remove pipe (2) from left engine side.

F0180025b1

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10a
Page 3

Unscrew hex screws (3), remove pipe clamp halves,


1
release two clamps (1) and fit rubber sleeve over the


2 remaining pipe end.
Remove pipe (2) from right engine side.

F0180026b1

Release hex screws (1) from clamps.


Unscrew hex screws (3) from pipe retainer (2), press
off pipe retainer to remove.

F0180027b1

Release clamp(s) from rubber sleeve(s) (1) and (2). Fit


rubber sleeve(s) over remaining pipe(s).



2
F0180028b1

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 a Crankcase Ventilation
Page 4

Remove pipe clamp halves (2) and separate pipe (3)


1
from nut (1).



3

2

F0180036b1

Remove pipe clamp halves (1) and separate pipe (3)


from nut (1).



3


2

F0180037b1


Unscrew hex screws (2), remove clamps (3) with oil


separator (1) and spacer sleeves.
1



3


2

F0180029b1

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10a
Page 5

Unscrew hex screw (1), withdraw sleeve (2) from oil

1
2 separator and remove.
Note: Sleeve is not included in scope of delivery
of new oil separator.

F0180060a0

Note: After removing lines, seal all open connections by installing suitable plugs.

C 018.10.08 a Inspection and Repair


Note: Make sure that air-carrying components are perfectly clean.
Clean all components.
Replace oil separator.
Dispose of parts in accordance with local regulations.
Visually inspect components for damage and wear; replace components as necessary.
Check sealing and mating faces for damage and defects; rub down with an oilstone or replace parts if necessary.
Check pipes for damage, repair if necessary. Check for leaks in water bath, using compressed air which contains
corrosion inhibitor.

WARNING
Compressed air is highly pressurized.
Risk of injury! Pressure must not exceed 0.5 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.

Air test pressure: 0.5 bar


Water temperature min. 30 C, max. 40 C.

WARNING
Hydrochloric acid is extremely caustic. Risk of injury and suffocation!
Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale.
Always wear protective clothing, protective gloves and protective goggles/safety mask.
Ventilate working area well.
After welding or hot-bending pipework, allow pipework to cool slowly and then pickle with a hydrochloric acid sol-
ution (9 parts water and 1 part hydrochloric).
Pickling period up to 2 hours depending on layer of scale or rust.

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 a Crankcase Ventilation
Page 6

CAUTION
Compressed air is highly pressurized. Risk of injury!
If compressed air is used for blowing out or blow-drying components, always wear protective goggles
or safety mask. Pressure must not exceed 3.0 bar.

After pickling, wash lines with hot water and blow dry with compressed air.
Preserve lines in oil bath and allow to drip dry.
Check condition of threads; rechase threads if necessary or replace threaded inserts if necessary.
Replace gaskets and O-rings.

C 018.10.11 a Installation
Note: Prior to installation, remove all plugs and ensure they are perfectly clean.
Install all pipes tension-free.

Coat O-ring (arrow) with denaturated ethanol. Insert


sleeve, see next illustration.
Note: Denaturated ethanol acts as an anti-fric-
tion coating during fitting.

Insert sleeve (1) and tighten with hex screw (2).

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10a
Page 7

Mount clamps (4) with spacer sleeves (arrow) and hex



1
screws (2) on retainer (3) do not fully tighten.
Mount oil separator (1) and align, see overview draw-
ing C 018.05.01.a.


2
3

F0180031b1

Check mounting surface, clean if necessary.


Coat mounting surface of pipe retainer (4) with Loctite
5910 and fit pipe retainer with hex screws (3) on cool-
ant distribution housing. Fit rubber sleeve(s) (arrow)
over the pipe(s) (2) and mount with clamp(s) (1).

F0180038b1

Fit rubber sleeves (1) and (2) over the respective join-
ing sockets and secure with clamps, see overview
drawing C 018.05.01 a.



2
F0180028b1

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 a Crankcase Ventilation
Page 8

Mount pipe (3) with pipe clamp halves (2) and pipe


1
loosely at the partition area (1).



3


2

F0180036b1

Mount pipe (2) with pipe clamp halves (1) on equipment


carrier. Tighten nut (3), holding reduction union firmly


in place, see overview drawing C 018.10.01 a.
1 Tighten nut and pipe clamp halves and pipe (2) at the
partition areas.



3 F0180037b1

Engine side, right


Align pipe (1) and mount pipe clamp halves (2) but
do not yet tighten.
Fit rubber sleeves over the pipe ends.
Mount clamps (arrow) and tighten pipe clamp halves
with hex screws on heat exchanger housing.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.10a
Page 9

Engine side, left


1
2 Align pipe (2) and mount pipe clamp halves (1).

Fit rubber sleeves over the pipe ends.


Mount clamps (arrow) and tighten pipe clamp halves



with hex screws on heat exchanger housing.

F0180033b1

C 018.10.12 a After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Perform operations as per Assembly Plan B 005


x Install engine B 007
x Install engine B 007
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.10 a Crankcase Ventilation
Page 10

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.12
Page 1

C 018.12 Crankcase Ventilation


C 018.12.01 Overview Drawing Version I

1 Pipe system assembly 11 Pipe system assembly 21 Grommet


2 Bracket 12 Reduction union 22 Hex screw
3 Pipe clamp half 13 Sealing ring 23 Rubber sleeve
4 Grommet 14 Bracket 24 Clamp
5 Hex screw 15 Pipe clamp half 25 Pipe system assembly
6 Pipe system assembly 16 Grommet 26 Nut
7 Spacer bushing L = 62 17 Hex screw 27 Nut
8 Pipe clamp half 18 Bracket 28 Sealing cone
9 Grommet 19 Pipe clamp half
10 Hex screw 20 Pipe clamp half

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.12 Crankcase Ventilation
Page 2

1 Vent pipe assembly 5 Oil separator 9 Vent pipe


2 Vent pipe assembly 6 Guide sleeve 10 Rubber sleeve
3 Gasket 7 Rubber sleeve 11 Clamp
4 Hex screw 8 Clamp 12 Plug

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.12
Page 3

1 Carrier 12 Intake manifold assembly 23 Vent line assembly


2 Washer 13 Distributor assembly 24 Nut
3 Hex screw 14 Pipe clamp half 25 Banjo screw
4 Mounting bracket 15 Hex screw 26 Sealing ring
5 Hex screw 16 Washer 27 Union
6 Hex nut 17 Vent line assembly 28 Rubber sleeve
7 Washer 18 Nut 29 Clamp
8 Clamp 19 Rubber sleeve 30 Threaded bush
9 Washer 20 Clamp 31 Sealing ring
10 Spacer bushing L = 62 21 Reduction union
11 Hex screw 22 Sealing ring

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.12 Crankcase Ventilation
Page 4

C 018.12.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Remove engine B 003


x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions

C 018.12.05 Removal

Version I: Release hex screws from clamp(s) (1), fit


rubber sleeve(s) (arrow) over pipe end.
Remove clamps.

Release hex screw(s) from clamp(s) (2) and (3).


Release and disconnect pipe(s) (1).

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.12
Page 5

Release hex screw(s) from clamp(s) (1) and (2).


Remove pipe(s).
Remove four hex screws (3) for each oil separator
and remove clamps with spacer bushing, see next
illustration.

Remove clamps (2) and spacer sleeves (1), see


overview drawing C 018.12.01.
Remove oil separator from rubber sleeve.

Remove hex screws (2) and take off pipe-clamp


halves (1) with intake manifold (3).

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.12 Crankcase Ventilation
Page 6

Remove hex screws (2) and (3) with nuts and


washers.
Remove carrier (4) with mounting bracket (1).

Remove hex screw (3) and take off pipe clamp


halves (4).
Remove hex screws (1) from carrier (2) and take off
carrier.

Version II: Release hex screws from clamp(s) (1), fit


rubber sleeve(s) (arrow) over pipe end.
Remove clamps.
Unscrew hex screws (2) and take off pipe clamp
halves.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.12
Page 7

Remove hex screw(s) (1) and take off pipe clamp


halves.
Unscrew hex screw (2) from pipe clamp halves and re-
move pipe.

Remove pipe-clamp half (2).


Unscrew hex screws (1), place retainer (3) with electri-
cal line aside.

Remove hex screws (2) anFtake off pipe clamp halves.


Release piping system (arrow) and disconnect pipe(s).
Remove hex screws (1) from carrier.

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.12 Crankcase Ventilation
Page 8

Release hex screws from clamp(s) (arrow).

WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting equipment.

Attach oil separator with rope to crane and remove via


driving end (arrow).

Note: After removing lines, seal all open connections by installing suitable plugs.

C 018.10.08 Inspection and Repair


Note: Make sure that air-carrying components are perfectly clean.
Clean all components.
Visually inspect components for damage and wear; replace components as necessary.
Replace oil separator.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.12
Page 9

Unscrew hex screw (1), withdraw sleeve (2) from oil

1
2 separator and remove.
Note: Sleeve is not included in scope of delivery
of new oil separator.

F0180060a0

WARNING
Fuels and fuel mists are flammable and poisonous. Risk of fire, explosions and poison-
ing! When working with fuel: No open flame, no electric sparks. Do not smoke. Do not spill
fuel. Do not inhale. Always wear protective gloves and protective goggles/safety mask.
Ventilate working area well.

Dispose of parts in accordance with local regulations.

WARNING
Compressed air is highly pressurized.
Risk of injury! Pressure must not exceed 0.5 bar.
Always wear protective clothing, protective gloves and protective goggles/safety mask.

If necessary, pressure-test lines and pipes in air in water bath for leaks.
Air test pressure: 0.5 bar
Water temperature min. 30 C, max. 40 C.

CAUTION
Compressed air is highly pressurized. Risk of injury!
If compressed air is used for blowing out or blow-drying components, always wear protective goggles
or safety mask. Pressure must not exceed 3.0 bar.

After pickling, wash lines with hot water and blow dry with compressed air.
Preserve lines in oil bath and allow to drip dry.
Check condition of threads; rechase threads if necessary or replace threaded inserts if necessary.
Replace rubber sleeves, O-rings and sealing rings.

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.12 Crankcase Ventilation
Page 10

C 018.10.11 Installation
Note: Prior to installation, remove all blanking plugs and ensure oil-carrying components are perfectly clean.
Install all pipes tension-free.

Version I:
DRIVING END
Mount vent pipes (1) if they were previously dis-
mantled, ensuring that they are correctly positioned,
see overview drawing C 018.12.01.
Mount pipe (2) on partition area but do not yet tighten.

Mount carrier (2) with hex screws (1) and pipe clamp
halves (4) with new grommet.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.12
Page 11

Fit carrier (4) with mounting bracket (1) on exhaust


manifold, see overview drawing C 018.12.01.

Coat O-ring (arrow) with denaturated ethanol. Insert


sleeve, see next illustration.
Note: Denaturated ethanol acts as an anti-fric-
tion coating during fitting.

Insert sleeve (1) and tighten with hex screw (2).

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.12 Crankcase Ventilation
Page 12

Mount rubber sleeve(s) (2) with clamps (3).


Insert oil separator (1) in rubber sleeve(s) and align
(arrow).

Guide four hex screws for each oil separator through


the specified bores in the mounting bracket. Mount
clamps (2) with spacer sleeves, ensuring they are posi-
tioned correctly, and insert hex screws but do not fully
tighten.
Install pipe(s) (5) with rubber sleeve(s) (4) and clamps
(3).

Install intake manifold (5) with pipe clamp halves (4)


and distributor (6) on mounting bracket.
Fit rubber sleeves (3) over the pipe ends. Install clamps
(1) and vent pipe(s) (2). Align pipe clamps, tighten
hex screws for pipe clamps.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.12
Page 13

Fit clamps loosely over the rubber sleeves and slide


the rubber sleeves (1) over the pipe ends of the dis-
tributor. Align pipe clamps (2), tighten hex screws for
pipe clamps.

Ensure that rubber sleeves, clamps and pipe connec-


tions are installed tension-free and tighten.
Tighten pipe connection (arrow).

Version II:
Fit rubber sleeves (arrow) and pipes (arrow) and align.

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.12 Crankcase Ventilation
Page 14

Ensure pipework (1) and (2) is particularly clean and


that it is not damaged and installed free of tension.
Mount pipe clamp halves (3) with hex screws.

Mount rubber sleeves (4) with clamps (1).


Install retainer (2) and pipe clamp half (3).
Note: Mount second clamp per rubber sleeve,
ensuring it is free of tension.

Install preassembled ventilation unit.


Insert hex screws (2) and secure carrier. Screw-
fasten pipes (arrow).
Install pipe clamp half/halves (1) and retainer (3).
Install pipe clamp half/halves (4) with hex screws (5).
Note: Ensure that pipes are installed free of ten-
sion.

MTU 01.12 MR20108/00E


Task Description Section C
Crankcase Ventilation Group 018.12
Page 15

Align intake manifold (arrow) and fit pipe clamp halves


(1).
Fit clamps (2) loosely over the rubber sleeve(s) and
slide the rubber sleeves over the pipe ends.
Align pipe clamps, tighten hex screws for pipe clamps.

C 018.12.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Perform operations as per Assembly Plan B 005


x Install engine B 007
x Install engine B 007
x Connect vent lines C 202.65.11
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 018.12 Crankcase Ventilation
Page 16

MTU 01.12 MR20108/00E


Task Description Section C
Gear Train Group 020
Page 1

Contents

C 020 Gear Train

C 024.05 Gear case, free end


C 024.05.01 Overview drawing
C 024.05.02 Special tool
C 024.05.04 Before-removal operations
C 024.05.05 Removal
C 024.05.08 Inspection and repair
C 024.05.11 Installation
C 024.05.12 After-installation operations

C 025.05 Gear train, free end


C 025.05.01 Overview drawing
C 025.05.04 Before-removal operations
C 025.05.05 Removal
C 025.05.08 Inspection and repair
C 025.05.11 Installation
C 025.05.12 After-Installation operations

MR20108/00E 01.12 MTU


Section C Task Description
Group 020 Gear Train
Page 2

C 020 Gear Train


TB version

Number of Tooth backlash (mm) Axial clearance (mm)


teeth
1 Gear, coolant pump, low-temperature circuit 32 0.201 $ 0.065 to gear 9
2 Gear, coolant pump, high-temperature circuit 32 0.201 $ 0.065 to gear 9
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
7 Gear, generator 19 0.222 $ 0.128 to gear 6
8 Gear, oil pump 34 0.279 $ 0.077 to gear 9
9 Idler gear 89 0.285 $ 0.080 to gear 3 0.2 to 0.6
10 Gear, hydrostatic pump 34 0.201 $ 0.065 to gear 9

MTU 01.12 MR20108/00E


Task Description Section C
Gear Train Group 020
Page 3

The following is a list of auxiliary equipment and materials needed for the assembly operations:

CAUTION
When using these chemical substances, it is essential to observe the manufacturers instructions for
use, safety instructions and waste disposal specifications.

Materials and consumables Designation MTU Order No. Remarks


Emery cloth
Bottle brush
Inspection lamp
Magnifying glass
Endoscope with cold light
Liquid nitrogen
Vaseline Petroleum jelly, white 40317
Corrosion inhibitor Caramba Express 40008
Surface sealant Loctite No. 518 50592 Final strength  72 h
Multipurpose grease Shell Retinax 40333
Engine oil
Cleansing agent Loctite 7063 50593
Kerosene or diesel fuel
Sealing paste Elastosil N 189 50545
Denaturated ethanol 40250
Engineers blue blue 40641
Dry compressed air
Magnetic crack-testing equipment with fluor-
escent magnetic powder
Surface crack-testing equipment with red
penetrant dye

MR20108/00E 01.12 MTU


Section C Task Description
Group 020 Gear Train
Page 4

MTU 01.12 MR20108/00E


Task Description Section C
Gear Case (Equipment Carrier) Free End Group 024.05
Page 1

C 024.05 Gear Case (Equipment Carrier) Free End


C 024.05.01 Overview Drawing

1 Equipment carrier 12 Hex nut 23 Pipe clamp half/halves 34 O ring


2 O ring 13 Cover 24 Oil line 35 O ring
3 Hex screw 14 Gasket 25 Gasket 36 Drain plug
4 Sealing ring 15 Stud 26 Cover 37 O ring
5 Plug 16 Oil pump 27 Grommet 38 Gasket
6 Main bearing, free end 17 Threaded bush 28 Pressure reduction valve 39 Cover
7 Idler gear, right side 18 Sealing ring 29 Sealing ring(s) 40 O ring
8 Idler gear, left side 19 Plug 30 Banjo screw 41 Plug
9 Washer 20 Hex screw 31 Seal carrier, free end 42 Sealing ring
10 Washer 21 Sealing ring 32 Radial-lip shaft seal 43 Bearing bush
11 Stud 22 Plug 33 Axle, intermediate gear

MR20108/00E 01.12 MTU


Section C Task Description
Group 024.05 Gear Case (Equipment Carrier) Free End
Page 2

Arrangement of alignment tool for equipment carrier and equipment carrier cover

1 Equipment carrier 4 Hex screw


2 Alignment tool 5 Guide bush
3 Marking, top 6 Hex screw

MTU 01.12 MR20108/00E


Task Description Section C
Gear Case (Equipment Carrier) Free End Group 024.05
Page 3

Arrangement of installation tool for equipment carrier

1 Installation tool 4 Notch marking, installation tool


2 Crankshaft support bearing 5 Position mark, crankshaft bearing
3 Installation tool

MR20108/00E 01.12 MTU


Section C Task Description
Group 024.05 Gear Case (Equipment Carrier) Free End
Page 4

C 024.05.02 Special Tool


Designation Application Number

Alignment tool (free end), equipment carrier 2


Guide bush (free end), crankshaft 1
Drift for bearing bush, idler gear axle 1
Installation tool for shaft/bush in equipment carrier 1
Puller for shaft/bush in equipment carrier 1
Guide pin for vibration damper 2
Support bracket for vibration damper 1
Installation tool, crankshaft support bearing 1
Locating device, crankshaft support bearing 1

C 024.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions
x Drain engine coolant (high temperature) Operating Instructions
x Drain charge air coolant (low temperature) * Operating Instructions
x Drain or draw off engine oil Operating Instructions
x x Remove vibration damper C 035.05.05
x x Disconnect and remove electric wiring C 500
x x Remove governor C 508.95.05
x x Remove charge air coolant pump * C 203.05.05
x x Remove coolant pump C 202.05.05
x x Remove charge air coolant line * C 203.25.05
x x Remove coolant vent lines C 202.65.05
x x Remove charge air coolant vent lines * C 203.55.05
x x Remove coolant housing with thermostat C 206.05.05
x x Remove generator C 213.05.05
x x Remove H.P. pump C 073.05.05
x x Remove centrifugal filter C 183.10.05
x x Remove engine mount, free end C 231.10.05
x x Remove oil filter C 183.05.05
x x Remove driver flange C 035.05.05

* TB version

MTU 01.12 MR20108/00E


Task Description Section C
Gear Case (Equipment Carrier) Free End Group 024.05
Page 5

C 024.05.05 Removal

Removing equipment carrier

2 Remove hex screws (2) for seal carrier together with

washers.
1 Remove seal carrier (3).

Version I:
Screw two eyebolts (arrows) into equipment carrier.
Attach equipment carrier to crane with ropes and
tension ropes equally.
Remove oil line, see C 181.05.05.
Remove pressure reduction valve, see C 181.05.05.
Idler gears are designed as disc wheels.
Plugs (1) and (2) with securing screws behind them,
as in Version II, are not used in Version I.

Version II:

Screw two eyebolts (arrows) into equipment carrier.



Attach equipment carrier to crane with ropes and
tension ropes equally.


Remove oil line, see C 181.05.05.


Remove pressure reduction valve, see C 181.05.05.
1


2 Idler gears are provided with bores.
Unscrew plugs (1) and (2) and remove with sealing
ring.
Note: Unscrew hex screws through bores in
idler gears and remove.
When not visible, bar crankshaft accord-
ingly.

F0240009a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 024.05 Gear Case (Equipment Carrier) Free End
Page 6

Mark all screws on equipment carrier circumference


(arrows) (differing lengths) and remove.











F0240010a0

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

Release nuts (1), left and right sides of crankcase


and remove with washers.
Carefully push equipment carrier (2), with the ropes
pretensioned, in direction of free end until it is freed
from crankcase.
Remove O-rings.

After removing equipment carrier, check whether


there is a woollen thread on the equipment carrier
(arrow) or crankcase sealing surface. This is import-
ant for installing the equipment carrier.
Follow instructions for installing equipment carrier.

MTU 01.12 MR20108/00E


Task Description Section C
Gear Case (Equipment Carrier) Free End Group 024.05
Page 7

C 024.05.08 Inspection and Repair

Clean gear case.


Enter measurement values in data sheet.
Thoroughly clean oilways and chambers in equip-
ment carrier and check that they are perfectly clean.
Using magnetic crack-testing method and fluor-
escent magnetic powder, check equipment carrier
for cracks; if cracks are detected, replace equipment
carrier.
Check crankshaft bearing for wear, scoring and
marks; replace crankshaft bearing if necessary.
Check condition of threads in equipment carrier; re-
chase threads as necessary.

FG020004ao

Check thread and shaft of hex screws and studs for


damage; replace screws if necessary.
Check all contact, sealing and mating faces: If
necessary, smooth by polishing with an oilstone or
emery cloth.
Replace O-rings.

Fit radial-lip shaft seal (2), with sealing lip facing


down, on installation mandrel (1).
Coat sealing face of radial-lip oil seal with denatu-
rated ethanol.
Note: Denaturated ethanol acts as lubricant for
press-fitting.
Clean and degrease sealing face for radial-lip oil seal
in seal carrier (3).
Press-fit radial-lip shaft seal with drift into seal
carrier.

MR20108/00E 01.12 MTU


Section C Task Description
Group 024.05 Gear Case (Equipment Carrier) Free End
Page 8

Removing crankshaft bearing in equipment


housing
Note: Replace crankshaft bearing as part of
every W6 overhaul.
Before removing, release main bearing by making an

axial cut with a saw to leave a remaining wall thick-


ness of approx. 1 mm.


Using removal tool and manual press, force bearing
out of equipment carrier.

WARNING
Equipment which is faulty, installed incorrectly
or not in accordance with specifications may
become loose or drop off and cause serious
injury.
F0240012a0 Risk of knocks or crushing!
Liquids emerging under high-pressure can lead
to serious injury!
Hydraulic installation/removal must be carried
out only by qualified personnel. Only use
specified and tested equipment.
The specified expansion and push-on pressure
must not be exceeded.
No-one is permitted to enter the danger zone
while installation/removal is in progress. Do
not attempt to bend or exert force on H.P. lines.
Always wear protective gloves and protective
goggles/safety mask.

Measuring main bearing bore in equipment


carrier
Adjust bore gauge (1) and dial gauge with micro-
meter or gauge ring (2) to basic size for main bear-
ing bore as per Tolerance and Wear Limits List.

MTU 01.12 MR20108/00E


Task Description Section C
Gear Case (Equipment Carrier) Free End Group 024.05
Page 9

Measure diameter of main bearing bore with bore


gauge.
Enter measurement values in data sheet.
For measuring points and limit values, see Tolerance
and Wear Limits List.
Replace equipment carrier if limit values are ex-
ceeded.

C 024.05.11 Installation

WARNING
Heavy object.

Risk of injury!

Oben Top
Use suitable tools and lifting equipment.

Installing main bearing in equipment carrier


Install eyebolts in equipment carrier


and attach with rope to crane.


Lift equipment carrier, move into installation position,
1 place on a firm and level surface and secure under
tension.
Clean crankshaft bearing bore with Loctite cleaner
7063.
Install locating device and spacer (1).
F0240001a0 Note: Pay attention to arrow and marking Oben
und Top (arrow).
Clean crankshaft bearing with Loctite cleaner 7063,
rub with lint-free cloth and check for possible dam-
age.

F0240002a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 024.05 Gear Case (Equipment Carrier) Free End
Page 10

Insert crankshaft bearing (1) in locating device (2).


Ensure correct positioning of the bearing marking
(arrow) with regard to the main bearing installation
position.

F0240013a0

Insert installation tool (2).


Note: Insert main bearing (3) and installation
tool (2), ensuring they are correctly posi-
1
tioned with regard to position mark/notch
1 mark) (arrow).

2 Lock installation tool (2) with sliding bar handle (1).

F0240003a0

CAUTION
Nitrogen is liquid at 200 C.
Danger of freezing and suffocation!
Do not allow liquid nitrogen to come into con-
tact with parts of body (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ventilate working area well.

Using installation tool, chill crankshaft bearing in


liquid nitrogen.
Heat equipment carrier to 80 C.

CAUTION
Component is hot.
F0240004a0
Risk of injury!
Handle components only when wearing protec-
tive gloves.

MTU 01.12 MR20108/00E


Task Description Section C
Gear Case (Equipment Carrier) Free End Group 024.05
Page 11

Use installation tool (2) to introduce chilled main



1
bearing (1) into locating device until contact is felt.
Note: Location is by means of an asymmetrical
pin guide.

2 After a brief dwell period, release and remove the


installation tool.

F0240005a0

Check position of oil bores at crankshaft bearing/


equipment carrier.

F0240006a0

Install equipment carrier


Install intermediate gears and axles, see
C 025.05.11.
Install delivery valve (see C 184.10.11) and pressure
reduction valve (see C 181.05.11).
Coat cleaned alignment tool (2) and guide bush with
engine oil and fit on equipment carrier with hex
screws (1).
Note: Pay attention to TOP/OBEN marking,
which must always face up, independently
of the crankcase position.
After assembly of alignment device, remove guide
bush.

L93_2198

MR20108/00E 01.12 MTU


Section C Task Description
Group 024.05 Gear Case (Equipment Carrier) Free End
Page 12

Clean crankshaft butt, driving end. Now mount first


the flange and then the guide bush (2) with hex
screws (1) on the crankshaft butt.

L93_2198

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

Install eyebolts (arrow) in equipment carrier and se-


cure to crane with rope.

Degrease and dry mating face (arrow).


Apply surface sealant with spatula/roller to sealing
surface of equipment carrier, guide woollen thread
(2) closely past the annular grooves (1) provided.
Insert O-rings (1) in groove on equipment carrier (3).
Note: Woollen thread is not applicable if not
fitted during disassembly.

L93_2198

MTU 01.12 MR20108/00E


Task Description Section C
Gear Case (Equipment Carrier) Free End Group 024.05
Page 13

Different features between Version I and



3 Version II must be observed, see overview drawing
C 024.05.01.


Using crane, carefully position equipment carrier (3)


1 2 over crankshaft guide bush (1) see overview draw-
ing C 024.05.01.
Ensure that studs (2) are properly aligned.
Note: Make sure components are reinstalled in
accordance with markings, and note that
screws differ in length.

Note: Ensure correct final strength of surface


sealant 5910, see C 020!

Note: Do not cut off woollen thread projecting


over oil pan sealing surface. Further pro-
cedure, see C 014.05.11.
FG020011aO
Ensure that that both idler gears and crankshaft gear
are perfectly aligned.
Version II: Similarly, in this case ensure that one of
the round recesses is positioned at both idler gears
to permit subsequent screw tightening.
When not visible, bar engine accordingly.
Refer to next illustration for tightening torque.
Install nuts and washers and tighten.
Note: Relieve load on crane before tightening
nuts and screws!

Tighten screws in sequence 5, 6, 3, 2, 4, and 1 up to


final torque.

MR20108/00E 01.12 MTU


Section C Task Description
Group 024.05 Gear Case (Equipment Carrier) Free End
Page 14

Install all securing screws (arrows) and tighten uni-


formly.
Remove securing screws of alignment tool from
equipment carrier and guide bush from crankshaft.






F0240010a0

Install plugs (1) and (2) (only with Version II) with
new sealing rings.
Remove ropes and eyebolts.
Install oil line, see C 181.05.11.


1
2

F0240011a0



Installing seal carrier
2


Install seal carrier (1) in equipment carrier (4).
3


1 Coat O-ring with petroleum jelly and press seal
carrier evenly into equipment carrier and ensure that

4 it is perfectly flush.
Install guard plate (3) and tighten to specified torque
with hex screws (2) and washers diagonally and
evenly, see overview drawing C 035.05.01.

F035 0002b0

MTU 01.12 MR20108/00E


Task Description Section C
Gear Case (Equipment Carrier) Free End Group 024.05
Page 15

C 024.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007
x x Install Driver flange C 035.05.11
x x Install H.P. pump C 073.05.11
x x Install generator C 213.05.11
x x Install oil filter C 183.05.11
x x Install centrifugal filter C 183.10.11
x x Install and connect electric wiring C 500
x x Install coolant housing with thermostat C 206.05.11
x x Install charge air coolant pump * C 203.05.11
x x Install coolant pump C 202.05.11
x x Install charge air coolant line * C 203.05.11
x x Install coolant vent lines C 202.65.11
x x Install charge air coolant vent lines * C 203.55.11
x x Install vibration damper C 035.05.11
x Fill oil system with engine oil Operating Instructions
x Add charge air coolant (low temperature) * Operating Instructions
x Add engine coolant (high temperature) Operating Instructions
x Release engine start Operating Instructions

* TB version

MR20108/00E 01.12 MTU


Section C Task Description
Group 024.05 Gear Case (Equipment Carrier) Free End
Page 16

MTU 01.12 MR20108/00E


Task Description Section C
Gear Train, Free End Group 025.05
Page 1

C 025.05 Gear Train, Free End


C 025.05.01 Overview Drawing

TC version

1 Engine coolant pump drive gear 6 Engine carrier, free end (equipment carrier)
2 Axle 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

MR20108/00E 01.12 MTU


Section C Task Description
Group 025.05 Gear Train, Free End
Page 2

Overview drawing

TB version

1 Engine coolant pump drive gear 6 Engine carrier, free end (equipment carrier)
2 Axle 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 Charge air coolant pump drive gear

MTU 01.12 MR20108/00E


Task Description Section C
Gear Train, Free End Group 025.05
Page 3

C 025.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions
x Drain engine coolant (high temperature) Operating Instructions
x Drain charge air coolant (low temperature) * Operating Instructions
x Drain or draw off engine oil Operating Instructions
x x Remove vibration damper C 035.05.05
x x Disconnect and remove electric wiring C 507.10.05
x x Remove governor C 508.95.05
x x Remove charge air coolant pump * C 203.05.05
x x Remove coolant pump C 202.05.05
x x Remove charge air coolant pump * C 203.05.05
x x Remove charge air coolant line * C 203.25.05
x x Remove coolant vent lines C 202.65.05
x x Remove charge air coolant vent lines * C 203.55.05
x x Remove coolant housing with thermostat C 206.05.05
x x Remove generator C 213.05.05
x x Remove H.P. pump C 073.05.05
x x Remove centrifugal filter C 183.10.05
x x Remove engine mounting, free end C 231.10.05
x x Remove oil filter C 183.05.05
x x Remove drive flange C 035.05.05
x x Remove gear case, free end C 024.05.05

* TB version

MR20108/00E 01.12 MTU


Section C Task Description
Group 025.05 Gear Train, Free End
Page 4

C 025.05.05 Removal

Removing idler gears


Note: Note the different versions.
Version I
Version II
Place engine carrier on a clean and even surface.
Version I
Unscrew and remove hex screws (1).
Screw in jackscrews M 8 (arrow) with continuous
thread in thread of axle (2).
Press off axle evenly.

Version II
Unscrew hex screws (1) and (2) and remove.
Screw in jackscrews M 8 (arrow) with continuous
thread in thread (arrow) of axle (3).
Press off axle evenly.

Removing axles
Mark respective axle according to installation posi-
tion and remove from equipment carrier.
Remove idler gears from fit.

FG020013aO

MTU 01.12 MR20108/00E


Task Description Section C
Gear Train, Free End Group 025.05
Page 5

Removing bearing bush from idler gear


Ensure there is sufficient ease of movement.
Using a suitable sleeve and manual press, remove
bearing bush (1) from idler gear (2).

C 025.05.08 Inspection and Repair

Clean all components.


Using magnetic crack-testing method and fluorescent magnetic powder, check idler gears for cracks; if cracks are
detected, replace idler gear.
Check surface condition of idler gear with magnifying glass; replace idler gear if necessary.
Check running surface of axles, bearing bushes in idler gears and axial friction faces of gears for wear and scores.

Remove minor scoring and wear by rubbing down


with emery cloth or oilstone; replace component if
necessary.
Check taper seat and bolt-on surface of axles for
scoring and wear.
Check screws for damage and check condition of
threads; replace screws if necessary. Thoroughly
clean all axle oilways (arrow); make sure oilways are
perfectly clean.
For limit values, see Tolerance and Wear Limits List.

MR20108/00E 01.12 MTU


Section C Task Description
Group 025.05 Gear Train, Free End
Page 6

Measuring bearing bush bore in idler gear


Set bore gauge to basic size of bearing bush bore in
idler gear.
Measure diameter of bore.
For limit values, see Tolerance and Wear Limits List.
If limit values are exceeded, replace idler gear.

Measuring bearing diameter on axles


Using micrometer, measure outside diameter of
axles at running surface.
For limit values, see Tolerance and Wear Limits List.
Replace axle if limit values are exceeded.

MTU 01.12 MR20108/00E


Task Description Section C
Gear Train, Free End Group 025.05
Page 7

C 025.05.10 Assembly

Installing bearing bush idler gear


Measure basic bore (3) in idler gear (2) see
C 025.05.08.
Place idler gear on suitable rest to ensure that when
bush (1) is installed there is no side projection.

CAUTION
Nitrogen is liquid at 200 C).
Danger of freezing and suffocation!
Do not allow liquid nitrogen to come into con-
tact with parts of body (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ventilate working area well.

Cool bush in liquid nitrogen and heat idler gear to


80 C.

CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.

Insert cooled bush into idler gear. Observe distance


A 0.35 mm $ 0.15 mm when installing.

C 025.05.11 Installation

Note: Make sure all components are perfectly clean.

Installing idler gear in equipment carrier


Coat bearing bushes in idler gear with engine oil.
Insert idler gear (2) via opening (arrow) in equipment
carrier (1), ensuring it is positioned correctly as
shown in overview drawing, see C 025.05.01.

MR20108/00E 01.12 MTU


Section C Task Description
Group 025.05 Gear Train, Free End
Page 8

Installing axles
Note: Ensure oil bores of axle (3) are perfectly
clean.
Coat O-ring (1) and (2) with petroleum jelly.
Insert O-ring (2) into groove of equipment carrier (4).
Secure O-ring (1) in groove in axle base with petro-
leum jelly.
Insert axles in equipment carrier, paying attention to
fit of idler gear.

Version I
Press axle (2) into equipment carrier (3).
Install hex screws (1) and tighten evenly.

Version II
Press axle (3) into equipment carrier.
Install hex screws (1) and tighten evenly.
Fit hex screw (2) to secure equipment carrier.

MTU 01.12 MR20108/00E


Task Description Section C
Gear Train, Free End Group 025.05
Page 9

Checking axial clearance and backlash

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

Install two eyebolts in equipment carrier.


Attach equipment carrier to crane with ropes and
tension ropes equally.
Position equipment carrier vertically.
Mount magnetic dial-gauge holder (3) with dial
gauge (2) in equipment carrier.
Place dial gauge stylus with preload on lateral collar
of idler gear (1).
Set dial gauge to zero.
Check axial play by moving idler gear back and forth
in axial direction.
To measure backlash, place switch of Puppi gauge
with preload on tooth flank of idler gear.
Set dial gauge with preload to zero.
Move idler gear back and forth in radial direction to
check backlash.
For axial clearance and backlash, see C 020.
If limit values are exceeded, replace idler gears.

MR20108/00E 01.12 MTU


Section C Task Description
Group 025.05 Gear Train, Free End
Page 10

C 025.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007
x x Install gear case, free end C 024.05.11
x x Install drive flange C 035.05.11
x x Install oil filter C 183.05.11
x x Install centrifugal filter C 183.10.11
x x Install generator C 2 13.05.11
x x Install coolant housing with thermostat C 206.05.11
x x Install charge air coolant pump * C 203.05.11
x x Install coolant pump C 202.05.11
x x Install charge air coolant line * C 203.25.11
x x Install charge air coolant vent lines * C 203.55.11
x x Install coolant vent lines C 202.65.11
x x Install vibration damper C 035.05.11
x x Install and connect electric wiring C 507.10.11
x x Install governor C 508.95.11
x x Install engine mount, free end C 231.10.11
x Fill oil system with engine oil Operating Instructions
x Add engine coolant (high temperature) Operating Instructions
x Fill charge air coolant (low temperature) * Operating Instructions
x Release engine start Operating Instructions

* TB version

MTU 01.12 MR20108/00E


Task Description Section C
Running Gear Group 030
Page 1

Contents

C 030 Running Gear

C 031.05 Crankshaft
C 031.05.01 Overview drawing
C 031.05.02 Special tool
C 031.05.04 Before-removal operations
C 031.05.05 Removal
C 031.05.06 Assembly
C 031.05.08 Inspection and repair
C 031.05.10 Disassembly
C 031.05.11 Installation
C 031.05.12 After-Installation operations

C 032.10 Main PTO, driving end


C 032.10.01 Overview drawing
C 032.10.02 Special tool
C 032.10.04 Before-removal operations
C 032.10.05 Removal
C 032.10.06 Assembly
C 032.10.08 Inspection and repair
C 032.10.10 Disassembly
C 032.10.11 Installation
C 032.10.12 After-installation operations

C 035.05 Crankshaft, free end, with PTO and vibration damper


C 035.05.01 Overview drawing
C 035.05.02 Special tool
C 035.05.04 Before-removal operations
C 035.05.05 Removal
C 035.05.06 Assembly
C 035.05.08 Inspection and repair
C 035.05.10 Disassembly
C 035.05.11 Installation
C 035.05.12 After-installation operations

MR20108/00E 01.12 MTU


Section C Task Description
Group 030 Running Gear
Page 2

C 037.05 Pistons and conrods


C 037.05.01 Overview drawing
C 037.05.02 Special tool
C 037.05.04 Before-removal operations
C 037.05.05 Removal
C 037.05.06 Assembly
C 037.05.08 Inspection and repair
C 037.05.10 Disassembly
C 037.05.11 Installation
C 037.05.12 After-installation operations

MTU 01.12 MR20108/00E


Task Description Section C
Running Gear Group 030
Page 3

C 030 Running Gear

1 Flywheel 5 Crankpin
2 Ring gear 6 Crankshaft gear, free end
3 Piston 7 Vibration damper
4 Conrod 8 Crankshaft counterweight

MR20108/00E 01.12 MTU


Section C Task Description
Group 030 Running Gear
Page 4

The following is a list of auxiliary equipment and materials needed for the assembly operations:

CAUTION
When using these miscellaneous materials, it is essential to observe the manufacturers instructions
for use, safety instructions and waste disposal specifications.

Materials and consumables Designation MTU Order No. Remarks


Chamois leather
Bottle brush
Roller brush
Brass brush
Emery cloth
Magnifying glass
Spray gun
Inspection lamp
Endoscope with cold light
Liquid nitrogen
Activator
Vaseline Petroleum jelly, white 40317
Denaturated ethanol 40250
Surface sealant Loctite No. 5910 50570 Final strength  h
Thread-locking compound Loctite No. 270 40083 Final strength  h
Thin-film lubricant Molycote g-N plus 40041
Engine oil
Corrosion inhibitor
Cleaning agent
Engineers blue blue 40641
Kerosene or diesel fuel
Synthetic shot-blasting pellets Dry Strip Type 216/20 20098
Cleaning agent (carbon-deposit remover)
Dry compressed air
Magnetic crack-testing equipment with fluor-
escent magnetic powder
Surface crack-testing equipment with red
penetrant dye
Surface crack-testing equipment with fluor-
escent penetrant dye

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 1

C 031.05 Crankshaft
C 031.05.01 Overview Drawing

1 Vibration damper 11 Crankshaft counterweight 14 Nut


2 Main bearing, free end 12 Socket-head screw 15 Main bearing cap
3 Equipment carrier Lubricant: Engine oil 16 Crankshaft gear
* Pretightening torque: 80 Nm
4 Piston * Tightening torque: 280 Nm+ 20Nm 17 O ring
5 Cylinder liner 13 Stud ** 18 Crankshaft
6 O ring Lubricant: Engine oil 19 O ring
7 Oil spray nozzle Screw elongation: 20 Hex screw
l = 1.15 mm + 0.05 mm
8 Conrod Remaining screw elongation: 21 Seal carrier
9 Crankcase l = 0.9 mm + 0.05 mm 22 Driver flange
10 Conrod screw

* Tightening sequence starting from driving end:


1. Pretighten all socket-head screws on left side and then on right side
2. Fully tighten all socket-head screws on left side and then on right side

** Newly fitted studs must be elongated before initial tightening.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 2

Crankshaft 16V

1 Crankshaft
2 Counterweight
3 Stress bolt
Max. shaft length: 132.0 mm
Lubricant: Engine oil
Pretightening torque: 320 Nm + 30 Nm
Additional angle of rotation: 120 + 10
Checking torque: 800 Nm + 50 Nm
4 End cover
5 Crankshaft gear

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 3

Main bearing

1 Main bearing, upper half


2 Main bearing, lower half
3 Crankshaft alignment bearing, upper half
4 Crankshaft alignment bearing, lower half

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 4

C 031.05.02 Special Tool


Designation Application Number

Crankshaft lifting sling 2


Crankshaft locating device 2
Installation tool, crankshaft bearing, free end 1
Installation tool, crankshaft bearing, driving end 1
Crankshaft slip protection 2
Crankshaft removal tool 2
Crankshaft bearing installation/removal 1
Crankshaft bearing installation aid 1
Crankshaft bearing cap installation/removal tool 1
Barring tool 1

C 031.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x x Removal of crankshaft not scheduled

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 5

C 031.05.05 Removal
Checking marking on crankshaft bearing cap
Check marking on crankshaft bearing cap to crank-
shaft, and if necessary mark according to sequence.
1 Starting at driving end, stamp number of main
bearing with 6 mm numbers main bearing so
that they can be read from same direction.

Removing main bearing caps


Remove socket-head screw (arrows), remove block
(1) from crankcase (2).

L92_22985

Turn crankcase upside down in assembly dolly with


oil pan mating face horizontal.
Remove all lateral hex socket screws for main bear-
ing cap.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 6

Beginning with the 1st bearing cap (driving end),


mount hydraulic preloading device on studs of crank-
shaft bearing cap.
Insert jacking nuts (1) by hand as far as stop and
then back off one revolution.
Connect hydraulic hand pump to hydraulic preload-
ing device.
1 Mount magnetic dial gauge holders with dial gauges
on crankcase mating face. The dial gauges are for
measuring the elongation of the studs.
Place dial gauge stylus centrally on respective
measuring point on face of nut.
Set dial gauges to zero with preload.
Operate hydraulic hand pumps and elongate both
studs at same time (max. 0.25 mm) until nuts of
main bearing caps can be released with the aid of a
F031 0023a0
tommy bar.
Release nuts with tommy bar.
Relieve tension on studs, mount dial gauges with
magnetic holders and hydraulic preloading devices
on studs of next adjacent main bearing cap and fol-
low the same procedure to release all remaining
nuts.
Remove loose nuts from studs.

Screw eyebolt (arrow) into bearing cap.


Using ropes and crane, carefully raise bearing cap
vertically until clear of crankcase.

CAUTION


Components have sharp edges.
Risk of injury!
Touch components only when wearing protec-
tive gloves.

Mark bearing shell of respective bearing cap and re-


move.
Note: Protect bearing shells from damage!

F0310012a0

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 7

Removing crankshaft
1 To protect the crankshaft (3), fit protective sleeves
(2) on the pins of the last bearing and locating device
at the first bearing.

WARNING
3 Suspended load.
Risk of injury!
2 Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

Using rope loops (1) and crane, raise crankshaft


clear of crankcase.
Take care to keep crankshaft horizontal.
Lower crankshaft onto a sturdy base.
F031 0035a0

Remove bearing shells from bearing pedestals and


mark bearing shells on housing side with number of
respective main bearing.
Make markings (arrow) by etching or with a non-wipe
felt marker pen.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 8

C 031.05.06 Disassembly
Installing crankshaft gear, free end

CAUTION
Ground material is hot.
Risk of injury!
Wear protective clothing (including gloves and
closed shoes) and goggles.
Remove grinding dust.
Note: Do not remove gear unless necessary
(e.g. damage).
Cut axial groove (A) in crankshaft gear (1), leaving
wall thickness of approx. 1 mm to relieve tension in
gear.
Note: Cover crankshaft with heat-resistant cloth
(sparks).
Observe cutting procedure and take into consider-
ation appropriate cooling periods.
Determine separation depth (B) before starting work
and check frequently.
Expand crankshaft gear with suitable wedge and
remove.
Smooth seating surface with emery cloth and re-
move minor scoring
Clean crankshaft see C 031.05.08.

Removing counterweight
Note: If counterweights are removed after bal-
ancing, mark relevant counterweight in its
installation position with regard to crank-
shaft beforehand.
Determine and record distance A (web to counter-
weight).
Check that counterweights are numbered in con-
secutive order; stamp new numbers if necessary.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 9

Note: Remove counterweights with crankshaft


in a sturdy stand.
Remove screws (2) and counterweight (1).

C 031.05.08 Inspection and Repair


Cleaning and checking crankshaft
Always consult MTU/DDC before cleaning the crankshaft.

CAUTION
Compressed air is highly pressurized. Risk of injury!
If compressed air is used for blowing out or blow-drying components, always wear protective goggles
or safety mask. Pressure must not exceed 3.0 bar.

Remove rust spots, scores and individual foreign body impressions by localized polishing.
Crack-test crankshaft using magnetic test method.
Remove foreign body indentations by regrinding to next stage.
Request information from MTU/DDC Service.
After grinding, carry out hardness test.
Check bearings for scoring or thermal cracks, regrind to next stage if necessary request information from MTU/
DDC Service.
Using a micrometer, measure crankshaft main bearing and crankpin journals each in four positions. See Toler-
ances and Wear Limits List.
Remove any burrs in the oilway to running surface transitions by polishing.
Remove any irregularities in the crankshaft webs and connecting rod guide faces by localized polishing.
Remove any corrosion traces or minor scores from the crankshaft taper by polishing.
Check the threaded bores at driving and free ends of crankshaft with new screws.
Remove cold welds by polishing.
Crack-test the crankshaft gear, particularly the gear tooth flanks.
Remove minor surface cracks (hairline cracks) on tooth flanks by polishing.
If several surface fissures or deeper fissures are found, replace the gear.
Remove individual scores by polishing.
If several scores are found, replace the gear.
Note: Never use a wire brush!

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 10

Checking crankshaft for cracks


Check counterweight mating faces (2) for wear; ma-
chine-grind if necessary.
It is imperative to contact MTU and/or DDC.
Using the magnetic crack-testing method with fluor-
escent magnetic powder, check crankshaft for longi-
tudinal and transverse cracks. Include oil bores and
journal bores (3), counterweight mating faces and
tapped bores (1) in scope of inspection.
Install crankshaft in longitudinal direction between
jaws of test device.
For the test, a magnetic electric field strength of
20 A/cm to 60 A/cm must be applied at every part of
the component.
Demagnetize crankshaft after crack-testing. The
maximum permissible residual field strength after
demagnetization is 2.5 A/cm to 4 A/cm.

Remarks on cracks caused by grinding


Fine branching is characteristic of thermal cracking,
(arrows). The illustration shows a bearing journal
with grinding cracks.
Replace crankshaft with such cracks.
Grind cracks occur on account of insufficient cooling
during grinding or through excessive feed.

2476/1

Remarks on hot-running cracks


Characteristic of hot-running cracks is that they are
almost always parallel to the axis of the component
(see arrows).
Transverse cracks sometimes come out from these
cracks. Heavy thermal cracks are mostly of a depth
approximately corresponding to the thickness of the
hardness layer. Replace crankshaft with such
cracks.
Crankshafts exhibiting minor hot-running cracks can
be repaired. This is provided that regrinding to a re-
pair stage or local grinding will remove the damage.
It is imperative to contact MTU and/or DDC .

L90_20256/1

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 11

Checking crankshaft journal


Rub down all journals with emery cloth.
Standardised roughness height (Rz) of journal sliding
surface = 2.5 m to 6.3, m see also crankshaft
regrinding.
Polish all fillets and transitions.
Check main bearing and crankpin surfaces for scor-
ing and damage. If necessary, regrind relevant jour-
nal to next repair stage.
Check friction washer sliding surface of first main
bearing for wear. Regrind to next repair stage if
necessary.
For limit values, see Tolerances and Wear Limits
List.
Remove minor scoring and damage by polishing with
emery cloth.

Measuring crankshaft journal


Using micrometer, measure main bearings and
crankpins of crankshaft for out-of-round and surface
irregularities; record measured values in Data Sheet.
For limit values, see Tolerances and Wear Limits
List.
If limit values are exceeded, grind crankshaft to next
repair size.

Checking crankshaft taper


Check taper surfaces (arrows) for scoring and dam-
age.
Remove minor scoring and damage by polishing with
emery cloth.
Check tapers 1:50 with taper gauge.
If necessary, machine taper to MTU/DDC specifica-
tions.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 12

Checking hardness of journals


Check hardness of all journals using the Microdur
tester or other suitable hardness tester.
Test hardness of each journal at four points at 90
intervals around circumference.
Specified hardness = from 49 HRC to 53 HRC
Replace crankshaft if a bearing journal has lost its
hardness on account of bearing scuffing.
Note: Hardness tests on installed or ready-to-be
installed crankshafts are not permitted.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 13

Checking crankshaft concentricity


Illustration showing 12V crankshaft

16V: Place crankshaft in main bearings 1 and 2

Using adjustable dial gauge holder and dial gauge, check main bearing journal concentricity.
If wear across circumference of journal is irregular, check at transition from cylindrical section of journal to radius.
For limit values, see Tolerances and Wear Limits List.
If measured values differ from those specified in Tolerances and Wear Limits List, grind relevant journals to next
repair stage.
Important: Do not straighten crankshaft after hardening!
Always consult DDC or MTU before grinding crankshaft journals.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 14

Regrinding crankshaft
Only journals which are not dimensionally stable must be reconditioned to next repair stage.
When regrinding, make every effort to remove only as much material as is required to achieve next repair size.
Adhere strictly to all specifications for sizes and tolerances.
This also applies to transition radii and surface finish.
Record crankshaft serial number, main bearing journal and crankpin diameters, guide bearing width, concentricity
values and journal hardness values in Crankshaft Data Sheet.
Thoroughly clean oil bores after grinding.
Necessary checks after grinding:
Check dimensions and surface finish of all bearing journals
Check radii at bearing journals
Check that oilway bores are correctly radiused and polished;
perform this check with meticulous care, in order to prevent damage to the bearing shells and ensure adequate
lubrication.
Check concentricity and axial runout
Check hardness
Check for cracks
Example of 12 V crankshaft
Hardness transient across journal
A = Main bearings 2 to 7
B = Main bearing 1
C = Crankpins 1 to 6

Hardness characteristic at main bearings 2 to 7


A = 7 mm (Max. hardened zone depth)
B = 4 mm (Min. hardened zone depth)
C = 9 mm (Max. hardened zone depth at radius)
D = 7 mm (Min. hardened zone depth at radius)
E = 2.5 mm (Min. hardened zone depth at radius)
F = 5.5 mm (Max. hardened zone depth at radius)
R = from (4.9 to 5.1) mm
Maximum peak-to-valley height at radii = 4 m

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 15

Hardness characteristic at crankpins 1 to 6


A = 11 mm (Max. hardened zone depth)
B = 8 mm (Min. hardened zone depth)
C = 9 mm (Max. hardened zone depth at radius)
D = 7 mm (Min. hardened zone depth at radius)
E = 21 mm
F = 2.5 mm (Min. hardened zone depth at radius)
G = 5.5 mm (Max. hardened zone depth in radius
area)
R = from (4.9 to 5.1) mm
Maximum peak-to-valley height at radii = 4 m

Hardness characteristic at main bearing 1


A = 80.5 mm
B = 77.5 mm
A to B hardness width 3 mm
C = 9 mm (Max. hardened zone depth)
D = 6 mm (Max. hardened zone depth)
E = 19 mm (Max. hardened zone depth in radius
area)
F = 17 mm (Min. hardened zone depth)
G = 2.5 mm (Min. hardened zone depth in radius
area)
H = 5.5 mm (Max. hardened zone depth in radius
area)
R = from (4.9 to 5.1) mm
Maximum peak-to-valley height at radii = 4 m

Checking counterweights
Using the magnetic crack-testing method with fluor-
escent magnetic powder, check counterweight for
cracks.
If cracks are detected, replace counterweight.
Check crankshaft mating face (1) for wear; machine-
grind if necessary.
It is imperative to contact MTU and/or DDC .
Using engineers blue, check contact pattern of mat-
ing face (2) for stress bolt heads; remove surface
irregularities as necessary.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 16

Checking screws for counterweights


Measure shaft length of screws with depth gauge;
max. permissible shaft length, see C 031.05.01. Re-
place screws if necessary.
Using the magnetic crack-testing method with fluor-
escent magnetic powder, check screws for cracks.
Replace screw if cracks are found.
Make sure that threads are in perfect condition.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 17

Dynamic balancing
Illustration showing 16V crankshaft

Prior to balancing, seal all oilways to prevent the ingress of foreign matter.
16V: Place crankshaft in main journals 2 and 8
Weight of balancing group: 710 kg

Max. operating speed: 1800 rpm


Balancing speed: 150 rpm
Permissible residual imbalance per balancing plane for
initial balancing: 200 gcm
Permissible residual imbalance per balancing plane for
comparative balancing in different configuration or
balancing machine: 300 gcm
Remove material to balance crankshaft only from counterweights by drilling radially with twist drill.
For specified bore values see following illustrations.
After balancing, recheck numbers on counterweights and renumber if necessary.
Remove material to balance crankshaft only from counterweights by drilling radially with twist drill.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 18

Bore values at counterweights


A = 5_ (min.)
B = 10_
C = 32_ (min.)
D = 18 mm (max. bore diameter)
E = 40 mm (max. bore depth)
Minimum wall strength around balancing bores:
5 mm

Cleaning and checking oil bores


Important: Remove end cover and clean oil bores
only in a specialised workshop or at ma-
nufacturer.
Endoscopically inspect all oilways with cold light
source and make sure they are perfectly clean.

F031 0020a0

Checking and assessing crankshaft bearing shells


Replace bearing shells as part of every W6 overhaul.
In event of reuse (e.g. unscheduled removal), check bearing shells for surface wear, scoring, cracking, corrosion,
erosion and damage; replace if necessary.
Check condition bearing shell butt and bearing reverse side and check for friction corrosion (pitting); if there is evi-
dence of friction corrosion, replace bearing shell and determine cause.
Possible causes: Screws not sufficiently pretensioned, assembly fault, bearing shell spread dimension is outside
Tolerances limit and defective bearing support bore.
Measure bearing shells spread dimension.
If spread dimension is too low (see Tolerances and Wear Limits List), replace bearing shells.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 19

Crankshaft bearing shell (grooved bearing)

(upper half)


a
b Bearing shell has the following material structure:

a Sliding layer (thickness 16 m, central axle dis-


tance 0.2 mm)
c b Intermediate layer (nickel barrier)
c Barrier layer (from 1 m to 3 m sputtered)
In new condition, the running surface has approx.
75% sliding layer, approx. 20% intermediate layer
and max. 5% barrier layer.
Wear of the bearing running surfaces starts at the
galvanised wear layer (a).
This removes the wear layer in the groove by a few
0.001 mm.
In event of further wear, the difference between the
intermediate layer and sliding layer remains almost
constant, i.e. at approx. 0.005 mm.
A magnifying glass is required for a more accurate
assessment of the wear condition of the running sur-
face (magnification min. 5x).
In doing so, the sliding layer is to be seen as the
dark zone and the intermediate layer as the light
zone.
The relationship between the width of the intermedi-
ate layer and the width of the groove and the extent
of the worn area are decisive factors when evaluat-
ing the wear condition of the grooved bearings.
The grooved bearing is still functional if the sliding
layer is partially missing in the grooves.
Practice has shown that the grooved bearing with
partially empty grooves can continue in use without
negatively affecting the function of the bearing.
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.

Crankshaft bearing shell (sputtered bearing)


(lower half)
Bearing shell has the following material structure:
1 Wear layer (from 12 m to 18 m sputtered)
2 Barrier layer (nickel barrier, from 1 m to 3 m
sputtered)
3 Intermediate layer corresponds to approx. 10% of
bearing thickness.
4 Protective steel shell corresponds to approx. 88%
of bearing thickness.
An important indicator for assessing extent of wear
on bearing shell is the shape and extent of the nickel
barrier (barrier layer) areas exposed.
Use of bearing shell is already restricted in friction
area once the sliding layer is reduced to 70%!

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 20

Checking main bearing shell bore


Note: The crankshaft bearing bore must first be tested without installed main bearings and then with installed
main bearings. The following describes the test with installed main bearings. The procedure is the same
for testing the crankshaft bearing bore without installed main bearings.

Installing bearing shells


Note: Always make sure that all components
are perfectly clean.
Turn crankcase upside down in assembly dolly with
oil pan mating face horizontal.
Wipe bores for crankshaft bearing in crankcase and
bearing shells on both sides.
Note: Top and bottom bearing shells have differ-
ent part numbers.
Check codes for repair size and journal
diameter of new shells and bearing
number of used shells. These markings
must be on sides facing toward driving
end.
First main bearing is designed as an
alignment bearing see next illustration.
Using installation/removal tool, insert bearing shells
on housing side in accordance with bearing number
into housing bore to form a positive connection and
align with press-fitting tool.
Oil bores (arrow) in bearing shells and in crankcase
must be aligned.

Wipe bearing shell on both sides and insert into


crankshaft bearing cap according to markings or
bearing number.
Bearing numbers on shells must be aligned and all
numbers must be toward driving end.
Position installation tool (1) between bearing cap
stud and rear face of shell on side where butting joint
is.
Compress main bearing cap shell (2) until free end
can be pressed down onto butting face of crankcase
shell.
Butting joint must be closed.
Axially align bearing shells.
Install main bearing cap and tighten lateral socket-
head screws see Section C 031.05.11 Installation
Installing main bearing cap .

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 21

Measuring crankshaft bearing ID


Adjust bore gauge (1) and dial gauge with micro-
meter or gauge ring to basic size for crankshaft
bearing bore as per Tolerances and Wear Limits List.
Coat wear faces of main bearing shells with engine
oil.
Measure I.D. of main bearing bore with shells in-
stalled.
Enter measurement values in data sheet.
For measuring points and limit values, see Toler-
ances and Wear Limits List.
Replace bearing shells or use repair-size bearings if
limit values are exceeded.
After measuring main bearing bore ID, if necessary
mark bearing shell according to bearing shell
number.
Remove main bearing cap see C 031.05.05.

CAUTION
Components have sharp edges.
Risk of injury!
Touch components only when wearing protec-
tive gloves.

Remove bearing cap and bearing shells.


Note: Protect bearing shells from damage!

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 22

C 031.05.10 Assembly
Installing counterweights
Measure shaft length of screws for counterweights;
for max. shaft length, see C 031.05.01.
Clean and degrease mating face on crankshaft and
counterweight (2).
Coat threads and screw head mating face of screws
(1) with engine oil.
Note: Install counterweights in accordance with
markings.
Fit counterweight on crankshaft and tighten slightly
with screws.

Align counterweight to mark applied before removal


and dimension A.
Pretighten screws to specified pretightening torque
see C 031.05.01
Check that marking and measured distances are
correct.

Mark screw heads.


Tighten screws through specified additional angle of
rotation.
After installing counterweights, recheck identification
marks on counterweights and webs.
Note: If new counterweights have been in-
stalled, dynamically balance crankshaft.
Also apply identification numbers to
counterweights using punch numerals
and beginning at driving end.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 23

Installing crankshaft gear, free end


Clean and degrease surface of main journal and
gear bore.
Heat crankshaft gear, free end, with heating unit to
approx. 130 C + 50 C.

CAUTION
Component is hot.
Risk of injury!
Touch components only when wearing protec-
tive gloves.
Fit heated crankshaft gear (1), free end, on crank-
shaft (3).
Calculate push-on distance (A) by measuring dis-
tance from end face of crankshaft to end face of
crankshaft gear with depth gauge.
Force-on depth (A) measured from face of crank-
shaft to face of crankshaft gear is 145.2 mm to 145.8
mm.
When the components have cooled, lubricate crank-
shaft gear with engine oil.
Coat O-ring with petroleum jelly and fit in groove (2)
on crankshaft.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 24

C 031.05.11 Installation
Installing crankshaft
Note: Always make sure that all components
are perfectly clean.

1 Turn crankcase upside down in assembly dolly with


oil pan mating face horizontal.
Wipe bores for crankshaft bearing in crankcase and
bearing shells on both sides.
Light up oil bores to main bearings in crankcase with
cold light and check that they are perfectly clean.
Note: Top and bottom bearing shells have differ-
ent part numbers.
First main bearing (2), driving end, is de-
signed as an alignment bearing.
2 Using installation/removal tool, manually insert bear-
ing shells on housing side in accordance with bear-
F031 0026a0
ing number into housing bore to form a positive con-
nection.
Note: Check repair stage of crankshaft main
bearing bore and repair stage of bearing
shells see crankcase data sheet and
crankshaft characteristics record.
Align alignment bearing shell (2) and remaining bear-
ing shells with press-fitting tool (1) into housing bore.

Spray running faces of crankcase bearing shells with


engine oil.
To protect crankshaft, slip locating device (1) over
main bearing cap studs of first bearing (2).

F031 0025a0

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 25

Fit protective sleeves (2) over studs of last bearing.


1 Wipe crankshaft bearing surfaces (3).
Inspect oil bores with lamp and ensure they are per-
fectly clean.

WARNING
3 Suspended load.
Risk of injury!
2 Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

Lift crankshaft using rope slings (1) and crane.


Align crankshaft horizontally and vertically with line
of bores in crankcase and gradually lower crank-
F031 0035a0 shaft.

Remove protective sleeves and locating device.


Important: Do not rotate the crankshaft until the
axial alignment bearing has been instal-
led.
Wipe bearing shell and crankshaft bearing cap with
chamois leather, spray running surface with engine
oil and install.
Note: Bearing numbers on shells must be
aligned and all numbers must be toward
driving end.
Check alignment of upper and lower bear-
ing shells.

F0310021a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 26

Position installation tool (1) between bearing cap


stud and rear face of shell on side where butting joint
is.


Compress main bearing cap shell until free end can


1 be pressed down onto butting face of crankcase
shell.
Note: Butting joint must be closed.
Axially align bearing shells.

F0310022

Installing main bearing cap


Wipe bearing shell mating faces on crankshaft bear-
ing cap.

CAUTION
Compressed air is highly pressurized.
Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Pressure must not exceed 3.0 bar.
Check mating faces on crankshaft bearing cap and
bores for cleanness and blow out with compressed
air.

Note: Crankshaft bearing caps must not be in-


terchanged!
1 Stamp number of main bearing, starting from
driving end, ensuring it is legible.
Allocate bearing cap according to crankcase marking
to respective bearing.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 27

CAUTION
Narrow gap.
Risk of crushing!
Keep fingers clear of the danger zone.
Using crane and rope, place respective bearing cap
carefully on appropriate bearing, ensuring it is cor-
rectly positioned.

FG030085 aO

Hit the crankshaft bearing cap lightly to settle in final


position.

FG030086 aO

Coat thread and mating face of side hex socket


screws (2) and studs (1) with engine oil.
Turn nuts for bearing cap to mating face of bearing
caps.
Install hex socket screws but do not tighten.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 28

Beginning with the 1st bearing cap (driving end),


mount hydraulic preloading device on studs of crank-
shaft bearing cap.
Fit nuts (1) by hand till they contact.
Connect hydraulic hand pump to hydraulic preload-
ing device.
Important: Newly fitted studs must be elongated as
1 follows before initial tightening:
1. Elongation of studs with 1500 bar (309 kN,
valid for device with effective piston area
AK= 20.6 cm2)
2. Release
3. Elongation as in Point 1.
4. Release

F031 0023a0

Mount magnetic dial gauge holders with dial gauges on crankcase mating face. The dial gauges are for measuring
the elongation of the studs.
Position a dial gauge stylus against end of each sleeve measuring stud.
Set dial gauges to zero with preload.
Operate the hydraulic hand pump and, at the same time, elongate studs (max. 1.15 mm + 0.05 mm).
Tighten nuts on crankshaft bearing cap with a pin (arrow).
Relieve tension on studs, mount dial gauges with magnetic holders and hydraulic preloading devices on studs of
next adjacent main bearing cap and install all nuts in same order.
Note: Remaining elongation of studs after release: 0.9 mm + 0.05 mm.
If remaining elongation of studs is outside tolerance, release nuts, see C 031.05 .05 and repeat nut tightening pro-
cedure; if necessary, replace studs.
Tighten hex socket screws (arrow) to specified
tightening torque see overview drawing
C 031.05.01.
Install locating device on crankshaft (driving end) to
rotate the crankshaft without the flywheel.
Bar crankshaft manually and check for ease of
movement.
Install block with two socket-head screws see
C 011.05.10.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft Group 031.05
Page 29

Crankshaft barring
Important: In order to prevent damage to the main
bearing, it is imperative to install a loca-
ting device before the crankshaft is bar-
red.
Install locating device (1) on crankshaft (driving end).
Turn crankshaft by hand or with barring tool (see
next illustration) and check ease of movement.

Install barring tool (2) with hex socket screws on


crankshaft (1) (free end).

Measuring crankshaft axial play


Note: Measure axial clearance only with drive
flange or flywheel mounted.
Mount magnetic dial gauge holder with dial gauge (1)
on crankcase.
Position dial gauge stylus against front face of crank-
shaft.
Using pry bar, press crankshaft axially as far as it will
go.
Set dial gauge with preload to zero.
Move crankshaft from stop to stop (arrows) and
enter measured value (axial clearance) in data
sheet.
If determined measured value is outside permissible
Tolerances see Tolerances and Wear Limits List,
remove crankshaft and check cause.

MR20108/00E 01.12 MTU


Section C Task Description
Group 031.05 Crankshaft
Page 30

C 031.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007

MTU 01.12 MR20108/00E


Task Description Section C
Main PTO, Driving End Group 032.05
Page 1

C 032.05 Main PTO, Driving End


C 032.05.01 Overview Drawing

1 Flywheel 6 Spring pin 11 End cover


2 Graduated disc 7 Dished washer 12 Spring washer
3 Radial-lip shaft seal 8 Hex screw 13 Hex screw
4 Hex screw Tightening torque: 180 Nm + 18 Nm Tightening torque: 100 Nm + 10 Nm
Lubricant: Engine oil Thread-locking liquid: Loctite 270
Tightening torque: 21 Nm +2 Nm
Lubricant: Engine oil 9 O ring 14 Cover
5 Spring washer 10 O ring 15 O ring

MR20108/00E 01.12 MTU


Section C Task Description
Group 032.05 Main PTO, Driving End
Page 2

PTO with flywheel

1 Flywheel housing 8 Spring washer


2 Flywheel ring gear 9 Hex screw
3 Flywheel Tightening torque: 180 Nm + 18 Nm
Lubricant: Engine oil
4 O ring 10 Radial-lip shaft seal
5 End cover 11 Hex screw
6 O ring Tightening torque: 21 Nm +2 Nm
7 Hex screw Lubricant: Engine oil
12 Graduated disc
Tightening torque: 100 Nm + 10 Nm
Thread-locking liquid: Loctite 270 13 Crankshaft

MTU 01.12 MR20108/00E


Task Description Section C
Main PTO, Driving End Group 032.05
Page 3

Layout for installation/removal tool for flywheel

1 Spacer 8 Draw spindle


2 Screw 9 Hydraulic nut (press)
3 Flywheel 10 Pressure line
4 Flange 11 Support
5 Connection for SKF compressed oil unit 12 Bush
6 Flange 13 Hex screw
7 Pressure bush

Reference dimension A = 374 mm


Push-on dimension B = 20 mm to 16.7 mm
Reference surface C = press-fitted flush

MR20108/00E 01.12 MTU


Section C Task Description
Group 032.05 Main PTO, Driving End
Page 4

C 032.05.02 Special Tool


Designation Application Number

Installation/removal tool for flywheel 1


Press-fitting tool, radial-lip oil seal in flywheel housing 1
Hydraulic nut M 90 X 2 1
Support 1
Bush 1
Hex nut M 36 X 3 1
Draw spindle 1
Pressure bush 1
Flange 1
Spacer 1
Flange 1
Socket-head screws M 16 6
Tool kit (hydraulic hand pump) 0 3500 bar 1
SKF hand pump, 0 1000 bar 1
Reducer R 1/4 x R 1/4 1
Assembly sleeve for flywheel 1
Removal tool 1

C 032.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Remove engine B 003


x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions
x x Separate engine from gearbox or alternator

MTU 01.12 MR20108/00E


Task Description Section C
Main PTO, Driving End Group 032.05
Page 5

C 032.05.05 Removal

Removing flywheel
Unscrew hex screws (2) and remove with spring
washers (3).
Remove end cover (1) from flywheel.
Unscrew and remove hex screws (4).

Install cover (2) for puller (3) with hex screws


(5).
Remove cover (4) using impact extractor from
flywheel.

Fit spacer (1), flange (4), flange (6) with hex


screws (2) onto crankshaft journals, driving end,
and tighten, see overview drawing C 032.05 Ar-
rangement of installation/removal.
Rotate crankshaft so that locating element (1) of
pressure bush (2) engages in flywheel.

MR20108/00E 01.12 MTU


Section C Task Description
Group 032.05 Main PTO, Driving End
Page 6


WARNING

2 Equipment which is faulty, installed incorrectly


or not in accordance with specifications may
1 become loose or drop off and cause serious
injury.
Risk of knocks or crushing!
Liquids emerging under high-pressure can lead
to serious injury!
Hydraulic installation/removal must be carried
out only by qualified personnel. Only use
specified and tested equipment.


The specified expansion and push-on pressure
must not be exceeded.

3 No-one is permitted to enter the danger zone


behind the device while installation/removal is
in progress. Do not attempt to bend or exert
F0320001a0 force on high-pressure hoses while they are
under pressure.
Always wear protective gloves and protective
goggles/safety mask.
Screw draw spindle (6) into flange, see overview
drawing C 032.05.01.
Mount pressure sleeve (2) and hydraulic nut (press)
(1) over draw spindle and install nut (3).

Screw connector (2) into flywheel and connect H.P.


1 2 line (1).
Connect H.P. line of Lukas hand pump to hydraulic
nut (press).
Fully tighten nut then back off nut distance equal to
push-on dimension.
Push-on dimension see overview drawing
032.05.01.
Note: Before tightening nut, make sure that hy-
draulic press is in initial position (0
stroke).
Connect H.P. line (3) of Lukas hand pump to hy-
draulic press.



3 F0320002a0

MTU 01.12 MR20108/00E


Task Description Section C
Main PTO, Driving End Group 032.05
Page 7

Fill hydraulic hand pumps with SAE10 engine oil.


Prime pumps and lines until oil escaping is free of
bubbles.
Tighten high-pressure line.
Operate Lukas hand pump (2) for hydraulic nut
(press) and, by applying minimum pressure (p2)
(start of pressure increase), seat press against hub.
Note: The hydraulic press acts as a buffer, stop-
ping the flywheel as it slips off its taper
seat.
Operate hydraulic hand pump (1) for expanding the
flywheel taper until expansion pressure is half the
permitted maximum (p1).
Maintain this pressure for approx. 5 minutes.
Maximum expansion pressure pmax, is stamped on
drive flange.

Increase expansion pressure in stages of 0.1 x pmax, waiting approx. 2 minutes between increases, until flywheel is
released from crankshaft.
Do not exceed the maximum permissible expansion pressure pmax.
Operate pump to maintain constant expansion pressure.
An increase in pressure (p2) at the hydraulic press indicates that the flywheel is released from tapered seat.
Gradually relieve pressure in hydraulic press while steadily operating pump for expansion fluid.
Relieve pressure in hydraulic hand pumps.
Insert eyebolt into flywheel and attach to rope and crane.
Remove high-pressure line and reducer.
Remove nut, hydraulic nut (press), pressure bush and draw spindle.

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-
turer and observe lifting instructions.
Never stand beneath a suspended load.

Remove flywheel via forcing thread.


Slightly tension flywheel with crane and rope
sling. Using crane and rope sling, lift flywheel via
the pressure bush out of flywheel housing.

MR20108/00E 01.12 MTU


Section C Task Description
Group 032.05 Main PTO, Driving End
Page 8

C 032.05.06 Disassembly

Removing radial-lip shaft seal from flywheel


housing
1
Note: Replace shaft seal as part of every W6
overhaul.


Remove end housing (1), see C 016.30.05.


2 Using suitable mandrel and hammer, drive shaft
sealing ring (2) out of end housing.

FG030032aO

C 032.05.08 Inspection and Repair


Clean all components.
Using the magnetic crack-testing method with fluorescent magnetic powder, check flywheel with ring gear for
cracks.
Replace flywheel if cracks are found.
Check mating faces on flywheel for evenness, wear, scoring and indentations; recondition if necessary.
Renew flywheel if scoring and indentations are greater than the maximum permissible material removal see Tol-
erance and Wear Limits List.
Check all sealing, mating and bearing faces on flywheel for wear, scoring and indentations.
Remove minor wear, indentations and scoring by rubbing down with emery cloth or an oilstone; replace flywheel if
necessary.
Check taper surfaces of flywheel for scoring and damage.
Remove minor scoring and damage by polishing with emery cloth.
Check taper 1:50 with taper gauge.
Replace flywheel if taper bore is oversized.
Check thread of expansion bore; rechase if necessary.
Check ring gear for wear, replace if necessary.
Remove slight burrs and chipping from teeth by grinding or filing.

MTU 01.12 MR20108/00E


Task Description Section C
Main PTO, Driving End Group 032.05
Page 9

C 032.05.10 Assembly

Installing radial-lip shaft seal into flywheel hous-


ing
WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting equipment.


Note: The radial-lip shaft seal can only be in-
stalled in the flywheel housing with the
press-fitting tool if it is mounted on the
crankcase. Installation of flywheel housing
see Section C 016.30.
Install flange with spacer (see overview drawing
C 032.05.01) on face (arrow) of crankshaft.
F0320004a0 Fit radial-lip shaft seal, with sealing lip facing out-
wards, on press-fitting tool.
Coat sealing face (arrow) of radial-lip oil seal with
denaturated ethanol.
Note: Denaturated ethanol acts as lubricant for
press-fitting.

Clean and degrease support bore for radial-lip oil


seal in flywheel housing.
Use pressure spindle to install radial-lip shaft seal
flush in flywheel housing.
Remove pressure spindle with flange from crank-
shaft.

FG030034aO

MR20108/00E 01.12 MTU


Section C Task Description
Group 032.05 Main PTO, Driving End
Page 10

C 032.05.11 Installation
When installing a new flywheel, mount graduated
disc from old flywheel on new one.
Install graduated disc (2) with hex screws (1) on fly-
wheel, but do not tighten.



1
Drive spring pins (arrow) into flywheel.
Tighten hex screws (1), see overview drawing
C 032.05.01.

F0320005a0

Pressing on flywheel

WARNING
Equipment which is faulty, installed incorrectly
or not in accordance with specifications may
become loose or drop off and cause serious
injury.
Risk of knocks or crushing!
Liquids emerging under high-pressure can lead
to serious injury!
Hydraulic installation/removal must be carried
out only by qualified personnel. Only use
specified and tested equipment.
The specified expansion and push-on pressure
must not be exceeded.
No-one is permitted to enter the danger zone
behind the device while installation/removal is
in progress. Do not attempt to bend or exert
force on high-pressure hoses while they are
under pressure.
Always wear protective gloves and protective
goggles/safety mask.
Clean and degrease taper surface on crankshaft
with cleaner and dry and degrease with lint-free
cloth.
Coat running surface of flywheel for radial-lip
shaft seal with thin-film lubricant.
Coat lip of radial-lip oil seal with petroleum jelly.

MTU 01.12 MR20108/00E


Task Description Section C
Main PTO, Driving End Group 032.05
Page 11

Join spacer (3) and flange (4) together and use



screws to install on face of crankshaft, paying atten-
tion to centring pin guide (2).


3 Screw in draw spindle (1).


2 Reference dimension A of draw spindle, see over-
view drawing C 032.05.01.

F0320007a0

WARNING
Suspended load.
Risk of injury!
Only use lifting device provided by manufac-


turer and observe lifting instructions.


Never stand beneath a suspended load.

Install guide sleeve (arrow).


Using crane and rope sling, remove flywheel via
guide sleeves into flywheel housing.
Note: Take care not to damage radial seal
lip.

Remove guide sleeve.


Mount pressure sleeve and hydraulic nut (press) (1)
over spindle and install nut (3).

2
Connect H.P. line (2).

Connect H.P. line (4) of Lukas hand pump to hy-

1 draulic nut (press).


Fully tighten nut then back off nut distance equal to
push-on dimension.


For push-on dimension B and expansion pressure,
see information on face of flywheel.

3
Note: Before tightening nut, make sure that hy-
draulic press is in initial position (0

stroke).

4 Pressure bush with centering pin (7), centres the


driver flange and defines the installation position,
see overview drawing C 032.05.01. Clean and de-
grease tapers of crankshaft and hub.

MR20108/00E 01.12 MTU


Section C Task Description
Group 032.05 Main PTO, Driving End
Page 12

Fill hydraulic hand pumps with SAE 10 engine oil.


Prime pumps and lines until oil escaping is free of
bubbles.
Tighten high-pressure line.
Before installing, coat taper faces with expansion
fluid by operating hydraulic hand pump (1) until ex-
pansion fluid emerges at both sides of hub.
Operate Lukas hand pump (2) for hydraulic nut
(press) and, by applying minimum pressure, seat
press against flywheel.
Operate pump for expansion fluid until no further
increase in expansion pressure (p1) is possible, then
operate force-on pump to increase force-on pressure
(p 2).
Repeat this process until crankshaft gear is seated
on flywheel.
Select force-on pressure such as to seat shaft in
approx. 5 steps.
When installing, make sure that expansion pressure
never exceeds the maximum permissible expansion
pressure pmax.
pmax see information stamped on flywheel.
Hydraulic installation is completed when pressure
sleeve is seated against flywheel.
Open valve screw in hydraulic oil pump to relieve
expansion pressure.
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.
Unscrew H.P. lines.
Allow specified retention time to elapse and remove
nut, hydraulic nut (press), pressure sleeve and draw
spindle.
Note: Do not subject press fitting to operating
load for at least 8 hours.

MTU 01.12 MR20108/00E


Task Description Section C
Main PTO, Driving End Group 032.05
Page 13

Coat O-ring with petroleum jelly and insert into


groove on cover (7).
Press cover into flywheel and insert with hex
screw (6) and tighten to specified torque, see
overview drawing C 032.05.01.
Insert O-ring (1) and (3) into groove in end cover
(2) and coat with petroleum jelly.
Press end cover into flywheel, centre and screw
in hex screws (4) secured with thread locking
agent Loctite 270 and washers (5) and tighten to
specified torque, see overview drawing
C 032.05.01.

C 032.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Perform operations as per Assembly Plan B 005


x Install engine B 007
x Connect engine with gearbox/alternator
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 032.05 Main PTO, Driving End
Page 14

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft PTO, Free End Group 035.05
Page 1

C 035.05 Crankshaft PTO, Free End


C 035.05.01 Overview Drawing

1 Protective plate 6 Spacer sleeve 11 O ring


2 Washer 7 Sealing plug 12 Seal carrier, free end
3 Hex screw 8 Drive flange 13 O-rings
4 Vibration damper 9 O ring 14 Hex screw
5 Hex screw 10 Radial-lip shaft seal Tightening torque: 500 Nm + 50 Nm
Tightening torque: 74 Nm + 7 Nm Lubricant: Engine oil
Lubricant: Engine oil

MR20108/00E 01.12 MTU


Section C Task Description
Group 035.05 Crankshaft PTO, Free End
Page 2

PTO with vibration damper

1 Hex screws 9 Hex screw


Tightening torque: 74 Nm + 7 Nm Tightening torque: 400 Nm
Lubricant: Engine oil Lubricant: Thread with engine oil
2 Seal carrier 10 Washer
3 Crankshaft gear Coat both sides
Thread-locking liquid: Loctite 275
4 Crankshaft 11 Hex screw
5 O ring Tightening torque: 500 Nm + 50 Nm
Lubricant: Engine oil
6 Drive flange
12 Sealing plug
7 O ring
13 O ring
8 Radial-lip shaft seal

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft PTO, Free End Group 035.05
Page 3

Arrangement of drive flange installation/removal tool

1 Draw spindle 8 Flange


2 Hex nut 9 Spacer bush
3 Bush 10 Drive flange
4 Support 11 Crankshaft
5 Connection for SKF compressed oil unit 12 Seal carrier
6 Hydraulic press 13 Socket-head screw
7 Pressure bush

Reference dimension A = 473 mm


Push-on dimension B = from 76.95 mm to 77.05 mm
Push-on distance a = from 15.5 mm

MR20108/00E 01.12 MTU


Section C Task Description
Group 035.05 Crankshaft PTO, Free End
Page 4

C 035.05.02 Special Tool


Designation Application Number

Hydraulic pressure testing device, drive flange 1


Hydraulic nut M 90 X 2 1
Support 1
Bush 1
Hex nut 36 X 3 1
Draw spindle 1
Pressure bush 1
Flange 1
Spacer bushing 1
Socket-head screws M 16 X 100 6
Tool kit (hydraulic hand pump) 0 3500 bar 1
SKF hand pump, 0 1000 bar 1

C 035.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Remove engine B 003


x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions

C 035.05.05 Removal


Removing vibration damper


Remove hex screws (1) together with washers.
2


Remove guard plate (2).
1

F0350001a0

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft PTO, Free End Group 035.05
Page 5

Secure flywheel to flywheel housing (lock).


Remove hex screws (1), one screw is left for secur-

ing purposes.


1 Screw in two opposing guide pins in threaded bore
of driver flange.
Remove remaining hex screws, insert two jack-



screws M 12 with continuous thread in press-off
thread (arrow).

Press off vibration damper.

WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting equipment.

F0350003a0 Attach vibration damper with rope and crane and


remove from guide pin.
Unscrew and remove guide pin.

Removing drive flange

WARNING
Equipment which is faulty, installed incorrectly
or not in accordance with specifications may
become loose or drop off and cause serious
injury.
Risk of knocks or crushing!
Liquids emerging under high-pressure can lead
to serious injury!
Hydraulic installation/removal must be carried
out only by qualified personnel. Only use
specified and tested equipment.
The specified expansion and push-on pressure
must not be exceeded.
No-one is permitted to enter the danger zone
behind the device while installation/removal is
in progress. Do not attempt to bend or exert
force on H.P. lines.
Always wear protective gloves and protective
goggles/safety mask.
Screw draw spindle (4) into crankshaft.
Check reference dimension A of draw spindle see overview drawing C 035.05.01.
Mount pressure sleeve (1) and hydraulic press (3) over spindle and install nut (5).
Screw connector (2) into driver flange and connect H.P. line.
Connect H.P. line (6) of Lukas hand pump to hydraulic press.
Fully tighten nut then back off nut distance equal to push-on dimension.
Force-on distance a is stamped on driver flange.
Note: Before tightening nut, make sure that hydraulic press is in initial position (0 stroke).

MR20108/00E 01.12 MTU


Section C Task Description
Group 035.05 Crankshaft PTO, Free End
Page 6

Fill hydraulic hand pumps with SAE 10 engine oil.


Prime pumps and lines until oil escaping is free of
bubbles.
Tighten high-pressure line.
Operate Lukas hand pump (2) for hydraulic press
and, by applying minimum pressure (p2) (start of
pressure increase), seat press against driver flange.
Note: The hydraulic press acts as a buffer, stop-
ping the hub as it slips off its taper seat.
Operate hydraulic hand pump (1) for expanding the
driver flange taper until expansion pressure is half
the permitted maximum (p1).

Maintain this pressure for approx. 5 minutes.


Maximum expansion pressure pmax, is stamped on driver flange.
Increase expansion pressure in stages by 0.1  pmax, holding for approx. 2 minutes between each stage, until drive
flange is released from crankshaft.
Do not exceed maximum permissible expansion pressure pmax.
Operate pump to maintain constant expansion pressure.
An increase in pressure (p2) in the hydraulic press indicates that driver flange is released from taper seat.
Gradually relieve pressure in hydraulic press while steadily operating pump for expansion fluid.
Relieve pressure in hydraulic hand pumps.
Disconnect high-pressure line.
Remove nut, hydraulic press, pressure sleeve, and draw spindle.
Unscrew reducer.

WARNING
Heavy object. Risk of injury!
Use suitable tools and lifting equipment.
Remove driver flange from crankshaft.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft PTO, Free End Group 035.05
Page 7

Removing seal carrier


2
Remove hex screws (1) together with washers.


1
3 Remove guard plate (3).
Press seal carrier (2) from fit and remove.
Note: The radial-lip shaft seal can only be re-
placed after the driver flange has been
removed. If the specified assembly se-
quence is not observed, the sealing ring
may be damaged or destroyed.

C 035.05.06 Disassembly

Disassembling vibration damper


Remove hex screws (1) and dished washers.
Remove side plate (2).
Remove O-rings.
Note: A complete inspection is possible in this
condition. The spring pack can only be
disassembled with the aid of special tools
and should only be carried out by Geis-
linger Service.

C 035.05.08 Inspection and Repair


Removal and installation of the vibration damper is not possible without appropriate special tools (centring bench
etc.)
Clean all components.
Visually inspect spring pack of vibration damper, inner teeth of inner star and side plate for damage and wear.
Replace vibration damper if there is excess wear or damage.
Check O-ring sealing surfaces for wear and rust.
Remove minor wear or rust by rubbing down with oilstone or emery cloth.
Check condition of threads in flange; rechase threads as necessary.
Ensure that oilways are particularly clean.
Check sealing surface of inner star to driver flange for wear and scoring.
Check hex screws for damage and check threads for ease of movement; replace hex screw if necessary.
Replace O-rings.

MR20108/00E 01.12 MTU


Section C Task Description
Group 035.05 Crankshaft PTO, Free End
Page 8

C 035.05.10 Assembly
Assembling vibration damper

CAUTION
Compressed air is highly pressurized.
Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Pressure must not exceed 3.0 bar.
Blow through oil bores in vibration damper with com-
pressed air and ensure that they are perfectly clean.
Coat Y gasket (10) and 0-Ring (6) with petroleum
jelly and insert in grooves of side plate (9).
Coat inner circumference of side plate and outer cir-
cumference of inner star (1) and driver grooves with
thin-film lubricant.

Clean and degrease contact areas of dished


washers (7).
Coat dished washers on both sides sufficiently with
Loctite 275 and fit correctly on screws.
Convex end of dished washer must point to screw
head! It is advisable to replace dished washers for
each new installation.
Install side plate in correct position, tighten hex
screws (8), offset by 90_ uniformly in small steps to
specified tightening torque (see A 003) so that side
plate does not jam and fit is not damaged.
Note: Ensure correct final strength of surface
sealant see C 030!
When replacing Y-ring (2) and O-ring (4), an ap-
propriate special tool is required.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft PTO, Free End Group 035.05
Page 9

After specified tightening torque is reached, check


measurement levels AB and C.
Reference dimension A = 6 mm
Reference dimension B = 109 mm
Reference dimension C = 116.5 mm



2 Installing seal carrier


1 3 Install seal carrier (1) in equipment carrier (4).
Coat O-ring with petroleum jelly and press seal


carrier evenly into equipment carrier and ensure that
4 it is perfectly flush.
Install guard plate (3) and tighten hex screws (2)
with washers diagonally to specified tightening
torque see overview drawing C 035.05.01.

Coat O-ring with petroleum jelly and fit on


crankshaft gear (arrow), see also overview drawing
C 035.05.01.

MR20108/00E 01.12 MTU


Section C Task Description
Group 035.05 Crankshaft PTO, Free End
Page 10

C 035.05.11 Installation

Installing drive flange

WARNING
Equipment which is faulty, installed incorrectly
or not in accordance with specifications may
become loose or drop off and cause serious

injury.


Risk of knocks or crushing!
b
Liquids emerging under high-pressure can lead
to serious injury!
Hydraulic installation/removal must be carried
out only by qualified personnel. Only use
specified and tested equipment.
The specified expansion and push-on pressure
must not be exceeded.
No-one is permitted to enter the danger zone
F0350004a0 behind the device while installation/removal is
in progress. Do not attempt to bend or exert
force on H.P. lines.
Always wear protective gloves and protective
goggles/safety mask.

Clean and degrease tapers of crankshaft and vibra-


tion damper.
Coat running surface of crankshaft bearing and drive
flange with oil.
Coat lip of radial-lip oil seal with petroleum jelly.

WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting equipment.

Mount driver flange on crankshaft taper.


To calculate force-on distance, measure distance
from end face of crankshaft to end face of drive
flange using depth gauge. Make a note of this figure.
Calculate difference (=push-on distance) between
measured dimension and push-on dimension (b),
see C 035.05.01.
Push-on dimension (b) = distance from face of
crankshaft to face of driver flange after hydraulic in-
stallation.
Force-on distance a is stamped on drive flange.
If calculated distance is less than push-on distance
a, check dimensional accuracy of taper.

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft PTO, Free End Group 035.05
Page 11

Screw draw spindle (4) into crankshaft.


Check reference dimension (A), see C 035.05.01.
Mount pressure sleeve (1) and hydraulic press (3)
over spindle.
Install nut (5) and hand-tighten.
Note: Before tightening nut, make sure that hy-
draulic press is in initial position (0
stroke).
Screw connector (2) into driver flange and connect
H.P. line.
Connect H.P. line (6) of Lukas hand pump to hy-
draulic press.

Fill hydraulic hand pumps with SAE 10 engine oil.


Prime pumps and lines until oil escaping is free of
bubbles.
Tighten high-pressure line.
Before press-fitting, coat taper faces with expansion
fluid; operate hydraulic hand pump (1) until expan-
sion fluid escapes at driver flange end.
Operate Lukas hand pump (2) for hydraulic press
and, by applying minimum pressure, seat press
against driver flange.
Operate pump for expansion fluid until no further
increase in expansion pressure (p1) is possible, then
operate force-on pump to increase force-on pressure
(p 2).
Repeat this process until driver flange is correctly
seated.

Select force-on pressure such as to seat shaft in approx. 5 steps.


During installation, do not allow the expansion pressure to exceed the maximum permissible expansion pressure
pmax.
pmax see specification on driver flange.
Hydraulic installation is completed when pressure sleeve is seated against crankshaft.
Open valve screw in hydraulic oil pump to relieve expansion pressure.
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.
Disconnect high-pressure line.
Allow specified retention time to elapse and remove nut, hydraulic press, pressure sleeve and draw spindle.
Note: The press-on connection must not be subjected to operational load for at least 8 hours.
Check push-on dimension (B), see C 035.05.01, crankshaft end face to driver flange end face.
If push-on dimension is not achieved, hydraulically remove driver flange and determine the cause.

MR20108/00E 01.12 MTU


Section C Task Description
Group 035.05 Crankshaft PTO, Free End
Page 12

Insert two guide pins for installing vibration damper


in threaded bore (arrow) of driver flange.

Coat O-rings (1) with petroleum jelly and fit on driver

1 flange.
Note: Make sure parts are perfectly clean.
Attach vibration damper with rope and crane and
install over guide pins.
Coat thread and underside of hex screw heads with


engine oil and install.


Secure flywheel to flywheel housing (lock).

Heavy object.
WARNING

Risk of injury!
Use suitable tools and lifting equipment.
F0350006a0

Remove guide pins, insert two remaining hex


screws and tighten to specified torque, see over-
view drawing C 035.05.01.


1
Mount guard plate (1).
Install hex screws (2) with washers and tighten.



Important: Remove fixture for flywheel.
2

F0350005a0

MTU 01.12 MR20108/00E


Task Description Section C
Crankshaft PTO, Free End Group 035.05
Page 13

C 035.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See

x Perform operations as per Assembly Plan B 005


x Install engine B 007
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 035.05 Crankshaft PTO, Free End
Page 14

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 1

C 037.05 Pistons and Conrods


C 037.05.01 Overview Drawing

1 Piston
2 Conrod
3 Conrod cap
4 Conrod bearing, top
5 Conrod bearing, bottom
6 Conrod screw *
Max. shaft length: 104.5 mm
Lubricant: Engine oil
Pretightening torque: 240 Nm + 20 Nm
Angle of further rotation: 90 + 10
Checking torque: 450 Nm + 20 Nm

* Sequence: short connecting rod arm long connecting rod arm

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 2

1 Snap ring 9 Conrod


2 Piston pin 10 Conrod cap
3 Rectangular-section ring 11 Conrod screw
4 Taper face compression ring, new version Lubricant: Engine oil
Rectangular-section ring, old version replace with new Shaft length: 102.6 mm to 103.2 mm
version Maximum elongation: 104.5 mm
Version Screw tightening:
5 DSF ring Sequence: 1 short arm, 2 long arm
6 Piston Pretightening torque: 240 Nm + 20 Nm
7 Pressure plate Angle of further rotation: 90 + 10
8 Piston crown screw Checking torque: 450 Nm + 20 Nm
Shaft length: Manufacture dimension 48.9 mm to 49.1 mm *
Maximum length after reassembly: 49.8 mm *
Shaft length: Manufacture dimension 49.9 mm to 50.1 mm **
Maximum length after reassembly: 50.8 mm **
Lubricant: Molykote paste GN Plus
Screws tightened diagonally and evenly: 17 Nm
Screws again released
Screws tightened diagonally and evenly: 10 Nm + 3 Nm
Angle of further rotation: 60 + 5
Checking torque: 20 Nm + 3 Nm

* Corresponds to piston with E=13.2, to be seen from last four figures on piston upper section part no.
* Corresponds to piston with E=13.7, to be seen from last four figures on piston upper section part no.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 3

C 037.05.02 Special Tool


Designation Application Number

Adjusting mandrel for connecting rod 1


Installation tool for conrod 1
Barring tool 1
Assembly sleeve, piston/conrod 2
Lifting device, piston removal 1
Socket insert, 22 A/F, conrod screws 1
Piston ring pliers 1
Ring gauge for piston ring end clearance measuring 1
Sliding block for connecting rod 1

C 037.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions
x Drain engine coolant Operating Instructions
x Drain or draw off engine oil Operating Instructions
x x Remove air filter C 121.05
x x Remove intake housing C 123.05
x x Remove crankcase breather C 018.12
x x Remove coolant vent line C 202.65
x x Remove coolant line C 202.75
x x Remove exhaust system after exhaust turbocharger C 145.05
x x Remove exhaust turbocharger C 101.01
x x Remove exhaust manifolds C 141.10
x x Remove rocker arm assembly C 055.05
x x Remove pushrods C 055.05
x x Remove fuel injector C 075.05
x x Remove charge air manifolds C 124.05
x x Remove H.P. line to cylinder head C 077.05
x x Disconnect fuel return lines C 086.05
x x Remove cylinder head C 041.05
x x Remove engine mount, free and driving ends (as required) C 231.10
x x Remove starter (as required) C 172.05
x x Remove oil dipstick and oil filler neck C 011.05
x x Remove oil pan inspection port cover C 014.05/C 13.05

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 4

C 037.05.05 Removal
Removing piston with connecting rod with oil
pan installed (via access port)
Remove carbon scraper ring see C 013.05.
Install barring tool.
Remove inspection port covers, left and right sides,
from respective cylinders.


Turn crankpin of respective cylinder on right side 40
before TDC and left side 40 after TDC.

Release conrod screws with socket and large ratchet


through inspection port (arrow).
With the exception of the unchanged position of the
crankcase (engine in normal position), rest of re-
moval procedure is the same as for Removing piston
with conrod in assembly dolly.
Before removal, mount the sliding block on the con-
rod to be removed see next illustration.
V037 0012a0

1 Connecting rod
2 Sliding block
3 Cylinder liner

V037 0012a0

Removing piston with conrod in assembly dolly


Turn crankcase in assembly dolly so that conrod
bearing cap (1) of piston to be removed is horizontal.
Note: The crankshaft must only be turned with
the flywheel or axial locating element in-
stalled.
Turn crankpin of respective cylinder on right side 40
before TDC and left side 40 after TDC.
Release conrod screw (3) with socket (2), extension
and ratchet.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 5

Check marking (arrows) of conrod cap to conrod.


Mark parts as necessary.


Note: Bearing cap and conrod are a single unit
and must not be interchanged.

FG030070aO



1
Remove conrod screws (arrows) with socket and
ratchet and remove conrod cap (1).
Remove bearing shell from conrod cap and protect
from damage.


Note: The toothing on the conrod and conrod
cap mating faces must not be damaged.

If necessary, replace conrod.

Check markings from bearing shell to conrod; re-

apply markings if necessary.



FG030039aO

WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting gear.

Turn crankcase in assembly dolly so that piston to


be removed with conrod is vertical.
Note: When removing piston do not damage or
warp oil spray nozzle.
Remove bearing shell from conrod and protect from
damage.
Secure lifting device (1 ) on piston crown (2).
Withdraw piston and connecting rod with rope and
crane from cylinder liner fit.
Remove lifting device from piston crown.

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 6

C 037.05.06 Disassembly
Removing conrod from piston
Place piston and conrod on workbench.
Check marking on conrod, piston and piston pin; cor-
rect markings if necessary.
Using snap ring pliers (1), remove snap ring (2).

Use wooden rod to press out piston pin (2).


Note: Do not use sharp-edged tool to force out
piston pin.
Hold conrod (1) and remove piston pin.
Remove conrod from piston.

L92_19149

Removing piston rings


Remove piston rings with piston ring pliers in se-
quence from top to bottom.
Note: Stretch piston rings only until they can be
removed from the piston.
Do not overstretch piston rings, as they
may break.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 7

Removing piston crown


Install piston on suitable retaining device.
Use socket to unscrew piston crown screw (1) and
remove with pressure plate (2).
Remove piston crown.

C 037.05.08 Inspection and Repair


Piston
Checking piston crown
Treat carbon deposits on piston crown and piston
ring grooves with decarbonizer.
Clean area of piston ring grooves (2) with rotating
brush.
Clean oil chamber and compression surface (1) with
synthetic abrasive.
Using the magnetic crack-testing method with fluor-
escent magnetic powder, check piston crown for
cracks.
Clamp piston crown axially in magnetic crack-testing
machine.
When testing, turn piston through 180.
Carefully inspect piston ring grooves for cracks.
If cracks are found in piston crown, replace complete
L92_16162 piston.

Check bedding pattern at sealing surface of piston crown and piston skirt.
If minor wear is found, smooth sealing surface with oilstone.
Check that bore for spring pin is in perfect condition.
In event of scorched valve clearance pockets or piston edges, the complete piston must be replaced.
Remove scoring or scuffing on top land of piston crown if local and not extending as far as first ring groove.
Replace complete piston if damage is more extensive, i.e. if scoring or pitting extends as far as the first annular
groove.

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 8

Inspecting piston skirt


Note: The graphite layer on the piston skirt must
not be mechanically removed or treated
with strong cleaners!
Check piston skirt surface condition for wear, pitting
and scoring.
Note: The friction scores (arrow) on the circum-
ference are artificial depressions which
are filled with oil and result in improved
lubrication.
The piston skirt wear pattern must cover most of the
surface as the friction scores must be easily identifi-
able in this area.
In the event of extensive polishing wear on piston
skirt (appears dull rather than shiny) and concen-
F037 0039a0 trated scoring, replace piston.
Replace pistons exhibiting even minor, localized
scuffing on piston skirt.

Measuring piston skirt diameter


Use an outside micrometer to measure outside di-
ameter on points free from graphite.
If measurements are below permissible limit values
as per Tolerance and Wear Limits List, replace pis-
ton.

FG030049aO

Checking piston crown screws


Make sure threads are in perfect condition; replace screw as necessary.
Measure shaft length of screw with depth gauge.
If limit as per Tolerance and Wear Limits List is exceeded, replace screw.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 9

Inspecting piston ring grooves


Check groove width with final measurements.
Note: Alternatively, a new piston ring (2) can be
inserted into groove and axial clearance
measured with feeler gauge (1).
If the permissible limits as per Tolerance and Wear
Limits List are exceeded, or measurements are
below limit values for groove for oil control ring, re-
place piston.

Inspecting piston pin boss


Adjust bore gauge and measure piston pin bore.
If measurements are above permissible limit values
as per Tolerance and Wear Limits List, replace pis-
ton.
Check sliding surfaces of bronze bushing for wear
and scoring; replace piston as necessary.

FG030050aO

Inspecting piston pin


Using magnetic crack-testing method and fluor-
escent magnetic powder, check piston pin for cracks;
if cracks are detected, replace piston pin.
Remove minor traces of wear and scoring by polish-
ing.
Replace piston pins exhibiting scuffing, indentations
and severe wear.
Measure outside diameter with outside micrometer
and determine pin clearance see Tolerance and
Wear Limits List.
If permissible limit is exceeded, replace piston pin.

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 10

Inspecting piston rings


Replace piston rings during W6 overhaul.
Clean piston rings of combustion residue and check
for damage; replace if necessary.
Condition or wear of chrome layer (x) is a deciding
factor when reusing or replacing rectangular ring (1),
taper-face compression ring (2) and DSF ring (3).
Chrome layer must not show signs of scoring, cracks
or heat discoloration.
Replace sharp-edged piston rings.

Place piston ring (1) in ring gauge (3) to measure


piston ring end clearance.
Ensure that piston ring is fitted evenly in ring gauge!
Check piston ring gap with feeler gauge (2).
If measurements are above permissible limit values
as per Tolerance and Wear Limits List, replace pis-
ton rings.
Note: Piston rings must only be replaced in
sets. Hone cylinder liners if new piston
rings are installed.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 11

Connecting rod
Using magnetic crack-testing method with fluorescent magnetic powder, check conrod, conrod cap and conrod
screws for cracks.
Replace cracked components.
Check conrod and conrod screw threads for ease of movement.
Polish out all traces of nicks in conrod; replace conrod if necessary.
Use a brass brush to clean toothing on conrod and conrod cap mating faces and blow dry with compressed air.
Smooth wear on toothing with oilstone, check bedding pattern by ink-check method.
Check conrod for blue colouring; if blue colouring is detected (due to bearing damage), replace connecting rod.
Check main bore for wear and scoring; if necessary machine bore to repair size or replace conrod.
Check conrod bush for scoring, dirt, wear and hot runs; burnish minor scoring with emery cloth; replace conrod
bush if necessary.
Smooth conrod main bore with emery cloth.

CAUTION
Compressed air is highly pressurized. Risk of injury!
If compressed air is used for blowing out or blow-drying components, always wear protective goggles
or safety mask. Pressure must not exceed 3.0 bar.

Check that lube oil bore in connecting rod is perfectly clean; if necessary clean with bristle brush and blow with
compressed air.
Note: Never use a wire brush!

Checking conrod bore axial parallelism and twist


Arrangement of testing device
1 Dial gauge for axial parallelism
2 Test mandrel, small conrod eye
3 Dial gauge for conrod twist
4 Conrod
5 Test mandrel, large conrod eye
6 V-block
7 Base plate
8 Resilient stop
9 Adjustable dial gauge holder

Note: For checking axial parallelism and twist of


conrod bores, conrod cap is installed and
conrod screws tightened as per tightening
specifications.
L93_7722

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 12

Clean large and small conrod bore.


Insert test mandrel (2) in large conrod bore.
Make sure that installation position is correct.
Wide fit end of test mandrel (arrow) must point to
conrod shaft, narrow fit side to conrod cap.
Lightly secure test mandrel with securing screw.
Take care test mandrel is properly inserted.
Insert test mandrel (1) in small conrod bore.
Make sure that installation position is correct.
The wide fit of test mandrel (arrow) must point to-
ward conrod shaft, narrow fit to oil bores of small
conrod bore.
Lightly secure test mandrel with securing screw.
Note: Insert test mandrels so that tension pins
L93_7716
of narrow fit of test mandrels are in a
single plane.

Checking axial parallelism


Insert conrod with test mandrel (3) in large conrod
bore into prisms (4) of testing device.
Place small conrod eye on adjustable stop (5).
Adjust the rigid stop of adjustable stop so that axle of
test mandrel (2) is approx. 2.0 mm below dial gauge
stylus (1).
Adjust both dial gauges at highest point on test man-
drel, with approx. 2.0 preload, set to zero.
Rotate conrod through 180 and carefully place in
testing device.
Move test mandrel in small conrod eye through dial
gauge styluses at highest point of test mandrel axle.
Determine and record deviations on dial gauges.

L93_7719

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 13

Calculating axial parallelism


The testing device is set for measuring axial parallel-
ism at 200 mm intervals.
In order to achieve correct value at 100 mm intervals
as per Tolerance and Wear Limits List, calculate va-
lues read off at dial gauges as in the example.
Example:
Left dial gauge A = 0.05 mm
Right dial gauge B = + 0.03 mm
0.08 mm
Axial parallelism as per example:
0.08 mm : 4 = 0.02 mm
For specified limit, see Tolerance and Wear Limits
List.
If limit value is exceeded, replace conrod.
K038 0011 b0

Checking axial twist


Set both dial gauges (1) for axial twist with setting
gauge (2) via dial gauge stylus to zero.
Remove setting gauge from testing device (3).

G003 0162 b0

Insert conrod with test mandrel (2) into prisms of


testing device (3).
Fixed support of adjustable stop is set so that dial
gauge stylus travel is approx. 2 mm.
Press conrod at small conrod eye on fixed support.
Read and record values on dial gauges (1).

L93_7721

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 14

Calculating axial twist


To determine conrod bore axial twist, calculate value
measured at 100 mm intervals as shown in example.
Example:
Left dial gauge A = 0.06 mm
Right dial gauge A = ) 0.04 mm
Difference = 0.10 mm
Axial twist A as per example
A = 0.10 mm : 2 = 0.05 mm
For specified limit, see Tolerance and Wear Limits
List.
If limit value is exceeded, replace conrod.

K038 0013 b0

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 15

Checking and assessing conrod bearing shells


Replace bearing shells as part of every W6 overhaul.
In event of reuse (e.g. unscheduled removal), check bearing shells for surface wear, scoring, cracking, corrosion,
erosion and damage; replace if necessary.
Check condition of bearing shell butt and bearing reverse side and check for friction corrosion (pitting); if there is
evidence of friction corrosion, replace bearing shell and determine cause.
Possible causes: Screws not sufficiently pretensioned, assembly fault, bearing shell spread dimension is outside
tolerance limit and defective bearing support bore.
Measure bearing shells spread dimension.
If spread dimension is too low (see Tolerance and Wear Limits List), replace bearing shells.



Conrod bearing shell (grooved bearing lower
half)


a
b Bearing shell has the following material structure:

a Sliding layer


(Thickness 16 m, central axle distance 0.2 mm)
c b Intermediate layer (nickel barrier)
c Barrier layer (from 1 m to 3 m sputtered)
In new condition, the running surface has approx.
75% wear layer, approx. 20% intermediate layer and
max. 5% barrier layer.
Wear of the bearing running surfaces starts at the
galvanised wear layer (a).
This removes the wear layer in the groove by a few
0.001 mm.
In event of further wear, the difference between the
intermediate layer and sliding layer remains almost
constant, i.e. at approx. 0.005 mm.
A magnifying glass is required for a more accurate
assessment of the wear condition of the running sur-
face (magnification min. 5x).
In doing so, the sliding layer is to be seen as the
dark zone and the intermediate layer as the light
zone.
The relationship between the width of the intermedi-
ate layer and the width of the groove and the extent
of the worn area are decisive factors when evaluat-
ing the wear condition of the grooved bearings.
The grooved bearing is still functional if the sliding
layer is partially missing in the grooves.
Practice has shown that the grooved bearing with
partially empty grooves can continue in use without
negatively affecting the function of the bearing.
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.

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 16

Conrod bearing shell (sputtered bearing, upper


half)
Bearing shell has the following material structure:
1 Wear layer (from 12 m to 18 m sputtered)
2 Barrier layer (nickel barrier, from 1 m to 3 m
sputtered)
3 Intermediate layer corresponds to approx. 10% of
bearing thickness.
4 Protective steel shell corresponds to approx. 88%
of bearing thickness.
An important indicator for assessing extent of wear
on bearing shell is the shape and extent of the nickel
barrier (running-in layer) areas exposed.
Use of bearing shell is already restricted in friction
area once the sliding layer is reduced to 70%!
Note: It is often difficult to differentiate between
the hard nickel barrier and softer sliding
layer. If in doubt, consult a bearing
specialist.

Checking conrod cap screw


Check screw head support and thread (arrows) for
scoring or damage; replace screw if necessary.
Measure shaft length of conrod screw with depth
gauge.
Max. permissible shaft length see overview draw-
ing C 037.05.01.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 17

Storing conrod

CAUTION
Compressed air is highly pressurized.
Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Pressure must not exceed 3.0 bar.
Blow out interfaces (arrows) on connecting rod and
conrod cap with compressed air and check that they
are clean.
The toothing on the conrod and conrod cap mating
faces must not be damaged. If necessary, replace
conrod.
Wipe bearing shell mating faces on connecting rod
and conrod cap.

Note: New conrod bearing shells (1) must be


installed as part of every W6 overhaul.
Prior to installing conrod bearing shells,
compare repair stage marking on con-
necting rod and in crankshaft data sheet.
Mark conrod bearing shells according to cylinder
number on front face (A).

K038 0008 b0



Secure conrod in assembly trolley or in vice with alu-
1 minium jaws with mating face horizontal.
Place conrod bearing groove (2) (BOTTOM),
(identifying feature, running surface shiny), in conrod
cap so that bearing shell recess engages in locating


pin.


Place conrod bearing sputter (1) (TOP), (identifying
feature, running surface mat) in connecting rod so
that conrod bearing projects approx. 40 (arrows)
over short conrod arm.
Carefully press conrod cap by hand onto conrod.


Pay attention to locating pin and correct location of


bearing shell.


Coat threads of screw head mating face and screw
head seating surfaces with engine oil.
2

F0370019a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 18

Carefully insert conrod screw into bearing cap bore


by hand to first contact with thread flanks, then turn
first three rotations without a tool.
Note: Do not drop screws into conrod cap bore.
Thread must not be recut.
Install conrod cap screws until screw heads make
contact and use socket wrench to tighten firmly by
hand.
Conrod and conrod cap serrations on short and long
conrod arms must be closed.
Using torque wrench (1), first tighten conrod cap
screw at short conrod arm (A) and then on long con-
rod arm (B) to specified torque see overview draw-
ing C 037.05.01.

L93_5517

Adjust bore gauge and dial gauge with micrometer to


basic size for conrod bearing bore as per Tolerance
and Wear Limits List.

F037 0002a0

Measuring conrod bore


Coat sliding surfaces of bearing shells with engine
oil.
Measure conrod bearing bore.
For permissible limits and measuring points, see Tol-
erance and Wear Limits List.
Enter measurement values in data sheet.
If permissible limits are exceeded or not reached,
replace bearing shells or machine conrod basic bore
to repair size.
Remove conrod screws, conrod cap and bearing
shells.
Note: Protect bearing shells from damage!

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 19

Measuring conrod basic bore


Check conrod bore for wear and scoring; if necess-
ary machine bore to repair size or replace conrod.
Before measuring, smooth main bore (2) with emery
cloth.
Adjust bore gauge (1) and measure conrod main
bore.
For basic size of conrod basic bore, permissible li-
mits and measuring points see Tolerance and
Wear Limits List.
If permissible values as per Tolerance and Wear Li-
mits List are exceeded, recondition bore to next re-
pair stage or replace conrod.
When reconditioning bore, recondition locating pin
bore as required and replace locating stud.

Measuring conrod bush bore or main bore


Set bore gauge (1) to zero dimension of conrod bush
bore and measure conrod bush bore (2).
If permissible values are exceeded, replace conrod
bush.
After removing conrod bush, use bore gauge to
measure main bore.
If permissible values are exceeded, machine bore to
repair size or replace conrod.
For permissible values, see Tolerance and Wear Li-
mits List.

L92_11619

Checking conrod bush axial seating


Use test mandrel (1) and hydraulic press to check
conrod bush axial seating.
Required test force F see Tolerance and Wear Li-
mits List.
If test force is not reached, use mandrel and hy-
draulic press to remove conrod bush from conrod
(2).

L92_20192

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 20

Removing conrod bush


Note: Remove conrod bush only if required (e.g.
wear, damage, etc.).
Use mandrel (1) and hydraulic press to remove con-
rod bush from conrod (2)
It is imperative to contact MTU and/or DDC.

L93_8428

C 037.05.10 Assembly
Note: Always make sure that all components are perfectly clean.
Installing conrod bush

CAUTION
Nitrogen is liquid at 200 C.
Danger of freezing and suffocation!
Do not allow liquid nitrogen to come into con-
tact with parts of body (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ventilate working area well.

Cool new conrod bush (1) in liquid nitrogen and use


plastic or wooden mandrel, without pressure, to in-
sert in conrod bore (2).
Make sure that lube oil bores are aligned.
K038 0010 b0
Check that conrod bush is firmly seated (see
C 037.05) and use a fine drilling tool to machine to
specified final dimension.
After machining, provide edges (A) of conrod bush
with felt washer dia. 30 40.
Stamp conrod bush repair stage diameter on face (B)
of conrod bush with 2 mm numeral punch and on
surface (C) of conrod with 4 mm numeral punch.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 21

Installing piston crown

1
2
Note: Piston crown (2) and piston skirt (1) form
a matched pair and must not be separ-
ated.
Measure shaft length of piston crown screws, see
C 037.05.08 Inspection and repair.


Place piston crown right way round on piston skirt.


Check that spring pin (arrow) is correctly seated.


Coat thread of piston crown screw with thin-film lu-
bricant.

FG030054aO0

Note: Piston crown screw version is indepen-


dent of piston upper section (Epsilon).
Marking (1) MTU part no.
Marking (2) Mahle designation, piston upper sec-
tion.
Marking (3) MTU upper section part no.

Tighten piston crown screws (1) as per tightening


specifications see overview drawing C 037.05.01.
Note: It is essential to proceed exactly as laid
down in tightening specification.

FG030056aO

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 22

Installing piston rings


Turn coiled spring expander (2) in DSFring (1) to
1 offset ring spring butting face (arrow) to DSF ring
butt by 180.

F037 0006a0

In sequence from bottom to top (DSF-ring first), in-


sert piston rings with piston ring pliers into annular
grooves on piston.
Note: Stretch piston rings only until they can be
fitted over the piston. Do not overstretch
piston rings, as they may break.
Make sure piston rings are installed in correct se-
quence see next illustration.
Note: TOP marking on piston rings must point
upwards.
Check that piston rings move freely in their grooves.

Sequence of piston rings:


1 Rectangular-section ring
2 Taper-face compression ring
3 DSF ring
Note: Piston rings must only be replaced in
sets.
Hone cylinder liners if new piston rings
are installed.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 23

Wipe down piston pin, conrod bushing and piston pin


bore with chamois leather and coat with engine oil.
Using snap ring pliers, insert first snap ring into pis-
ton pin bore.
Note: Make sure snap ring is perfectly seated in
groove.
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).

L92_20205

Push associated piston pin (2) into piston and con-


rod (1) until seated against snap ring installed be-
forehand.

L92_19149

Insert second snap ring (2) with snap ring pliers (1).



Note: Make sure snap ring is perfectly seated in


groove.


1
2

FG030067aO

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 24

C 037.05.11 Installation
Installing piston with conrod in assembly dolly
Note: Always make sure that all components
are perfectly clean.
Rotate crankcase in assembly dolly until cylinder
liner (arrow) is vertical.
Note: The crankshaft must only be turned with
the flywheel or axial locating element in-
stalled.
Turn crankpin of crankshaft of piston to be installed
and connecting rod to assembly position.
Wipe crankpin and running surface of cylinder liner
and spray with engine oil.

Cylinder liner
Running surface of piston crown is machined ac-
cording to carbon scraper ring.
1 Piston
2 Carbon scraper ring
3 Cylinder liner
4 Crankcase
Important: Install piston without carbon scraper
ring.

Installing piston with conrod in assembly dolly


Note: Always make sure that all components
are perfectly clean.
Spray the piston and piston rings with engine oil.
Position piston ring butts (arrows) consecutively at
120 intervals.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 25

CAUTION
Compressed air is highly pressurized.
Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Pressure must not exceed 3.0 bar.
Blow out interfaces (arrows) on connecting rod and
conrod cap with compressed air and check that they
are clean.
Toothing on mating faces must not be damaged. Re-
place conrod as necessary.
Wipe bearing shell mating faces on connecting rod
and conrod cap.

Place conrod bearing groove (bottom) in assembly


device (1) so that conrod bearing recess (3) engages
in locating pin (2).
Coat friction face of bearing shell with engine oil.

Press assembly device (arrow) with bearing shell


half by hand on crankshaft crankpin.

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 26

Coat sputter (top) running surface of bearing shell



1

with engine oil.
Position second bearing shell half (1) with recess for

2 locating pin on crankpin (2) so that the two recesses


are aligned.

FG030042aO



1

2 Note: In order to guide the conrod and avoid
damage to the oil spray nozzle, piston in-


stallation must be carried out by two
people.

3 Attach lifting appliance (1) for piston (2).


Lubricate running surface of piston assembly sleeve
(3) with oil.
Place piston assembly sleeve on appropriate cylin-
der liner (4).

WARNING
Heavy object.
Risk of injury!

Use suitable tools and lifting gear.


4
FG030043aO Suspend piston with ropes and pass through assem-
bly sleeve into cylinder liner.
Install piston into cylinder liner so that short arm of
conrod points outwards to air intake side.
Gently turn piston when inserting so that the oil
spray nozzle is not damaged when the conrod is in-
stalled.
If the oil spray nozzle is damaged, remove spray
nozzle and replace.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 27

Use mandrel (1) to press piston into cylinder liner


(2).

Place conrod on assembly device (2) for conrod


bearing.
At same time, position assembly device with guide
pin (1).
Remove assembly device and press conrod cap by
hand onto conrod.
Pay attention to fit of locating pin in recess in conrod
cap.

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 28

Measure shaft length of conrod screws; for max.


shaft length see C 037.05.01.
Coat threads and screw head seating surfaces (ar-
rows) with engine oil.
Carefully insert conrod screw into bearing cap bore
by hand to first contact with thread flanks, then turn
first three rotations without a tool.
Install conrod cap screws (arrow) until screw heads
make contact and use socket wrench to tighten by
hand.
Conrod and conrod cap serrations must be closed.
First tighten conrod cap screw at short conrod arm
and then on long conrod arm to specified torque
see overview drawing C 037.05.01.
Checking axial clearance of connecting rod see
next section.
L94_2131
Mark screw heads (arrows).
Tighten conrod screws through specified angle of
further rotation.
Check checking torque in tightening direction as per
tightening specifications.
Again check axial clearance.
Note: Remove lifting device and assembly
sleeve for piston with connecting rod.
Bar crankshaft and ensure that there is ease of
movement between oil spray nozzle, piston and con-
rod.
Installing carbon scraper ring see C 013.05.

Checking axial clearance of connecting rod


Check distance between crankshaft web and conrod
or between conrod and conrod, pressed towards
each other.
The above-stated components must not touch each

other.

Use feeler gauge (arrow) to measure ring end clear-


ance, pressing on three levels.
Min. clearance = 0.20 mm
Max. clearance = 0.60 mm
If the specified clearance is exceeded or undershot,
adjustment is necessary.
Release conrod cap screws, compensate clearance
in axial area and again tighten as per tightening


specifications.


L94_2131
FG030076aO

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 29

Installing piston with connecting rod with oil


pan installed (via access port)
Apart from the unaltered installation position of the
crankcase (engine in normal position), installation of
the conrod bearings, conrod caps and conrod
screws through the access port (arrow), is in princi-
pal the same as for Installing piston with connect-
ing rod in assembly dolly.


Before installing, mount the sliding block on the con-
necting rod to be installed, see next illustration.

FG030070aO

1 Connecting rod
2 Sliding block
3 Cylinder liner

Insert carbon scraper ring.


Before installing, spray cylinder liner and carbon
scraper ring with engine oil.
Insert carbon scraper ring.

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 30

Defining piston TDC



1
Install pointer (1) on equipment carrier.
Install graduated disc (2) with barring tool on crank-
shaft, free end.

F037 0038a0

Install dial gauge (2) under preload in measuring unit


(4) and clamp with screw (1).
Install measuring unit into cylinder head and secure
with knurled-head screw (3).
Set dial gauge to zero.
Move piston several times up and down through
TDC until needle of dial gauge registers its highest
reading.
Set dial gauge to zero and readjust index plate ac-
cordingly.
Bar crankshaft in normal direction of rotation to 5
before TDC, read dial gauge and make a note of
measured value.
Bar crankshaft past TDC to approx. 10 (to take up
bearing play).
Bar crankshaft in direction opposite to normal direc-
tion of rotation to 5 after TDC, read dial gauge and
make a note of measured value.
Example:
Piston to 5 before TDC 0.36 mm
Piston to 5 after TDC 0.32 mm

Total values = 0.68 mm
Mean value = 0.34 mm
Bar crankshaft to approx. 10 after TDC, then bar in
direction opposite to normal direction of rotation until
dial gauge reads mean value, i.e. = 0.34 mm.
Set pointer of index plate to 5 after TDC and
tighten.
Inspection: Absolute TDC is reached when the dial
gauge shows the same values before and after TDC
at the same angle. To eliminate bearing clearance,
the piston must always move in direction of TDC.

MTU 01.12 MR20108/00E


Task Description Section C
Pistons and Conrods Group 037.05
Page 31

C 037.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Release engine start Operating Instructions
x x Assembly in reverse sequence to disassembly C 037.05.04
x Fill oil system with engine oil Operating Instructions
x Fill engine coolant system Operating Instructions
x Release engine start Operating Instructions
x Fill fuel system Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 037.05 Pistons and Conrods
Page 32

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Head Group 040
Page 1

Contents

C 040 Cylinder Head with Attachments

C 041.05 Cylinder head


C 041.05.01 Overview drawing
C 041.05.02 Special tool
C 041.05.04 Before-removal operations
C 041.05.05 Removal
C 041.05.06 Disassembly
C 041.05.08 Inspection and repair
C 041.05.10 Assembly
C 041.05.11 Installation
C 041.05.12 After-installation operations

MR20108/00E 01.12 MTU


Section C Task Description
Group 040 Cylinder Head
Page 2

C 040 Cylinder Head with Fixtures

1 Cylinder head screw 8 Valve spring (inlet valve) a Charge air


2 Cylinder head 9 Valve guide (inlet valve) b Exhaust gas
3 Hold-down clamp 10 Sealing ring c Coolant
4 Spring retainer (exhaust valve) 11 Inlet valve
5 Hex screw 12 Exhaust valve
6 Injector 13 Sliding pin
7 Spring retainer (inlet valve)

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Head Group 041.05
Page 1

C 041.05 Cylinder Head


C 041.05.01 Overview Drawing

1 Sealing ring 4 Thrust washer


2 Gasket 5 Cylinder head screw
3 Cylinder head screw

Cylinder head tightening diagram


Lubricant: Engine oil
1. Fitting screws: approx. 25 Nm
2. Tightening screws: 180 Nm + 10 Nm
3. Additional angle of rotation: 180 + 10
4. Checking torque: 450 Nm
Tighten screws at every respective stage in the fol-
lowing sequence: 1, 2 ,3 ,4 ,5 , 6
A = Exhaust side
B = Inlet side

MR20108/00E 01.12 MTU


Section C Task Description
Group 041.05 Cylinder Head
Page 2

C 041.05.02 Special Tool


Designation Application Number

Installation/removal tool for blanking plugs 1


Blanking plugs for oil duct at cylinder head screw
1
bores.
Cylinder head support bracket 1
Angle of rotation tightening tool for cylinder head
1
screws
Alignment gauge for cylinder heads 1

C 041.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions
x Drain engine coolant Operating Instructions
x x Remove exhaust turbocharger C 101.01
x x Remove exhaust manifolds C 141.10
x x Remove rocker arm assembly C 055.05
x x Remove pushrods C 055.05
x x Remove fuel injector C 075.05
x x Remove charge air manifolds C 124.05
x x Remove H.P. line to cylinder head C 077.05
x x Disconnect fuel return lines C 086.05

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Head Group 041.05
Page 3

C 041.05.05 Removal

Removing cylinder head


Using a large ratchet or power assist (2), remove
hex screws (1) evenly.

L93_16929

Before removing cylinder head, seal oil supply line to


valve gear in crankcase as follows:
Fit blanking plugs (2) on installation/removal tool and
1 2 lock slightly in position with the retaining grip (1).

F041 L93_16929
0047a0

Screw blanking plugs with installation/removal


1 tool (1) into oil supply line (arrow) in crankcase
(10 oclock position) and spread.
Unscrew installation/removal tool from blanking plug
and remove.

F041 L93_16929
0048a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 041.05 Cylinder Head
Page 4

WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting equipment.

Using the lifting device (1), lift the cylinder head (2)
out of the crankcase and place it on a suitable base.
Note: With injector installed, place cylinder head
to the side. Injector protrudes at bottom of
cylinder head.
Remove cylinder head gasket from crankcase mat-
ing face.
Remove blanking plug from oil supply bore for valve
gear.
FGG

Using a screwdriver, carefully lever sealing ring (1)


out of cylinder head lower section.

L93_301

C 041.05.06 Disassembly
Disassembly of cylinder head is not envisaged.
The cylinder head is a replacement part and available in the replacement programme.

C 041.05.08 Inspection and Repair


Visually inspect outside of cylinder head for damage and condition.
Check cylinder head interfaces (combustion chamber side) for evenness and damage; replace as necessary.
Check that thread and screw head mating face of cylinder head screws are in perfect condition; replace screws if
necessary.
Check all threads in cylinder head for ease of movement; rechase threads as necessary.
Replace sealing rings and gaskets.

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Head Group 041.05
Page 5

C 041.05.11 Installation

Install cylinder head


Note: Prior to installation, remove all plugs and
ensure oil bores are perfectly clean.
Check that cylinder head mating face and crankcase
partition surface are in perfect condition. Wipe and
clean as necessary.
Note: Always use new cylinder head gaskets.
Fit cylinder head gasket (1).
Install adjusting mandrel (2) for positioning cylinder
head gasket and cylinder head in crankcase.

L93_3012

To improve clamping effect of sealing ring in cylinder


head, tap sealing ring with a plastic mallet to pro-
duce a slight oval shape.
Insert sealing ring in groove on combustion chamber
side of cylinder head.

L93_3012
V0410013a0

Ensure that sealing ring is fitted correctly:


A = Cylinder head side
B = Piston side

MR20108/00E 01.12 MTU


Section C Task Description
Group 041.05 Cylinder Head
Page 6

WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting equipment.

Using lifting equipment (1), install cylinder head (2)


on crankcase.

Coat thread, head and shaft of cylinder head screws


(1) with engine oil.
Ensure correct allocation of cylinder head
screws (engine lifting eye), see overview drawing
C 041.05.01.
Install cylinder head screws with thrust washers
manually in crankcase.
Fit alignment tool (2) on inlets of cylinder heads and
tighten.
Important: Carry out cylinder head alignment care-
fully, otherwise deformation and cracks
may result in exhaust and intake pipe-
work.

Tighten cylinder head screws in steps to specified


pretightening torque in accordance with the tighten-
ing sequence, see overview drawing C 041.05.01.
Mark screw heads.
Using a large ratchet or power amplifier, tighten cyl-
inder head screws to angle of rotation in specified
sequence as per tightening specifications.
Remove alignment tool.

L93_3012

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Head Group 041.05
Page 7

C 041.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007
x x Assembly in reverse sequence to disassembly C 041.05.04
x x Adjusting valve clearance C 055.05.11
x Fill engine coolant system Operating Instructions
x Release engine start Operating Instructions
x Fill fuel system Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 041.05 Cylinder Head
Page 8

MTU 01.12 MR20108/00E


Task Description Section C
Valve Gear Group 050
Page 1

Contents

C 050 Valve Gear

C 051.05 Camshaft
C 051.05.01 Overview drawing
C 051.05.02 Special tool
C 051.05.04 Before-removal operations
C 051.05.05 Removal
C 051.05.08 Inspection and repair
C 051.05.11 Installation
C 051.05.12 After-installation operations

C 052.05 Camshaft drive


C 052.05.02 Special tool
C 052.05.04 Before-removal operations
C 052.05.05 Removal
C 052.05.06 Disassembly
C 052.05.08 Inspection and repair
C 052.05.10 Assembly
C 052.05.11 Installation
C 052.05.12 After-installation operations

C 053.05 Camshaft axial alignment bearing


C 053.05.01 Overview drawing
C 053.05.02 Special tool
C 053.05.04 Before-removal operations
C 053.05.05 Removal
C 053.05.06 Disassembly
C 053.05.08 Inspection and repair
C 053.05.10 Assembly
C 053.05.11 Installation
C 053.05.12 After-installation operations

MR20108/00E 01.12 MTU


Section C Task Description
Group 050 Valve Gear
Page 2

C 055.05 Valve drive


C 055.05.01 Overview drawing
C 055.05.02 Special tool
C 055.05.04 Before-removal operations
C 055.05.05 Removal
C 055.05.06 Disassembly
C 055.05.08 Inspection and repair
C 055.05.10 Assembly
C 055.05.11 Installation
C 055.05.12 After-installation operations

C 055.10 Cylinder head cover


C 055.10.01 Overview drawing
C 055.10.04 Before-removal operations
C 055.10.05 Removal
C 055.10.08 Inspection and repair
C 055.10.11 Installation
C 055.10.12 After-installation operations

MTU 01.12 MR20108/00E


Task Description Section C
Valve Gear Group 050
Page 3

C 050 Valve Gear

1 Camshaft gear 10 Hex nut


2 Rocker arm, inlet 11 Adjusting screw
3 Rocker arm, exhaust 12 Rocker arm, exhaust
4 Rocker shaft 13 Bearing pedestal
5 Camshaft 14 Valve bridge, exhaust
6 Pushrod, inlet 15 Hex nut
7 Pushrod, exhaust 16 Adjusting screw
8 Axle 17 Valve bridge, inlet
9 Rocker arm, inlet

MR20108/00E 01.12 MTU


Section C Task Description
Group 050 Valve Gear
Page 4

The following is a list of auxiliary equipment and materials needed for the assembly operations:

CAUTION
When using these miscellaneous materials, it is essential to observe the manufacturers instructions
for use, safety instructions and waste disposal specifications.

Materials and consumables Designation MTU Order No. Remarks


Chamois leather
Bottle brush
Roller brush
Brass brush
Emery cloth
Magnifying glass
Spray gun
Inspection lamp
Endoscope with cold light
Liquid nitrogen
Activator
Vaseline Petroleum jelly, white 40317
Denaturated ethanol 40250
Surface sealant
Thin-film lubricant Molycote g-N plus 40041
Engine oil
Corrosion inhibitor
Cleaning agent
Engineers blue blue 40641
Kerosene or diesel fuel
Synthetic shot-blasting pellets Dry Strip Type 216/20 20098
Cleaning agent (carbon-deposit remover)
Dry compressed air
Magnetic crack-testing equipment with fluor-
escent magnetic powder
Surface crack-testing equipment with red
penetrant dye
Surface crack-testing equipment with fluor-
escent penetrant dye

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Group 051.05
Page 1

C 051.05 Camshaft
C 051.05.01 Overview Drawing

1 Hex screw M 12 X 70 4 Camshaft gear


Tightening torque: 100 Nm + 10 Nm 5 Hex screw
Lubricant: Engine oil 6 Thrust bearing flange
2 Spring washer 7 Dowel pin
3 Graduated disc 8 Camshaft

MR20108/00E 01.12 MTU


Section C Task Description
Group 051.05 Camshaft
Page 2

C 051.05.02 Special Tool


Designation Application Number

Camshaft guide sleeve 1

Camshaft locating device 1


Camshaft installation/removal jig 1

Measuring unit (TDC position) 1

Graduated disc with pointer 1


Feeler gauge 0.3 mm 1.4 mm 1

Retaining ring for camshaft 1

C 051.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x x Removal not scheduled
x Disable engine start Operating Instructions
x Drain engine coolant (high temperature) Operating Instructions
x Drain charge air coolant (low temperature) Operating Instructions
x x Remove ECU housing C 508.95.05
x x Remove vibration damper (as required) C 035.05.05
x x Remove Y-pipe from exhaust outlet housing C 141.10.05
x x Remove air pipework from exhaust turbocharger to intercooler C 125.05.05
x x Remove oil supply lines for turbochargers C 185.10.05
x x Remove oil return lines for turbochargers C 185.25.05
x x Remove exhaust turbocharger C 101.01.05
x x Remove charge air coolant lines (low temperature) C 203.25.05
x x Remove engine coolant vent lines (high temperature) C 202.65.05
x x Remove charge air coolant vent line (low temperature) C 202.55.05
x x Remove coolant lines (high temperature) C 202.10.05
x x Remove cylinder head covers C 055.10.05
x x Remove valve drive C 055.05.05

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Group 051.05
Page 3

C 051.05.05 Removal

Removing camshaft
Turn engine with barring tool in normal direction of
rotation until TDC mark and arrow on flywheel hous-
ing are aligned.
If rocker arms on cylinder A1 are unloaded, the pis-
ton is in firing TDC.
If rocker arms on cylinder A1 are loaded, the piston
is in overlap TDC.
Remove valve drive see C 055.05

Separate electrical plug-in connection.


Remove hex screw (arrow).
Turn speed sensor (1) slightly to remove from hous-
ing fit.

L93 2167

MR20108/00E 01.12 MTU


Section C Task Description
Group 051.05 Camshaft
Page 4

Removing graduated disc (camshaft gear)


Position locating device (1) on securing plane of
rocker shaft, driving end.
Insert dowel pin of guide tube (3) into camshaft bore
(2) see following illustration and screw locating
device into place (arrow).

L93 2167

Locating bore (arrow) for locating device dowel pin.

F 051 0010aO
L93 2167

Note: Cover bottom of equipment carrier so that


no objects can fall into housing.
Remove hex screws (4).
Remove graduated disc (2) and camshaft gear (1)
from camshaft or dowel pins (3).

L93 2167

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Group 051.05
Page 5

Removing camshaft axial alignment bearing


Remove hex screws (1) and remove axial alignment
bearing flange (2).
Remove locating device.

L93 2167

Removing camshaft
Screw inner guide sleeve (2) to face of camshaft,
free end.
1 2
Secure guide flange (1) to crankcase.

F051 L93
0024a0
2167

Secure outer guide sleeve (3) to guide camshaft to


be removed with hex screws (1) on crankcase (2),
driving end.
Screw on inner guide sleeve (4), free end, on cam-
shaft and centre guide sleeve with respect to cam-
shaft bearing.

L93 2167

MR20108/00E 01.12 MTU


Section C Task Description
Group 051.05 Camshaft
Page 6

Centre guide flange (1) with guide sleeve (2) on


crankcase (free end) with regard to camshaft bear-
ings and secure.
1 2

F051 L93
0024a0
2167

Install sliding block on camshaft (2).


Carefully withdraw camshaft (2) from crankcase so
that bearings are not damaged.

WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting equipment.

Attach rope (1) midway along camshaft.


Take up slack and continue carefully withdrawing
camshaft from crankcase.
Remove insertion sleeve.

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Group 051.05
Page 7

C 051.05.08 Inspection and Repair

Clean camshaft.
Pre-polish bearing journals and cams with emery cloth.
Using the magnetic crack-testing method with fluorescent magnetic powder, check camshaft for cracks; replace
camshaft if necessary.
Check axial sliding surface, journal faces and roller tracks of cams for scoring, wear and indentations.
Check gear mating face and rub down with oilstone or emery cloth if necessary.
Check surface condition of camshaft gear teeth with magnifying glass; replace gear if necessary.
Remove minor scoring, wear and indentations by polishing with emery cloth; if necessary, machine to MTU and/or
DDC specifications or replace camshaft.
For dimensions, see Tolerance and Wear Limits List.
Note: Make sure parts are perfectly clean.

Checking hardness of cam and journal


Check hardness of cam (inlet and exhaust rocker
arms) and journal on camshaft using Microdur test-
ing unit or another suitable hardness testing unit.
Test hardness of each journal at four points at 90
intervals around circumference.
For dimensions, see Tolerance and Wear Limits List.
If dimension is not achieved, machine camshaft to
MTU or DDC specifications or replace as necessary.
Required hardness = 61 HRC  2 HRC
Note: Smoothen traces of wear with emery
cloth.

Checking concentricity and cam lift


Set camshaft at outer journals on V-blocks (2) or
roller stands.
Place supporting mount (3) at centre journal.
Measure radial runout of cam base circle and bear-
ings with dial gauge (1).
For values, see Tolerance and Wear Limits List.
Measure cam lift over base circle diameter of valve
and roller track with dial gauge.
For tolerance values, please contact MTU and/or
DDC.

MR20108/00E 01.12 MTU


Section C Task Description
Group 051.05 Camshaft
Page 8

C 051.05.11 Installation

Install camshaft
Note: Make sure all components are perfectly
clean.
Attach outer insertion sleeve (1) to driving end of
crankcase and centre carefully to camshaft bearings
with inner insertion sleeve (2).

Centre guide flange (1) with guide sleeve (2) on


crankcase (free end) with regard to camshaft bear-
ings and secure.
1 2

F051 L93
0024a0
2167

Position inner insertion sleeve (2) on front of cam-


shaft (1) and tighten.

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Group 051.05
Page 9

WARNING
Heavy object.
Risk of injury!
Use suitable tools and lifting equipment.

Attach camshaft (arrow) in centre with rope and


wipe.
Spray camshaft, camshaft bearing, and insertion
sleeve with engine oil.
Install sliding block at outermost cam on camshaft.
Taking care not to damage bearings, slowly intro-
duce camshaft into crankcase up to second-last
bearing.

Position assembly extension (1) on camshaft (2) and


insert camshaft up to last bearing.
Note: Locate camshaft axially and/or ensure
that it cannot fall out until axial alignment
bearing and camshaft gear are installed.
Remove inner/outer guide sleeve and assembly ex-
tension.


Installing camshaft axial alignment bearing


Coat axial sliding surfaces with engine oil.
1


2 Note: Cover bottom of equipment carrier so that
no screws can fall into housing.
Tighten axial alignment bearing flange (1) with hex
screws (2).

MR20108/00E 01.12 MTU


Section C Task Description
Group 051.05 Camshaft
Page 10

Installing transportation locking device


Install ring (2) with hex screw (1) on camshaft.
Note: The ring serves only to secure the cam-
shaft axially and prevent it falling out dur-
ing crankcase transportation.

Turn camshaft until locating bore (arrow), driving end,


is visible and at position shown.

F 051 L93
0010aO
2167

Installing locating device


Position locating device (1) on securing plane of
rocker shaft, driving end.
Insert dowel pin of guide tube (3) into camshaft bore
(2) and screw locating device into place (arrows).

L93 2167

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Group 051.05
Page 11

Install pointer (2) on equipment carrier.


Install index plate (1) with barring tool on crankshaft,
set to TDC marking of A1 and tighten.
Position piston A1 to firing TDC see Section
C 037.05.11.
Note: If installed, remove ring securing cam-
shaft.

Insert camshaft gear (1) into camshaft so that dowel


pins (3) engage in camshaft gear bore in a vertical
line.
Install graduated disc (2) (see overview drawing
C 051.05.01) via dowel pins.
Note: Cover bottom of equipment carrier so that
no objects can fall into housing.
Screw in hex screws (4) with spring washers and
tighten see C 051.05.01.
Note: Ensure that dowel pin and screw bores
are aligned.

Measuring backlash
Note: Remove camshaft locating device.
Mount magnetic dial gauge holder with dial gauge on
crankcase, free end.
Position dial gauge stylus with low preload on one
tooth flank of camshaft gear.
Set dial gauge to zero.
Check backlash by moving camshaft gear back and
forth.
Backlash see C 020.

MR20108/00E 01.12 MTU


Section C Task Description
Group 051.05 Camshaft
Page 12

Measuring camshaft axial play


Mount magnetic dial gauge holder with dial gauge on
crankcase, free end.
Place dial gauge stylus on graduated disc (arrow).
Press camshaft on camshaft gear axially as far as it
will go.
Set dial gauge with preload to zero.
Move camshaft from stop to stop and record
measured value (axial clearance).
For axial clearance, see Section C 020 or Clearance
in Tolerance and Wear Limits List.

Installing speed sensor


Replace O-ring (arrow) and coat with petroleum jelly.
Turn speed sensor (2) slightly to install in housing fit.
Install hex screws (1) and tighten.

Checking speed sensor clearance


Pull camshaft on camshaft gear axially (arrow) as far
as it will go.
Measure distance (X).
Specified value is 0.3 mm to 1 mm
If distance is less than 0.3 mm
Fit appropriate number of adjusting shims of 0.3 mm
thickness.
Measure distance.

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Group 051.05
Page 13

Checking camshaft timing


Note: Check timing with cylinder head and valve
drive installed.
Determine TDC position of piston as follows:
Install measuring device (2) with dial gauge (1),
starting at cylinder head A1.
To apply TDC mark (index plate) on diaphragm
coupling flange or crankshaft journal, free end, install
suitable TDC pointer on equipment carrier or crank-
case, driving end.
Using the barring tool, bar the engine until the piston
of cylinder A1 is in the firing TDC.
Note: The piston is at firing TDC when both
rocker arms are unloaded, i.e. have clear-
ance.
Move piston several times up and down through
TDC until needle of dial gauge registers its highest
reading. Set dial gauge to zero.
Rotate crankshaft against normal direction of rota-
tion to approx. 10_.
Rotate crankshaft in direction of rotation to 0.3 mm
(dial gauge) before TDC and apply exact mark to
index plate, driving end, or crankshaft journal, free
end, opposite TDC pointer.
Bar crankshaft in direction of rotation past TDC to
approx. 10_ (to take up bearing play).
Bar crankshaft in direction opposite to normal direc-
tion of rotation to 0.3 mm after TDC and make a sec-
ond mark.
Note: To eliminate bearing clearance, the piston
must always move in direction of TDC.
Apply third mark at exact centre between marks.
Align index plate so that mark for cylinder A 1 corre-
sponds to pointer.

MR20108/00E 01.12 MTU


Section C Task Description
Group 051.05 Camshaft
Page 14

Again check TDC position.


Remove measuring device with dial gauge.

Measuring valve stroke


Measure valve stroke as follows:
Starting from cylinder A 1, turn cylinder A 1 to firing
TDC.
Release locknuts (arrows) and insert adjusting
screws until there is no more play and then slightly
tighten locknuts.
Note: Ensure there is no valve play in order to
obtain valid measurements!
Mount magnetic-base indicator holder with dial
gauge on cylinder A1.
Position dial gauge stylus with low preload on valve
bridge of inlet valve and set scale to zero.
Slowly turn crankshaft further in engine direction of
rotation 360_ exactly to overlap TDC, in accordance
with applied mark.
Read valve stroke from dial gauge and record read-
ings in Data Sheet.
Position dial gauge stylus on valve bridge of exhaust
valve and set scale to zero.
Further rotate crankshaft slowly in engine direction
of rotation until pointer of dial gauge no longer
moves.
Read valve stroke from dial gauge and record read-
ings in Data Sheet.
For specified values, see A 004.
Check camshaft if tolerance deviation is above per-
mitted level.
Remove magnetic-base indicator holder with dial
gauge and TDC indicator.
Set valve clearance on cylinder A1 see
C 055. 05.11.

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Group 051.05
Page 15

C 051.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007
x x Install main oil gallery C 011.05.11
x x Install pushrods C 054.10.11
x x Install valve drive C 055.05.11
x x Install cylinder head covers C 055.10.11
x x Install coolant lines (high temperature) C 202.10.11
x x Install charge air coolant vent line (low temperature) C 202.55.11
x x Install engine coolant vent lines (high temperature) C 202.65.11
x x Install charge air coolant lines (low temperature) C 203.25.11
x x Install turbocharger C 101.01.11
x x Install oil return lines for turbochargers C 185.25.11
x x Install oil supply line for turbochargers C 185.10.11
x x Install intake air system from turbocharger to intercooler C 125.05.11
x x Install Y-pipe at exhaust outlet housing C 141.10.11
x x Install vibration damper (if removed) C 035.05.11
x x Install ECU housing C 508.95.11
x x Install engine carrier, free end (gear case) C 231.05.11
x Add engine coolant (high temperature) Operating Instructions
x Add charge air coolant (low temperature) Operating Instructions
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 051.05 Camshaft
Page 16

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Drive Group 052.05
Page 1

C 052.05 Camshaft Drive


C 052.05.01 Overview Drawing

1 Hex screw M 12 X 70 3 Graduated disc


Tightening torque: 100 Nm + 10 Nm 4 Camshaft gear
Lubricant: Engine oil 5 Hex screw
2 Spring washer 6 Axial alignment bearing flange

MR20108/00E 01.12 MTU


Section C Task Description
Group 052.05 Camshaft Drive
Page 2

C 052.05.02 Special Tool


Designation Application Number

Piston measuring device 1

Index plate with pointer 1


Camshaft locating device 1

Retaining ring for camshaft 1

C 052.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x x Removal not scheduled
x Disable engine start Operating Instructions
x Drain engine coolant (high temperature) Operating Instructions
x Drain charge air coolant (low temperature) Operating Instructions
x x Remove ECU housing C 508.95.05
x x Remove vibration damper (as required) C 035.05.05
x x Remove Y-pipe from exhaust outlet housing C 141.10.05
x x Remove air pipework from exhaust turbocharger to intercooler C 125.05.05
x x Remove oil supply lines for turbochargers C 185.10.05
x x Remove oil return lines for turbochargers C 185.25.05
x x Remove exhaust turbocharger C 101.01.05
x x Remove charge air coolant lines (low-temperature) C 203.25.05
x x Remove engine coolant vent lines (high temperature) C 202.65.05
x x Remove charge air coolant vent line (low temperature) C 202.55.05
x x Remove coolant lines (high temperature) C 202.10.05
x x Remove cylinder head cover C 055.10.05
x x Remove valve drive C 055.05.05
x x Remove pushrods C 054.10.05
x x Remove main oil gallery C.011.05.05

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Drive Group 052.05
Page 3

C 052.05.05 Removal

Removing camshaft drive


Turn engine with barring tool in normal direction of
rotation until TDC mark and arrow on flywheel hous-
ing are aligned.
If rocker arms on cylinder A1 are unloaded, the pis-
ton is in firing TDC.
If rocker arms on cylinder A1 are loaded, the piston
is in overlap TDC.
Remove valve drive see C 055.05

Separate electrical plug-in connection.


Remove hex screw (arrow).
Turn speed sensor (1) slightly to remove from hous-
ing fit.

L93 2167

Removing graduated disc (camshaft gear)


Position locating device (1) on securing plane of
rocker shaft, driving end.
Insert dowel pin of guide tube (3) into camshaft bore
(2) see following illustration- and screw locating
device into place (arrow).

L93 2167

MR20108/00E 01.12 MTU


Section C Task Description
Group 052.05 Camshaft Drive
Page 4

Locating bore (arrow) for locating device dowel pin.

L93 2167

Remove hex screws (4). Remove graduated disc (2)


and camshaft gear (1) from camshaft or dowel pins
(3).
Note: Cover bottom of equipment carrier so that
no objects can fall into housing.
Remove locating device.

L93 2167

Installing transportation locking device


Install ring (2) with hex screw (1) on camshaft.
Note: The ring serves only to secure the cam-
shaft axially and prevent it falling out dur-
ing crankcase transportation.

C 052.05.08 Inspection and Repair

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Drive Group 052.05
Page 5

Clean camshaft gear.


Check surface condition of camshaft gear teeth with magnifying glass; replace gear if necessary.
Remove minor scoring, wear and indentations by polishing with emery cloth; if necessary, machine to MTU and/or
DDC specifications or replace camshaft.
Note: Make sure parts are perfectly clean.

C 052.05.11 Installation

Removing transportation locking device


Remove ring (2) with hex screw (1) from camshaft.
Note: The ring serves only to secure the cam-
shaft axially and prevent it falling out dur-
ing crankcase transportation.

F 051 0014aO

Turn camshaft until locating bore (arrow), driving end,


is visible and at position shown.

L93 2167

MR20108/00E 01.12 MTU


Section C Task Description
Group 052.05 Camshaft Drive
Page 6

Installing locating device


Position locating device (1) on securing plane of
rocker shaft, driving end.
Insert dowel pin of guide tube (3) into camshaft bore
(2) and screw locating device into place (arrow).

L93 2167

Install pointer (2) on equipment carrier.


Install index plate (1) with barring tool on crankshaft,
set to TDC marking of A1 and tighten.
Position piston A1 to firing TDC see Section
C 037.05.11.

F0510009aO

Insert camshaft gear (1) into camshaft so that dowel


pins (3) engage in camshaft gear bore in a vertical
line.
Install graduated disc (2) I (see overview drawing
C 051.05.01) via dowel pins.
Note: Cover bottom of equipment carrier so that
no objects can fall into housing.
Fit hex screws (4) with spring washers and tighten
see C 051.05.01.
Note: Ensure that dowel pin and screw bores
are aligned.

F 051 0013aO

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Drive Group 052.05
Page 7

Measuring backlash
Note: Remove camshaft locating device.
Mount magnetic dial gauge holder with dial gauge on
crankcase, free end.
Position dial gauge stylus with low preload on one
tooth flank of camshaft gear.
Set dial gauge to zero.
Check backlash by moving camshaft gear back and
forth.
Backlash see C 020.

Measuring camshaft axial play


Mount magnetic dial gauge holder with dial gauge on
crankcase, free end.
Place dial gauge stylus on graduated disc (arrow).
Press camshaft on camshaft gear axially as far as it
will go.
Set dial gauge with preload to zero.
Move camshaft from stop to stop and record
measured value (axial clearance).
Axial clearance see Section C 020.
Measuring camshaft timing and valve stroke see
Section C 051.05.11.

Installing speed sensor


Replace O-ring (arrow) and coat with petroleum jelly.
Turn speed sensor (2) slightly to install in housing fit.
Install hex screws (1) and tighten.

MR20108/00E 01.12 MTU


Section C Task Description
Group 052.05 Camshaft Drive
Page 8

Checking speed sensor clearance


Pull camshaft on camshaft gear axially (arrow) as far
as it will go.
Measure distance (X).
Specified value is 0.3 mm to 1 mm
If distance is less than 0.3 mm
Fit appropriate number of adjusting shims of 0.3 mm
thickness.
Measure distance.

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Drive Group 052.05
Page 9

C 052.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007
x x Install main oil gallery C 011.05.11
x x Install pushrods C 054.10.11
x x Install valve drive C 055.05.11
x x Install cylinder head covers C 055.10.11
x x Install coolant lines (high temperature) C 202.10.11
x x Install charge air coolant vent line (low temperature) C 202.55.11
x x Install engine coolant vent lines (high temperature) C 202.65.11
x x Install charge air coolant lines (low temperature) C 203.25.11
x x Install turbocharger C 101.01.11
x x Install oil return lines for turbochargers C 185.25.11
x x Install oil supply line for turbochargers C 185.10.11
x x Install intake air system from turbocharger to intercooler C 125.05.11
x x Install Y-pipe at exhaust outlet housing C 141.10.11
x x Install vibration damper (if removed) C 035.05.11
x x Install ECU housing C 508.95.11
x x Install engine carrier, free end (gear case) C 231.05.11
x Add engine coolant (high temperature) Operating Instructions
x Add charge air coolant (low temperature) Operating Instructions
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 052.05 Camshaft Drive
Page 10

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Axial Alignment Bearing Group 053.05
Page 1

C 053.05 Camshaft Axial Alignment Bearing


C 053.05.01 Overview Drawing

1 Hex screw M12 X 70 3 Graduated disc


Tightening torque: 100 Nm + 10 Nm 4 Camshaft gear
Lubricant: Engine oil 5 Hex screw
2 Spring washer 6 Axial alignment bearing flange

MR20108/00E 01.12 MTU


Section C Task Description
Group 053.05 Camshaft Axial Alignment Bearing
Page 2

C 053.05.02 Special Tool


Designation Application Number

Piston measuring device 1

Index plate with pointer 1


Camshaft locating device 1

Retaining ring for camshaft 1

C 053.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x x Removal not scheduled
x Disable engine start Operating Instructions
x Drain engine coolant (high temperature) Operating Instructions
x Drain charge air coolant (low temperature) Operating Instructions
x x Remove ECU housing C 508.95.05
x x Remove vibration damper (as required) C 035.05.05
x x Remove Y-pipe from exhaust outlet housing C 141.10.05
x x Remove air pipework from exhaust turbocharger to intercooler C 125.05.05
x x Remove oil supply lines for turbochargers C 185.10.05
x x Remove oil return lines for turbochargers C 185.25.05
x x Remove exhaust turbocharger C 101.01.05
x x Remove charge air coolant lines (low temperature) C 203.25.05
x x Remove engine coolant vent lines (high temperature) C 202.65.05
x x Remove charge air coolant vent line (low temperature) C 202.55.05
x x Remove coolant lines (high temperature) C 202.10.05
x x Remove cylinder head covers C 055.10.05
x x Remove valve drive C 055.05.05
x x Remove pushrods C 054.10.05
x x Remove main oil gallery C.011.05.05

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Axial Alignment Bearing Group 053.05
Page 3

C 053.05.05 Removal

Removing camshaft axial alignment bearing


Turn engine with barring tool in normal direction of
rotation until TDC mark and arrow on flywheel hous-
ing are aligned.
If rocker arms on cylinder A1 are unloaded, the pis-
ton is in firing TDC.
If rocker arms on cylinder A1 are loaded, the piston
is in overlap TDC.
Remove valve drive see C 055.05.05.

Separate electrical plug-in connection.


Remove hex screw (arrow).
Turn speed sensor (1) slightly to remove from hous-
ing fit.

L93 2167

Removing graduated disc (camshaft gear)


Position locating device (1) on securing plane of
rocker shaft, driving end.
Insert dowel pin of guide tube (3) into camshaft bore
(2) see following illustration and screw locating
device into place (arrow).

L93 2167

MR20108/00E 01.12 MTU


Section C Task Description
Group 053.05 Camshaft Axial Alignment Bearing
Page 4

Locating bore (arrow) for locating device dowel pin.

L93 2167

Remove hex screws (4). Remove graduated disc (2)


and camshaft gear (1) from camshaft or dowel pins
(3).
Note: Cover bottom of equipment carrier so that
no objects can fall into housing.
Remove locating device.

L93 2167


Remove hex screws (1) and remove axial alignment


bearing flange (2).
1
2

L93 2167

C 053.05.08 Inspection and Repair

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Axial Alignment Bearing Group 053.05
Page 5

Clean all components.


Using the surface crack-testing method with red penetrant dye, check housing and axial alignment bearing flange
for cracks.
If cracks are detected, replace part.
Check all mating faces, running surfaces and fits. Rub down with oilstone or emery cloth as necessary.
Check all components for damage or excessive wear; replace components as necessary.
Check thread of hex screws for ease of movement; replace screws if necessary.
Note: Make sure parts are perfectly clean.

C 053.05.11 Installation

Installing camshaft axial alignment bearing


Coat axial sliding surfaces with engine oil.
Tighten axial alignment bearing flange with hex
screws as per Table A 003.
Note: Cover bottom of equipment carrier so that
no objects can fall into housing.

Installing transportation locking device


Install locking device only if necessary.


Install ring (1) with hex screw (2) on camshaft.
2


Note: The ring serves only to secure the cam-
1
shaft axially and prevent it falling out dur-
ing crankcase transportation.

F 051 0014aO

MR20108/00E 01.12 MTU


Section C Task Description
Group 053.05 Camshaft Axial Alignment Bearing
Page 6

Turn camshaft until locating bore (arrow), driving end,


is visible and at position shown.

F 051 0010aO
L93 2167

Installing locating device


Position locating device (1) on securing plane of
rocker shaft, driving end.
Insert dowel pin of guide tube (3) into camshaft bore
(2) and screw locating device into place (arrow).

L93 2167

Install pointer (2) on equipment carrier.


Install index plate (1) with barring tool on crankshaft,
set to TDC marking of A1 and tighten.
Position piston A1 to firing TDC see Section
C 037.05.11.
Note: If installed, remove ring securing cam-
shaft.

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Axial Alignment Bearing Group 053.05
Page 7

Insert camshaft gear (1) into camshaft so that dowel


pins (3) engage in camshaft gear bore in a vertical
line.
Install graduated disc (2) (see overview drawing
C 051.05.01) via dowel pins.
Note: Cover bottom of equipment carrier so that
no objects can fall into housing.
Fit hex screws (4) with spring washers and tighten
see C 051.05.01.
Note: Ensure that dowel pin and screw bores
are aligned.

F 051 0013aO

Measuring backlash
Note: Remove camshaft locating device.
Mount magnetic dial gauge holder with dial gauge on
crankcase, free end.
Position dial gauge stylus with low preload on one
tooth flank of camshaft gear.
Set dial gauge to zero.
Check backlash by moving camshaft gear back and
forth.
Backlash see C 020.

Measuring camshaft axial play


Mount magnetic dial gauge holder with dial gauge on
crankcase, free end.
Place dial gauge stylus on graduated disc (arrow).
Press camshaft on camshaft gear axially as far as it
will go.
Set dial gauge with preload to zero.
Move camshaft from stop to stop and record
measured value (axial clearance).
Axial clearance see Section C 020.
Measuring camshaft timing and valve stroke see
Section C 051.05.11.

MR20108/00E 01.12 MTU


Section C Task Description
Group 053.05 Camshaft Axial Alignment Bearing
Page 8

Installing speed sensor


Replace O-ring (arrow) and coat with petroleum jelly.
Turn speed sensor (2) slightly to install in housing fit.
Fit hex screw (1).

Checking speed sensor clearance


Pull camshaft on camshaft gear axially (arrow) as far
as it will go.
Measure distance (X).
Specified value is 0.3 mm to 1 mm
If distance is less than 0.3 mm
Fit appropriate number of adjusting shims of 0.3 mm
thickness.
Measure distance.

MTU 01.12 MR20108/00E


Task Description Section C
Camshaft Axial Alignment Bearing Group 053.05
Page 9

C 053.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007
x x Install main oil gallery C 011.05.11
x x Install pushrods C 054.10.11
x x Install valve drive C 055.05.11
x x Install cylinder head cover C 055.10.11
x x Install coolant lines (high temperature) C 202.10.11
x x Install charge air coolant vent line (low temperature) C 202.55.11
x x Install engine coolant vent lines (high temperature) C 202.65.11
x x Install charge air coolant lines (low temperature) C 203.25.11
x x Install turbocharger C 101.01.11
x x Install oil return lines for turbochargers C 185.25.11
x x Install oil supply line for turbochargers C 185.10.11
x x Install intake air system from turbocharger to intercooler C 125.05.11
x x Install Y-pipe at exhaust outlet housing C 141.10.11
x x Install vibration damper (if removed) C 035.05.11
x x Install ECU housing C 508.95.11
x x Install engine carrier, free end (gear case) C 231.05.11
x Add engine coolant (high temperature) Operating Instructions
x Add charge air coolant (low temperature) Operating Instructions
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 053.05 Camshaft Axial Alignment Bearing
Page 10

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 1

C 055.05 Valve Drive


C 055.05.01 Overview Drawing

Rocker arm assembly

1 Bearing pedestal 8 Washer


2 Rocker arm, inlet 9 Rocker arm, exhaust
3 Rocker arm, exhaust 10 Rocker arm, inlet
4 Adjusting shim 11 Rocker shaft
5 Snap ring 12 Hex screw
6 Valve bridge
7 Hex screw
Max. shaft length: 179.2 mm to 180.8mm
Tightening torque: 250 Nm + 25 Nm
Lubricant: Engine oil

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 2

Rocker shaft support

1 Snap ring 8 Bearing pedestal


2 Adjusting shim 9 Spring pin
3 Bush 10 Spring pin
4 Version I: Adjusting screw M 16 11 Sealing plug
Version II: Adjusting screw M 12 12 Axle
5 Rocker arm, inlet 13 Rocker arm, exhaust
6 Version I: Nut, 24 A/F 14 Thrust pad
Lubricant: Engine oil
Tightening torque: 90 Nm + 9 Nm
Version II: Nut, 19 A/F
Lubricant: Engine oil
Tightening torque: 35 Nm + 5 Nm
7 Grooved pin

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 3

Rocker arm

1 Bush 5 Roller
2 Ball socket 6 Bush

3 Rocker arm, exhaust 7 Pin

4 Rocker arm, inlet

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 4

Valve bridge

1 Valve bridge 3 Adjusting screw


2 Nut
Lubricant: Engine oil
Tightening torque: 90 Nm + 9 Nm

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 5

C 055.05.02 Special Tool


Designation Application Number

Valve clearance adjustment gauge 0.2 mm/0.5 mm. 1


Allen key, 8 A/F, for valve clearance adjustment 1
Barring tool 1
Pointer for barring tool 1
Graduated disc with pointer 1
Assembly device for pushrods 1

C 055.05.04 Before-Removal Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x x Removal not scheduled
x Disable engine start Operating Instructions
x Drain engine coolant (high temperature) Operating Instructions
x Drain charge air coolant (low temperature) Operating Instructions
x x Remove ECU housing C 508.95.05
x x Remove vibration damper (as required) C 035.05.05
x x Remove Y-pipe from exhaust outlet housing C 141.10.05
x x Remove air intake C 123.05.05
C 123.20.05
x x Remove air pipework from exhaust turbocharger to intercooler C 125.05.05
x x Remove oil supply lines for turbochargers C 185.10.05
x x Remove oil return lines for turbochargers C 185.25.05
x x Remove exhaust turbocharger C 101.01.05
x x Remove charge air coolant lines (low temperature) C 203.25.05
x x Remove engine coolant vent lines (high temperature) C 202.65.05
x x Remove charge air coolant vent line (low temperature) C 202.55.05
x x Remove coolant lines (high temperature) C 202.10.05
x x Remove oil heat exchanger with coolant distribution housing and C 183.15.05
thermostat C 206.05.05
x x Remove cylinder head covers C 055.10.05
x x Remove pushrods C 054.10.05
x x Remove main oil gallery C.011.05.05

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 6

C 055.05.05 Removal
Removing rocker arm assembly
Bar crankshaft to bring appropriate piston of cylinder
to firing TDC.
Note: The piston is at firing TDC when both
rocker arms are unloaded, i.e. have clear-
ance.
Remove hex screw (1) and remove rocker shaft sup-
port (2) from cylinder head.
When raising rocker shaft support, ensure that no
pushrod (suction effect, ball socket) is raised with it.
Important: Fit tab washers to pushrods that have a
collar below the pushrod seat, see follo-
wing illustration.
Note: Take care not to damage grooved pin,
see overview drawing C 055.05.01.

Mark pushrods.
Remove pushrods (2) and tab washer (1) if necess-
ary.

Mark valve bridges (2) and remove from sliding pins


(3) in cylinder head.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 7

Removing rocker arm


Remove hex screws (1).
Remove rocker shaft with rocker arm (2) from crank-
case.

C 055.05.06 Disassembly
Disassembling rocker arm assembly
Clamp shaft support in vice with aluminium jaws.
Using snap ring pliers, remove snap ring (2) from
shaft.
Remove washer (1).

Remove rocker arm (1) from axle.


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

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 8

Clamp valve bridge (3) in vice with aluminium jaws.


Release nut (1) and remove adjusting screw (2).

Removing rocker arm bush


Note: Remove rocker arm bush only if necess-
ary see C 055.05.08.
Use mandrel and hydraulic press to remove rocker
arm bush (2) from rocker arm (1).

Removing pin and roller


Note: Remove pin and roller only if necessary
see C 055.05.08.
To remove pin, place rocker arm between two prisms
so that both sides of pin bore have sufficient support.
Use mandrel to remove pin (1) from rocker arm (2).
Remove roller (3) from fit.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 9

Removing exhaust rocker arm bush


Note: Remove rocker arm bush only if necess-
ary see C 055.05.08.
Use mandrel and hydraulic press to remove rocker
arm bush (1) from rocker arm (2).

Removing inlet rocker arm bush


Note: Remove rocker arm bush only if necess-
ary see C 055.05.08.
Use mandrel and hydraulic press to remove rocker
arm bush (1) from rocker arm (2).

C 055.05.08 Inspection and Repair

Clean all components.


Using the magnetic crack-testing method with fluorescent magnetic powder, check rocker shaft support and axles,
rocker arms, valve bridges, roller, pins, rocker shafts, pushrods, hex screws and adjusting screws for cracks.
Replace cracked components.
Check cylinder head covers for condition and damage; replace component if necessary.
Check mating and sealing faces of cylinder head cover; rub down with oilstone or emery cloth if necessary.
Check running surfaces of axles, rollers, valve bridges and rocker arms for wear, indentations and scoring.
Remove scoring and indentations by polishing with emery cloth; replace components as necessary.
Check snap rings and washers for damage and wear; replace components as necessary.
Check condition of mating faces on rocker shaft support; burnish with oilstone if necessary.
Check condition of axle snap ring grooves; replace rocker shaft support as necessary.
The ball element within the swivel angle, at least 10_ all round, must not jam and must move freely.
Check slot of adjusting screws for wear and damage; replace component if necessary.
Check heads and seating faces of nuts for damage; replace adjusting screw as necessary.
Check threads of nuts, adjusting screws and collar screws for ease of movement; replace component as necess-
ary.

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 10

Check threaded bores in rocker arms and valve bridges for ease of movement; remachine if necessary.
Measure register bores in valve bridges with bore gauge.
Check pushrod seat and ball socket of push rod for wear; replace push rod if necessary.
Check concentricity of push rod; replace push rod if necessary.
Check sliding pins in cylinder head for wear and protrusion (A) see C 041.05.08.
Replace gaskets and sealing washers during W6 overhaul.
Make sure that all components are perfectly clean and that flow through lube oil bores is unobstructed.

Measuring diameter of bush bore in rocker arm


Rocker arm, inlet
Adjust bore gauge to basic size of bush bore and
measure diameter of bore.
For dimensions, see Tolerance and Wear Limits List.
Replace bearing bushings if limit values are ex-
ceeded.

Rocker arm, exhaust


Adjust bore gauge to basic size of bush bore and
measure diameter of bore.
For dimensions, see Tolerance and Wear Limits List.
Replace bearing bushings if limit values are ex-
ceeded.

F055 0020a0

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 11

Measuring diameter of bearing pedestal axles


Using micrometer, measure outside diameters of
bearings.
If measurements are below limit values, replace
rocker shaft support.
For limit values, see Tolerance and Wear Limits List.

Checking hex screws for rocker shaft support


Measure shaft length of hex screw; for max. shaft
length see C 055.05.01.
Check that thread and screw head mating face (ar-
rows) are in perfect condition; replace screw if
necessary.
Check hexagon for damage; replace screw if
necessary.

Measuring inlet rocker arm


Adjust bore gauge to basic size of bush bore and
measure diameter of bore.
Replace bearing bushings if limit values are ex-
ceeded.
For dimensions, see Tolerance and Wear Limits List.

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 12

Measuring exhaust rocker arm


Adjust bore gauge to basic size of bush bore and
measure diameter of bore.
Replace bearing bushings if limit values are ex-
ceeded.
For dimensions, see Tolerance and Wear Limits List.

Measuring roller diameter


Using an outside micrometer, measure outside diam-
eter (arrow) at several points on the roller.
If the value is below minus 0.1 mm, replace the
roller.
Perform hardness test with rebound hardness tester.
Hardness: 710 70 HV 30
60 2 HRC

C 055.05.10 Assembly

Assembling rocker arm assembly


Clamp rocker shaft support in vice with aluminium
jaws.
Note: Make sure parts are perfectly clean.
Insert adjusting screw (3) into rocker arm (1).
Attach nut (2) to adjusting screw; do not tighten!
Coat axles on rocker shaft support and bushes of
rocker arm with engine oil.
Fit rocker arm on axle.
Install second rocker arm similarly.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 13

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

CAUTION
Snap ring pretension
Risk of injury!
Use suitable snap ring pliers. Always wear pro-
tective goggles/safety mask.

Make sure that snap ring is correctly seated.


Check minimum axial clearance of rocker arm.
Install second rocker arm similarly.

Insert adjusting screw (2) into valve bridge (1).


Attach nut (3) to adjusting screw; do not tighten!

Assembling inlet/exhaust rocker arms


Note: Make sure parts are perfectly clean.
Chill bushes (2) in liquid nitrogen and press fit in
rocker arm (1) on both sides. Observe bush clear-
ance of 0.5 mm 0.5 mm, see following illustration.

CAUTION
Nitrogen is liquid at 200 C (328F). Danger of
freezing and suffocation!
Do not allow liquid nitrogen to come into contact
with parts of body (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ventilate working area well.

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 14

Press in bushes (1) on both sides.


Observe bush clearance (A) of 0.5 mm 0.5
mm.

Note: Make sure parts are perfectly clean.


Blow out bore in rocker arm with compressed air.

CAUTION
Compressed air is air which has been com-
pressed under pressure. Risk of injury!
If compressed air is used for blowing out or blow-
drying components, always wear protective
goggles or safety mask.
Compressed air must not be directed at the body.
Pressure must not exceed 3.0 bar (40 lb/in2).

Heat rocker arm to approx. 130 _C to 150 _C.

CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.

Insert roller (3) in rocker arm.


Chill pin (1) in liquid nitrogen and insert by hand
flush in rocker arm (1).

CAUTION
Nitrogen is liquid at 200 C (328F). Danger of
freezing and suffocation!
Do not allow liquid nitrogen to come into contact
with parts of body (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ventilate working area well.

Note: Subsequent press fitting is not per-


mitted.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 15

Assembling exhaust rocker arm


Note: Make sure parts are perfectly clean.
Chill bush (1) in liquid nitrogen.
CAUTION
Nitrogen is liquid at 200 C (328F). Danger of
freezing and suffocation!
Do not allow liquid nitrogen to come into contact
with parts of body (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ventilate working area well.
Heat rocker arm to approx. 200_.

CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.
Insert bush (2) so that it is flush.
Protrusion is not permissible.

Assembling inlet rocker arm


Note: Make sure parts are perfectly clean.
Chill bush (1) in liquid nitrogen.

CAUTION
Nitrogen is liquid at 200 C (328F). Danger of
freezing and suffocation!
Do not allow liquid nitrogen to come into contact
with parts of body (eyes, hands).
Wear protective clothing (including gloves and
closed shoes) and goggles.
Ventilate working area well.
Heat rocker arm to approx. 200_.

CAUTION
Component is hot.
Risk of injury!
Handle components only when wearing protec-
tive gloves.
Insert bush (2) so that it is flush.
Protrusion is not permissible.

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 16

C 055.05.11 Installation

Adjusting and installing valve bridges


Note: Make sure parts are perfectly clean. Carry
out adjustment only with engine cold or
heated to 40_ C.
Measure projection of sliding pins with respect to
cylinder head see C 041.05.08.

Note: If valve seats in cylinder head or valves


have been machined, valve bridges must
be adjusted.
Secure valve bridge (1) in vice with aluminium jaws,
release locknut (2) and back off adjusting screw (3)
by approx. 3 revolutions.

Make sure oil bore is perfectly clean.

CAUTION
Compressed air is air which has been com-
pressed under pressure. Risk of injury!
If compressed air is used for blowing out or
blow-drying components, always wear protec-
tive goggles or safety mask.
Compressed air must not be directed at the body.
Pressure must not exceed 3.0 bar (40 lb/in2).

Blow lube-oil bores of valve bridges clear with com-


pressed air to check for obstructions.

Fit valve bridge(s) on sliding pins in cylinder head in


accordance with the markings (installation location).
Adjusting screw(s) face charge air manifold.



Press valve bridge downwards and hold. Valve
bridge must be in contact with valve stem (A).
With valve bridge pressed down, install adjusting
screw (arrow) with Allen key until adjusting screw
slightly contacts valve stem and a pressure point is
noticeable. Check clearance between valve bridge
and valve stem. Using a second feeler gauge (b),


measure distance from opposite valve stem.

b Valve clearance is set correctly if it is possible to pull


the feeler gauge 0.05 mm through with slight resis-

a tance.

F0550037a0

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 17

Hold adjusting screw firmly with Allen key and


tighten locknut by hand (s).
Remove valve bridge.

F0550036a0

Clamp valve bridge(s) (1) in vice with aluminium


jaws, tighten locknut (2) to specified torque holding
adjusting screw firmly in place.
Tightening torque see overview drawing
1 C 055.05.01 of valve bridge.
2

F0550035a0

Fit valve bridge(s) on sliding pins in cylinder head in


accordance with the installation location.
Using feeler gauge (0.05 mm), measure distance
between valve stem and valve bridge (arrow).

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 18

Coat axle and bushes of rocker arm with engine oil.


Fit exhaust and inlet rocker arms on rocker shaft,
ensuring they are positioned correctly (arrows).

Coat rollers and camshaft bushings with engine oil.


Match rocker arms to left and right cylinder banks
and carefully insert into camshaft chamber.

Screw in hex screws (1) and tighten to specified


torque see overview drawing C 055.55.01.
Correct installation position (arrow) can be seen in
this illustration.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 19

Measure shaft length of hex screw; for max. shaft


length see overview drawing C 055.05.01.
Coat thread and mating face (arrows) of hex screws
with engine oil.

Installing pushrods
Coat pushrod seats and ball sockets of pushrods
with engine oil.
Insert pushrods (2) through cylinder head into push-
rod seat of rocker arm.
Install tab washer (1) depending on design of push-
rods (with collar).

Release nuts (1) of adjusting screws (2) on rocker


arm (3) and back off adjusting screw.
Fit rocker shaft support on cylinder head and check
fit of grooved pins.
Check position of ball joints in pushrods (6).
Remove tab washer if installed.
Install hex screw (5) with washer (4) in cylinder head
and tighten to specified tightening torque see over-
view drawing C 055.55.01.
Note: Fill adjusting screws with engine oil
(arrow). This is necessary after initial in-
stallation and after extended out-of-ser-
vice period.

Fo55 0033a0

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 20

Using the barring tool, set piston of cylinder to be


checked to firing TDC.
Note: At firing TDC, both rollers of rocker arm of
respective cylinder are in base circle
(arrow) of camshaft.
Carry out valve clearance adjustment for entire en-


gine as follows.





F0550034a0

Note: Before starting adjustment work, it is imperative to check that valve bridges have been provided with
adjusting screw M 16 (locknut 24 A/F) Version I or adjusting screws M 12 (locknut 19 A/F)
Version II. Select appropriate Task Description.

Adjusting valve clearance


Note: Before valve clearance is adjusted, valve
bridge must be checked.
Adjust with valve closed and max. 40_ C engine
coolant temperature.
Install engine barring tool.
Use barring tool to turn engine in normal direction of
rotation until TDC A1 mark on flywheel ring gear and
arrow on flywheel housing are aligned.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 21

Adjusting valve clearance in two crankshaft


positions
Adjust all valve clearances at two crankshaft posi-
tions (firing TDC and overlap TDC, cylinder A 1) in
accordance with adjacent diagram. Crankshaft must
be turned in engine direction of rotation.
If rocker arms on cylinder A1 are unloaded, the pis-
ton is in firing TDC.
1 = Firing TDC at cylinder A1
If rocker arms on cylinder A1 are loaded, the piston
is in overlap TDC.
2 = Overlap TDC at cylinder A1
X = Exhaust valve
O = Inlet valve

Checking valve bridge adjustment


Use feeler gauge to determine distance between
valve bridge and rocker arm.
Note: It must be possible to pull feeler gauge
through with slight resistance.

Place feeler gauge with determined value between


valve bridge and valve stem (B).
Using a second feeler gauge, measure distance be-
tween opposite valve stem and valve bridge (A).
Clearance greater/smaller than 0.05 mm is not per-
mitted.
The valve bridge must be adjusted if the deviation
from the determined value is greater than
$ 0.05 mm.

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 22

Version I: Adjusting screw M 16


Locknut 24 A/F
Setting valve bridge adjustment

CAUTION
When releasing the
locknut, the valve bridge must be
held firmly in position with the retaining device,
as otherwise the valves may be bent.

Install retaining device.


Insert locating pin of retaining device into oil
bore of valve bridge.
Note: The locating pin can be inserted into
the valve bridge oil bore only when
the valves are closed/unloaded.

Release locknut.

Withdraw locating pin of retaining device from oil


bore of valve bridge.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 23

Place a feeler gauge of determined distance be-


tween valve bridge and valve stem (A) and (B), e.g.
0.20 mm.
The valve bridge must be adjusted so that both
feeler gauges can still be just pulled through.
Hold adjusting screws firmly with Allen key and
tighten locknut by hand to valve bridge.
Insert locating pin of retaining device into oil bore of
valve bridge.
Note: The locknut and adjusting screw must
move easily.

Tighten locknut with torque wrench, holding adjusting


screw firmly with Allen key.
The adjusting screw must not also turn.
Tightening torque see overview drawing
C 055.05.01 of valve bridge.
Coat parts with engine oil.
Withdraw locating pin of retaining device from oil
bore of valve bridge.

Again check valve bridge adjustment.


Remove retaining device.

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 24

Caution
Before barring the engine,
remove the retaining device, as otherwise,
in event of a fixed valve bridge, the valve gear or
the retaining device will be damaged.

Adjust valve clearance


Inlet valves: long rocker arm.
Exhaust valves: short rocker arm.
Valve clearance: inlet = 0.2 mm
Valve clearance: exhaust: = 0.5 mm
Carry out adjustment with engine cold or heated to
40_ C coolant temperature.
Release locknut (1) and back off adjusting screw (2)
slightly with Allen key.
Insert feeler gauge between valve bridge and rocker
arm.
Set adjusting screw so that the feeler gauge can just
be pulled through when locknut is tightened.
Tighten locknut to tightening torque see overview
drawing C 055.05 01.
Hold adjusting screw firmly in position.
Coat parts with engine oil.
Again check valve clearance.
Remove engine barring tool.

Version II: Adjusting screw M 12


Locknut 19 A/F
Setting valve bridge adjustment

CAUTION
When releasing the locknut, the valve bridge
must be held firmly, as otherwise the valves will
be bent.

Loosen locknut (2), holding valve bridge (1)


firmly in position with an open-end wrench.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 25

Place a feeler gauge of determined distance be-


tween valve bridge and rocker arm (A) and (B), e.g.
0.20 mm.
The valve bridge must be adjusted so that both
feeler gauges can just be pulled through.
Hold adjusting screw securely in position with Allen
key and fit locknut by hand on valve bridge.
Note: The locknut and adjusting screw must
move easily.

Using torque wrench, tighten locknut (2); for this pur-


pose hold valve bridge (1) in position with open-end
wrench.
Tightening torque see overview drawing
C 055.05.01 of valve bridge.
Coat parts with engine oil.

Again check valve bridge adjustment.

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 26

Adjusting valve clearance


Inlet valves: long rocker arm.
Exhaust valves: short rocker arm.
Valve clearance: Inlet: = 0.2 mm
Valve clearance: Exhaust: = 0.5 mm
Release locknut (1) and back off adjusting screw (2)
slightly with Allen key.
Insert feeler gauge between valve bridge and rocker
arm.
Set adjusting screw so that the feeler gauge can just
be pulled through when locknut is tightened.
Tighten locknut to tightening torque see overview
drawing C 055.05 01.
Hold adjusting screw firmly in position.
Note: The locknut and adjusting screw must
move easily.
Hold adjusting screw firmly in position.
Coat parts with engine oil.
Again check valve clearance.
Remove engine barring tool.

MTU 01.12 MR20108/00E


Task Description Section C
Valve Drive Group 055.05
Page 27

C 053.05.12 After-Installation Operations

A distinction must be made as to whether:


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

1 2 3 Operations See
x Perform operations as per Assembly Plan B 005
x Install engine B 007
x x Install main oil gallery C 011.05.11
x x Install pushrods C 054.10.11
x x Install cylinder head covers C 055.10.11
x x Install oil heat exchanger with coolant distribution housing and ther- C183.15.11/
mostat C206.05.11
x x Install coolant lines (high temperature) C 202.10.11
x x Install charge air coolant vent line (low temperature) C 202.55.11
x x Install engine coolant vent lines (high temperature) C 202.65.11
x x Install charge air coolant lines (low-temperature) C 203.25.11
x x Install turbocharger C 101.01.11
x x Install oil return lines for turbochargers C 185.25.11
x x Install oil supply line for turbochargers C 185.10.11
x x Install intake air system from turbocharger to intercooler C 125.05.11
x x Install air intake C 123.05/123.20
x x Install Y-pipe at exhaust outlet housing C 141.10.11
x x Install vibration damper (if removed) C 035.05.11
x x Install ECU housing C 508.95.11
x x Install engine carrier, free end (gear case) C 231.05.11
x Add engine coolant (high temperature) Operating Instructions
x Add charge air coolant (low temperature) Operating Instructions
x Release engine start Operating Instructions

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.05 Valve Drive
Page 28

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Head Cover Group 055.10
Page 1

C 055.10 Cylinder Head Cover


C 055.10.01 Overview Drawing

Cylinder head cover arrangement 12V


also applies to 16V

1 Cylinder head cover 4 Washer


2 Cylinder head 5 Hex screw
3 Gasket

MR20108/00E 01.12 MTU


Section C Task Description
Group 055.10 Cylinder Head Cover
Page 2

C 055.10.04 Before-Removal

A distinction must be made as to whether:


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

1 2 3 Operations See
x Remove engine B 003
x Perform operations as per Disassembly Plan B 004
x Disable engine start Operating Instructions

C 055.10.05 Removal

Removing cylinder head cover


Remove hex screws.
Remove cylinder head cover and gasket.

C 055.10.08 Inspection and Repair

CAUTION
Compressed air is air which has been compressed under pressure. If compressed air is used for blowing
out or blow-drying components, always wear protective goggles or safety mask. Compressed air must not
be directed at the body.
The pressure must not exceed 3.0 bar (40 lb/in2).
Clean cylinder head cover with cleaner, blow out with compressed air and make sure it is perfectly clean.
Make visible inspection of cylinder head cover for wear and damage paying particular attention to the mating and
sealing surfaces; rub down with emery cloth or an oilstone or replace cylinder head cover as necessary.
Clean hex screws and check condition; replace if necessary.
Check thread of hex screws for ease of movement; replace hex screw if necessary.
Replace gaskets as part of every W6 major overhaul.

MTU 01.12 MR20108/00E


Task Description Section C
Cylinder Head Cover Group 055.10
Page 3

C 055.10.11 Installation

Install cylinder head cover


Note: Make sure parts are perfectly clean.
Check mounting surface, cle