Manual SAP

MTU_ValueService
Technical Documentation
Diesel Engine
12 V 4000 G23, G23R, G43, G63, G73, G83
16 V 4000 G23, G43, G63, G73, G83
Instructions for Overhaul

of Sub-assemblies
MS20012/01E
Printed in Germany
© 2008 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the
prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution,
translation, microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or
damage during operation.
Subject to alterations and amendments.
Table of Contents 01
1 General Information ............................................................ 05

1.1 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
1.1.1 Reman assemblies, prerequisites for maintenance work and general assembly
instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
1.2 General Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
1.2.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
1.2.2 Personnel and organizational requirements ............................ 09
1.2.3 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.4 Auxiliary materials, fire prevention and environmental protection . . . . . . . . . . . . . 13
1.2.5 Standards for warning notices in the publication . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.6 General information regarding the Tolerances and Wear Limits List . . . . . . . . . . . 16
1.2.7 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.8 Torque specifications for screws, nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.9 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.10 Repairing threaded bores with threaded inserts (Heli-Coil) . . . . . . . . . . . . . . . . . 35
1.2.11 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2 Maintenance .................................................................. 39
2.1 Preface ................................................................ 39
2.2 Maintenance schedule matrix .............................................. 40
2.3 Maintenance tasks ....................................................... 42
3 Task Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1 Crankcase and Add-on Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1.1 Crankcase ventilation – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1.2 Crankcase ventilation – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1.3 Crankcase breather – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2.1 Cylinder head and attachments – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2.2 Valve-seat turning machine for cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2.3 Cylinder head – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2.4 Cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.2.5 Cylinder head – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.6 Cylinder head – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2.7 Cylinder head – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2.8 Cylinder head – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2.9 Cylinder head – Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.2.10 Cylinder head – Plug repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2.11 Cylinder head – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.2.12 Cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.2.13 Cylinder head – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.3.1 Camshaft running surfaces and swing followers – Visual inspection . . . . . . . . . . 95
3.3.2 Valve drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.3.3 Valve drive – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.3.4 Valve drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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02 Table of Contents
3.3.5 Valve drive – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.3.6 Valve drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.3.7 Valve drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.3.8 Valve drive – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.3.9 Valve drive – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.3.10 Valve drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.3.11 Valve drive – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.4 Low-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.4.1 Fuel delivery pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.4.2 Fuel delivery pump – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.4.3 Fuel delivery pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.4.4 Fuel delivery pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.4.5 Fuel delivery pump – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.4.6 Fuel delivery pump – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.5 Exhaust Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.5.1 Exhaust turbocharger – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.5.2 Exhaust turbocharger – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.5.3 Exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.5.4 Exhaust turbocharger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.5.5 Exhaust turbocharger – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.5.6 Exhaust turbocharger – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.6 Charge-Air Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.6.1 Intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.6.2 Intercooler – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.6.3 Intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.6.4 Intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.6.5 Intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.6.6 Intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.6.7 Intercooler – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.7 Air Intake / Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.7.1 Air intake / air supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.7.2 Air filter with retainers – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.7.3 Air filter with retainers – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.7.4 Air filter with retainers – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.7.5 Intake air system to cylinders, left – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.7.6 Air supply system to cylinders, left – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.7.7 Air supply system to cylinders, left – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.7.8 Air supply system to cylinders, left – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.7.9 Air supply system to cylinders, right – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.7.10 Air supply system to cylinders, right – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.7.11 Air supply system to cylinders, right – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.7.12 Air supply system to cylinders, right – Installation . . . . . . . . . . . . . . . . . . . . . . . . 152
3.7.13 Air supply from turbocharger to intercooler – Overview . . . . . . . . . . . . . . . . . . . . 153
3.7.14 Air supply from turbocharger to intercooler – Removal . . . . . . . . . . . . . . . . . . . . . 154
3.7.15 Air supply from turbocharger to intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . 155
3.7.16 Air supply from turbocharger to intercooler – Installation . . . . . . . . . . . . . . . . . . . 156
3.8 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.8.1 Exhaust pipework after cylinder head – Overview . . . . . . . . . . . . . . . . . . . . . . . . 157
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Table of Contents 03
3.8.2 Exhaust pipework after cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 158

3.8.3 Exhaust pipework after cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . 159
3.8.4 Exhaust pipe bellows after engine – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.8.5 Exhaust pipe bellows after engine – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.8.6 Exhaust pipe bellows after engine – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.9 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.9.1 Starter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.9.2 Starter – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.9.3 Starter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.9.4 Starter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.9.5 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.9.6 Starter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.9.7 Starter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.9.8 Starter – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.9.9 Starter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.9.10 Starter – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.9.11 Starter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.9.12 Starter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.9.13 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.9.14 Starter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3.9.15 Starter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.9.16 Starter – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.10 Lube Oil System, Lube Oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.10.1 Centrifugal oil filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.10.2 Centrifugal oil filter – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.10.3 Centrifugal oil filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.10.4 Centrifugal oil filter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.10.5 Centrifugal oil filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.10.6 Centrifugal oil filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.10.7 Centrifugal oil filter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.10.8 Centrifugal oil filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.10.9 Centrifugal oil filter – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3.10.10 Turbocharger oil supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3.10.11 Turbocharger oil supply – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.10.12 Turbocharger oil supply – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.11 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.11.1 Engine coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.11.2 Engine coolant pump – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3.11.3 Engine coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.11.4 Engine coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.11.5 Engine coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3.11.6 Engine coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3.11.7 Engine coolant pump – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.11.8 Engine coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.11.9 Engine coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.11.10 Engine coolant pump – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.11.11 Coolant supply for engine coolant pump, intake side – Overview . . . . . . . . . . . . 228
3.11.12 Engine coolant pump pipework, intake side – Removal . . . . . . . . . . . . . . . . . . . . 230
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3.11.13 Coolant supply for engine coolant pump, intake side – Installation . . . . . . . . . . . . 231
3.11.14 Coolant pipework after cylinder – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3.11.15 Coolant pipework after cylinder – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.11.16 Coolant pipework after cylinder – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3.11.17 Preheating unit – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.11.18 Preheating unit – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.11.19 Preheating unit, screw-in heating element – Replacement . . . . . . . . . . . . . . . . . . 237
3.11.20 Preheating unit, coolant pump – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3.11.21 Preheating unit, thermostat – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.11.22 Preheating unit – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3.11.23 Engine coolant and charge-air coolant ventilation – Overview .............. 242
3.11.24 Engine coolant and charge-air coolant ventilation – Removal . . . . . . . . . . . . . . . 246
3.11.25 Engine coolant and charge-air coolant ventilation – Installation . . . . . . . . . . . . . . 247
3.11.26 Charge-air coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3.11.27 Charge-air coolant pump – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3.11.28 Charge-air coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3.11.29 Charge-air coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3.11.30 Charge-air coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3.11.31 Charge-air coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3.11.32 Charge-air coolant pump – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3.11.33 Charge-air coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.11.34 Charge-air coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3.11.35 Charge-air coolant pump – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3.11.36 Coolant pipework from/to intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . 272
3.11.37 Coolant pipework from/to intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 273
3.11.38 Coolant pipework from/to intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . 274
3.11.39 Thermostat – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3.11.40 Thermostat – Preparatory steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
3.11.41 Thermostat – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3.11.42 Thermostat – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.11.43 Thermostat – Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3.11.44 Thermostat element – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3.12 Monitoring, Control and Regulation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3.12.1 Sensors, actuators and injectors – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3.12.2 HP fuel sensor – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
4.1 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
4.2 Special tools – Overview .................................................. 292
4.3 General workshop equipment – Overview .................................... 340
5 Appendix ..................................................................... 347
5.1 Manufacturer’s documentation ............................................. 347
5.2 MTU contact/service partner ............................................... 348
5.3 Index .................................................................. 353
MS20012/01E 2008-10 © MTU

General Information 05
1 General Information
1.1 Important Notes
1.1.1 Reman assemblies, prerequisites for maintenance work

and general assembly instructions
This maintenance manual is intended for the technical personnel assigned to maintenance work.
Content: Component repair.
REMAN assemblies
The following assemblies are only available by the substitution method:
BR 2000 BR 4000
Crankcase
Crankshaft
Piston rod
Vibration damper Vibration damper
Injection pump (only accumulator) High-pressure fuel pump
Injector
Prerequisites for maintenance work

If maintenance work is carried out by the customer, the following needs to be ensured:
• Observance of safety regulations.
• Deployment of trained and qualified personnel.
• Suitable shop equipment and general tools.
• Suitable testing equipment.
• Approved special-purpose tools.
General assembly instructions

Components that come into contact with oil, fuel, engine coolant and combustion air must be clean. Prior to assembly,
clean components with “Special cleanness” requirement (e.g. oil and fuel-carrying parts) using suitable cleaning
methods and then check for cleanness. Remove any packaging from components immediately before assembly.
Do not wash elastomer components (e.g. rubber, etc.) using diesel fuel, solvent or cold cleaner.
• Remove any oil or fuel film. Wipe parts down with a dry cloth to clean them.
• Do not paint elastomer components, such as e.g. engine mounts, damping elements, clutches and
V-belts. Only install them after painting the engine or cover them prior to painting.
Radial shaft seals that have been treated with oil by the manufacturer, have a defined moisture expansion on
delivery. Prior to installation, they may only be cleaned using abrasion-proof paper (not washed).
If not otherwise specified, the surfaces of parts that slide on each other should be moistened with SAE 30 engine oil.
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If not otherwise specified, O-rings and surfaces (bores or shafts) that slide along them during installation, should
be coated with petroleum jelly. During the assembly of O-rings with counterrings in coolant pumps, observe the
assembly instructions. After assembling O-rings in the grooves on shafts, push a rounded scriber under the O-ring
in circumferential direction, if the O-ring diameter is large enough. The O-ring may not be damaged.
Prior to assembling shaft seals:
• Coat shaft and sealing lip of shaft seal with petroleum jelly and coat shaft running surface
with thin-film lubricant or SAE 30 engine oil.
MS20012/01E 2008-10 © MTU

• If no other information is specified on the drawing, coat the outer surface of mounting bores
on metal outer liners with surface sealant. Coat the outer surface of elastomer outer liners
or combined metal/elastomer outer liners with ethanol.
Graphical symbol applies to radial shaft seals and depends on the position. Dimension
arrow indicates the position of the sealing lip.
Use sealing paste to fix the position of flat gaskets. Apply sealing paste thinly and in the form of dots on the
flat gasket or opposite surface. Flat gaskets should be attached to a component shortly after applying the
sealing paste and the sealing point should then be bolted (at the latest after 20 minutes) .
Prior to installing antifriction bearings, lubricate the bearing seats. Only take bearings out of their original packaging
immediately before installation. Do not remove corrosion inhibitor from bearings in original packaging. To clean the
antifriction bearings, use denatured spirit or acid-free kerosene. After cleaning, lubricate bearings with engine oil.
• Do not apply assembly forces (axial) over rolling elements and do not knock bearing
rings with hammers (use assembly aids).
• Do not use naked flames to heat inner bearing races!
• The temperature should be between 80 °C and 100 °C and may not exceed 120 °C.
• Freezing as a method for the assembly of anti-friction bearings is not permitted (danger
of cracks, rust formation due to condensate).
Do not lubricate dry bearings with oil.
When installing gears, use SAE 30 engine oil to moisten teeth.
Prior to assembly, mating and contact surfaces of components (e.g. contact surfaces for centering,
flange and sealing faces, joint surfaces of press-fit assembles) must be clean, bright or have the
specified surface protection and also be free of surface irregularities and damage. Remove any
corrosion inhibitor (e.g. oil, grease) from mating and contact surfaces.
After joining components that are chilled with liquid nitrogen, remove any condensate
and preserve with SAE 30 engine oil.
Prior to installation in immersion sleeves, coat the sensor area of measuring sensors with long-life lubricant.
Preassemble line links with cutting ring union in the bench vise and tighten; coat thread with thin-film lubricant first.
If components need to be marked by means of etching, use neutralization agent to remove the marking
solution afterwards. Preserve the relevant areas with SAE 30 engine oil.
The mating/contact surfaces of components used in the hot-component area (e.g. V-belt clamps, bellows,
plug-in pipes), should be coated with assembly paste, if not otherwise specified.
The assembly surfaces of screws, nuts, washer components and parts to be tensioned must be clean,
bright or have surface protection and also be free of surface irregularities and damage. Remove
any corrosion inhibitors (e.g. oil, grease). Prior to assembly according to tightening specifications,
coat threads and screw bearing surfaces with lubricant.
If not otherwise specified, use engine oil (SAE 30) as lubricant and in the hot-component area assembly paste.
Screw connections without tightening specification can be tightened freely, i.e. machine-tightening with
screwdriver or hand-tightening with open-end wrench or box wrench. For machine-tightening, take the torque
specification for thread size and property class from the general tightening specifications.
Screw connections with tightening specification:
• Establish the screw connections by hand-tightening with snap wrench or torque indicator wrench. Apply
tightening torque without taking the tolerance specified on the snap wrench into account. If a torque indicator
wrench is used, the torque must be within the tightening torque limit range. Proceed in the same way
for connections protected against torsion. This information also applies to test torques.
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• If no tolerance is specified for the tightening torque, the tightening tolerance is +10 % of the specified torque.
• Rotation angle tightening:
The angles of further rotation specified in the torque specification must be established. They may be exceeded
within the specified tolerance range. If no tightening torque is specified, maintain the following tolerances: +5 °
for angle of further rotation below/equal 90 ° +10 ° for angle of further rotation above 90 °. Prior to rotation angle
tightening, apply a color line mark to each screw head to allow the inspection of the correct angle of rotation after
tightening (exception: the color line mark is not required for tightening using self-monitoring NC screwdrivers).
• Elongation tightening:
MS20012/01E 2008-10 © MTU

Tighten according to tightening specification, taking the tightening tolerance into account.
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MS20012/01E 2008-10 © MTU

1.2 General Regulations
1.2.1 General Instructions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized engine modifications compromise safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.
Reworking components
During repair or engine overhaul reworking can be carried out in workshops authorized by MTU.
However, no generally valid instructions can be issued for the reworking of components as
the machining tools available on site may differ.
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1.2.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).
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MS20012/01E 2008-10 © MTU

1.2.3 Safety precautions when working on the engine
Safety precautions when putting the equipment into operation

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

During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections when
installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
MS20012/01E 2008-10 © MTU

Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. When subjected to fire
or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. Hydrogen fluoride
vapors are released in this case. The resulting acid leads to serious burning if it contacts the skin. Do not touch
elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Do not touch hot components of the compressor and the exhaust system ⇒ Risk of injury!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable bonding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. The welding
current could be induced in the cable harnesses and could possibly damage the electrical plant.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
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component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
MS20012/01E 2008-10 © MTU

Prior to working on assemblies, the power of the appropriate areas must be switched off. Any measures
requiring power supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
Always tighten connectors with connector pliers.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when despatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.
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1.2.4 Auxiliary materials, fire prevention and environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible fluids near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
noises indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applicable, which
means work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling
hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.
Lead
• When working with lead or lead-containing pastes, avoid direct contact with the
skin and do not inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust!
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
Painting
• When painting in other than spray booths equipped with extractors, ensure good ventilation.
Make sure that adjacent work areas are not affected.
• No naked flames!
• No smoking.
• Observe fire prevention regulations!
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• It is absolutely necessary to wear masks providing protection against paint and solvent fumes.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing.
• Wear protective clothing, gloves, closed shoes and protective goggles!
• Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
MS20012/01E 2008-10 © MTU

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

In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures
Note: This Publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:
Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!
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1.2.6 General information regarding the Tolerances and Wear Limits List
The tolerances and wear limits are intended as a guide for the examination of engine components
as well as for engine inspection and repair.
Explanation of terms for dimensions of new components
Toleranced size Designed size followed by a fit symbol (e.g. 24 H6) or by

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

dimensional deviation
Deviation Permissible tolerance of toleranced/basic size.

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

diameter is greater than shaft diameter
Interference Difference between bore and shaft diameter when bore

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

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

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

2 Right side 4 Left side
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1.2.8 Torque specifications for screws, nuts and bolts
Cylinder head
Designation Torque specification Lubricant
Sleeve for injector 60 Nm +6 Nm Engine oil
M14 plug screw 35 Nm +3.5 Nm
Screw for cylinder head.

• Nominal length: 282.7 mm to 283.3 mm
• Max. elongation: 284.3 mm
• Nominal length: 332.7 mm to 333.3 mm with engine lifting eye
• Max. elongation: 334,3 mm
Tightening sequence of screws: 1 to 6
1 Pre-application torque 25 Nm
2 Pretightening torque 180 Nm +10 Nm
3 Angle of further rotation 180° +10°
4 Test torque 400 Nm
A Exhaust side
B Inlet side
Valve gear
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Screw of rocker shaft support. 250 Nm +25 Nm

Max. shaft length: 180.8 mm
MS20012/01E 2008-10 © MTU

Exhaust turbocharger
M10 x 40 26 Nm +2 Nm Engine oil

ETC to exhaust manifold screws
M10 x50
Screw for turbine housing V-band clamp to bearing 17 Nm +2 Nm

housing
Screw for compressor housing V-band clamp to bearing 12.4 Nm +2.3 Nm

housing
Exhaust pipework
M10 x 120 screw for exhaust line to cylinder 42 Nm + 4 Nm Ultra-Therm MTU

head
Starting equipment, electric – Prestolite S152 starter

M10 nuts for terminals 30, 31 9 Nm to 10 Nm
Nuts for terminals R, S, A 1.5 Nm to 1.7 Nm
Starting equipment, electric – Prestolite MS7 starter

M12 nut for terminals 30, 31, 45 24.4 Nm to 29.8 Nm
M5 nut for terminals 31, 50 2.25 Nm to 2.85 Nm

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Pneumatic starter
Screw for disc in turbine housing 3,4 Nm
Screw for turbine housing nozzle 3,4 Nm
Screw for stage 2 rotor attachment to shaft 11,3 Nm
Screw for attachment of housing on nozzle 9 Nm Screw locking compound

ring and turbine housing (Loctite 270)
Screw for securing flange to turbine housing 19 Nm
Grooved nut 67.8 Nm to 90.4 Nm
Screw for securing gearbox housing to turbine 10.2 Nm to 13.6 Nm

housing
Screw joint drive housing to gearbox housing 10.2 Nm to 13.6 Nm
Lube Oil System

Centrifugal oil filter cover screw 5 Nm +2 Nm
Centrifugal oil filter cover clamp 8 Nm +2 Nm
Monitoring, control and regulating equipment

Sensor Type Remark Torque Lubricant
specification
B48 Pressure sensor High fuel pressure 30 Nm ±3 Nm
Tightening specifications for setscrew and stud connections as per MTN 5008 standard
This standard applies to setscrews not subjected to dynamic loads as per MMN 384, DIN 912,
EN 24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and for
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and to the corresponding nuts.
It does not apply to heat-resistant screws in the hot-component area.
Tightening torques MA are specified for screws of strength class 8.8 (surface condition bright, phosphatized
or galvanically zinc-plated) and 10.9 (surface condition bright or phosphatized).
The table values are based on a friction coefficient of µges.= 0.125. Precondition: prior to assembly, threads
and screw-mating faces of screws and nuts need to be lubricated with engine oil.
When tightening by hand, due to unavoidable deviations of the tightening torques from the
table value during tightening, e.g. due to reading inaccuracies and overtightening, an assembly
tolerance of +10 % of the table values is permitted.
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For machine-tightening, the permissible assembly tolerance is +15 %.
Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA=tightening torques
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Tightening specifications for stress bolt connections as per MTN 5007 standard
This standard applies to stress bolt connections subjected to static and dynamic loads of
strength class 10.9 and for the corresponding nuts.
Shaft and transition dimensions as per MMN 209 and material and production as per MMN 389
(surface condition bright or phosphatized).
The table values are based on a friction coefficient of µges.= 0.125. Precondition: prior to assembly, threads
and screw-mating faces of screws and nuts need to be lubricated with engine oil.
MS20012/01E 2008-10 © MTU

For unavoidable deviations of the tightening torques from the table value during tightening, e.g. due to reading
inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.
The table values are for tightening by hand with a torque wrench.
Thread not protected from torsion MA(Nm) protected from torsion MA(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*protect screw neck from twisting loads during tightening.

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

This standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed ends
DIN 3852 shape A (sealed with sealing ring DIN 7603-Cu).
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Tightening torques MA are specified for plug screws made of steel (St) with surface protection: phosphatized and
oiled or galvanically zinc-plated. Threads and screw-mating surfaces under head need to be lubricated with engine
oil prior to assembly. For unavoidable deviations of the tightening torques from the table value during tightening, e.g.
due to reading inaccuracies and overtightening, an assembly tolerance of +10 % of the table values is permitted.
Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed end)
inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
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Tightening specifications for plug screws as per DIN 7604C (with long screwed end)
inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
Tightening specifications for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws as per MMN 223 and N 15011, sealed with sealing ring DIN 7603-Cu.
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Tightening torques MA are specified for banjo screws made of steel (St) with surface protection: phosphatized
and oiled or galvanically zinc-plated and of copper/aluminum alloys.
Prior to assembly, threads and screw-mating surfaces under head need to be lubricated with engine oil.
Tightening specifications for banjo screws made of steel

inserted in steel/gray cast iron/AI alloy MA
Thread
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
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Tightening specifications for banjo screws made of copper/aluminum alloys

inserted in steel/gray cast iron/AI alloy MA
Thread
(Nm)
M10 x 1 15
M16 x 1.5 30
Tightening specifications for male connectors as per MTN 5183-3 standard

This standard applies to male connectors, DIN 2353 L series, with screwed end, DIN 3852
shape A (sealed with sealing ring DIN 7603-Cu).
Tightening torques MA are specified for male connectors made of steel (St) with surface protection:
phosphatized and oiled or galvanically zinc-plated.
Prior to assembly, threads and screw-mating surfaces under head need to be lubricated with engine oil.
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inserted in steel/gray cast iron MA

Thread
(Nm)
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
Tightening torques for union nuts on ISO 6149-3 screw-in taps
1 Union nut
2 Junction block
3 O-ring
4 Linear ball bearing
Union nut: On installing the linear ball bearing, after tightening the union nut firmly by hand (noticeable
increase in force), it should be tightened another 1/4 turn (90°) past this point.
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1.2.9 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km

nm 1.852 = km
yd 3 = ft
yd 36 = in
Unit B multiplied by factor = Unit A

mm 0.3937 = in
m 3.281 = ft
km 0.6215 = stat. mile
Area
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.5889 = km2
Unit B multiplied by factor Unit A

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

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

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

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

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

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Torque
ft lb 1.3563 = Nm
Nm 0.7373 = ft lb
Pressure
lb/sq in (psi) 703.1 = kp/m2 (mm WS)
lb/sq in (psi) 0.06895 = bar
lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m2
atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m2 (mm WS)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lb/sq in
bar 14.503 = lb/sq in
Mass moment, 2nd grade

ft lb s2 1.3563 = kg m2
kg m2 0.7373 = ft lb s2
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Energy
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
Power
HP (horse power) 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 =W
HP 550 = ft lb/s
kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
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Temperature
Celsius Kelvin Fahrenheit Réaumur
x°C = x + 273.15 K = 9/5x + 32 °F = (4/5x) °R
xK = x − 273, 15 °C = 9/5(x − 273.15) + 32 °F = 4/5 (x − 273.15) °R
x°F = 5/9(x − 32) °C =5/9 (x − 32) + 273.15 = 4/9 (x − 32) °R

K
x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F
Fuel consumption
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km
km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
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1.2.10 Repairing threaded bores with threaded inserts (Heli-Coil)

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

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

installation tool.
8. Driver journal of the thread insert must be in
groove (arrow).
1 Spindle
2 Thread insert
9. Use spindle to turn thread insert through snout

until it is flush at front (arrow).
10. Mount installation tool on threaded hole and install

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

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

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ISO International Organization for

Standardization
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
MS20012/01E 2008-10 © MTU

Abbrevia- Meaning Explanation

tion
LCD Liquid Crystal Display, Liquid Crystal

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

Unit
OT Oberer Totpunkt Top dead center (TDC()
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
UPS Unit Pump System
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps
SPC Spare Parts Catalog
SS Safety System Alarm initiated by safety system
SSK Schnellschlussklappe(n) Emergency Air Shutoff Flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TC Tools Catalog
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TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom dead center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water Jet Waterjet drive
MS20012/01E 2008-10 © MTU

Maintenance 39
2 Maintenance
2.1 Preface
MTU maintenance concept

The maintenance system for MTU products is based on a preventive maintenance concept. Preventive
maintenance facilitates advance planning and ensures a high level of equipment availability.
The maintenance schedule is based on the load profile / load factor specified below. The time intervals at which
the maintenance work is to be carried out and the relevant checks and tasks involved are average values based
on operational experience and are therefore to be regarded as guidelines only. Special operating conditions
and technical requirements may require additional maintenance work and/or modifications of the maintenance
intervals. Maintenance personnel charged with carrying out maintenance work must be appropriately qualified
depending on the complexity of the task concerned. The various Qualification Levels QL1 to QL4 reflect
the levels of training offered in MTU courses and the contents of the tool kits required:
QL1: Operational monitoring and maintenance which can be carried out during a break
in operation without disassembling the engine.
QL2: Exchange of components (corrective only).
QL3: Maintenance work which requires partial disassembly of the engine.
QL4: Maintenance work which requires complete disassembly of the engine.
The maintenance schedule matrix normally finishes with extended component maintenance. Following
this, maintenance work is to be continued at the intervals indicated.
The "Task" numbers stated in the list of jobs to be done/action to be taken indicate the relevant maintenance item. They
serve as a reference for the scope of parts needed and also appear on the labels of the corresponding spare parts.
Preventive maintenance instructions

Specifications for fluids and lubricants, guideline values for their maintenance and change intervals and lists of
recommended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications A001061 and in
the fluids and lubricants specifications produced by the component manufacturers. They are therefore not listed in
the maintenance schedule (exception: deviations from the Fluids and Lubricants Specifications). Only use fluids
and lubricants which meet MTU specifications or are approved by the component manufacturer concerned.
Amongst other items, the operator/customer must perform the following additional maintenance work:
• Protect components made of rubber or synthetic material from oil. Never treat them
with organic detergents. Wipe with a dry cloth only.
• Fuel prefilter:
The maintenance interval depends on how dirty the fuel is. The paper inserts in fuel prefilters
must be replaced every 2 years at the latest (Task 9998).
• Battery:
Battery maintenance depends on use and ambient conditions. The battery
manufacturer’s instructions must be obeyed.
The relevant manufacturer’s instructions apply with respect to the maintenance of any components
which do not appear in this maintenance schedule.
Items that are listed in this maintenance schedule but that do not refer to the respective engine model, can be ignored.
Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures in
accordance with the MTU Fluids and Lubricants Specifications, Publication No. A001061/.
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Application group
3B Continuous operation, variable
3D Standby operation
MS20012/01E 2008-10 © MTU

40 Maintenance
2.2 Maintenance schedule matrix
Maintenance schedule matrix for application group 3B, 0-10,000 operating hours
Item Operating hours [hrs]
Limit years
10,000
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
8,500
9,000
9,500
Daily
500
Engine oil filter 2
Engine operation - X
Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X X X
Valve gear - X X X X X X X X X X
Fuel filter 2 X X X X X X X X X X
Belt drive 2 X X X X X X
Air filter 3 X X X
Fuel injector - X X
Cylinder chambers 4 X X
Rubber sleeves 5 X X
Crankcase breather - X
Exhaust turbocharger - X
Component maintenance - X
Fuel delivery pump - X
Cylinder head - X
Extended component maintenance 18 X
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Maintenance 41
Maintenance schedule matrix for application group 3C, 0-6,000 operating hours
Item Operating hours [hrs]
Limit years
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
Daily
500
Engine oil filter 2
Engine operation - X
Centrifugal oil filter 2 X X X X X X X X X X X X
Valve gear - X X X X X X
Fuel filter 2 X X X X X X
Belt drive 2 X X X X X X
Air filter 3 X X
Rubber sleeves 6 X X
Fuel injector - X
Cylinder chambers 4 X
Crankcase breather - X
Exhaust turbocharger - X
Component maintenance - X
Cylinder head - X
Extended component maintenance 18 X

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42 Maintenance
2.3 Maintenance tasks

Qual- Interval Item Maintenance tasks Task
ifica-
tion [h] [a]
QL1 Engine oil filter Replace oil filter when changing engine oil, or when the interval W1008
(years) is reached, at the latest (→Operating Instructions).
QL1 Engine operation Check engine oil level (→Operating Instructions). W0500
Check engine visually for leaks and general condition (→Operating W0501
Instructions).
Check intercooler drain (if fitted) (→Operating Instructions). W0502
Check signal ring position of service indicator (→Operating W0503

Instructions).
Check water pump(s) relief bores (→Operating Instructions). W0505
Check for abnormal running noise, exhaust gas color and vibrations W0506
(→Operating Instructions).
Drain water and contaminants from fuel prefilter (if fitted) (→Operating W0507
Instructions).
Check reading on differential pressure gauge of fuel prefilter (if fitted) W0508
QL1 Centrifugal oil filter Centrifugal oil filter (if fitted): Check layer thickness of the oil residue, W1009
clean out and replace filter sleeve (→Operating Instructions).
QL1 Fuel filter Replace fuel filter or fuel filter element (→Operating Instructions). W1001
QL1 Valve gear Check valve clearance (→Operating Instructions). W1002
QL1 Belt drive Check drive belt condition and tension, replace if necessary W1241
(→Operating Instructions); adjust belt tension (→Operating
Instructions).
QL1 Air filter Replace air filter (→Operating Instructions). W1005
QL1 Fuel injector Replace fuel injectors (→Operating Instructions). W1006
QL1 Cylinder chambers Perform endoscopic examination (→Operating Instructions). W1011
QL1 Rubber sleeves Replace all rubber sleeves (→Operating Instructions) and W1250
QL1 Crankcase breather Crankcase breather: Replace filter or filter element (→Operating W1046
Instructions).
QL3 Exhaust turbocharger Replace exhaust turbocharger (→ Page 130). W1041
QL3 Component maintenance Prior to maintenance work, drain coolant and flush coolant circuits. W2000
Check rocker arms and valve bridge for wear (→ Page 100) visually W2001
inspect swing followers and camshaft running faces with endoscope
through pushrod bore (→ Page 95).
Clean air system (→ Page 140). W2002

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Clean intercooler and check for leaks (→ Page 131). W2003
Replace fuel HP sensor (→ Page 288). W2004
Check engine coolant thermostat and replace thermostat insert W2006

(→ Page 275).
Check charge-air coolant thermostat and replace thermostat insert W2007

(→ Page 275).
MS20012/01E 2008-10 © MTU

Maintenance 43
Qual- Interval Item Maintenance tasks Task

ifica-
tion [h] [a]
Overhaul engine coolant preheating (if fitted) (→ Page 235). W2008
Check centrifugal oil filter for wear (if fitted) (→ Page 190). W2009
Overhaul starter (→ Page 167). W2010
Overhaul charge-air coolant pump (→ Page 248). W2070
Replace sealing materials of all disassembled components. W2062
Overhaul engine coolant pump (→ Page 204). W2110
QL3 Fuel delivery pump Replace fuel delivery pump (→ Page 122). W1051
QL3 Cylinder head Overhaul cylinder heads (→ Page 50). W1134
QL4 Extended component Disassemble engine completely. Inspect engine components acc. to W3000
maintenance assembly Instructions; repair or replace as necessary (→Workshop
Manual).
Replace all elastomer parts and seals. W3001
Replace piston rings (→Workshop Manual). W3002
Replace conrod bearings (→Workshop Manual). W3003
Replace crankshaft bearings (→Workshop Manual). W3004
Replace cylinder liners (→Workshop Manual). W3005
Replace auxiliary PTO antifriction bearing (→Workshop Manual). W3006
Replace high-pressure fuel pump (→Workshop Manual). W3007
Overhaul battery-charging generator (→Workshop Manual). W3042

TIM ID: 0000020890 – 004
MS20012/01E 2008-10 © MTU

44 Maintenance
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MS20012/01E 2008-10 © MTU

Task Descriptions 45
3 Task Descriptions
3.1 Crankcase and Add-on Components
3.1.1 Crankcase ventilation – Overview
100 Vent housing 950 Plug screw 1950 Retainer

150 Bracket for oil separator 1000 Sealing ring 2050 Screw
200 Bracket for oil separator 1050 Plug screw 2100 Washer
380 Screw 1150 Plug-in pipe 2150 Pipe half-clamp
400 Washer 1200 O-ring 2200 Grommet
450 Gasket 1350 Nut 2210 Oil line
460 Cover 1400 Sealing cone 2220 Screw
465 O-ring 1500 Oil line 2300 Retainer
470 Screw 1600 Oil line 2350 Pipe half-clamp
500 Oil separator 1610 Retainer 2400 Grommet
550 Screw 1620 Pipe half-clamp 2450 Screw
600 Washer 1625 Grommet 2500 Screw
800 Screw 1630 Screw 2550 Screw
810 Screw 1700 Pipe half-clamp 2560 Washer
850 Screw 1750 Grommet 2650 Adapter
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860 Washer 1800 Screw 2700 Sealing ring
MS20012/01E 2008-10 © MTU

46 Task Descriptions
650 Manifold 3050 Retainer 3270 Screw

700 Clamp 3100 Screw 3350 Clamp
2800 Intake hose 3150 Clamp 3400 Screw
2810 Intake hose 3200 Screw 3450 Washer
2850 Intake hose 3250 Washer 3500 Nut
2860 Intake hose 3260 Clamp
2900 Clamp 3265 Spacer
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MS20012/01E 2008-10 © MTU

Oil separator
1 Diaphragm 2 Insert 3 Gasket

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MS20012/01E 2008-10 © MTU

3.1.2 Crankcase ventilation – Removal
Preconditions
• Engine is stopped and starting disabled.
Crankcase ventilation – Removal
1. Remove lines and oil separator as per overview drawings (→ Page 45).
2. After removal, seal all connections with suitable plugs.
3. Protect oil separator from damage. Even minor damage may cause oil separator failure.
TIM ID: 0000020468 – 001
MS20012/01E 2008-10 © MTU

3.1.3 Crankcase breather – Installation
Material
Designation / Use Part No. Qty.

Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Spare parts

O-ring
Installing the crankcase breather

1. Prior to installation, remove all blanking plugs.
2. Coat O-rings with grease.
3. Install crankcase breather as per overview drawing (→ Page 45) .
TIM ID: 0000020470 – 002
MS20012/01E 2008-10 © MTU

3.2 Cylinder Head
3.2.1 Cylinder head and attachments – Overview
Cylinder head and attachments – Overview
1 Cylinder head 6 Spring retainer

2 Inlet valve 7 Valve collet
3 Exhaust valve 8 Valve rotator
4 Valve spring, inner 10 Plug screw
5 Valve spring, outer 11 Sealing ring
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2 Valve-seat insert, inlet * 6 Valve guide 11 Cylinder head

3 Valve-seat insert, exhaust * 7 Plug * Only on cylinder heads of
4 O-ring 8 Plug corresponding design
5 Sleeve 9 Plug
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1 Sealing ring 3 Cylinder head screw 5 Cylinder head screw

2 Gasket 4 Thrust washer
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3.2.2 Valve-seat turning machine for cylinder head
Working principle of valve-seat turning machine
The valve-seat turning machine is an inside turning device. While the cutter (3) rotates around the valve-seat
(5), a feed gear mechanism ensures a continuous outward feed motion (1). The feed motion under the proper
valve-seat angle (4) is defined by an inclined slideway in the exchangeable adapter head.
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Installing the solid pilot
Precondition:
Valve guide is installed and machined to finished dimension.
Valve guide was cleaned.
Cylinder head is securely clamped and valve guide accessible from both sides.
Mounting the supporting spider

To achieve maximum accuracy, the pilot must be supported by the supporting spider (7) below the valve seat. Slide
the supporting spider (7) over the pilot shaft to such position that the spring-loaded spider elements (1) rest just
below the valve seat level when the pilot is installed in the valve guide (4) and tighten the clamping screw (6).
Inserting the pilot into the valve guide
Remove clamping nut (3) from pilot and insert the threaded end of the pilot into the valve guide (4), until
the tapered portion (5) bears against the conical seating of the valve guide (4). The spring-loaded elements
TIM ID: 0000020069 – 001
(1) of the spider (7) will bear against the exhaust/inlet canal below the valve seat.
Locking the pilot
Screw clamping nut (3) onto the pilot and tighten with moderate force. Tighten the screws (6) on
top of the spider to lock the spring-loaded elements (1) of the spider (7). Apply standard machine
oil to the top and around the periphery of the pilot shaft.
MS20012/01E 2008-10 © MTU

Setting up valve turning machine
Mounting the cutter

Fit the appropriate tool holder of the cutter (8) with an indexable insert and attach to the tool slide (7).
Placing the valve-turning machine on the pilot
Take care that the cutter (8) does not bump against the cylinder head.
Slide the valve-seat cutting machine over the pilot (10) until either the depth stop (3) rests upon
the pilot (10) or the cutter (8) contacts the cylinder head.
Aligning the cutting edge with the valve-seat center
Turn rapid tool adjuster (11) to position cutting edge of cutter over the valve-seat center (9). Hold
the machine with one hand. Loosen screw (4) of depth stop (3) and allow machine to slide down
until the cutting edge contacts the valve seat (9) lightly. Push depth stop (3) slightly downward
against the pilot (10) and then tighten depth stop locking screw (4).
Connecting the machine to power supply
Insert the round plug of the outlet cable (6) of the power supply unit (5) into the corresponding socket
(1) on the driving assembly (2) and allow the securing latch to engage.
TIM ID: 0000020069 – 001
MS20012/01E 2008-10 © MTU

Valve seat turning
Positioning the cutter at the inner valve-seat edge

Slightly lift machine with one hand and then turn rapid tool adapter (11) with the other hand until the
cutting edge is just clear of the inner edge of the valve seat (10).
Setting cutting depth
To set the depth of cut, turn depth feed (3) counterclockwise. One notch of the depth-feed scale (4) corresponds
to a depth feed of 0.025 mm. As the valve seat (10) usually shows unequal wear, the depth of the first turning
cycle must be selected (max. 0.2 mm) to ensure that the entire valve-seat surface is undercut.
If the cutting edge is just scraping along the surface instead of undercutting the hard surface zone,
there is a risk of premature wear and chipping of the cutting edge.
Lubricating the valve seat
Apply a few drops of metalworking lubricant on hard valve-seat surfaces before turning.
Valve seat turning
Make sure that the pivoted lever (8) is engaged in the groove of the feed actuator (12). Select proper speed by
shifting the switch (6) at the power supply unit (5). Speed can be increased by changing over from 30 VDC to 42 VDC.
TIM ID: 0000020069 – 001
Hold driving unit (2) with both hands at the motors (1) and press pushbutton switch (7) to start the cutting pass.
Release the pushbutton switch (7) as soon as the cutter has been traversed beyond the top edge of the valve seat (10).
Repeating the cutting pass
Repeat steps with a cutting depth between 0.05 mm and 0.1 mm until the valve seat surface (10) is plane all around.
To ensure a smooth valve-seat surface (10) finish, proceed with a final pass at high speed with 0.025 mm cutting depth.
MS20012/01E 2008-10 © MTU

Replacing the adapter head
Removing the adapter head

Unscrew the two screws (1) from the adapter head (2).
Turn adapter head (2) in the direction of the arrow until the back of the toothed rack (4) is no longer engaged with
the pinion (4) in the gear housing (6). Now the adapter head can be withdrawn off the gear housing (6).
Mounting the adapter head
Place adapter head (2) onto gear housing (6) so that the pinion (5) projecting from the gear housing (6)
is seated in the corresponding bore of the adapter head (2).
The adapter head (2) must be seated flush with the gear housing (6).
Screw the two screws (1) loosely into the gear housing so that the adapter head (2) can still be moved
to adjust proper clearance between toothed rack (4) and pinion.
Adjust the adapter head so that the gap between the toothed side of the rack (4) and the opposite side of
the recess (3) is approximately 0.3 mm to 0.5 mm. Tighten both screws (1).
Turn the rapid tool adjuster to move the tool slide back and forth. If tool slide does not
move freely, readjust the adapter head.
TIM ID: 0000020069 – 001
MS20012/01E 2008-10 © MTU

3.2.3 Cylinder head – Preparatory steps
Preconditions
Preparatory steps
1. Drain engine coolant (→Operating Instructions ).
2. Remove exhaust pipework after cylinder (→ Page 158).
3. Remove charge-air pipes (→ Page 146).
4. Remove coolant pipework after cylinder (→ Page 233).
5. Remove valve gear/rocker arms (→ Page 100).
6. Remove injector (→Operating Instructions).
7. Remove fuel return line (leak-off fuel) between cylinder head and fuel return line (manifold).
TIM ID: 0000020356 – 002
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3.2.4 Cylinder head – Removal
Preconditions
• Preparatory steps have been completed.
Special tools

Tightening equipment (power amplifier) F6553658 1
Plug for oil supply bore B80144872 1
Installation/removal tool for plugs F30378956 1
Support bracket for cylinder head T80090944 1
Hook-ended chain sling (4 off) T80090748 1
Material

Protective plug
Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
TIM ID: 0000020074 – 001
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Cylinder head – Removal

1. Release hex bolts (1) on the cylinder head with
power amplifier (2) evenly and unscrew.
2. Screw plug (2) on to installation and removal tool

and lock it by turning the handle (1).
3. Screw plugs with installation/removal tool (1) into

oil supply line (arrow) in crankcase and spread.
4. Ensure that the plug is firmly anchored.
5. Release insertion/removal tool (1) and remove. TIM ID: 0000020074 – 001
MS20012/01E 2008-10 © MTU

6. Using support bracket (1) and hook-ended chain

sling, lift the cylinder head (2) out of the crankcase
and place it on a stable base.
7. Remove cylinder head gasket from mating face
of crankcase.
8. Remove plug from oil supply bore and close
with protective plug.
9. Use a screwdriver to remove sealing ring from

lower side of cylinder head.
TIM ID: 0000020074 – 001
MS20012/01E 2008-10 © MTU

3.2.5 Cylinder head – Disassembly
Special tools

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

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

Risk of injury!
WARNING • Only use specified tool and equipment.
Removing valves
1. Place cylinder head on base plate (3).
2. Mount valve-spring compressor (2).
3. Screw in spindle (1) and compress valve springs
with valve-spring compressor (2) until the valve
collets (4) can be removed.
4. Remove valve collets (4) with a magnet.
5. Release valve springs and remove valve-spring
compressor (2).
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MS20012/01E 2008-10 © MTU

6. Remove valve spring retainer, valve springs

and valve rotators.
7. Lay cylinder head on its side.
8. Mark exhaust and inlet valves so that they can be
reinstalled in their original positions.
9. Place valves in storage rack (1).
Removing sleeve
1. Secure cylinder head.
2. Using socket, remove sleeve from cylinder head.
3. Remove O-ring from sleeve.
TIM ID: 0000020042 – 001
MS20012/01E 2008-10 © MTU

3.2.6 Cylinder head – Cleaning
Material

Cleaner (Snow-White 11-0) 40460
Cleaner (Hakupur 312) 30390
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Heavy object.
Risk of crushing!

Risk of injury!
Cleaner is extremely caustic.

Risk of injury and suffocation!
WARNING • Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.
Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
Cylinder head – Cleaning

1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow out all parts with compressed air.
TIM ID: 0000020046 – 001
MS20012/01E 2008-10 © MTU

3.2.7 Cylinder head – Check
Special tools

Limit plug gauge for valve guide (as-new dimension), 11 mm H7 Y20090113 1
Limit plug gauge for repaired ready-to-use valve guide, 11 mm H9 Y20097473 1
Limit plug gauge for valve guide bore in cylinder head, 19.00 mm H7 Y20091080 1
Check gauge for inlet valve seat Y4340442 1
Check gauge for exhaust valve seat Y4340443 1
Depth gauge, 500 mm Y20002779 1
Pressure testing device Y4343688 1
C-frame micrometer, 0-25 mm Y20000083 1
Material

Corrosion inhibitor
Spare parts

Cylinder head
Sealing ring
Gasket
Cylinder head screws
Thrust washer
Valve guides
Valves
Sleeve
Valve springs
Sliding pin
Valve rotator
Spring retainer
TIM ID: 0000020092 – 001
Valve collet
Compressed air.
Risk of injury!
MS20012/01E 2008-10 © MTU

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

Risk of injury and scalding!
WARNING • Wear protective clothing, gloves, and goggles / safety mask.
Cylinder head - Check
Item Findings Task
Measure cylinder head height. Minimum height not reached Replace cylinder head.
Values (→ Page 68)
Check cylinder head mating face Damaged • Recondition

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

cylinder head for scores and wear. • Wear • Replace cylinder head.
visible.
Measure valve guides with limit plug Not dimensionally accurate Replace valve guides.
gauge. Values (→ Page 68)
Check valve springs for damage. • Damaged Replace valve springs

Check spring power and length of • Values below specification
valve springs. Values (→ Page 68)
Check thread for ease of movement. Sluggish • Recondition

• Replace cylinder head.
Check valve seats on cylinder head Pitting or wear • Recondition: (→ Page 53)
for pitting and wear. • Replace cylinder head.
Check cylinder head screw threads, Damaged Replace

screw head mating faces and thrust
washer for damage.
Measure shaft length of the cylinder Values exceeded (→ Page 68). Replace
head screws with depth gauge.
Check valves for damage. • Chrome layer damaged Replace

Check valves for concentricity and • Valve keyways damaged or
dimensional accuracy. Values burnt
(→ Page 68) • Out-of-round
Check spring retainer and valve • Scores Replace

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

TIM ID: 0000020092 – 001
Check sliding pin and valve bridge • Signs of wear Replace sliding pin.
bore for wear and damage. Values • Damage visible
(→ Page 68) • Not dimensionally accurate
MS20012/01E 2008-10 © MTU

Checking cylinder head for leaks

Note: Install sleeve prior to leak test (→ Page 87).
1. Prepare water for water bath with corrosion inhibitor.

2. Install pressure testing device.
3. Place cylinder head in a water bath heated to 80 °C until cylinder head has warmed up.
4. Pressure-test cylinder head with 0.5 bar compressed air.
5. Pressure must be maintained with cylinder in water bath for at least 30 minutes. No air bubbles must emerge.
6. Remove hydraulic pressure testing device.
7. Replace leaking plugs (→ Page 85).
TIM ID: 0000020092 – 001
MS20012/01E 2008-10 © MTU

3.2.8 Cylinder head – Tolerances
Cylinder head – Tolerances with valve-seat insert

Inlet and exhaust valve-seat insert
No. Designation Repair Tol. size Deviation Clearance Interference Wear limit
size Basic
lower upper min. max. min. max.
size
1 Cylinder head 0 19.000 H7 0 +0.021 +0.007 +0.041

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

outer Ø
1 19.100 r6
2 19.300 r6
2 Valve guide bore 11.000 H7 0 +0.018 0.055 0.093

installed
Valve stem Ø 10.935 −0.010 +0.010

TIM ID: 0000020750 – 001
2 Finished valve 11.000 H9 0 +0.043 0.055 0.118

guide bore
installed
Valve stem Ø 10.935 −0.010 +0.010
MS20012/01E 2008-10 © MTU

Valve clearance
No. Designation stage Tol. size Deviation Clearance Interference Wear limit
Basic
size
1 Valve protrusion +0.100 up to max.

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

or protrusion 1.100
inlet
TIM ID: 0000020750 – 001
MS20012/01E 2008-10 © MTU

Inlet and exhaust valve seat ring
Basic
size
1 Valve seat ring 57.000 H6 0 +0.019

bore, exhaust
2 Valve-seat insert 11.200 −0.050 +0.050

depth
3 Valve-seat insert 58.000 H6 0 +0.019

bore, inlet
Rework instructions:
• If a valve seat insert is replaced before the rework depth of 1.100 mm is reached, it must be machined until it
is flush with the contour depth to avoid that the valve seat insert protrudes into the combustion chamber.
• Max. rework of the valve-seat inserts by 0.300 mm into the depth, without machining the contour or the
valve cone.
TIM ID: 0000020750 – 001
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Inlet and exhaust valve-seat insert
Basic
size
1 Plug gauge 73.200 0 0

diameter
2 Plug gauge 87.130 0 0

diameter
3 Valve seat 4.800 −0.200 +0.200 up to min.

surface 3.700
Reference
dimension
Plug gauge
4 Cylinder head 13.800 0 +0.100

depth
Combustion
chamber sealing
ring surface
TIM ID: 0000020750 – 001
MS20012/01E 2008-10 © MTU

Exhaust valve
Basic
size
1 Valve head 56.000 −0.200 +0.200

external
diameter
2 Reference 54.000
dimension
with ring gauge
Valve seat
diameter
Valve seat height 4.680 −0.200 +0.100 up to min.

3.480
3 Reference 3.200 −0.200 +0.100 up to min.

dimension 3.000
without ring
gauge
Valve seat height
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MS20012/01E 2008-10 © MTU

Inlet valve
Basic
size
1 Valve head 57.000 −0.200 +0.200

external
diameter
2 Reference 54.000
dimension
with ring gauge
Valve seat
diameter
Valve seat height 4.050 −0.200 +0.100 up to min.

3.350
3 Reference 3.200 −0.200 +0.100 up to min.

dimension 3.000
without ring
gauge
Valve seat height
TIM ID: 0000020750 – 001
MS20012/01E 2008-10 © MTU

Valve springs, exterior
Basic
size
1 Spring length 83.900

released

compressed
Spring length 65.100

when mod. valve
rotator is used
2.1 Spring force 530.000 N

at compressed
spring length

compressed

when mod. valve
rotator is used
TIM ID: 0000020750 – 001
3.1 Spring force at 952.000 N -39 N +39 N Spring

spring length force
pos. 3 min. 897.000 N
4 Spring length 47.700 Block

Block dimension dimension
max. 47.700
MS20012/01E 2008-10 © MTU

Basic
size
5 Winding dia. 34.400
6 Wire dia. 5.300
e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.500
e2 Spring seat, permissible parallelism deviation max. 0.600
Valve springs, interior
Basic
size

released

compressed

TIM ID: 0000020750 – 001
when mod. valve

rotator is used
2.1 Spring force 256.000 N

at compressed
spring length
MS20012/01E 2008-10 © MTU

Basic
size

compressed

when mod. valve
rotator is used
3.1 Spring force at 466.000 N -19 N +19 N Spring

spring length force
pos. 3 min. 420.000 N
4 Spring length 42.500 Block

Block dimension dimension
max. 42.500
5 Winding dia. 23.000
6 Wire dia. 3.600
e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.300
e2 Spring seat, permissible parallelism deviation max. 0.400
TIM ID: 0000020750 – 001
MS20012/01E 2008-10 © MTU

Cylinder head – mating surface – protective sleeve
Basic
size
1 Cylinder head 184.000 −0.100 +0.100 183.600

height
2 Protective sleeve 124.000 0 +0.200

mating surface
3 Protective sleeve 44.200 0 +0.100 0.100 0.300

bore
Protective sleeve 44.100 −0.100 0

external
diameter
4 Cylinder head M 24 x 1.5

and protective
sleeve thread
Rework instructions:
• Rework only until a satisfactory mating surface has been achieved.
• If the cylinder head height was reworked, the fire face contour of 13.800 +0.100 is to be re-established.
TIM ID: 0000020750 – 001
MS20012/01E 2008-10 © MTU

Cylinder head screws
Basic
size
1 Cylinder head 333.000 −0.300 +0.300

screw with
engine lifting eye
2 Cylinder head 283.000 −0.300 +0.300

screw
TIM ID: 0000020750 – 001
MS20012/01E 2008-10 © MTU

3.2.9 Cylinder head – Repair
Special tools

Tool kit without elliptical chamfer reconditioning F6783749 1
Tool kit (accessory) for elliptical chamfer reconditioning F6783751 1
Tool kit for valve-seat insert removal F6784421 1
Indexable insert F30450433 1
Mounting plate for valve guide installation F6554300 1
Valve guide extractor F30450348 1
Valve guide mandrel F6781747 1
Reamer, Ø19.00 mm for stage 0 cylinder head bore F30091631 1
Reamer, Ø19.10 mm for stage I cylinder head bore F30047578 1
Reamer, Ø19.30 mm for stage II cylinder head bore F30028269 1
Plug gauge for valve guides Y20090113 1
Plug gauge for finished valve guide Y20097473 1
Plug gauge for stage 0 cylinder head bore Y20091080 1
Plug gauge for stage I cylinder head bore Y20097512 1
Plug gauge for stage II cylinder head bore Y20097513 1
Valve seat contour restoring tool for exhaust valve with valve-seat insert F30450631 1
Valve seat contour restoring tool for inlet valve with elliptical chamfer and F30450632 1
with/without valve-seat insert
Turning handle for valve seat contour restoring tool 8205890451/00 1
Exhaust valve gauge Y4340443 1
Inlet valve gauge Y4340442 1
Valve seat test device Y4341935 1
Countersink reamer tool F30451554 1
Inserting mandrel for valve-seat insert, inlet F30450751 1
Inserting mandrel for valve-seat insert, exhaust F30450750 1
Material

Liquid nitrogen
Corrosion inhibitor
TIM ID: 0000020050 – 002
MS20012/01E 2008-10 © MTU

Spare parts

Valve guide, inlet
Valve guide, exhaust
Nitrogen is liquid (at -200°C).

Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Ventilate working area well.
Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
Contamination of components.
• Check components for special cleanness.
Incorrect installation of components and lines.

CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
Removing the valve-seat insert

1. Clean valve guide using a hole brush.
2. Insert pilot into valve guide of cylinder head
(3) and secure.
3. Install head (2) and lathe tool on valve seat
lathe (1).
4. Position valve seat lathe (1) on pilot and install
steady rest.
5. Setup valve seat lathe (1) (→ Page 53).
6. Machine valve-seat insert so that the seat insert
extractor can be installed.
7. Remove steady rest, valve seat lathe (1) and pilot.
TIM ID: 0000020050 – 002
MS20012/01E 2008-10 © MTU

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

insert to be removed (2).
9. Using seat insert extractor (1), remove valve-seat
insert (2).
10. Check bore of valve-seat insert (1) in cylinder
head. Values (→ Page 68).
Result: Replace cylinder head if the value
is exceeded.
Removing the valve guide

1. Place cylinder head on hydraulic press. Ensure
correct positioning of the cylinder head side.
2. Using the extractor and working from the
combustion side, press valve guide out of cylinder
head.
3. Check valve guide bore in cylinder head. Values
(→ Page 68).
Result: If the value is exceeded, recondition
bore to next stage.
4. Secure cylinder head on boring mill.
5. Ream valve guide bore in cylinder head.
Installing the valve guide

1. Prepare water for water bath with corrosion
inhibitor.
2. Place cylinder head (4) in water bath heated to
80°C until cylinder head (4) has warmed up.
3. Chill valve guide (2) in liquid nitrogen for approx.
20 to 30 mins.
4. Position heated cylinder head (4) on assembly
jig (3).
5. Using mandrel (1), position chilled valve guide
(2) in bore of cylinder head (4) until the stop of
assembly jig (3) is reached.
TIM ID: 0000020050 – 002
MS20012/01E 2008-10 © MTU

Installing the valve-seat insert

1. Prepare water for water bath with corrosion inhibitor.
2. Place cylinder head in water bath heated to 80 °C until cylinder head has warmed up.
3. Chill valve-seat insert in liquid nitrogen for approx. 20 to 30 mins.
4. Position heated cylinder head on suitable surface.
5. Using the inserting mandrel, install chilled valve-seat insert into the cylinder head bore until the stop is reached.
Machining the valve seat surface

1. Clean valve guide using a hole brush.
2. Insert pilot (3) and support (2) into valve guide of
cylinder head (1) and secure.
3. Install suitable head (2) and lathe tool to valve

seat lathe (1).
4. Position valve seat lathe (1) on pilot and install
steady rest.
5. Setup valve seat lathe (1) (→ Page 53).
Note: Note recondition dimension, required when
machining elliptical chamfer.
6. Only recondition valve seat surface until a

satisfactory surface has been established. Values
(→ Page 68).
7. Remove steady rest, valve seat lathe (1) and pilot.
TIM ID: 0000020050 – 002
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8. Recondtion valve seat surface (2) with associated

valve seat contour restoring tool (1).
9. Clean cylinder head after machining.
Checking valve seat concentricity

1. Insert pilot into valve guide.
2. Mount clamp ring (2) over inserted pilot and
secure.
3. Mount the tester (1) on clamp ring.
4. Set preloaded feeler of tester on valve seat
center (arrowed).
5. Check concentricity of valve seat in relation to
valve guide, values (→ Page 68).
Result: In event of deviation from test values,
recondition valve seat again.
6. Remove tester (1), clamp ring (2) and pilot.
Measuring valve seat depth

1. Adjust distance from plug gauge to ring gauge.
2. Set scale on dial gauge to zero.
3. Measure valve seat depth. Values (→ Page 68).
is exceeded.
TIM ID: 0000020050 – 002
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Regrinding valve seats

1. Mount valve (1) as directly as possible behind
valve head in valve grinder (2).
2. Set valve seat grinding angle on valve seat grinder.
3. Using low feed, grind valve seat only until a
satisfactory surface is achieved.
4. Measure height of outer valve seat edge as well as
valve seat width. Value (→ Page 68).
Result: If the value is not reached, replace valve.
Reconditioning elliptical chamfer (if required)

1. Insert pilot (3) for elliptical chamfer (2) into valve
guide.
2. Mount tester (1) over inserted pilot (3) and secure.
3. Set preloaded tester pointer (1) to elliptical
chamfer (2).
4. Align pilot (3) and elliptical chamfer (2) using
tester (1).
5. Secure pilot (3).
6. Remove tester (1).
7. Install suitable head and lathe tool to valve seat
lathe.
8. Position valve seat lathe on pilot and install
steady rest.
9. Set up valve seat lathe (→ Page 53).
Note: Use recondition dimension as for
machining valve seat surface.
10. Only recondition elliptical chamfer (2) until a

satisfactory surface has been achieved.
11. Check elliptical chamfer (2). Value (→ Page 68).
is exceeded.
Reconditioning the protective sleeve mating face.
1. Install countersink reamer tool in bore for protective sleeve.
2. Recondition seating surface for protective sleeve with countersink reamer tool. Value (→ Page 68).
TIM ID: 0000020050 – 002
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3.2.10 Cylinder head – Plug repair
Special tools

Mandrel, Ø 20 mm F30378617 1
Guide sleeve for mandrel F30377862 1
Mandrel, Ø 24 mm F30271842 1
Mandrel, Ø 30 mm F30377635 1
Material

Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1
Cleaner (Loctite 7063) 50594 1
Screw locking compound (Loctite 270) 40083 1
Spare parts

Plug
Plug
Plug
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!

Risk of injury!

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Replacing plug
Note: Replace plug only if required.
1. Using a drift and hammer, carefully knock the

edge of one side of the end cover inwards until
it tilts into the bore.
2. Use pliers to withdraw end cover, taking care that
end cover does not fall into the bore.
3. Clean coolant chambers with cleaner
(Snow-White 11-0), then rinse with cleaner
(Hakupur 312).
4. Blow out coolant chambers with compressed air.
5. Clean mating surface of new plug and cylinder
head bore ensuring they are free of grease and dry.
6. Coat mating surface with screw locking compound.
7. Using a mandrel, knock plug into the cylinder

head bore until flush.
8. Check cylinder head for leaks (→ Page 65).
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3.2.11 Cylinder head – Assembly
Special tools

Valve spring compressor F6783833 1
Dial gauge Y20011268 1
Holder 0015890321/00 1
Torque wrench 20-100 Nm F30026582 1
Ratchet adapter F30027340 1
Socket F30377634 1
Material

Petroleum jelly, white 40317
Engine oil
Spare parts

O-ring
Sealing ring

Risk of injury!
Heavy object.
Damage to equipment due to falling components!
WARNING • Ensure that all components are secured during removal and installation work.
TIM ID: 0000020053 – 001
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Installing sleeve
1. Clean sealing surface (arrowed).
2. Coat O-ring (2) with petroleum jelly and insert in
groove of sleeve (1).
3. Clamp cylinder head firmly.

4. Clean sealing surface of cylinder head.
5. Use torque wrench to tighten prepared sleeve to
specified tightening torque (→ Page 18).
Installing valves
1. Lay cylinder head on its side.
2. Wipe valves with chamois leather and coat valve
stems with engine oil.
3. Insert valves into valve guides. Observe correct
valve arrangement. Markings are on the end of
the valve stem.
IN Inlet
EX Exhaust
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4. The markings and installation positions of the

valves are located on the upper side of the
cylinder head.
IN 2 x inlet (1)
EX 2 x exhaust (2)
5. The marking is visible on the lower side of the

valve in the form of a countersink.
• Inlet (1) = Ø 20 mm
• Exhaust (2) = Ø max. 8 mm
6. Mount supporting plate for valve spring

compressor on cylinder head.
7. Stand up cylinder head.
8. Slide valve rotator onto valve guide.
9. Fit outer and inner valve springs.
10. Fit valve spring retainers.
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11. Mount valve spring compressor (2).

12. Screw in spindle (1) and compress valve springs
with valve-spring compressor (2).
13. Insert valve collets (4) into spring retainer and
center.
14. Make sure that lip of valve collet is securely seated
in groove at end of stem.
15. Release valve springs.
16. Following installation of all valve collets, remove
valve spring compressor (2) and mounting
plate (3).
17. Place cylinder head in installation position or on

its side.
18. Make sure valves move freely.
19. Using a plastic mallet, lightly tap the valve stem to
ensure that the valve collets contact the valve
stem.
Measuring valve clearance to cylinder head

1. Install dial gauge (2) on dial-gauge holder (1).
2. Set dial gauge (2) with preload onto plane face
of cylinder head (4).
3. Set dial gauge to 0.
4. Position dial-gauge stylus on valve head of
valves (3) and measure valve clearance to plane
surface.
5. If the reading is not within the tolerance
(→ Page 68), check valve seat at cylinder head
and valve head.
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3.2.12 Cylinder head – Installation
Special tools

Support bracket for cylinder head T80090944 1
Hook-ended chain sling (-4 off) T80090748 1
Tightening device for cylinder head screws F6553658 1
Alignment tool for 8V-12V cylinder heads F6558582 1
Alignment tool for 16V-20V cylinder heads F6553648 1
Adjusting mandrel F30378324 2
Material

Engine oil
Spare parts

Sealing ring
Gasket

Risk of injury!
Heavy object.
Risk of crushing!
Contamination in blind hole.

CAUTION • Inspect and clean blind hole.
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Cylinder head – Installation

1. Insert two adjusting mandrels (2) in crankcase
upper deck.
2. Fit gasket (1).
3. Ovalize sealing ring by tapping it lightly.

4. Insert sealing ring with groove on combustion
chamber side of cylinder head.
5. When installing sealing ring, ensure position

is correct:
• A = Cylinder head side
• B = Piston side TIM ID: 0000020057 – 001
MS20012/01E 2008-10 © MTU

6. Remove protective plugs.

7. Place cylinder head (2) with support bracket (1)
and hook-ended chain sling on crankcase.
8. Coat thread, shaft and mating surfaces on heads

of cylinder head screws (1) with engine oil.
9. Observe assignment of cylinder head screws (1)
(engine lifting eye). Install cylinder head screws (1)
with thrust washers manually in crankcase.
10. Fit alignment tool (2) on inlet channels of cylinder
heads and tighten.
11. Carefully align cylinder heads.
Note: Make marks on screw heads after

tightening with initial torque (to check angle
of further rotation).
12. Tighten cylinder head screws (1) evenly with large

ratchet or force multiplier (2). Observe tightening
sequence and torques (→ Page 18).
13. Remove alignment tool.
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3.2.13 Cylinder head – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 58).
2. Fill with engine coolant (→Operating Instructions ).
3. Fill fuel system (→Operating Instructions ).
4. Enable engine start.
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3.3 Valve Gear
3.3.1 Camshaft running surfaces and swing followers – Visual inspection
Special tools

Endoscope Y20045885 1
Spare parts

Camshaft
Roller tappet
Visually inspecting camshaft running surfaces

and swing followers
1. Remove valve drive (swing followers remain
installed) (→ Page 100).
2. Insert endoscope into crank drive through every
pushrod bore.
3. Visually check roller surface of cams, roller running
surfaces on the camshaft as well as swing
followers for damage and wear.
4. Replace swing follower if signs of corrosion are
visible, see illustrations (→Workshop Manual).
5. Replace camshaft if signs of corrosion are visible,
see illustrations (→Workshop Manual).
Install valve drive (→ Page 113).

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3.3.2 Valve drive – Overview
Swing follower, swing follower assembly
1 Rocker shaft support 5 Snap ring 9 Swing follower

2 Rocker arm 6 Hex screw 10 Swing follower
3 Rocker arm 7 Washer 11 Swing follower shaft
4 Precision washer 8 Valve bridge 12 Hex screw
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Rocker, shaft support
1 Snap ring 8 Rocker shaft support

2 Precision washer 9 Spring pin
3 Bushing 10 Spring pin
4 Adjusting screw 11 Sealing plug
5 Rocker arm, inlet valve 12 Shaft
6 Nut 13 Rocker arm, exhaust valve
7 Notched pin 14 Thrust element
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Swing follower
1 Bushing 4 Swing follower, inlet valve 7 Bolt

2 Ball seat 5 Roller
3 Swing follower, exhaust valve 6 Bushing
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3.3.3 Valve drive – Preparatory steps
Preconditions
Preparatory steps
1. Remove cylinder head cover (→Operating Instructions ) .
2. Protect cylinder head covers from damage.
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3.3.4 Valve drive – Removal
Preconditions
Removing rocker arms
1. Bar crankshaft to bring piston of appropriate
cylinder to firing TDC. The piston is at firing TDC
when both rocker arms are unloaded.
Note: Ensure that no pushrod is removed by the
suction effect on the ball socket.
2. Remove screw (2) and remove rocker shaft

support (1) from cylinder head.
3. Remove valve bridges (2).

4. Pull out pushrods (1).
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Removing swing followers

1. Remove screws (1).
2. Remove swing follower shaft with swing followers
(2) from crankcase.
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3.3.5 Valve drive – Disassembly

Risk of injury!
Disassembling rocker arms

1. Clamp rocker shaft support in vise with aluminum
jaws.
2. Use snap ring pliers to remove snap ring (2)
from shaft.
3. Take off washer (1).
4. Remove nut (2) and adjusting screw (3).
Removing swing follower bushing

1. Check whether the swing follower bushing must be
removed (→ Page 105).
2. If so, press out swing follower bushing (2) off swing
follower (1) using mandrel and hydraulic press.
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Removing bolt and roller

1. Check whether bolt and roller must be removed
(→ Page 105).
2. If removal is required:
2.1. Position swing follower between two prisms
ensuring sufficient support at both sides
of the bolt bore.
2.2. Using mandrel and hydraulic press, remove
bolt (1) from swing follower (2).
2.3. Remove roller (3) from installation position.
Removing bushing from exhaust rocker arm

2. If so, press out rocker arm bushing (1) off exhaust
rocker arm (2) using mandrel and hydraulic press.
Removing bushing from inlet rocker arm

2. If so, press out rocker arm bushing (1) off inlet
rocker arm (2) using mandrel and hydraulic press.
TIM ID: 0000019940 – 001
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3.3.6 Valve drive – Cleaning
Material

Compressed air.
Risk of injury!


Valve drive – Cleaning

2. Thoroughly blow out all components with compressed air.
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3.3.7 Valve drive – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Dial gauge Y20011268 1
Holder 0015890321/00 1
Material

Fluorescent magnetic powder for magnetic crack-testing procedure
Spare parts

Snap ring
Lockwasher
Rocker shaft support
Bearing bush
Swing follower
Swing follower shaft
Valve bridge
Roller
Pushrod
Hex screw
Adjusting screw
TIM ID: 0000019945 – 001
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Valve drive – Check
Item Findings Task
Using the magnetic crack-testing Crack indication Replace

method, check following
components for cracks.
• Rocker shaft support and axles
• Rocker arms
• Valve bridges
• Swing followers
• Roller
• Pin
• Swing follower shaft
• Pushrods
• Hex screws
• Adjusting screws
Check running surfaces of axles, • Wear • Recondition

rollers, valve bridges and rocker • Indentations • Replace
arms for wear, indentations and • Scores
scoring. visible
Check mating faces on rocker shaft Damaged • Recondition

support. • Replace
Check snap ring grooves of axles Damaged • Recondition

for condition. • Replace
Check ball element. The ball Sluggish Replace

element must not jam within the
swivel angle, on all sides at least
10°, and must move freely.
Check screws, nuts and adjusting Damaged Replace

screws for damage.
Check pushrod concentricity. Out-of-round Replace
Measuring diameter of bushing bore in rocker arm

1. Adjust bore gauge to basic size of bushing
bore and measure diameter of bore. Values
(→ Page 108).
2. If limits are exceeded, replace bearing bushing. TIM ID: 0000019945 – 001
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Measuring diameter of rocker shaft support axles

1. Using outside micrometer, measure outside
diameters of bearings. Values (→ Page 108).
2. If values are not attained, replace rocker shaft
support.
Measuring swing follower bushing bore

1. Adjust bore gauge to basic size of bushing bore
and measure diameter of bore.
2. If limits are exceeded, replace bearing bushing.
Values (→ Page 108).
3. Replace gaskets and sealing washers.
4. Make sure that oil bores are perfectly clean and
free of obstruction.
TIM ID: 0000019945 – 001
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3.3.8 Valve drive – Tolerances
Rocker shaft support, inlet and exhaust
size Basic
size
1 Rocker arm bore 50.000 H7 0 +0.025 0.018 0.059
Bush OD 50.000 s6 +0.043 +0.059
2 Bush bore
installed 45.000 0 +0.050 0.025 0.091 Clearance

max.
removed 45.000 E6 +0.050 +0.066 0.100
Rocker shaft OD 45.000 f6 –0.041 –0.025
3 Rocker shaft 45.000 U7 –0.086 –0.061 0.020 0.061

support bore
Rocker shaft OD 45.000 f6 –0.041 –0.025

TIM ID: 0000019965 – 001
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Swing follower support, inlet and exhaust
size Basic
size
1 Swing follower 36.000 H7 0 +0.025 0.018 0.059

bore
Bush OD 36.000 s6 +0.043 +0.059
2 Bush bore
installed 32.000 0 +0.050 0.025 0.091 Clearance

max.
removed 32.000 E6 +0.050 +0.066 0.100
Shaft OD 32.000 f6 –0.041 –0.025
3 Roller bore 21.000 E7 +0.040 +0.061 0.040 0.082 Clearance

max.
Bush OD 21.000 H7 –0.021 0 0.090
4 Bush bore 14.000 E7 +0.032 +0.050 0.032 0.058 Clearance

max.
Pin OD 14.000 h5 –0.008 0 0.065
TIM ID: 0000019965 – 001
5 Swing follower 14.000 P6 –0.026 –0.015 0.007 0.026

bore
Bush OD 14.000 h5 –0.008 0
MS20012/01E 2008-10 © MTU

3.3.9 Valve drive – Assembly
Material

Liquid nitrogen
Engine oil
Nitrogen is liquid (at -200°C).

Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Ventilate working area well.
Compressed air.
Risk of injury!
Component is hot.
Risk of burning!

Risk of injury!
Assembling rocker arm assembly

1. Clamp rocker shaft support in vise with aluminum
jaws.
2. Insert adjusting screw (3) into rocker arm (1).
3. Attach nut (2) to adjusting screw, do not tighten.
4. Coat axles on rocker shaft support and bushings
of rocker arms with engine oil.
5. Fit rocker arm on axle.
6. Install second rocker arm similarly.
TIM ID: 0000019966 – 001
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7. Fit washer (1) and secure with snap ring (2).

8. Check correct seating of snap ring .
9. Check minimum axial clearance of rocker arm.
Assembling inlet and exhaust swing followers

1. Chill bushings (2) in liquid nitrogen and press into
both sides of swing follower (1).
2. Observe bushing retention (A) 0.5 mm ±0.5 mm.

TIM ID: 0000019966 – 001
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3. Heat swing follower to approx. 130 °C to 150 °C.

4. Insert roller (3) in swing follower.
5. Chill bolt (1) in liquid nitrogen. Fit in swing
follower (2) by applying hand force, ensure flush
seating. Do not press the bolt repeatedly.
Assembling rocker arm assembly

1. Chill bushing (1) in liquid nitrogen.
2. Heat exhaust rocker arm (2) to approx. 200° C.
3. Insert bushing, ensure flush seating. Projection is
not acceptable.
TIM ID: 0000019966 – 001
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3.3.10 Valve drive – Installation
Special tools

Barring tool F6555791 1
Pointer for barring tool F6555792 1
Timing disc, free end Y4341124 1
Box wrench, 19 mm F30038493 1
Box wrench, 24 mm F30501562 1
Ratchet F30027341 1
Material

Engine oil
Compressed air.
Risk of injury!
Installing swing followers

1. Coat axle and bushes of swing followers with
engine oil.
2. Fit exhaust and inlet swing follower on
swing-follower shaft, ensuring they are correctly
positioned (arrows).
TIM ID: 0000019967 – 002
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3. Coat rollers and camshaft bushings with engine oil.

4. Match swing followers to left and right cylinder
banks and carefully insert into camshaft chamber.
5. Install swing-follower shaft (1) with screws.

6. Ensure correct position of installation (arrow).
Installing pushrods
1. Coat ball seats and ball sockets of pushrods
(1) with engine oil.
2. Insert pushrods (1) through cylinder head into ball
seat of swing follower.
TIM ID: 0000019967 – 002
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Installing the rocker arm

1. Release nuts (6) of adjusting screws (1) on rocker
arm (4) and back off adjusting screw (1).
2. Place rocker shaft support (4) onto cylinder head.
Take care not to damage fit of grooved pins.
3. Check position of ball joints in pushrods (5).
4. After initial assembly and after extended
out-of-service period: Fill adjusting screws (1)
with engine oil (arrow).
5. Insert hex screw (2) with washer (3) into the
cylinder head and use torque wrench to tighten to
the specified torque (→ Page 18).
6. Adjust valve clearance (→Operating Instructions ).
TIM ID: 0000019967 – 002
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3.3.11 Valve drive – Final steps

Final steps
2. Adjust valve clearance (→Operating Instructions ).
TIM ID: 0000018002 – 003
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3.4 Low-Pressure Fuel System
3.4.1 Fuel delivery pump – Overview
3 Fuel delivery pump 8 Washer 12 Screw

5 Coupling element 10 Bracket
6 O-ring 11 Washer
TIM ID: 0000019750 – 001
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3.4.2 Fuel delivery pump – Preparatory steps
Preconditions
Fuels are combustible.

Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Preparatory steps
1. Shut off fuel supply.
2. Remove charge-air pipe (→ Page 150).
3. Remove fuel line (3).
4. Remove pipe half-clamps (1).
5. Remove snap rings (2) from ring groove and move
over plug-in pipes.
6. Move plug-in pipes towards filter head (arrows).
TIM ID: 0000019751 – 001
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3.4.3 Fuel delivery pump – Removal
Preconditions

• Do not smoke.
• Do not smoke.
Removing fuel delivery pump

1. Remove fuel delivery pump as per overview drawing (→ Page 117).
2. Remove coupling element from the drive shaft of the fuel delivery pump.
3. Remove O-ring.
TIM ID: 0000020140 – 001
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3.4.4 Fuel delivery pump – Installation
Material

White petroleum jelly 40317 1
Engine oil
Spare parts

O-ring

• Do not smoke.
Installing fuel delivery pump

1. Coat O-ring (1) with petroleum jelly and insert
into groove.
2. Mount coupling element (2) on driver.
3. Align fuel delivery pump driver to coupling element.
4. Carefully insert fuel delivery pump into bore and
install as per overview drawing (→ Page 117).
5. If the pump cannot be moved to the stop, withdraw
the pump again and check the position of the driver
with regard to the coupling element.
TIM ID: 0000020144 – 001
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3.4.5 Fuel delivery pump – Final steps

Final steps
2. Open fuel inlet.
3. Fill fuel system (→Operating Instructions ).
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3.4.6 Fuel delivery pump – Replacement

Fuel delivery pump – Replacement
1. Remove fuel delivery pump (→ Page 119).
2. Install fuel delivery pump (→ Page 120).
TIM ID: 0000019753 – 001
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3.5 Exhaust Turbocharger
3.5.1 Exhaust turbocharger – Overview
100 Exhaust turbocharger 250 Screw

200 Screw 300 Gasket
TIM ID: 0000020730 – 002
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200 Y-pipe 500 Spacer sleeve 850 Screw

250 Sealing ring 550 Nut 900 Screw
350 Retainer 650 Sealing ring 950 Spacer bushing
400 Screw 700 Y-pipe 1000 Nut
450 Screw 800 Retainer
TIM ID: 0000020730 – 002
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3.5.2 Exhaust turbocharger – Preparatory steps
Preconditions
Preparatory steps
1. Remove air filter with retainer (→ Page 143).
2. Remove air supply from turbocharger to intercooler (→ Page 154).
3. Remove turbocharger oil supply (→ Page 202).
TIM ID: 0000020733 – 001
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3.5.3 Exhaust turbocharger – Removal

Exhaust turbocharger – Removal
1. Loosen nut (1) on Y-pipe/flange threaded
connection.
2. Remove screws (2).
3. Remove exhaust turbocharger from Y-pipe in the
direction of the arrow.
4. Take off gasket.
5. Loosen nut (3) of the threaded connection

Y-pipe/flange and remove together with spacer
bushing.
6. Remove Y-pipe (2).
7. Remove screws (4) and turbocharger (1).
TIM ID: 0000020735 – 001
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3.5.4 Exhaust turbocharger – Installation
Special tools

Torque wrench, 8-40 Nm F30043446 1
Material

Assembly paste (Ultra-Therm MTU) 50547 1
Spare parts

Gasket
Piston ring
Exhaust turbocharger – Installation

1. Coat thread and screw-head mating face of
screws (2) with assembly paste.
2. Position beaded gasket (3) on exhaust manifold.
3. Position exhaust turbocharger (1), arrange
retainer (4) and screw in screws (2) but do not
yet tighten.
4. Insert Y-pipe (5) in turbine outlet and install
retainer (4) as per overview drawing (→ Page 123).
5. Use torque wrench to tighten screws (2) crosswise
to the specified tightening torque (→ Page 18).
TIM ID: 0000020736 – 002
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6. Coat thread and screw-head mating face of

screws (5) with assembly paste.
7. Position beaded gasket (4) on exhaust manifold.
8. Position second turbocharger (1), inserting
Y-pipe (2) in turbine outlet at the same time.
9. Install screws (5) but do not yet tighten.
10. Install retainer (3) as per overview drawing
(→ Page 123).
11. Use torque wrench to tighten screws (5) crosswise
to the specified tightening torque (→ Page 18).
TIM ID: 0000020736 – 002
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3.5.5 Exhaust turbocharger – Final steps

Final steps
1. Loosen V-band clamp on compressor housing.
Note: Compressor housing installation position is determined by installing the air supply pipework.
2. Install air supply from turbocharger to intercooler (→ Page 156).

3. Tighten clamp with torque wrench to specified tightening torque (→ Page 18).
4. Install turbocharger oil supply (→ Page 203).
5. Install air filter with retainer (→ Page 144).
TIM ID: 0000020737 – 001
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3.5.6 Exhaust turbocharger – Replacement
Spare parts

Exhaust turbocharger
Remove exhaust turbocharger (→ Page 126).
Install new exhaust turbocharger (→ Page 127).
TIM ID: 0000020862 – 001
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3.6 Charge-Air Cooling
3.6.1 Intercooler – Overview
Intercooler
50 Intercooler 350 Washer 700 Screw

150 Mounting bracket 450 Screw 800 Stud
200 Mounting bracket 500 Screw 850 Nut
300 Screw 600 Carrier
TIM ID: 0000020524 – 002
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950 Elbow 1150 Plug screw 1350 Screw

1000 Plug screw 1200 Plug screw 1400 Washer
1100 Elbow 1300 O-ring
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3.6.2 Intercooler – Preparatory steps
Preconditions
Preparatory steps
1. Mark coolant pipework from/to intercooler as well as attachments.
2. Drain charge-air coolant (→Operating Instructions).
3. Remove vent line.
4. Remove air pipework from exhaust turbocharger to intercooler as per overview drawing (→ Page 153)
5. Remove coolant pipework from/to intercooler and attachments as per overview drawing (→ Page 272).
6. Seal openings with suitable covers.
TIM ID: 0000020544 – 002
MS20012/01E 2008-10 © MTU

3.6.3 Intercooler – Removal
Preconditions
Heavy object.
Risk of crushing!
Intercooler – Removal
1. Remove intercooler and elbow as per overview drawing (→ Page 131).
2. Attach intercooler to crane with rope and carefully raise from engine.
3. After removing the intercooler, seal all openings with suitable covers.
4. Protect intercooler from damage.
TIM ID: 0000020526 – 002
MS20012/01E 2008-10 © MTU

3.6.4 Intercooler – Cleaning

Work on the intercooler must always be carried out by qualified personnel.
The following contains instructions for the cleaning company.
Air-side cleaning
Grease and oil contamination of the intercooler’s air-side is to be removed in a closed cleaning unit.
The cleaning agent must circulate opposite to the cooling-air direction.
It is imperative to avoid damaging the cooler, especially the cooling fins.
To remove deposits, only use cleaning agents that do not attack metal surfaces (→Operating Instructions).
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits.
Water-side cleaning
It is recommended that the water-side be cleaned in a closed cleaning unit with forced flushing and filter.
The water-side can also be cleaned in an immersion- or ultrasonic bath.
To remove deposits, only use cleaning agents that do not attack metal surfaces (→Operating Instructions).
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits.
Intercooler flushing
After cleaning, flush the intercooler with water until pH values of clean water and rinsing water are
approximately the same (permissible difference pH value: 1 pH).
Intercooler drying and preservation
If the cooler is not to be put into operation immediately after cleaning, the cooler must be dried in
a drying oven for approx. 3 hours at a temperature of 110 to 120 °C.
After drying, the cooler must be preserved with a preservation agent.
TIM ID: 0000020171 – 001
MS20012/01E 2008-10 © MTU

3.6.5 Intercooler – Check
Material

Emery cloth
Spare parts

Intercooler
Elbow
Holder
Plug-in pipe with bell
Plug-in pipe
Drain valve
Compressed air.
Risk of injury!
Component is hot.
Risk of burning!
Compressed air is pressurized.

Hot testing liquid.
WARNING Risk of injury and scalding!
• Pressure must not exceed 0.5 bar.
Intercooler – Check
Item Findings Task
Visually inspect all components for Damaged • Recondition

damage. • Replace
Check all sealing, mating and • Damaged • Recondition:

contact faces for damage and • Uneven smooth with oilstone or emery
unevenness. cloth.
• Replace
Intercooler – Leak check

1. Seal coolant chamber connections on intercooler with suitable sleeves and covers with gaskets and clamps.
TIM ID: 0000020175 – 001
2. Connect compressed air line at plug.

3. Preheat test bath to 80 °C.
4. Immerse intercooler in test bath.
5. Open compressed air supply and set pressure reducer to 0.5 bar.
6. Pressure-test intercoolers with air in water bath for leaks. Verify that no bubbles rise to the surface.
MS20012/01E 2008-10 © MTU

7. Replace intercooler if leaks are found.

8. After checking, blow through cooling air ducts with compressed air in vertical direction.
TIM ID: 0000020175 – 001
MS20012/01E 2008-10 © MTU

3.6.6 Intercooler – Installation
Material

Petroleum jelly, white 40317 1
Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!
Installing intercooler
1. Remove all covers.
2. Use crane to place intercooler on engine.
3. Coat O-ring with petroleum jelly.
4. Assemble in reverse order to disassembly (→ Page 134).
TIM ID: 0000020549 – 001
MS20012/01E 2008-10 © MTU

3.6.7 Intercooler – Final steps
Material

Final steps
1. Install in reverse order of removal (→ Page 133)
2. Fill with charge-air coolant (→Operating Instructions).
TIM ID: 0000020573 – 001
MS20012/01E 2008-10 © MTU

3.7 Air Intake / Air Supply
3.7.1 Air intake / air supply – Overview
1 Air filter with retainers 3 Air supply to left-hand side cylinders

2 Air supply from exhaust 4 Air supply to right-hand side
turbocharger to intercooler cylinders
TIM ID: 0000020376 – 002
MS20012/01E 2008-10 © MTU

3.7.2 Air filter with retainers – Overview
05 Clamp 10 Air filter

TIM ID: 0000020383 – 001
MS20012/01E 2008-10 © MTU

100 Elbow 500 Retainer, left-hand side 750 Plug screw

250 Rubber sleeve 550 Screw 800 Sealing ring
300 Clamp 600 Screw 900 Retainer
400 Retainer, right-hand side 650 Washer
450 Retainer 660 Washer
TIM ID: 0000020383 – 001
MS20012/01E 2008-10 © MTU

3.7.3 Air filter with retainers – Removal

Air filter with retainers – Removal
1. Remove air filter and retainers as per overview drawing (→ Page 141).
TIM ID: 0000020386 – 001
MS20012/01E 2008-10 © MTU

3.7.4 Air filter with retainers – Installation

Air filter with retainers – Installation
2. Install air filter and retainers as per overview drawing (→ Page 141).
TIM ID: 0000020391 – 001
MS20012/01E 2008-10 © MTU

3.7.5 Intake air system to cylinders, left – Overview
1 Charge air manifold 5 Hex screw

2 Charge air manifold 6 Washer
3 O-ring 7 Plug
4 Gasket 8 Sealing ring
TIM ID: 0000020272 – 001
MS20012/01E 2008-10 © MTU

3.7.6 Air supply system to cylinders, left – Removal
Preconditions
• Engine is stopped and starting disabled
Removing the charge-air manifold
1. Remove charge-air manifold as per overview drawing (→ Page 145) starting from the free end.
2. Remove gaskets and O-rings.
3. After removal, seal all openings with suitable plugs or covers.
TIM ID: 0000020275 – 001
MS20012/01E 2008-10 © MTU

3.7.7 Air supply system to cylinders, left – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning charge-air manifold

1. Clean left charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow out charge-air manifold with compressed air.
TIM ID: 0000020284 – 001
MS20012/01E 2008-10 © MTU

3.7.8 Air supply system to cylinders, left – Installation
Material

Engine oil
Spare parts

O-ring
Gasket
Installing the charge-air manifold

1. Prior to installation, remove all blanking plugs
and/or covers.
2. Coat O-ring with petroleum jelly and mount on
charge-air manifold union (2).
3. Coat gaskets with petroleum jelly and place on
charge-air manifold (1) sealing faces (arrows).
4. Install charge-air manifolds as per overview
drawing (→ Page 145) starting from the driving
end.
5. Make sure that gasket is correctly positioned.
Place charge-air manifold once more in position
if necessary.
6. Install screws with washer and retainer in
charge-air manifold (1) and tighten.
TIM ID: 0000020288 – 001
MS20012/01E 2008-10 © MTU

3.7.9 Air supply system to cylinders, right – Overview
1 Charge air manifold 5 Hex screw 9 Threaded bush

2 Charge air manifold 6 Washer 10 Sealing ring
3 O-ring 7 Plug 11 Plug
4 Gasket 8 Sealing ring 12 Sealing ring
TIM ID: 0000020295 – 001
MS20012/01E 2008-10 © MTU

3.7.10 Air supply system to cylinders, right – Removal
Preconditions
• Engine is stopped and starting disabled
Removing the charge-air manifold
1. Remove charge-air manifold as per overview drawing (→ Page 149) starting from the free end.
2. Remove gaskets and O-rings.
3. After removal, seal all openings with suitable plugs or covers.
TIM ID: 0000020299 – 002
MS20012/01E 2008-10 © MTU

3.7.11 Air supply system to cylinders, right – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning the charge-air manifold

1. Clean right charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow out charge-air manifold with compressed air.
TIM ID: 0000020302 – 001
MS20012/01E 2008-10 © MTU

3.7.12 Air supply system to cylinders, right – Installation
Material

Engine oil
Spare parts

O-ring
Gasket
Installing the charge-air manifold

1. Prior to installation, remove all blanking plugs
and/or covers.
2. Coat O-ring with petroleum jelly and mount on
charge-air manifold union (2).
3. Coat gaskets with petroleum jelly and place on
charge-air manifold (1) sealing faces (arrows).
4. Install charge-air manifolds as per overview
drawing (→ Page 149) starting from the driving
end.
5. Make sure that gasket is correctly positioned.
Place charge-air manifold once more in position
if necessary.
6. Install screws with washer and retainer in
charge-air manifold (1) and tighten.
TIM ID: 0000020305 – 001
MS20012/01E 2008-10 © MTU

3.7.13 Air supply from turbocharger to intercooler – Overview
300 Elbow 800 Elbow

350 O-ring 850 O-ring
400 Screw 900 Screw
450 Spacer tube 950 Spacer tube
600 Charge-air pipe, left-hand side 1100 Charge-air pipe, right hand side
650 Hoseline 1150 Hoseline
700 Clamp 1200 Clamp
TIM ID: 0000020574 – 001
MS20012/01E 2008-10 © MTU

3.7.14 Air supply from turbocharger to intercooler – Removal
Preconditions
Air supply from turbocharger to intercooler – Removal
1. Before removing the air pipework, take photos or mark pipework accordingly.
2. Remove air supply pipework as per overview drawing (→ Page 153).
TIM ID: 0000020576 – 002
MS20012/01E 2008-10 © MTU

3.7.15 Air supply from turbocharger to intercooler – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning air pipework

2. Thoroughly blow out all parts with compressed air.
TIM ID: 0000020587 – 001
MS20012/01E 2008-10 © MTU

3.7.16 Air supply from turbocharger to intercooler – Installation
Material

Spare parts

O-rings
Hoseline
Clamp
Air supply from turbocharger to intercooler – Installation

2. Coat O-rings with grease.
3. Install air supply pipework as per overview drawing (→ Page 153) according to the photos taken or markings
made prior to removal.
TIM ID: 0000020583 – 003
MS20012/01E 2008-10 © MTU

3.8 Exhaust System
3.8.1 Exhaust pipework after cylinder head – Overview
200 Exhaust pipe 550 Screw 900 Lamellar ring

250 Exhaust pipe 600 Spacer sleeve 1000 Sealing ring
300 Exhaust pipe 700 Exhaust pipe 1050 Screw
400 Lamellar ring 750 Exhaust pipe 1100 Spacer sleeve
500 Gasket 800 Exhaust pipe
TIM ID: 0000020696 – 001
MS20012/01E 2008-10 © MTU

3.8.2 Exhaust pipework after cylinder head – Removal
Preconditions

Risk of injury!
Exhaust pipework – Removal

1. Remove screws (2) with spacers (3).
2. Take off exhaust pipes (1) from cylinder heads.
3. Pull and twist exhaust pipes (1) to separate
them from one another.
4. Remove gaskets from the cylinder head exhaust
outlets.
TIM ID: 0000020358 – 001
MS20012/01E 2008-10 © MTU

3.8.3 Exhaust pipework after cylinder head – Installation
Special tools

Material

Spare parts

Gasket
Lamellar ring

Risk of injury!
Installing exhaust pipework

2. Degrease and dry clean screw mating faces on
exhaust pipes and cylinder heads.
3. Coat lamellar rings (arrow) with assembly paste.
4. Insert screws (1) and spacers (2) into exhaust
pipe flanges.
5. Place gaskets (3) on the mating faces of the
exhaust inlet.
TIM ID: 0000020707 – 001
MS20012/01E 2008-10 © MTU

6. Install and connect exhaust pipes (1) as per

overview drawing (→ Page 157).
7. Install screws (2) with spacers (3) and use torque
wrench to tighten diagonally to the specified
tightening torque (→ Page 18).
TIM ID: 0000020707 – 001
MS20012/01E 2008-10 © MTU

3.8.4 Exhaust pipe bellows after engine – Overview
10 Exhaust pipe bellows 45 Gasket

20 Gasket 50 Screw
25 Screw 55 Washer
30 Washer 60 Nut
35 Nut 65 Washer
TIM ID: 0000020825 – 001
MS20012/01E 2008-10 © MTU

50 Flange 200 Washer

150 Screw 250 Nut
TIM ID: 0000020825 – 001
MS20012/01E 2008-10 © MTU

3.8.5 Exhaust pipe bellows after engine – Removal
Preconditions
Exhaust pipe bellows after engine – Removal
1. Remove exhaust pipe bellows as per overview drawing (→ Page 161).
TIM ID: 0000020826 – 001
MS20012/01E 2008-10 © MTU

3.8.6 Exhaust pipe bellows after engine – Installation
Material

Exhaust pipe bellows after engine – Installation

1. Before installation, remove all covers.
2. Coat screw threads with Ultra-Therm.
3. Install exhaust pipe bellows as per overview drawing (→ Page 161).
TIM ID: 0000020828 – 001
MS20012/01E 2008-10 © MTU

3.9 Starting Equipment
3.9.1 Starter – Overview
Electric starter
50 Starter, right 150 Screw

TIM ID: 0000020782 – 001
MS20012/01E 2008-10 © MTU

3.9.2 Starter – Preparatory steps
Preconditions
Preparatory steps
1. Remove charge-air manifold on left side of engine (→ Page 146).
2. Remove charge-air manifold on right side of engine (→ Page 150).
TIM ID: 0000017682 – 001
MS20012/01E 2008-10 © MTU

3.9.3 Starter – Removal
Preconditions
Electrical voltage.
Risk of serious injury - danger to life!
DANGER • Make certain that the power supply to the engine is switched off before starting to work.
Ensure that the power supply cannot be switched on unintentionally!
Heavy object.
Risk of crushing!
Disconnecting and removing starter

1. Mark all cables using suitable adhesive tape prior to removal.
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Remove starter screws as per overview drawing (→ Page 165).
5. Remove starter.
6. Protect starter from damage.
TIM ID: 0000020785 – 001
MS20012/01E 2008-10 © MTU

3.9.4 Starter – Disassembly
Starter – Disassembly
Entrust starter overhaul to an authorized and specialized company only.
TIM ID: 0000020791 – 001
MS20012/01E 2008-10 © MTU

3.9.5 Starter – Cleaning

Compressed air.
Risk of injury!
Starter – Cleaning
1. Clean starter with compressed air; do not wet-clean.
2. Protect starter against humidity.
TIM ID: 0000020786 – 001
MS20012/01E 2008-10 © MTU

3.9.6 Starter – Check
Spare parts

Starter
Compressed air.
Risk of injury!
Starter – Check
Item Findings Task
Check tooth flanks of drive gear for • Wear • Recondition

wear, indentations and chipping. • Indentations • Replace
• Chipping
visible
Check nuts and studs for condition Sluggish Replace

and check threads for ease of
movement.
Check mating face on end housing Wear traces are found. Recondition: smooth with oilstone
for wear. or emery cloth.
TIM ID: 0000020787 – 001
MS20012/01E 2008-10 © MTU

3.9.7 Starter – Installation
Special tools

Torque wrench 0015384230 1
Torque wrench F30043446 1
Ratchet F30027340 1
Material

Long-life grease (Longtherm 2 Plus) 40336 1
Electrical voltage.
Heavy object.
Risk of crushing!
Installing the starter

1. Coat starter pinion with Longtherm 2 Plus grease.
2. Install starter as per overview drawing (→ Page 165).
Connecting starter cables

1. Connect cables in accordance with the marking.
2. Install nuts and tighten with torque wrench to the specified tightening torques (→ Page 18).
3. Check starter operation.
TIM ID: 0000020781 – 001
MS20012/01E 2008-10 © MTU

3.9.8 Starter – Final steps

Final steps
TIM ID: 0000020778 – 001
MS20012/01E 2008-10 © MTU

3.9.9 Starter – Overview
Air starter
25 Air starter, left 40 Washer

35 Screw 50 Adapter
TIM ID: 0000020756 – 001
MS20012/01E 2008-10 © MTU

2 Screw 20 O-ring 38 Key disk

3 Washer 21 Screw 39 Grooved ball bearing
4 Rotor stage 2 22 Flange 40 Spring washer
5 Key disk 23 O-ring 41 Spacer
6 Sealing spacer 24 Adjusting screw 42 Plate
7 Sealing strip 25 Turbine housing 43 Lockwasher
8 Grooved ball bearing 26 Screw 44 Slotted nut
9 O-ring 27 Plug 45 Inertia-drive starter (pinion)
10 Spring washer 28 Ring gear 46 Gearcase
11 Nozzle ring 29 Spacer 48 Washer
12 O-ring 30 Washer 49 Nut
13 Rotor stage 1 31 Turbine shaft 50 Cover
14 Key disk 32 Clamp ring 51 Screw
15 Sealing strip 33 Planetary gear 52 Housing
16 Screw 34 Washer 53 Compression spring
17 Nozzle 35 Planet pinion 54 Screw
18 Nozzle 36 Needle bearing 55 Drive housing
19 Plug 37 Pin 57 Needle bearing
TIM ID: 0000020756 – 001
MS20012/01E 2008-10 © MTU

3.9.10 Starter – Preparatory steps
Preconditions
Preparatory steps
1. Observe safety instructions.
2. Shut off compressed-air supply.
3. Remove charge-air manifold on left side of engine (→ Page 146).
4. Remove charge-air manifold on right side of engine (→ Page 150).
TIM ID: 0000020759 – 001
MS20012/01E 2008-10 © MTU

3.9.11 Starter – Removal
Preconditions
Heavy object.
Risk of crushing!
Starter – Removal
1. Remove pressure hose.
2. Remove starter as per overview drawing (→ Page 173).
3. Protect starter from damage.
TIM ID: 0000020760 – 001
MS20012/01E 2008-10 © MTU

3.9.12 Starter – Disassembly
Special tools

Wrench TDI-52-20134 1
Shaft removal tool TDI-2-26945 1
Puller, rotor stage 2 TDI-52-20076 1
Carrier shaft holding jig TDI-52-20202 1
Heavy object.
Risk of crushing!
Equipment can drop off.

Liquid is highly pressurized.
WARNING Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.

Risk of injury!
Disassembling the starter

1. Mark relative positions of nozzle ring (1), turbine
housing (2), gearcase (3) and drive housing (5).
2. Unscrew nuts (4) and remove screws.
3. Pull drive housing (5) off gearcase (3).
4. Check needle bearing (→ Page 182).
• If needle bearing is damaged: Force needle
bearing out with a hydraulic press.
TIM ID: 0000020763 – 001
MS20012/01E 2008-10 © MTU

5. Remove snap ring (2) for grub screw (1) with

snap ring pliers.
6. Remove grub screw (1).
7. Pull inertia-drive starter (4) off shaft (5).
8. Remove compression spring (3).
9. Remove screws fastening gearcase to turbine
housing as per overview drawing (→ Page 173).
10. Remove gearcase.
11. Remove O-ring.
12. Place gearcase (2) on holding jig (3).

13. Drive spring keys out of groove in shaft.
14. Lever lug on lockwasher (4) out of chase in
slotted nut (5).
15. Apply wrench (1), counter gearcase (2) and
unscrew slotted nut (5).
16. Place gearcase (3) on spacer (4).

17. Press out shaft (8) with hydraulic press (1).
18. Press out shaft (8) with grooved ball bearing (5).
19. If grooved ball bearing (5) remains in gearcase (3),
press grooved ball bearing (5) out of gearcase (3).
20. Undo screws (2) and remove plate (7).
21. Press grooved ball bearing (5) out of gearcase (3).
22. Remove planet pinion as per overview drawing
(→ Page 173).
23. Remove clamp ring from groove in pin with snap
ring pliers.
TIM ID: 0000020763 – 001
24. Slide pin out through opening in planetary gear.

25. Remove planet pinion and disks.
26. Remove other planet pinions in the same way.
27. Check needle bearing (→ Page 182).
• If needle bearing is damaged: Force needle
bearing out with a hydraulic press.
MS20012/01E 2008-10 © MTU

28. Remove disk from turbine housing as per overview

drawing (→ Page 173).
29. Remove housing from nozzle ring as per overview
drawing (→ Page 173).
30. Counter rotor stage 2 (2) and remove screw with
washer as per overview drawing (→ Page 173).
Note: Note rotor installation position, this is
required for assembly.
31. Screw puller (1) onto shaft (3) and rotor 2 (2).
32. Pull rotor 2 (2) off shaft (3).
33. Drive spring key (4) out of groove in shaft (3).
34. Place turbine housing (4) on support (6).

35. Press shaft (2) completely out of turbine housing
with shaft removal tool (1) and hydraulic press.
36. Drive spring key (7) out of groove in shaft (2).
37. Remove spacer (3) from shaft (2).
38. Press shaft (2) out of grooved ball bearing (5) with
shaft removal tool (1) and hydraulic press.
TIM ID: 0000020763 – 001
MS20012/01E 2008-10 © MTU

39. Gently tap nozzle ring (2) all the way round with a
plastic mallet and remove from turbine housing (4).
Note: Do not exert pressure on rotor stage 1 with
the jackscrews.
40. If the nozzle ring (2) is too tightly seated, screw

two jackscrews (1) into the nozzle ring (2) through
the large bores in rotor stage 1 (3).
41. Press nozzle ring (2) off turbine housing (4).
Note: Note rotor installation position, this is
required for assembly.
42. Remove rotor stage 1 (3) from nozzle ring (2).

43. Undo screws (7) and remove nozzle (6).
44. Remove seal spacer (8) and sealing strip (9).
45. Drive seal spacer (8) out through shaft bore in
nozzle ring (2).
46. Remove sealing strips (10).
47. Press grooved ball bearing (11) out of nozzle
ring (2) with hydraulic press.
48. Unscrew flange (5).
49. Remove all O-rings.
TIM ID: 0000020763 – 001
MS20012/01E 2008-10 © MTU

3.9.13 Starter – Cleaning
Material

Rust remover Decorrdal 29/6-1 40420 1
Acetone 40590 1
Compressed air.
Risk of injury!


Cleaning the starter

1. Do not wash the inertia-drive starter (pinion) with solvent-based cleaning agents.
2. Clean the drive housing externally, do not wash needle bearings with solvent-based cleaning agents.
3. Clean corroded steel parts with rust remover.
4. Clean all metal parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
5. Blow out all parts with compressed air.
TIM ID: 0000020766 – 001
MS20012/01E 2008-10 © MTU

3.9.14 Starter – Check
Special tools

Pin Ø 0.084 inch 2
Pin Ø 0.096 inch 2
Pin Ø 0.0864 inch 2
Spare parts

Inertia-drive starter
Drive housing
Planetary gear
Planet gear
Pin
Washer
Spacer
Spacer
Sealing spacer
Turbine housing
Ring gear
Nozzle ring
Nozzle
Rotor
Checking the starter
Item Findings Action
Check pinion tooth flanks on • Traces of wear Replace

inertia-drive starter for traces of • indentations
wear, indentations and fissures. • fissures
visible
Check drive housing, gearcase and Cracks visible Replace

turbine housing for cracks.
Check tooth flanks of planet gear for • Traces of wear Replace

wear, indentations and fissures. • indentations
• fissures
TIM ID: 0000020769 – 001
visible
Measure planet gear (→ Table Wear Size not exact Replace

limits on page 184).
Check planetary gear for cracking • Cracks Replace

and burring in bores for pins and at • burrs
keyways. visible
MS20012/01E 2008-10 © MTU

Check for scoring on bearing Ø. Scoring > 0.005 inch Replace
Measure bearing Ø on shaft Size not exact Replace

(→ Table Wear limits on page 184).
Check pins and disks for scoring • Scoring Replace

and traces of wear. • traces of wear
visible
Measure pin Ø (→ Table Wear limits Size not exact Replace

on page 184) .
Measure disk thickness Size not exact Replace

Check turbine shaft for cracking and • Cracks Replace

burring at keyways. • burrs
visible
Check for scoring on bearing Ø. Scoring visible Replace
Measure bearing Ø on shaft Size not exact Replace

Check tooth flanks of sun gear for • Traces of wear Replace

wear, indentations and fissures. • indentations
• fissures
visible
Measure sun gear (→ Table Wear Size not exact Replace

Measure parallelism of spacers. Parallelism of ends > 0.0005 inch Replace
Check ring gear for traces of wear, • Traces of wear Replace

indentations and fissures. • indentations
• fissures
visible
Measure ring gear (→ Table Wear Size not exact Replace

Check spacers for scoring and • Scoring Replace

traces of wear. • traces of wear
visible
Check nozzle for corrosion and • Corrosion Minor surface damage is admissible
erosion. • erosion
visible
Check nozzle for cracks. Cracks visible Replace
Check nozzle for fissures at nozzle Fissures visible Replace

edges.
TIM ID: 0000020769 – 001
MS20012/01E 2008-10 © MTU

Check rotor for corrosion, erosion • Corrosion Replace

and cracks. • erosion
• cracks
visible
Check rotor for traces of wear, • Traces of wear Replace

indentations and fissures on tooth • indentations
tips, bore and keyways. • fissure
visible
Wear limits
Wear limits
Designation Limit value (inch)
Ring gear in turbine housing:
Measure inner dimension between 2 pins with Ø 0.084 Inner Ø max. 5.089
inch.
Turbine shaft:
Grooved ball bearing Ø Min. 0.669
Measure sun gear, outer dimension over 2 pins with Ø

0.096 inch.
• 7.5:1 Outer Ø min. 0.952
• 9:1 Outer Ø min. 0.808
• 11.4:1 Outer Ø min. 0.670
Planet gear:
Measure outer dimension over 2 pins with Ø 0.0864

inch.
• 7.5:1 Outer Ø min. 2.3067
• 9:1 Outer Ø min. 2.3699
• 11.4:1 Outer Ø min. 2.4359
Planetary gear shaft:
Grooved ball bearing Ø Min. 1.180
Pin bore Max. 0.875
Pin:
TIM ID: 0000020769 – 001
Needle bearing Ø Min. 0.873
Disk:
Thickness Min. 0.055
MS20012/01E 2008-10 © MTU

Wear tolerances for teeth
A Dimension, tooth center on new tooth

B Dimension, detrition on worn tooth *
* Max. admissible detrition dimension B on both tooth flanks
must not exceed 10 % of dimension A
TIM ID: 0000020769 – 001
MS20012/01E 2008-10 © MTU

3.9.15 Starter – Installation
Material

Long-life grease (Longtherm 2 Plus) 40336 1
Heavy object.
Risk of crushing!
Installing the starter

1. Coat starter pinion with Longtherm 2 Plus grease.
2. Attach starter to crane.
3. Insert starter into opening on end housing.
4. Align securing holes on starter with holes on end housing flange.
5. Secure starter with screws to flange.
6. Detach starter from crane.
7. Connect pressure hose to starter.
TIM ID: 0000020775 – 001
MS20012/01E 2008-10 © MTU

3.9.16 Starter – Final steps

Final steps
2. Open compressed-air supply.
TIM ID: 0000020776 – 001
MS20012/01E 2008-10 © MTU

3.10 Lube Oil System, Lube Oil Circuit
3.10.1 Centrifugal oil filter – Overview
50 Carrier 300 O-ring 500 O-ring

150 Screw 350 O-ring 550 Stud
200 Screw 400 Centrifugal oil filter 600 Washer
250 Washer 450 Restrictor 650 Nut
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3.10.2 Centrifugal oil filter – Preparatory steps
Preconditions
Preparatory steps
1. Comply with safety regulations.
2. Drain engine oil from centrifugal oil filter.
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3.10.3 Centrifugal oil filter – Removal
Preconditions
Centrifugal oil filter – Removal
1. Remove centrifugal oil filter according to overview drawing (→ Page 188).
2. Seal all openings with suitable covers.
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3.10.4 Centrifugal oil filter – Disassembly

Disassembling centrifugal oil filter
1. Loosen screw (1) on cover.
2. Release nut with toggle (2) and remove V-band
clamp (3).
3. Remove cover (1) from housing (2).

4. Drain remaining oil from centrifugal oil filter into
suitable container.
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5. Carefully remove rotor unit (1) from shaft/housing

(3). Avoid damaging bearing or shaft.
6. Remove O-ring (4).
7. Unscrew valve piston (2), plug and compression
spring.
8. Loosen nut (1) and remove rotor cover (2) with

rotor body (3) from lower rotor part.
9. Extract paper insert (3) from rotor body (4).

10. Remove rotor cover (5) from rotor body (4).
11. Remove partition plate (2) from lower rotor part (1).
12. Remove O-rings from lower rotor part (1).
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3.10.5 Centrifugal oil filter – Cleaning
Material

Cleaner
Compressed air.
Risk of injury!

Cleaning rotor unit

1. Clean all rotor components and inside surface of rotor cap thoroughly with cleaning agent.
2. Remove cleaner.
3. Blow out rotor components with compressed air.
4. Blow out pipe and nozzle with compressed air.
5. Clean pipe with brass brush.
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3.10.6 Centrifugal oil filter – Check
Material

Red dye penetrant for surface crack test procedure
Spare parts

Housing
Rotor
Nozzle
Pipe
Screw
Compression spring
Valve plunger
Plug
Checking centrifugal oil filter
Check all sealing, mating • Wear • Rework: Re-surface with oil stone or crocus cloth.
and sliding surfaces • Scores • Replace
for wear, scoring and • Indentations
indentations. visible.
Using red penetrant dye, Crack indication Replace rotor unit.

check the housing and
substructure for cracks.
Check all threads and Damaged • Rework: Re-cut thread(s).

tapped holes. • Replace
Check journals on rotor Wear visible • Rework: Re-surface with oil stone or crocus cloth.
and bearing running • Replace
surfaces on shaft for
wear.
Check plunger and spring Wear visible • Recondition

of valve for traces of wear • Replace
(→ Page 188).
Check bearing clearance Bearing clearance more Rotor unit, replace lower part
at rotor unit. than 0.25 mm
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3.10.7 Centrifugal oil filter – Assembly
Material

White petroleum jelly
Engine oil
Spare parts

Paper insert
O-ring
Sealing ring
Heavy object.
Risk of crushing!
Assembling rotor unit

1. Coat O-rings with petroleum jelly and insert in
groove on rotor cover and lower rotor part.
2. Place partition plate (2) on lower rotor part (1).
3. Place rotor body (4) on lower rotor part (1).
4. Insert new paper insert (3) in rotor body (4).
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5. Place cover (2) on to rotor body (3).

6. Screw in nut (1).
7. Coat shaft with engine oil.

8. Carefully insert rotor unit (1) in housing (3).
9. Check rotor (1) for smooth running.
10. Coat O-ring (4) with petroleum jelly and insert in
groove on housing (3).
11. Screw in valve plunger (2) with plug and
compression spring.
12. Place cover (1) onto housing (2).
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13. Tighten screw (1) to specified tightening torque

(→ Page 18).
14. Install V-band clamp (3) and use toggle (2) to
tighten to specified tightening torque (→ Page 18) .
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3.10.8 Centrifugal oil filter – Installation
Material

Spare parts

O-ring
Centrifugal oil filter – Installation

1. Remove all blanking plugs and/or covers.
2. Coat O-ring with petroleum jelly and install.
3. Installation is in reverse sequence to removal.
4. Install centrifugal oil filter as shown in overview drawing (→ Page 188).
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3.10.9 Centrifugal oil filter – Final steps

Final steps
1. Fill with engine oil, if necessary (→Operating Instructions).
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3.10.10 Turbocharger oil supply – Overview
150 Oil line 600 Gasket

200 Union 650 Screw
450 Oil return line, left-hand side 750 Gasket
500 Oil return line, left-hand side 800 Nut
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300 Oil line 1050 Screw

350 Union 1150 Gasket
900 Oil return line, right-hand side 1200 Nut
1000 Gasket 1300 Plug screw
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3.10.11 Turbocharger oil supply – Removal
Preconditions
Turbocharger oil supply – Removal
1. Remove oil lines as per overview drawing (→ Page 200).
3. Protect oil lines from damage.
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3.10.12 Turbocharger oil supply – Installation
Material

Engine oil
Spare parts

Sealing ring
Compressed air.
Risk of injury!
Turbocharger oil supply – Installation

2. Install oil lines as per overview drawing (→ Page 200).
3. Check oil lines for leaks after next engine start.
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3.11 Cooling System
3.11.1 Engine coolant pump – Overview
1 Engine coolant pump 4 Screw 7 Washer

2 O-ring 5 Screw
3 Screw 6 Nut
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1 Water pump shaft 8 Angular-contact ball bearing 15 Washer

2 Impeller 9 Cylindrical roller bearing 16 O-ring
3 Bearing housing 10 Snap ring 17 Screw
4 Seal carrier 11 Shaft seal 18 Washer
5 Volute 12 Rotary seal 19 Sealing ring
6 Spacer sleeve 13 O-ring 20 Plug screw
7 Gear 14 Screw
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MS20012/01E 2008-10 © MTU

3.11.2 Engine coolant pump – Preparatory steps
Preconditions
Preparatory steps
2. Remove engine coolant pump supply on intake side (→ Page 230).
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3.11.3 Engine coolant pump – Removal
Preconditions
Special tools

Lifting gear T80091388 1
Support bracket T80091384 1
Heavy object.
Risk of crushing!

Risk of injury!
Engine coolant pump – Removal

1. Attach engine coolant pump with lifting gear and support bracket to crane using a slightly tensioned rope.
2. Remove screws for engine coolant pump as per overview drawing (→ Page 204).
3. Use crowbar to separate engine coolant pump from front cover and remove.
4. Remove O-ring.
5. Seal all openings with suitable covers.
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3.11.4 Engine coolant pump – Disassembly
Special tools

Hydraulic spindle F6781539 1
Puller tool for impeller F6780562 1
Puller tool for gear F6780561 1
Holding fixture F6781573 1
Carrier for several mandrels F30275611 1
Impact extractor for shaft seal F30450991 1
Snap ring pliers F30002760 1
Heavy object.
Risk of crushing!


Risk of injury!
Engine coolant pump – Disassembly

1. Mark installation position of bearing housing (1)
and volute (3) in relation to one another.
2. Remove all bolts (2).
3. Use crowbar to separate volute (3) from bearing
housing (1) and remove it.
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4. Place engine coolant pump in (2) retaining

device (1).
5. Use hydraulic spindle (1) and puller tool for impeller

(2) to remove impeller (3) from pump shaft.
6. Holding the gear firmly in the retaining device
throughout.
7. Take off impeller (3) from engine coolant pump.
8. Remove bellows joint seal from pump shaft.
9. Take engine coolant pump out of retaining device.
10. Place bearing housing (3) with pump shaft in vise

with aluminum jaws.
11. Use hydraulic spindle (1) and puller tool (2) to
remove gear from water pump shaft.
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12. Use snap ring pliers (4) to remove snap ring (2)
for cylindrical roller bearing (3) from bearing
housing (1).
13. Remove all screws (1) using box wrench (2).
14. Take bearing housing (2) out of vise and take

off seal carrier (1).
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15. Use hydraulic press (1) to force pump shaft (2) off
bearing housing (3).
16. Place pump shaft (2) in holding fixture (6).

17. Use hydraulic press (1) to force pump shaft
(2) out of inner race (3), spacer sleeve (4) and
angular-contact ball bearing (5).
18. Use hydraulic press (1) and mandrel (2) to

press cylindrical roller bearing (3) out of bearing
housing (4).
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19. Press counterring (1) off bearing housing (3).

20. Use impact extractor to remove shaft seal (2) from
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3.11.5 Engine coolant pump – Cleaning
Material

Compressed air.
Risk of injury!


Engine coolant pump – Cleaning

2. Blow all components thoroughly with compressed air.
TIM ID: 0000019994 – 002
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3.11.6 Engine coolant pump – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

Penetrant remover (Standard-Check) 40002 1
Aqueous developer (Standard-Check) 40004 1
Dye penetrant (Standard-Check) 40488 1
Crack-test oil (No. 63) 40475 1
Crack-test paste (UV-Apelux paste 1031) 40483 1
Spare parts

Engine coolant pump
Water pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
Heavy object.
Risk of crushing!

Risk of injury!
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Engine coolant pump – Check
Item Findings Task
Check volute and impeller for Cavitation visible. Replace

cavitation.
Check bearing housing, impeller Crack indication Replace

and volute with red dye penetrant
for cracks.
Check water pump shaft with Crack indication Replace

magnetic crack-testing procedure
for cracks.
Check coolant pump shaft for wear • Wear • Recondition: smooth minor
and damage. • Damage traces of wear with emery cloth.
visible • Replace
Visually inspect sealing surfaces for • Wear • Recondition: smooth with

wear, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
visible
Check gear for indentations, traces • Wear • Recondition: smooth with

of wear and damage. • Indentations oilstone or emery cloth.
• Damage • Replace gear.
visible
Measure bearing seats and Not dimensionally accurate Replace

diameters on engine coolant pump,
impeller, seal carrier and bearing
housing and gear with inside and
outside micrometer. Values and
measuring points (→ Page 216)
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3.11.7 Engine coolant pump – Tolerances
size Basic
size
1 Seal carrier 90.000 K7 −0.025 +0.010 0.025 0.025
Angular-contact 90.000 −0.015 0

ball bearing
outer diam.
2 Bearing housing 90.000 K7 −0.025 +0.010 0.025 0.025

bore
Angular-contact 90.000 −0.015 0

ball bearing
outer diam.
3 Angular contact 40.000 −0.012 0 0.002 0.025

ball bearing bore
Shaft outer diam. 40.000 k5 +0.002 +0.013
4 Spacer sleeve 40.000 N7 −0.033 –0.008 0.010 0.046

bore
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5 Bearing housing 80.000 K7 −0.021 +0.009 0.022 0.021

bore
Cylindrical roller 80.000 −0.013 0

bearing
MS20012/01E 2008-10 © MTU

size Basic
size
6 Cylindrical roller 40.000 −0.012 0 0.002 0.025

bearing bore
7 Gear bore 39.000 H7 0 +0.025 0.018 0.059
Shaft outer diam. 39.000 s6 +0.043 +0.059
size Basic
size
1 Seal carrier bore 72.000 H8 0 +0.046 0.084 0.230
Shaft seal outer 72.000 +0.130 +0.230

diam.
2 Shaft outer diam. 48.000 −0.100 0
If running surface is worn: Recondition pump shaft by spray-metallizing and plunge-cut grinding.
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3 Rotary seal 35.000 h8 −0.039 0 0.040 0.100

inner diam.
Rotary seal outer 78.200 −0.030 0

diam.
MS20012/01E 2008-10 © MTU

size Basic
size
4 Impeller bore 35.000 H5 0 +0.009 0.032 0.050
Shaft outer diam. 35.000 t5 +0.048 +0.059
5 Rotary seal
Counterring
If wear traces are found: Replace components together
s1 : 0.7 to 1.1
s2 : 0.6 to 1.5
s3 : 0.5 to 0.65
s4 : 0.08 to 0.5
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3.11.8 Engine coolant pump – Assembly
Special tools

Press fit tool for angular-contact ball bearings F30378152 1
Press fit tool for ball bearings F30378153 1
Press fit tool for shaft seal F30450990 1
Press-in tool for rotary seal F6784612 1
Support for bearing housing F6780563 1
Support for shaft with bearing F6781573 1
Retaining device F6780561 1
Material

Ethanol 40250 1
Engine oil
Spare parts

Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Shaft seal
Rotary seal
O-ring
Component is hot.
Risk of burning!
Heavy object.
Risk of crushing!
TIM ID: 0000019997 – 001

Risk of injury!
MS20012/01E 2008-10 © MTU

Engine coolant pump – Assembly

Note: Apply pressure to bearing outer race.
1. Use hydraulic press (1) and mandrel (2) to press

cylindrical roller bearing into bearing housing (4).
2. Place snap ring (2) in groove of bearing

housing (3), using snap ring pliers (1).
3. Check that snap ring (2) is correctly seated.
4. Force angular-contact ball bearing (3) onto pump

shaft (4) with hydraulic press (1) and mandrel (2).
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5. Force spacer sleeve (3) onto pump shaft (4) with

hydraulic press (1) and mandrel (2).
6. Press inner race (2) of cylindrical roller bearing

onto pump shaft (3) with hydraulic press and
mandrel (1).
Note: Apply pressure to bearing outer race (3).

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Note: Make sure shaft seal (2) is in the correct

position.
8. Insert shaft seal (2) into press-in mandrel (1).

shaft seal into seal carrier (3).
10. Coat O-ring with petroleum jelly and place into

groove.
11. Place bearing housing (1) in holding fixture (4).
12. Use screws (2) to install seal carrier on bearing
housing (1) and tighten them evenly.
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13. Heat gear (2) to 200 °C.

14. Place bearing housing (3) with seal carrier and
holding fixture (4) onto hydraulic press (1).
15. Use hydraulic press (1) to push heated gear (2)
onto shaft to stop position and hold until shrink
connection between shaft and gear is fixed.
16. Coat O-ring of counterring (2) with petroleum jelly

and insert in bearing housing (2).
17. Clean sliding surface on counterring (2) with
ethanol.
18. Coat bellows joint seal (1) internal diameter with
low surface tension water.
19. Clean sliding surface on bellows joint seal (1)
with ethanol.
20. Fit bellows joint seal (1) on shaft (4) and use
press-in tool to push it against counterring (2).
21. Heat impeller (1) to 210 °C.
22. Place engine coolant pump onto hydraulic

press (1).
23. Place two feeler gauges (clearance
S1 = 0.7 mm to 1.1 mm), on seal carrier (3)
arranged at 180° towards one another.
24. Push heated impeller (2) with hydraulic press (1)
until it stops at feeler gauges.
25. Measure clearance S1 between impeller (2) and
seal carrier (3) with feeler gauge.
26. If measured value is out of tolerance, determine
the cause and replace components, if necessary.
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27. Set volute (3) onto bearing housing (1) according

to the installation position marking made before
removal.
28. Tighten screws (2).
29. Turn pump shaft to check for easy movement.
30. Measure clearance S2 (0.6 mm to 1.5 mm)
between impeller and volute (3) with feeler gauge.
31. If measured value is out of tolerance, determine
the cause and replace components, if necessary.
TIM ID: 0000019997 – 001
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3.11.9 Engine coolant pump – Installation
Special tools

Lifting gear T80091388 1
Support bracket T80091384 1
Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!

Risk of injury!
Engine coolant pump – Installation

1. Prior to installation, remove all covers.
2. Coat O-ring (1) with petroleum jelly.
3. Insert O-ring (1) in groove on bearing housing of
engine coolant pump.
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4. Attach engine coolant pump with lifting gear

and support bracket to crane using a slightly
tensioned rope.
Note: Make sure that gears are correctly meshed.
5. Install coolant pump (1) in bore on equipment

carrier, ensuring it is correctly positioned.
6. Install screws (2) and washers and tighten
uniformly.
7. Remove lifting gear and support bracket.
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3.11.10 Engine coolant pump – Final steps

Final steps
2. Fill with engine coolant (→Operating Instructions ).
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3.11.11 Coolant supply for engine coolant pump, intake side – Overview
Elbow with attached components
1 Elbow 6 Washer 11 Connecting piece

2 Plug screw 7 Retainer 12 Banjo screw
3 Sealing ring 8 Screw 13 Sealing ring
4 O-ring 9 Washer
5 Screw 10 Drain valve
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Coolant pipework
1 Plug-in pipe 5 Screw 9 Flange

2 Plug-in pipe 6 O-ring 10 O-ring
3 O-ring 7 Pipe 11 Screw
4 Flange 8 O-ring
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3.11.12 Engine coolant pump pipework, intake side – Removal
Preconditions
Removing coolant lines
1. Before removing the lines it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove all monitoring units installed in coolant lines.
3. Remove lines as shown in overview drawing (→ Page 228).
4. Seal all openings with suitable plugs.
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3.11.13 Coolant supply for engine coolant pump, intake side – Installation
Material

Engine oil
Spare parts

Sealing rings
O-rings
Compressed air.
Risk of injury!
Installing coolant lines

1. Remove all plugs.
2. Blow out coolant lines with compressed air.
3. Coat all O-rings with petroleum jelly.
4. Fit coolant lines tension-free with new gaskets and O-rings and install with pipe clamp halves or band clamps.
5. Install all monitoring units in coolant lines.
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3.11.14 Coolant pipework after cylinder – Overview
Coolant pipework after cylinder – Overview

Applies analogously to 12 V.
200 Manifold 800 O-ring 1350 Screw

250 Manifold 850 Screw 1450 O-ring
300 Manifold 950 Plug screw 1500 Screw
350 Connecting piece 1050 Manifold 1550 Screw
450 O-ring 1100 Manifold 1650 O-ring
500 Screw 1150 Manifold 1700 O-ring
550 Screw 1200 Connecting piece 1800 Screw
650 O-ring 1260 Plug screw 1850 Spacer bushing
700 O-ring 1300 O-ring 1900 Washer
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3.11.15 Coolant pipework after cylinder – Removal

Coolant pipework after cylinder – Removal
1. Remove manifolds as per overview drawing (→ Page 232).
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3.11.16 Coolant pipework after cylinder – Installation
Material

Engine oil
Spare parts

O-ring
Compressed air.
Risk of injury!
Coolant pipework after cylinder – Installation

2. Blow out manifolds with compressed air.
3. Coat O-rings with petroleum jelly.
4. Install manifolds as per overview drawing (→ Page 232) free of tension.
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3.11.17 Preheating unit – Overview
1 Pump 5 Thermostat
2 Gasket 6 Non-return flap
3 Screw-in heater 7 Plug
4 Gasket 8 Sealing ring
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MS20012/01E 2008-10 © MTU

3.11.18 Preheating unit – Removal

Electrical voltage.
Heavy object.
Risk of crushing!
Coolant is hot and under pressure.

WARNING • Let the engine cool down.
Removing preheating unit

1. Switch off preheating unit and disconnect from power supply.
2. Close shutoff valves.
3. Remove screws from flanges.
4. Attach preheating unit to crane and take up all slack on cables.
5. Remove all screws on mounting frame.
6. Loosen flanges.
7. Remove gaskets from flanges.
8. Use crane to lift preheating unit off mounting frame and set it down.
9. Fit open flanges with covers to protect against dirt.
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3.11.19 Preheating unit, screw-in heating element – Replacement
Special tools

Hot-air blower 0005388520 1
Spare parts

Seal
Screw-in heating element
Electrical voltage.

Removing the screw-in heating element

1. Check that there is adequate space to remove the
screw-in heating element: Preheating housing
length plus 5 cm. Remove the preheating unit if
this is not the case (→ Page 236).
2. Providing that adequate space is available for
removal:
2.1. Switch off the preheating unit.
2.2. Close shut-off valves in the supply and
return lines.
2.3. Disconnect the preheating unit power
supply.
3. Unscrew nuts on cover.
4. Remove cover and seal.
5. Remove heat-shrinkable hose at cable duct.
6. Note down cable connections.
7. Disconnect cables and pull out of cable duct.
8. Remove housing and seal.
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9. Unscrew screw-in heating element (2) at flange (3)

and pull out of housing.
10. Remove seal (1).
Installing the screw-in heating element

1. Clean screw-in heating element holder on housing.
2. Fit new seal on screw-in heating element.
3. Insert screw-in heating element into housing and screw in.
4. Fit new heat-shrinkable hose over the cable and slide the cable through the cable duct.
5. Connect cable to screw-in heating element.
6. Push the heat-shrinkable hose over the cable duct and shrink fit with a hot-air blower.
7. Fit cover with seal and screw down with nuts.
8. When the preheating unit has been removed: Install preheating unit (→ Page 241).
9. When the preheating unit has not been removed:
9.1. Connect preheating unit to power supply.
9.2. Open shut-off valves in the supply and return lines.
9.3. Switch on preheating unit.
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3.11.20 Preheating unit, coolant pump – Replacement
Special tools

Spare parts

Seal
Pump assy. with motor
Electrical voltage.

Removing the pump

1. Switch off the preheating unit.
2. Close shut-off valves in the supply and return lines.
3. Disconnect preheating unit from power supply.
5. Remove cover on pump motor.
6. Note down cable connections.
7. Disconnect cables from motor control and pull out of cable duct.
8. Remove screws at flanges (→ Page 235).
9. Pull out pump together with pump motor.
10. Remove seals at flanges.
Installing the pump

1. Clean flanges.
2. Fit new seals on flanges (→ Page 235).
3. Position pump and pump motor between flanges and screw on.
4. Fit new heat-shrinkable hose over the cable and slide the cable through the cable duct.
5. Connect cables to motor control.
6. Push the heat-shrinkable hose over the grommet and shrink fit with a hot-air blower.
7. Connect preheating unit to power supply.
8. Open shut-off valves in the supply and return lines.
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9. Switch on preheating unit
MS20012/01E 2008-10 © MTU

3.11.21 Preheating unit, thermostat – Replacement
Special tools

Spare parts

Thermostat
Electrical voltage.

Removing the thermostat

1. Check that there is adequate space to remove the screw-in heating element: Preheating housing length plus
5 cm. Remove the preheating unit if this is not the case (→ Page 236).
2. Providing that adequate space is available for removal:
2.1. Switch off the preheating unit.
2.2. Close shut-off valves in the supply and return lines.
2.3. Disconnect the preheating unit power supply.
3. Remove screws on thermostat cover and take off the cover (→ Page 235).
5. Disconnect cables on thermostat and pull out of cable duct.
6. Pull thermostat out of holder tube.
Installing the thermostat
1. Insert thermostat in holder tube (→ Page 235).
2. Fit heat-shrinkable hose over the cable.
3. Insert cable through cable duct and connect to thermostat.
4. Install cover.
5. Push the heat-shrinkable hose over the cable duct and shrink fit with a hot-air blower.
6. When the preheating unit has been removed: Install preheating unit (→ Page 241).
7. When the preheating unit has not been removed:
7.1. Connect preheating unit to power supply.
7.2. Open shut-off valves in the supply and return lines.
7.3. Switch on preheating unit.
TIM ID: 0000019962 – 001
MS20012/01E 2008-10 © MTU

3.11.22 Preheating unit – Installation
Spare parts

Seal
Electrical voltage.
Heavy object.
Risk of crushing!
Preheating unit – Installation

1. Remove covers from flanges.
Note: Pay attention to flow direction indicated by arrows on pump and non-return valve.
2. Position preheating unit with crane ensuring proper alignment with mounting frame and flanges.
3. Fit gaskets in the flanges.
4. Screw preheating unit into place with the screws on the mounting frame.
5. Detach preheating unit from crane.
6. Screw on flanges.
7. Connect preheating unit to power supply.
8. Open shut-off valves.
9. Vent cooling circuit.
10. Switch on preheating unit.
11. Check preheating unit for leaks during operation.
TIM ID: 0000020008 – 001
MS20012/01E 2008-10 © MTU

3.11.23 Engine coolant and charge-air coolant ventilation – Overview
200 Double union 4550 Double union 5500 Screw

250 Sealing ring 4600 Sealing ring 5560 Retainer
550 Vent line 4850 Retainer 5650 Pipe half-clamp
600 Vent line 4860 Spacer bushing 5700 Grommet
650 T piece 4900 Pipe half-clamp 5750 Screw
700 Vent line 4950 Grommet 5800 Nut
750 Vent line 5000 Screw 5850 Washer
800 T piece 5050 Nut 5950 Pipe half-clamp
850 Vent line 5150 Washer 6000 Pipe half-clamp
950 Vent line 5250 Washer 6050 Grommet
1950 Union 5300 Retainer 6100 Spacer bushing
2000 Sealing ring 5350 Screw 6150 Screw
4350 Vent line 5400 Pipe half-clamp
4400 Vent line 5450 Grommet
TIM ID: 0000020739 – 001
MS20012/01E 2008-10 © MTU

200 Double union 3400 Screw 4110 Screw

250 Sealing ring 3500 Retainer 4120 Washer
350 Vent line 3550 Screw 4150 Pipe half-clamp
400 T piece 3600 Washer 4200 Grommet
450 Vent line 3650 Pipe half-clamp 4250 Screw
500 Vent line 3700 Grommet 4300 Vent line
3050 Adapter union 3750 Screw 5250 Washer
3100 Sealing ring 3850 Double union 5300 Retainer
3150 Vent line 3900 Sealing ring 5350 Screw
3250 Retainer 3950 Vent line 5400 Pipe half-clamp
3300 Pipe half-clamp 4000 T piece 5450 Grommet
3350 Grommet 4100 Retainer 5500 Screw
TIM ID: 0000020739 – 001
MS20012/01E 2008-10 © MTU

1150 Distribution 1700 Sealing cone

1160 Plug screw 2400 Vent line
1170 Sealing ring 2410 Hoseline
1250 Retainer 2500 Banjo screw
1300 Screw 2550 Sealing ring
1400 Screw 2650 Union
1450 Nut 2700 Sealing ring
1550 Double union 2800 Pipe half-clamp
1600 Sealing ring 2850 Grommet
1650 Nut 2900 Screw
TIM ID: 0000020739 – 001
MS20012/01E 2008-10 © MTU

1050 Union 2250 Grommet 5000 Screw

1100 Sealing ring 2300 Screw 5050 Nut
1800 Vent line 2310 Washer 5150 Washer
1850 Vent line 4700 Plug screw 5600 Pipe half-clamp
1950 Union 4750 Sealing ring 5700 Grommet
2000 Sealing ring 4860 Spacer bushing 5750 Screw
2100 Union 4910 Pipe half-clamp 5800 Nut
2200 Pipe half-clamp 4950 Grommet 5850 Washer
TIM ID: 0000020739 – 001
MS20012/01E 2008-10 © MTU

3.11.24 Engine coolant and charge-air coolant ventilation – Removal
Preconditions
Removing vent lines
1. Before removing the lines, it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove lines as per overview drawing (→ Page 242).
3. After removal, seal all connections with suitable plugs.
TIM ID: 0000020150 – 001
MS20012/01E 2008-10 © MTU

3.11.25 Engine coolant and charge-air coolant ventilation – Installation
Material

Engine oil
Spare parts

Grommet
Pipe half-clamp
Compressed air.
Risk of injury!
Engine coolant and charge-air coolant ventilation – Installation

1. Remove all plugs.
2. Blow out coolant ventilation and charge air cooling with compressed air.
3. Install engine coolant and charge-air coolant ventilation as per overview drawing (→ Page 242) free of tension
and secure with pipe half-clamps.
TIM ID: 0000020153 – 002
MS20012/01E 2008-10 © MTU

3.11.26 Charge-air coolant pump – Overview
1 Charge-air coolant pump 4 Screw 7 Drain valve

2 O-ring 5 Nut
3 Screw 6 Washer
TIM ID: 0000020009 – 001
MS20012/01E 2008-10 © MTU

Charge-air coolant pump – Overview
1 Water pump shaft 8 Angular-contact ball bearing 15 Washer

2 Impeller 9 Cylindrical roller bearing 16 O-ring
3 Bearing housing 10 Snap ring 17 Screw
4 Seal carrier 11 Shaft seal 18 Washer
5 Volute 12 Rotary seal 19 Plug screw
6 Spacer sleeve 13 O-ring
7 Gear 14 Screw
TIM ID: 0000020009 – 001
MS20012/01E 2008-10 © MTU

3.11.27 Charge-air coolant pump – Preparatory steps
Preconditions
Preparatory steps
1. Drain charge-air coolant (→Operating Instructions ).
2. Remove charge-air coolant pump fluid lines as per overview drawing (→ Page 275).
TIM ID: 0000017717 – 001
MS20012/01E 2008-10 © MTU

3.11.28 Charge-air coolant pump – Removal
Preconditions
Heavy object.
Risk of crushing!

Risk of injury!
Charge-air coolant pump – Removal

1. Remove securing screws for coolant pump according to overview drawing (→ Page 248).
2. Use crowbar to separate charge-air coolant pump from equipment carrier and remove.
3. Mask installation hole for charge-air coolant pump.
4. Remove O-ring from charge-air coolant pump.
TIM ID: 0000020010 – 001
MS20012/01E 2008-10 © MTU

3.11.29 Charge-air coolant pump – Disassembly
Special tools

Hydraulic spindle F6781539 1
Puller tool for impeller F6780562 1
Puller tool for gear F6780561 1
Holding fixture F6781573 1
Impact extractor for shaft seal F30450991 1
Heavy object.
Risk of crushing!


Risk of injury!
Charge-air coolant pump – Disassembly

1. Mark installation position of bearing housing (1)
and volute (3) in relation to one another.
2. Remove all bolts (2).
3. Use crowbar to separate volute (3) from bearing
housing (1) and remove it.
TIM ID: 0000020011 – 001
MS20012/01E 2008-10 © MTU

4. Place engine coolant pump in (2) retaining

device (1).
5. Use hydraulic spindle (1) and removal tool for

impeller (2) to remove impeller (3) from water
pump shaft.
6. Holding the gear firmly in the retaining device
throughout.
7. Take off impeller (3) from engine coolant pump.
8. Remove bellows seal from pump shaft.
9. Remove charge-air coolant pump from retaining
device.
10. Place bearing housing (3) with pump shaft in vice

with aluminum jaws.
11. Use hydraulic spindle (1) and removal tool (2) to
remove gear from water pump shaft.
TIM ID: 0000020011 – 001
MS20012/01E 2008-10 © MTU

12. Use snap ring pliers (4) to remove snap ring (2)
for cylindrical roller bearing (3) from bearing
housing (1).
13. Remove all bolts (1) using box wrench (2).
14. Take bearing housing (2) out of vise and take

off seal carrier (1).
TIM ID: 0000020011 – 001
MS20012/01E 2008-10 © MTU

15. Use hydraulic press (1) to force pump shaft (2) off
16. Place pump shaft (2) in holding fixture (6).

17. Use hydraulic press (1) to force pump shaft
(2) out of inner race (3), spacer sleeve (4) and
angular-contact ball bearing (5).

cylindrical roller bearing out of bearing housing (4).
TIM ID: 0000020011 – 001
MS20012/01E 2008-10 © MTU

19. Press out counterring (1).

20. Use impact extractor to remove shaft seal (2) from
TIM ID: 0000020011 – 001
MS20012/01E 2008-10 © MTU

3.11.30 Charge-air coolant pump – Cleaning
Material

Compressed air.
Risk of injury!


Charge-air coolant pump – Cleaning

2. Blow all components thoroughly with compressed air.
TIM ID: 0000020012 – 002
MS20012/01E 2008-10 © MTU

3.11.31 Charge-air coolant pump – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

Dye penetrant remover (Standard-Check) 40002 1
Aqueous developer (Standard-Check) 40004 1
Dye penetrant (Standard-Check) 40488 1
Crack-test oil (No. 63) 40475 1
Crack-test paste (UV-Apelux paste 1031) 40483 1
Spare parts

Charge-air coolant pump
Pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000020013 – 001
MS20012/01E 2008-10 © MTU

Charge-air coolant pump - Check
Item Findings Task
Check volute and impeller for Cavitation visible. Replace

cavitation.
Check bearing housing, impeller Crack indication Replace

and volute with red dye penetrant
for cracks.
Using the magnetic crack-testing Crack indication Replace

method, check water pump shaft for
cracks.
Check pump shaft for wear and • Wear traces • Recondition: smooth minor
damage. • Damage traces of wear with emery cloth.
visible • Replace
Visually inspect sealing surfaces for • Wear • Recondition: smooth with

wear, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
visible
Check gear for indentations, traces • Wear traces • Recondition: smooth with
of wear and damage. • Indentations oilstone or emery cloth.
• Damage • Replace gear.
visible
Measure bearing seats and Not dimensionally accurate Replace

diameters on pump shaft, impeller,
seal carrier and bearing housing
and gear with inside and outside
micrometer. Values and measuring
points (→ Page 260)
TIM ID: 0000020013 – 001
MS20012/01E 2008-10 © MTU

3.11.32 Charge-air coolant pump – Tolerances
size Basic
size
1 Seal carrier 90.000 K7 –0.025 +0.010 0.025 0.025
Angular contact 90.000 –0.015 0

ball bearing
outer Ø
2 Bearing housing 90.000 K7 –0.025 +0.010 0.025 0.025

bore
Angular contact 90.000 –0.015 0

ball bearing
outer Ø
3 Angular contact 40.000 –0.012 0 0.002 0.025

ball bearing bore
Shaft outer Ø 40.000 k5 +0.002 +0.013
4 Spacer sleeve 40.000 N7 –0.033 –0.008 0.010 0.046

bore
TIM ID: 0000020015 – 001
Shaft outer Ø 40.000 k5 +0.002 +0.013
5 Bearing housing 80.000 K7 –0.021 +0.009 0.022 0.021

bore
Cylindrical roller 80.000 –0.013 0

bearing
MS20012/01E 2008-10 © MTU

size Basic
size
6 Cylindrical roller 40.000 –0.012 0 0.002 0.025

bearing bore
Shaft outer Ø 40.000 k5 +0.002 +0.013
7 Gear bore 39.000 H7 0 +0.025 0.018 0.059
Shaft outer Ø 39.000 s6 +0.043 +0.059

TIM ID: 0000020015 – 001
MS20012/01E 2008-10 © MTU

size Basic
size
1 Seal carrier bore 72.000 H8 0 +0.046 0.084 0.230
Shaft seal 72.000 +0.130 +0.230

outer Ø
2 Shaft outer Ø 50.000 –0.100 0
If running surface is worn: Recondition pump shaft by spray-metallizing and plunge-cut grinding.
3 Shaft seal 35.000 h8 –0.030 0 0.040 0.100

inner Ø
4 Impeller bore 35.000 H5 0 +0.011 0.032 0.050
Shaft outer Ø 35.000 t5 +0.048 +0.059
5 Rotary seal
Counterring
If wear traces are found: Replace components together
s1 : 0.4 to 0.6
TIM ID: 0000020015 – 001
s2 : 0.6 to 1.52
s3 : 0.08 to 0.5
MS20012/01E 2008-10 © MTU

3.11.33 Charge-air coolant pump – Assembly
Special tools

Installation tool for angular-contact ball bearing F30378152 1
Installation tool for roller bearing F30378153 1
Installation tool for shaft seal F30450990 1
Installation tool for rotary seal F6784612 1
Bearing housing support F6780563 1
Support for shaft with bearing F6781573 1
Support for various mandrels F30275611 1
Retaining device F6780561 1
Material

Ethanol 40250 1
Surface sealant (Loctite 573) 40031 1
Corrosion inhibitor oil
Spare parts

Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Shaft seal
Rotary seal
O-ring
Component is hot.
Risk of burning!
Heavy object.
Risk of crushing!
TIM ID: 0000020017 – 002

Risk of injury!
MS20012/01E 2008-10 © MTU

Assembling charge-air coolant pump

Note: Apply pressure to bearing outer ring.

2. Place snap ring (2) in groove of bearing

housing (3), using snap ring pliers (1).
3. Check that snap ring (2) is correctly seated.
TIM ID: 0000020017 – 002
MS20012/01E 2008-10 © MTU

4. Force angular-contact ball bearing (3) onto pump

shaft (4) using hydraulic press (1) and mandrel (2).
5. Force spacer sleeve (3) onto pump shaft (4) using

hydraulic press (1) and mandrel (2).
6. Force inner ring (2) of cylindrical roller bearing

onto pump shaft (3) using hydraulic press and
mandrel (1).
TIM ID: 0000020017 – 002
MS20012/01E 2008-10 © MTU

Note: Apply pressure to bearing outer ring (3).

pump shaft (2) into bearing housing (4).
Note: Make sure shaft seal (2) is in the correct

position.
8. Insert shaft seal (2) into press-in mandrel (1).

shaft seal into seal carrier (3).
TIM ID: 0000020017 – 002
MS20012/01E 2008-10 © MTU

10. Position intermediate washer in sealing ring

retainer (4).
11. Coat rotary seal (3) with liquid soap and water
(1:2).
rotary seal (3) into seal carrier (4).
13. Clean sliding surface with denatured ethanol
after assembly.
14. Coat O-ring with grease and place into groove.

15. Place bearing housing (1) in holding fixture (4).
16. Use screws (2) to install seal carrier on bearing
housing (1) and tighten evenly.
17. Heat gear (2) to 200 °C.

18. Place bearing housing (3) with seal carrier and
holding fixture (4) onto hydraulic press (1).
19. Use hydraulic press (1) to push heated gear (2)
onto shaft to stop position and hold until shrink
connection between shaft and gear is fixed.
TIM ID: 0000020017 – 002
MS20012/01E 2008-10 © MTU

20. Coat O-ring of counterring (2) with grease and

insert in bearing housing (2).
21. Clean sliding surface on counterring (2) using
ethanol.
22. Coat inner diameter of bellows seal (1) with
wetted water.
23. Clean sliding surface on bellows seal (1) using
ethanol.
24. Position bellows seal (1) on shaft (4) and push up
to counterring (2) using installation tool.
25. Heat impeller (1) to 210 °C.
26. Place charge-air coolant pump on hydraulic

press (1).
27. Use hydraulic press (1) to push heated impeller (2)
onto coolant pump shaft to stop position.
28. Set volute (3) onto bearing housing (1) according

to the installation position marking made before
removal.
29. Tighten screws (2).
30. Turn pump shaft to check ease of movement.
31. Use feeler gauge to check clearance S2 (0.6 mm to
1.5 mm) between impeller and volute (3).
32. If measured clearance is out of tolerance,
determine the cause and replace components,
if necessary.
TIM ID: 0000020017 – 002
MS20012/01E 2008-10 © MTU

3.11.34 Charge-air coolant pump – Installation
Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!

Risk of injury!
Preparing charge-air coolant pump for installation

1. Remove all blanking plugs.
2. Coat O-ring (1) with petroleum jelly.
3. Insert O-ring (1) in groove on the bearing housing
of charge-air coolant pump.
TIM ID: 0000020018 – 001
MS20012/01E 2008-10 © MTU

Note: Make sure that gears are correctly meshed.
4. Insert charge-air coolant pump (1) into the

bore in the equipment carrier, ensuring correct
installation position.
5. Screw in screws (2) with washers.
6. Tighten screws (2) evenly.
TIM ID: 0000020018 – 001
MS20012/01E 2008-10 © MTU

3.11.35 Charge-air coolant pump – Final steps

Final steps
1. Assemble fluid lines in reverse order of disassembly (→ Page 275).
2. Fill with charge-air coolant (→Operating Instructions).
TIM ID: 0000018277 – 002
MS20012/01E 2008-10 © MTU

3.11.36 Coolant pipework from/to intercooler – Overview
100 Coolant return line 700 Screw

150 Coolant return line 800 O-ring
200 Coolant supply line 850 Screw
250 Coolant supply line 950 Retainer
300 Pipe line 1000 Pipe half-clamp
350 O-ring 1010 Pipe half-clamp
450 O-ring 1050 Screw
500 Screw 1060 Nut
600 Twin elbow 1070 Washer
650 O-ring 1150 Screw
TIM ID: 0000020531 – 001
MS20012/01E 2008-10 © MTU

3.11.37 Coolant pipework from/to intercooler – Removal

Removing coolant line
1. Prior to removal of lines, make photographs of installed lines or mark lines and attachments.
2. Remove lines as shown in overview drawing (→ Page 272).
3. Remove sealant.
4. After removal, seal all connections with plugs.
TIM ID: 0000020535 – 001
MS20012/01E 2008-10 © MTU

3.11.38 Coolant pipework from/to intercooler – Installation
Material

Engine oil
Incorrect installation of components and lines.

CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
Coolant pipework from/to intercooler – Installation

1. Before installation, remove all covers.
2. Install coolant pipework from/to intercooler as shown in overview drawing (→ Page 272) .
TIM ID: 0000020543 – 001
MS20012/01E 2008-10 © MTU

3.11.39 Thermostat – Overview
Thermostat housing (HT)
10 Plug-in pipe 30 Screw 55 Flange

15 Plug-in pipe 35 O-ring 60 O-ring
20 O-ring 45 Line 65 Screw
25 Flange 50 O-ring
TIM ID: 0000019511 – 001
MS20012/01E 2008-10 © MTU

Thermostat housing (HT)
90 Thermostat housing 140 Thermostat insert 195 O-ring

100 Plug screw 145 Sealing ring 200 O-ring
110 Twin elbow 160 Screw 300 Plug screw
120 Plug screw 170 Screw 350 Plug screw
125 Sealing ring 175 Screw 400 Sealing ring
130 Plug screw 185 Plug-in pipe
135 Sealing ring 190 Flange
TIM ID: 0000019511 – 001
MS20012/01E 2008-10 © MTU

Thermostat housing (LT)
150 Thermostat housing 650 Washer 1250 Screw

200 Thermostat insert 750 Spacer tube 1300 Gasket
300 Thermostat housing 850 Screw 1450 Line
400 Screw 900 Screw 1500 O-ring
450 Screw 950 Washer 1600 Flange
550 O-ring 1050 Plug screw 1650 O-ring
600 Screw 1150 Elbow 1700 Screw
TIM ID: 0000019511 – 001
MS20012/01E 2008-10 © MTU

3.11.40 Thermostat – Preparatory steps
Preconditions
Heavy object.
Risk of crushing!

Risk of injury!
Preparatory steps
2. Drain charge-air coolant (→Operating Instructions ).
TIM ID: 0000019512 – 002
MS20012/01E 2008-10 © MTU

3.11.41 Thermostat – Removal
Preconditions
Removing the thermostat
1. Remove thermostat (high-temperature circuit) as per overview drawing (→ Page 275).
2. Remove thermostat (low-temperature circuit) as per overview drawing (→ Page 275).
TIM ID: 0000020486 – 002
MS20012/01E 2008-10 © MTU

3.11.42 Thermostat – Installation

Installing the thermostat
TIM ID: 0000020495 – 001
MS20012/01E 2008-10 © MTU

3.11.43 Thermostat – Final steps

Final steps
1. Fill with engine coolant (→Operating Instructions )
2. Fill with charge-air coolant (→Operating Instructions)
TIM ID: 0000019513 – 002
MS20012/01E 2008-10 © MTU

3.11.44 Thermostat element – Replacement
Special tools

Driving mandrel F30379297
Puller F6787262
Material

Petroleum jelly, white
Spare parts

Thermostat element
Thermostat element
Sealing ring
Removing the thermostat element

1. Remove thermostat element (2) with sealing ring
(3) from thermostat housing (1).
2. Pull sealing ring (4) out of thermostat housing
with puller.
TIM ID: 0000019509 – 003
MS20012/01E 2008-10 © MTU

Installing the sealing ring in the thermostat housing

1. Place sealing ring (2) on driving mandrel (1).
Note: Check installation position, see adjacent
figure.
2. Clean seating surface on sealing ring (2).
3. Punch sealing ring into thermostat housing (2) with

driving mandrel (1).
Inserting the thermostat element

1. Coat sealing ring (3) on thermostat element (2)
with petroleum jelly.
2. Coat sealing ring (4) on thermostat housing (1)
with petroleum jelly.
3. Insert thermostat element (2) into thermostat
housing (1).
TIM ID: 0000019509 – 003
MS20012/01E 2008-10 © MTU

3.12 Monitoring, Control and Regulation Equipment
3.12.1 Sensors, actuators and injectors – Overview

Illustrations also applicable to 12 V 4000 G
1 Injectors Y39.11 to Y39.18 4 B10 (charge-air pressure) 7 F33 (connection for external
(B-bank cylinders) 5 B09 (charge-air temperature) sensor F33)
2 B03 (intake air temperature) 6 F57 (connection for external 8 Engine governor
3 B16 (coolant pressure) sensor F57)
The injectors are located under the cylinder-head covers of the cylinders. For replacement of the
injectors and required operations, see (→Operating Instructions).
TIM ID: 0000020416 – 001
MS20012/01E 2008-10 © MTU

1 B13 (crankshaft speed)

TIM ID: 0000020416 – 001
MS20012/01E 2008-10 © MTU

1 Injectors Y39.1 to Y39.8 (A-bank

cylinders)
2 B34 (fuel pressure after filter)
TIM ID: 0000020416 – 001
MS20012/01E 2008-10 © MTU

1 B50 (crankcase pressure) 6 B33 (fuel temperature)

2 B05 (oil pressure) 7 B43 (charge-air coolant pressure)
3 B07 (oil temperature) 8 B26 (charge-air coolant
4 B48 (fuel pressure after H.P. pump) temperature)
5 B01 (camshaft speed) 9 B06 (coolant temperature)
TIM ID: 0000020416 – 001
MS20012/01E 2008-10 © MTU

3.12.2 HP fuel sensor – Replacement
Preconditions
Special tools

Crowfoot ring wrench F30373588 1
Material

White petroleum jelly
Spare parts

Pressure sensor

• Do not smoke.
Removing pressure sensor (B48)

1. Generally observe:
• Location and position of sensor (→ Page 284).
• When removing the sensor B48 (HP fuel),
small amounts of fuel may escape. Collect in
container at hand.
2. Undo bayonet connection (1) and remove
connector (2).
3. Remove sensor above nut (3).
TIM ID: 0000019514 – 003
MS20012/01E 2008-10 © MTU

Installing pressure sensor (HP fuel)

1. Generally observe:
• Location and position of sensor (→ Page 284).
2. Coat sensor O-ring with petroleum jelly.
3. Manually screw sensor into bore.
4. Use torque wrench to tighten nut (3) to specified
tightening torque (→ Page 18).
5. Connect connector (2) and tighten bayonet
coupling (1).
TIM ID: 0000019514 – 003
MS20012/01E 2008-10 © MTU

TIM ID: 0000019514 – 003
MS20012/01E 2008-10 © MTU

Special Tools 291
4 Special Tools
4.1 Standard tools – Overview
Order no. Designation Quan-

Use tity
8205891159/00 General tool kit 1

TIM ID: 0000019061 – 002
MS20012/01E 2008-10 © MTU

292 Special Tools
4.2 Special tools – Overview
Part No. Designation / Use Qty.
Y20090113 Limit plug gauge for valve 1

guide (as-new dimension), 11
mmH7
Y20097473 Limit plug gauge for repaired 1

ready-to-use valve guide,
11mm H9
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 293

guide bore in cylinder head,
19.00mm H7

19.10mm H7
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

294 Special Tools

19.30mm H7
Y4340442 Check gauge for inlet valve 1

seat
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 295
Y4340443 Check gauge for exhaust 1

valve seat
Y20002779 Depth gauge, 500 mm 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

296 Special Tools
Y4343688 Pressure testing device 1
Y20000083 C-frame micrometer, 0-25 mm 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 297
Y20000432 C-frame micrometer, 25-50 1

mm
F6553658 Tightening equipment (power 1

amplifier)
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

298 Special Tools
B80144872 Plug for oil supply bore 1
F30378956 Installation/removal tool for 1

plugs
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 299
T80090944 Support bracket for cylinder 1

head
T80090748 Hook-ended chain sling (4 off) 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

300 Special Tools
F6783833 Valve spring compressor 1
F30377634 Socket 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 301
F6783749 Tool kit without elliptical 1

chamfer reconditioning
F6783751 Tool kit (accessory) 1

for elliptical chamfer
reconditioning
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

302 Special Tools
F6784421 Tool kit for valve-seat insert 1

removal
F30450433 Indexable insert 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 303
F6554300 Mounting plate for valve guide 1

installation
F30450348 Valve guide extractor 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

304 Special Tools
F6781747 Valve guide mandrel 1
F30091631 Reamer, Ø19.00 mm for stage 1

0 cylinder head bore
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 305

I cylinder head bore

II cylinder head bore
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

306 Special Tools
Y20090113 Plug gauge for valve guides 1
Y20097473 Plug gauge for finished valve 1

guide
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 307
Y20091080 Plug gauge for stage 0 1

cylinder head bore
Y20097512 Plug gauge for stage I cylinder 1

head bore
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

308 Special Tools
Y20097513 Plug gauge for stage II 1

cylinder head bore
F30450631 Valve seat contour restoring 1

tool for exhaust valve with
valve-seatinsert
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 309
F30450632 Valve seat contour restoring 1

tool for inlet valve with
ellipticalchamfer and
with/without valve-seat
insert
8205890451/00 Turning handle for valve seat 1

contour restoring tool
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

310 Special Tools
Y4340443 Exhaust valve gauge 1
Y4340442 Inlet valve gauge 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 311
Y4341935 Valve seat test device 1
F30451554 Countersink reamer tool 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

312 Special Tools
F30450751 Inserting mandrel for 1

valve-seat insert, inlet
F30450750 Inserting mandrel for 1

valve-seat insert, exhaust
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 313
Y20011268 Dial gauge 1
0015890321/00 Holder 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

314 Special Tools
F30026582 Torque wrench 20-100 Nm 1
F30027340 Ratchet adapter 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 315
T80090944 Support bracket for cylinder 1

head
T80090748 Hook-ended chain sling (-4 1

off)
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

316 Special Tools
F6553658 Tightening device for cylinder 1

head screws
F6558582 Alignment tool for 8V-12V 1

cylinder heads
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 317
F6553648 Alignment tool for 16V-20V 1

cylinder heads
F30378324 Adjusting mandrel 2

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

318 Special Tools
F30378617 Mandrel, Ø 20 mm 1
F30377862 Guide sleeve for mandrel 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 319
F30271842 Mandrel, Ø 24 mm 1
F30377635 Mandrel, Ø 30 mm 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

320 Special Tools
Y20045885 Endoscope 1
Y20091481 Bore gauge, 18-100 mm 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 321
F6555791 Barring tool 1
F6555792 Pointer for barring tool 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

322 Special Tools
Y4341124 Timing disc, free end 1
F30038493 Box wrench, 19 mm 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 323
F30501562 Box wrench, 24 mm 1
F30047446 Torque wrench 60-320 Nm 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

324 Special Tools
F30027341 Ratchet 1
F30043446 Torque wrench, 8-40 Nm 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 325
F30026582 Torque wrench, 20-100 Nm 1
0015384230 Torque wrench 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

326 Special Tools
F30043446 Torque wrench 1
F30027340 Ratchet 1
Pin Ø 0.084 inch 2
Pin Ø 0.096 inch 2
Pin Ø 0.0864 inch 2

TIM ID: 0000019062 – 001
TDI-52-20134 Wrench 1
TDI-2-26945 Shaft removal tool 1
TDI-52-20076 Puller, rotor stage 2 1
TDI-52-20202 Carrier shaft holding jig 1
MS20012/01E 2008-10 © MTU

Special Tools 327
T80091388 Lifting gear 1
T80091384 Support bracket 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

328 Special Tools
F6781539 Hydraulic spindle 1
F6780562 Puller tool for impeller 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 329
F6780561 Puller tool for gear 1
F6781573 Holding fixture 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

330 Special Tools
F30275611 Carrier for several mandrels 1
F30450991 Impact extractor for shaft seal 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 331
F30002760 Snap ring pliers 1
F30378152 Press fit tool for 1

angular-contact ball bearings
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

332 Special Tools
F30378153 Press fit tool for ball bearings 1
F30450990 Press fit tool for shaft seal 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 333
F6784612 Press-in tool for rotary seal 1
F6780563 Support for bearing housing 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

334 Special Tools
F6781573 Support for shaft with bearing 1
F6780561 Retaining device 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 335
0005388520 Hot-air blower 1
F30378152 Installation tool for 1

angular-contact ball bearing
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

336 Special Tools
F30378153 Installation tool for roller 1

bearing
F30450990 Installation tool for shaft seal 1
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 337
F6784612 Installation tool for rotary seal 1
F6780563 Bearing housing support 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

338 Special Tools
F30275611 Support for various mandrels 1
F30379297 Driving mandrel
TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

Special Tools 339
F6787262 Puller
F30373588 Crowfoot ring wrench 1

TIM ID: 0000019062 – 001
MS20012/01E 2008-10 © MTU

340 Special Tools
4.3 General workshop equipment – Overview

Use tity
F30004455 Open-end wrench 1
F30006068 Double open-end 1

wrench
TIM ID: 0000019063 – 001
MS20012/01E 2008-10 © MTU

Special Tools 341

Use tity
F30025896 Open end wrench 1

bit

bit
TIM ID: 0000019063 – 001
MS20012/01E 2008-10 © MTU

342 Special Tools

Use tity

bit

bit
TIM ID: 0000019063 – 001
MS20012/01E 2008-10 © MTU

Special Tools 343

Use tity
F30047446 Torque wrench 1
F30450902 Ratchet bit 1

TIM ID: 0000019063 – 001
MS20012/01E 2008-10 © MTU

344 Special Tools

Use tity
F30501631 Starter wrench 1
Y20097353 Endoscope 1
TIM ID: 0000019063 – 001
MS20012/01E 2008-10 © MTU

Special Tools 345

Use tity
5505890921/00 Compression 1
pressure recorder
5505890921/06 Diagram sheets 1

TIM ID: 0000019063 – 001
MS20012/01E 2008-10 © MTU

346 Special Tools
TIM ID: 0000019063 – 001
MS20012/01E 2008-10 © MTU

Appendix 347
5 Appendix
5.1 Manufacturer’s documentation

See manufacturer’s documentation.
TIM ID: 0000019064 – 001
MS20012/01E 2008-10 © MTU

348 Appendix
5.2 MTU contact/service partner

You can find the MTU contacts/service partners for your region under www.mtu-online.com
on the left-hand navigation bar under worldwide.
TIM ID: 0000019065 – 001
MS20012/01E 2008-10 © MTU

Appendix 349
5.3 Index
A Air supply system to cylinders, right –
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . 37 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Air filter with retainers – Installation . . . . . . . . 144 Air supply system to cylinders, right –
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Air filter with retainers – Overview . . . . . . . . . . 141
Auxiliary materials, fire prevention and
Air filter with retainers – Removal . . . . . . . . . . 143
environmental protection . . . . . . . . . . . . . . . . . 13
Air Intake / Air Supply . . . . . . . . . . . . . . . . . . . 140
Air filter with retainers – Installation . . . 144
Air filter with retainers – Overview . . . . 141 C
Air filter with retainers – Removal . . . . . 143 Camshaft running surfaces and swing followers
Air intake / air supply – Overview . . . . . 140 – Visual inspection . . . . . . . . . . . . . . . . . . . . . 95
Air supply from turbocharger to intercooler Centrifugal oil filter – Assembly . . . . . . . . . . . . 195
– Cleaning . . . . . . . . . . . . . . . . . . . . . . 155
Air supply from turbocharger to intercooler Centrifugal oil filter – Check . . . . . . . . . . . . . . 194
– Installation . . . . . . . . . . . . . . . . . . . . . 156 Centrifugal oil filter – Cleaning . . . . . . . . . . . . 193
Air supply from turbocharger to intercooler Centrifugal oil filter – Disassembly . . . . . . . . . 191
– Overview . . . . . . . . . . . . . . . . . . . . . . 153 Centrifugal oil filter – Final steps . . . . . . . . . . . 199
Air supply from turbocharger to intercooler
– Removal . . . . . . . . . . . . . . . . . . . . . . 154 Centrifugal oil filter – Installation . . . . . . . . . . . 198
Air supply system to cylinders, left – Centrifugal oil filter – Overview . . . . . . . . . . . . 188
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 147 Centrifugal oil filter – Preparatory steps . . . . . 189
Air supply system to cylinders, left – Centrifugal oil filter – Removal . . . . . . . . . . . . 190
Installation . . . . . . . . . . . . . . . . . . . . . . 148
Air supply system to cylinders, left – Charge-air coolant pump – Assembly . . . . . . . 263
Removal . . . . . . . . . . . . . . . . . . . . . . . . 146 Charge-air coolant pump – Check . . . . . . . . . 258
Air supply system to cylinders, right – Charge-air coolant pump – Cleaning . . . . . . . 257
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 151 Charge-air coolant pump – Disassembly . . . . 252
Air supply system to cylinders, right –
Installation . . . . . . . . . . . . . . . . . . . . . . 152 Charge-air coolant pump – Final steps . . . . . . 271
Air supply system to cylinders, right – Charge-air coolant pump – Installation . . . . . . 269
Overview . . . . . . . . . . . . . . . . . . . . . . . . 149 Charge-air coolant pump – Overview . . . . . . . 248
Air supply system to cylinders, right – Charge-air coolant pump – Preparatory
Removal . . . . . . . . . . . . . . . . . . . . . . . . 150 steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Intake air system to cylinders, left –
Overview . . . . . . . . . . . . . . . . . . . . . . . . 145 Charge-air coolant pump – Removal . . . . . . . 251
Air intake / air supply – Overview . . . . . . . . . . 140 Charge-air coolant pump – Tolerances . . . . . . 260
Air supply from turbocharger to intercooler – Charge-Air Cooling . . . . . . . . . . . . . . . . . . . . . 131
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Intercooler – Check . . . . . . . . . . . . . . . . 136
Intercooler – Cleaning . . . . . . . . . . . . . . 135
Air supply from turbocharger to intercooler – Intercooler – Final steps . . . . . . . . . . . . 139
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Intercooler – Installation . . . . . . . . . . . . 138
Air supply from turbocharger to intercooler – Intercooler – Overview . . . . . . . . . . . . . 131
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Intercooler – Preparatory steps . . . . . . . 133
Air supply from turbocharger to intercooler – Intercooler – Removal . . . . . . . . . . . . . . 134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Conversion tables . . . . . . . . . . . . . . . . . . . . . . 29
Air supply system to cylinders, left – Coolant pipework after cylinder –
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Air supply system to cylinders, left – Coolant pipework after cylinder –
TIM ID: 0000019065 – 001
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Air supply system to cylinders, left – Coolant pipework after cylinder – Removal . . . 233
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Coolant pipework from/to intercooler –
Air supply system to cylinders, right – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Coolant pipework from/to intercooler –
Air supply system to cylinders, right – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
MS20012/01E 2008-10 © MTU

350 Appendix
Coolant pipework from/to intercooler – Engine coolant pump – Tolerances . . . . 216

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Engine coolant pump pipework, intake
Coolant supply for engine coolant pump, intake side – Removal . . . . . . . . . . . . . . . . . . . 230
side – Installation . . . . . . . . . . . . . . . . . . . . . . 231 Preheating unit – Installation . . . . . . . . . 241
Preheating unit – Overview . . . . . . . . . . 235
Coolant supply for engine coolant pump, intake
Preheating unit – Removal . . . . . . . . . . 236
side – Overview . . . . . . . . . . . . . . . . . . . . . . . 228
Preheating unit, coolant pump –
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 204 Replacement . . . . . . . . . . . . . . . . . . . . 239
Charge-air coolant pump – Preheating unit, screw-in heating element
Assembly . . . . . . . . . . . . . . . . . . . . . . . 263 – Replacement . . . . . . . . . . . . . . . . . . . 237
Charge-air coolant pump – Check . . . . 258 Preheating unit, thermostat –
Charge-air coolant pump – Replacement . . . . . . . . . . . . . . . . . . . . 240
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 257 Thermostat – Final steps . . . . . . . . . . . 281
Charge-air coolant pump – Thermostat – Installation . . . . . . . . . . . 280
Disassembly . . . . . . . . . . . . . . . . . . . . . 252 Thermostat – Overview . . . . . . . . . . . . . 275
Charge-air coolant pump – Final Thermostat – Preparatory steps . . . . . . 278
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Thermostat – Removal . . . . . . . . . . . . . 279
Charge-air coolant pump – Thermostat element – Replacement . . . 282
Installation . . . . . . . . . . . . . . . . . . . . . . 269
Crankcase and Add-on Components . . . . . . . 45
Charge-air coolant pump –
Crankcase breather – Installation . . . . . 49
Overview . . . . . . . . . . . . . . . . . . . . . . . . 248
Crankcase ventilation – Overview . . . . . 45
Charge-air coolant pump – Preparatory
Crankcase ventilation – Removal . . . . . 48
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Charge-air coolant pump – Crankcase breather – Installation . . . . . . . . . . 49
Removal . . . . . . . . . . . . . . . . . . . . . . . . 251 Crankcase ventilation – Overview . . . . . . . . . . 45
Charge-air coolant pump – Crankcase ventilation – Removal . . . . . . . . . . 48
Tolerances . . . . . . . . . . . . . . . . . . . . . . 260
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . 50
Coolant pipework after cylinder –
Cylinder head – Assembly . . . . . . . . . . 87
Installation . . . . . . . . . . . . . . . . . . . . . . 234
Cylinder head – Check . . . . . . . . . . . . . 65
Cylinder head – Cleaning . . . . . . . . . . . 64
Overview . . . . . . . . . . . . . . . . . . . . . . . . 232
Cylinder head – Disassembly . . . . . . . . 62
Cylinder head – Final steps . . . . . . . . . 94
Removal . . . . . . . . . . . . . . . . . . . . . . . . 233
Cylinder head – Installation . . . . . . . . . . 91
Coolant pipework from/to intercooler –
Cylinder head – Plug repair . . . . . . . . . 85
Installation . . . . . . . . . . . . . . . . . . . . . . 274
Cylinder head – Preparatory steps . . . . 58
Cylinder head – Removal . . . . . . . . . . . 59
Overview . . . . . . . . . . . . . . . . . . . . . . . . 272
Cylinder head – Repair . . . . . . . . . . . . . 79
Cylinder head – Tolerances . . . . . . . . . 68
Removal . . . . . . . . . . . . . . . . . . . . . . . . 273
Cylinder head and attachments –
Coolant supply for engine coolant pump,
Overview . . . . . . . . . . . . . . . . . . . . . . . . 50
intake side – Installation . . . . . . . . . . . . 231
Valve-seat turning machine for cylinder
Coolant supply for engine coolant pump,
head . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
intake side – Overview . . . . . . . . . . . . . 228
Engine coolant and charge-air coolant Cylinder head – Assembly . . . . . . . . . . . . . . . 87
ventilation – Installation . . . . . . . . . . . . 247 Cylinder head – Check . . . . . . . . . . . . . . . . . . 65
Engine coolant and charge-air coolant Cylinder head – Cleaning . . . . . . . . . . . . . . . . 64
ventilation – Overview . . . . . . . . . . . . . . 242
Cylinder head – Disassembly . . . . . . . . . . . . . 62
Engine coolant and charge-air coolant
ventilation – Removal . . . . . . . . . . . . . . 246 Cylinder head – Final steps . . . . . . . . . . . . . . 94
Engine coolant pump – Assembly . . . . . 219 Cylinder head – Installation . . . . . . . . . . . . . . . 91
Engine coolant pump – Check . . . . . . . 214 Cylinder head – Plug repair . . . . . . . . . . . . . . 85
Engine coolant pump – Cleaning . . . . . 213
Cylinder head – Preparatory steps . . . . . . . . . 58
TIM ID: 0000019065 – 001
Engine coolant pump – Disassem-

bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Cylinder head – Removal . . . . . . . . . . . . . . . . 59
Engine coolant pump – Final steps . . . . 227 Cylinder head – Repair . . . . . . . . . . . . . . . . . . 79
Engine coolant pump – Installation . . . . 225 Cylinder head – Tolerances . . . . . . . . . . . . . . 68
Engine coolant pump – Overview . . . . . 204
Cylinder head and attachments –
Engine coolant pump – Preparatory
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Engine coolant pump – Removal . . . . . 207
MS20012/01E 2008-10 © MTU

Appendix 351
E Exhaust turbocharger – Final steps . . . . . . . . 129

Engine coolant and charge-air coolant ventilation Exhaust turbocharger – Installation . . . . . . . . . 127
– Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Exhaust turbocharger – Overview . . . . . . . . . . 123
Engine coolant and charge-air coolant ventilation Exhaust turbocharger – Preparatory steps . . . 125
– Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Exhaust turbocharger – Removal . . . . . . . . . . 126
Engine coolant and charge-air coolant ventilation
Exhaust turbocharger – Replacement . . . . . . . 130
– Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Engine coolant pump – Assembly . . . . . . . . . . 219
Engine coolant pump – Check . . . . . . . . . . . . 214 F
Engine coolant pump – Cleaning . . . . . . . . . . 213 Fuel delivery pump – Final steps . . . . . . . . . . 121
Engine coolant pump – Disassembly . . . . . . . 208 Fuel delivery pump – Installation . . . . . . . . . . . 120
Engine coolant pump – Final steps . . . . . . . . . 227 Fuel delivery pump – Overview . . . . . . . . . . . . 117
Engine coolant pump – Installation . . . . . . . . . 225 Fuel delivery pump – Preparatory steps . . . . . 118
Engine coolant pump – Overview . . . . . . . . . . 204 Fuel delivery pump – Removal . . . . . . . . . . . . 119
Engine coolant pump – Preparatory steps . . . 206 Fuel delivery pump – Replacement . . . . . . . . . 122
Engine coolant pump – Removal . . . . . . . . . . 207
Engine coolant pump – Tolerances . . . . . . . . . 216 G
Engine coolant pump pipework, intake side – General information regarding the Tolerances
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 and Wear Limits List . . . . . . . . . . . . . . . . . . . . 16
Engine side and cylinder designations . . . . . . 17 General Instructions . . . . . . . . . . . . . . . . . . . . 08
Exhaust pipe bellows after engine – General Regulations . . . . . . . . . . . . . . . . . . . . 08
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Abbreviations . . . . . . . . . . . . . . . . . . . . 37
Auxiliary materials, fire prevention and
Exhaust pipe bellows after engine –
environmental protection . . . . . . . . . . . 13
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Conversion tables . . . . . . . . . . . . . . . . . 29
Exhaust pipe bellows after engine – Engine side and cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 designations . . . . . . . . . . . . . . . . . . . . . 17
Exhaust pipework after cylinder head – General information regarding the
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Tolerances and Wear Limits List . . . . . . 16
Exhaust pipework after cylinder head – General Instructions . . . . . . . . . . . . . . . 08
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Personnel and organizational
requirements . . . . . . . . . . . . . . . . . . . . . 09
Exhaust pipework after cylinder head –
Repairing threaded bores with threaded
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
inserts (Heli-Coil) . . . . . . . . . . . . . . . . . 35
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 157 Safety precautions when working on the
Exhaust pipe bellows after engine – engine . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . 164 Standards for warning notices in the
Exhaust pipe bellows after engine – publication . . . . . . . . . . . . . . . . . . . . . . 15
Overview . . . . . . . . . . . . . . . . . . . . . . . . 161 Torque specifications for screws, nuts and
Exhaust pipe bellows after engine – bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . 163
General workshop equipment – Overview . . . 340
Installation . . . . . . . . . . . . . . . . . . . . . . 159
Exhaust pipework after cylinder head – H
Overview . . . . . . . . . . . . . . . . . . . . . . . . 157 HP fuel sensor – Replacement ............ 288
Removal . . . . . . . . . . . . . . . . . . . . . . . . 158
Exhaust Turbocharger . . . . . . . . . . . . . . . . . . 123 I
TIM ID: 0000019065 – 001
Exhaust turbocharger – Final steps . . . 129 Important Notes . . . . . . . . . . . . . . . . . . . . . . . 05

Exhaust turbocharger – Installation . . . 127 Reman assemblies, prerequisites for
Exhaust turbocharger – Overview . . . . . 123 maintenance work and general assembly
Exhaust turbocharger – Preparatory instructions . . . . . . . . . . . . . . . . . . . . . . 05
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Exhaust turbocharger – Removal . . . . . 126
Intake air system to cylinders, left –
Exhaust turbocharger – Replace-
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
ment . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Intercooler – Check . . . . . . . . . . . . . . . . . . . . . 136
MS20012/01E 2008-10 © MTU

352 Appendix
Intercooler – Cleaning . . . . . . . . . . . . . . . . . . . 135 Preheating unit, screw-in heating element –

Intercooler – Final steps . . . . . . . . . . . . . . . . . 139 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Intercooler – Installation . . . . . . . . . . . . . . . . . 138 Preheating unit, thermostat – Replace-
ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Intercooler – Overview . . . . . . . . . . . . . . . . . . 131
Intercooler – Preparatory steps . . . . . . . . . . . . 133
Intercooler – Removal . . . . . . . . . . . . . . . . . . . 134 R
Reman assemblies, prerequisites for
maintenance work and general assembly
L instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
Low-Pressure Fuel System . . . . . . . . . . . . . . . 117 Repairing threaded bores with threaded inserts
Fuel delivery pump – Final steps . . . . . 121 (Heli-Coil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fuel delivery pump – Installation . . . . . 120
Fuel delivery pump – Overview . . . . . . . 117
Fuel delivery pump – Preparatory S
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Safety precautions when working on the
Fuel delivery pump – Removal . . . . . . . 119 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel delivery pump – Replacement . . . 122 Sensors, actuators and injectors –
Lube Oil System, Lube Oil Circuit . . . . . . . . . . 188 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Centrifugal oil filter – Assembly . . . . . . . 195 Special tools – Overview . . . . . . . . . . . . . . . . . 292
Centrifugal oil filter – Check . . . . . . . . . 194
Centrifugal oil filter – Cleaning . . . . . . . 193 Standard tools – Overview . . . . . . . . . . . . . . . 291
Centrifugal oil filter – Disassembly . . . . 191 Standards for warning notices in the
Centrifugal oil filter – Final steps . . . . . . 199 publication . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Centrifugal oil filter – Installation . . . . . . 198 Starter – Check . . . . . . . . . . . . . . . . . . . . . . . . 170,
Centrifugal oil filter – Overview . . . . . . . 188 182
Centrifugal oil filter – Preparatory Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . 169,
steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 181
Centrifugal oil filter – Removal . . . . . . . 190
Turbocharger oil supply – Starter – Disassembly . . . . . . . . . . . . . . . . . . . 168,
Installation . . . . . . . . . . . . . . . . . . . . . . 203 177
Turbocharger oil supply – Overview . . . 200 Starter – Final steps .................... 172,
Turbocharger oil supply – Removal . . . 202 187
Starter – Installation .................... 171,
186
M
Starter – Overview ..................... 165,
Maintenance schedule matrix . . . . . . . . . . . . . 40
173
Maintenance tasks . . . . . . . . . . . . . . . . . . . . . 42
Starter – Preparatory steps . . . . . . . . . . . . . . . 166,
Manufacturer’s documentation . . . . . . . . . . . . 347 175
Monitoring, Control and Regulation Starter – Removal . . . . . . . . . . . . . . . . . . . . . . 167,
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 176
HP fuel sensor – Replacement . . . . . . . 288
Starting Equipment . . . . . . . . . . . . . . . . . . . . . 165
Sensors, actuators and injectors –
Starter – Check . . . . . . . . . . . . . . . . . . . 170,
Overview . . . . . . . . . . . . . . . . . . . . . . . . 284
182
MTU contact/service partner . . . . . . . . . . . . . . 348 Starter – Cleaning . . . . . . . . . . . . . . . . . 169,
181
P Starter – Disassembly . . . . . . . . . . . . . . 168,
177
Personnel and organizational require- Starter – Final steps ............... 172,
ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 187
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Starter – Installation ............... 171,
TIM ID: 0000019065 – 001
Preheating unit – Installation . . . . . . . . . . . . . . 241 186

Preheating unit – Overview . . . . . . . . . . . . . . . 235 Starter – Overview ................ 165,
173
Preheating unit – Removal . . . . . . . . . . . . . . . 236 Starter – Preparatory steps . . . . . . . . . . 166,
Preheating unit, coolant pump – 175
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Starter – Removal . . . . . . . . . . . . . . . . . 167,
176
MS20012/01E 2008-10 © MTU

Appendix 353
T Valve drive – Installation . . . . . . . . . . . . . . . . . 113

Thermostat – Final steps . . . . . . . . . . . . . . . . 281 Valve drive – Overview . . . . . . . . . . . . . . . . . . 96
Thermostat – Installation . . . . . . . . . . . . . . . . . 280 Valve drive – Preparatory steps . . . . . . . . . . . 99
Thermostat – Overview . . . . . . . . . . . . . . . . . . 275 Valve drive – Removal . . . . . . . . . . . . . . . . . . 100
Thermostat – Preparatory steps . . . . . . . . . . . 278 Valve drive – Tolerances . . . . . . . . . . . . . . . . . 108
Thermostat – Removal . . . . . . . . . . . . . . . . . . 279 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Thermostat element – Replacement . . . . . . . . 282 Camshaft running surfaces and swing
followers – Visual inspection . . . . . . . . . 95
Torque specifications for screws, nuts and
Valve drive – Assembly . . . . . . . . . . . . . 110
bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Valve drive – Check . . . . . . . . . . . . . . . 105
Turbocharger oil supply – Installation . . . . . . . 203 Valve drive – Cleaning . . . . . . . . . . . . . 104
Turbocharger oil supply – Overview . . . . . . . . 200 Valve drive – Disassembly . . . . . . . . . . 102
Turbocharger oil supply – Removal . . . . . . . . . 202 Valve drive – Final steps . . . . . . . . . . . . 116
Valve drive – Installation . . . . . . . . . . . . 113
Valve drive – Overview . . . . . . . . . . . . . 96
V Valve drive – Preparatory steps . . . . . . 99
Valve drive – Assembly . . . . . . . . . . . . . . . . . . 110 Valve drive – Removal . . . . . . . . . . . . . 100
Valve drive – Check . . . . . . . . . . . . . . . . . . . . 105 Valve drive – Tolerances . . . . . . . . . . . . 108
Valve drive – Cleaning . . . . . . . . . . . . . . . . . . 104 Valve-seat turning machine for cylinder
head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Valve drive – Disassembly . . . . . . . . . . . . . . . 102
Valve drive – Final steps . . . . . . . . . . . . . . . . . 116
TIM ID: 0000019065 – 001
MS20012/01E 2008-10 © MTU

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MTU_ValueService

Instructions for Overhaul

1 General Information ............................................................ 05

MS20012/01E 2008-10 © MTU

3.3.5 Valve drive – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

MS20012/01E 2008-10 © MTU

3.8.2 Exhaust pipework after cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 158

MS20012/01E 2008-10 © MTU

MS20012/01E 2008-10 © MTU

1.1 Important Notes

1.1.1 Reman assemblies, prerequisites for maintenance work

Vibration damper Vibration damper

Injection pump (only accumulator) High-pressure fuel pump

Prerequisites for maintenance work

General assembly instructions

MS20012/01E 2008-10 © MTU

MS20012/01E 2008-10 © MTU

MS20012/01E 2008-10 © MTU

1.2 General Regulations

1.2.1 General Instructions

TIM ID: 0000019073 – 001

MS20012/01E 2008-10 © MTU

1.2.2 Personnel and organizational requirements

MS20012/01E 2008-10 © MTU

1.2.3 Safety precautions when working on the engine

Safety precautions when putting the equipment into operation

Always seal connections with caps or covers if a line is removed or opened.

MS20012/01E 2008-10 © MTU

MS20012/01E 2008-10 © MTU

TIM ID: 0000019075 – 001

MS20012/01E 2008-10 © MTU

1.2.4 Auxiliary materials, fire prevention and environmental protection

MS20012/01E 2008-10 © MTU

TIM ID: 0000019076 – 001

MS20012/01E 2008-10 © MTU

1.2.5 Standards for warning notices in the publication

MS20012/01E 2008-10 © MTU

Explanation of terms for dimensions of new components

Toleranced size Designed size followed by a fit symbol (e.g. 24 H6) or by

Basic size Designed size without fit symbol or permissible

Deviation Permissible tolerance of toleranced/basic size.

Clearance Difference between bore and shaft diameter when bore

Interference Difference between bore and shaft diameter when bore

Explanation of terms for reconditioning of components

Reworking instructions If wear limits are exceeded or values are below

TIM ID: 0000019078 – 001

MS20012/01E 2008-10 © MTU

1.2.7 Engine side and cylinder designations

1 KGS = Free end 3 KS = Driving end

MS20012/01E 2008-10 © MTU

1.2.8 Torque specifications for screws, nuts and bolts

Sleeve for injector 60 Nm +6 Nm Engine oil

M14 plug screw 35 Nm +3.5 Nm

Screw for cylinder head.

Tightening sequence of screws: 1 to 6

2 Pretightening torque 180 Nm +10 Nm

3 Angle of further rotation 180° +10°

4 Test torque 400 Nm

Screw of rocker shaft support. 250 Nm +25 Nm

MS20012/01E 2008-10 © MTU

M10 x 40 26 Nm +2 Nm Engine oil

Screw for turbine housing V-band clamp to bearing 17 Nm +2 Nm

Screw for compressor housing V-band clamp to bearing 12.4 Nm +2.3 Nm

M10 x 120 screw for exhaust line to cylinder 42 Nm + 4 Nm Ultra-Therm MTU