M020081_00_e_0310 (maintenance Manual).pdf

Technical Publication Diesel Engine 12V 183 TE94 Maintenance Manual M020081/00E Engine type: 444.901-520

DaimlerChrysler Off-Highway

Printed in Germany E 2004 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten. Printed in Germany E 2004 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. Imprimé en Allemagne E 2004 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne. Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. Modifications réservées. Impreso en Alemania E 2004 Copyright MTU Friedrichshafen GmbH Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones. Stampato in Germania E 2004 Copyright MTU Friedrichshafen GmbH Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH. II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche.

Printed in Germany  2004 Copyright MTU Friedrichshafen GmbH A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line. Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores. Salvo alterações.

Amendment Service! Any changes in contents will be sent to you in the form of an amendment, provided you complete the reverse of this receipt card and return it to us.

Maintenance Manual

M020081/00E

Postcard

MTU Friedrichshafen GmbH 12V 183 TE94

Department SCT 88040 Friedrichshafen GERMANY

No. Please mark all filed amendments here.

Date

Name

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Please use block capitals!

Receipt TICK ONE BOX ONLY!

Amendment No.

1. 2.

j Update as (PDF) file by E--mail j Update as (PDF) file as CD--ROM j Update in hardcopy form

3. 4. 5.

Publication number: M020081/00E

6.

Name

7. 8.

Manufacturer

9.

Department

E--mail

10.

Fax

Telephone

11. 12.

Street

13.

Postal box number

14.

(Postal code) City

15. 16.

Country

Wichtig - Important - Importante Bitte die Karte „Inbetriebnahmemeldung” abtrennen und ausgefüllt an MTU Friedrichshafen GmbH zurücksenden. Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten LogistikSupport (Gewährleistung, Ersatzteile etc.). Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.). Veuillez séparer la carte “Signalisation de mise en service” et la renvoyer à la MTU Friedrichshafen GmbH. Les informations concernant la signalisation de mise en service constituent la base pour l’assistance en exploitation contractuelle (garantie, rechanges, etc.). Rogamos separen la tarjeta “Aviso de puesta en servicio” y la devuelvan rellenada a MTU Friedrichshafen GmbH. Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logístico contractual (garantía, piezas de repuesto, etc.). Ritagliare “Avviso di messa in servizio” e rispedirlo debitamente compilato alla MTU Friedrichshafen GmbH. Le informazioni ivi registrate sono la base per il supporto logistico contrattuale (garanzia, ricambi, ecc.). É gentileza cortar o cartão ”Participação da colocação em serviço”, preenché-lo e devolvé-lo a MTU Friedrichshafen. Os dados referentes à colocação em serviço representam a base para o suporte logístico (garantia, peças sobressalentes, etc.) estabelecido contratualmente.

Postcard

MTU Friedrichshafen GmbH Abteilung SCSD 88040 Friedrichshafen GERMANY

Bitte in Blockschrift ausfüllen! Please use block capitals! Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello! Favor preencher com letras de forma!!

Motornr.: Engine No.: No du moteur: No de motor: Motore N.: No. do motor

Auftragsnr.: MTU works order No.: No de commande: No de pedido: N. commessa: No. do pedido

Motortyp: Engine model: Type du moteur: Tipo de motor: Motore tipo: Tipo do motor

Inbetriebnahmedatum: Date put into operation: Mise en service le: Fecha de puesta en servicio: Messa in servizio il: Data da colocação em serviço:

Eingebaut in: Installation site: Lieu de montage: Lugar de montaje: Installato: Incorporado em:

Schiffstyp / Schiffshersteller: Vessel/type/class / Shipyard: Type du bateau / Constructeur: Tipo de buque / Constructor: Tipo di barca / Costruttore: Tipo de embarcação/estaleiro naval:

Inbetriebnahmemeldung

Commissioning Note

Notice de mise en service

Aviso de puesta en servicio

Endabnehmer/Anschrift: End user‘s address: Adresse du client final: Dirección del cliente final: Indirizzo del cliente finale: Usuário final/endereço: Bemerkung: Remarks: Remarques: Observaciones: Commento: Observações:

Avviso di messa in servizio

Participação da colocação em serviço

Section Page

General

1 1

Contents 1.1

Important information

1.2

Hazards at the workplace

1.3

Designation of engine side

1.4

Tightening specifications

1.5

Settings

1.6

Publication overview

1.7

Repairing threaded bores

1.8

Keyword index

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

1 2

General

- 03.10 -

M020081/00E

Section Page

General

1.1

1.1 1

Important Information

This manual is intended for use by technical personnel responsible for the maintenance and servicing of the MTU Diesel Engine, 183 series. The manual describes the - scheduled maintenance tasks of the W5 and W6 maintenance schedule and the - non-scheduled service operation on the individual subassemblies. Index sheets divide this handbook into 3 main sections. Component group structure The third main section is subdivided into assemblies 01 to 88. The subdivision follows the structure of the Equipment List and Spare Parts Catalogue. Every assembly section is further divided into subassembly sections (where required). Example: 3. 1. 2 Subassembly group Assembly section Main section Since the component groups and subgroups are arranged in a module system which applies to different engine types, this numbering system is not in series. Alternative subassemblies are either without an index, or are provided with indices ”a, b, c” etc. Example: 3.1.2a There can be only one subassembly group 3.1.2 for any individual engine, thus: 3.1.2 without index or 3.1.2a or 3.1.2b etc.. The section on each subassembly group is divided into seven operations; the final digit is always identical for all of these: .1 Before-removal operations .2 Removal .3 Disassembly .4 Inspection and repair .5 Assembly .6 Installation .7 After-installation operations All seven procedures will not be required for every subassembly. In these cases, the corresponding sections will not appear in either the text or the table of contents, but the remaining sections will retain their respective end digits. Alternative operations are identified in the index with ”a, b, c” etc., while the basic operation is not provided with an index. Example: 3.1.2.1 3.1.2.2 3.1.2.4 3.1.2.6 3.1.2.7

M020081/00E - 03.10 -

Before-removal operations Removal Inspection and repair Installation After-installation operations

E MTU

Section Page

1.1 2

General

When several operations are combined in a single section (e.g. where no supplementary illustrations are required), a corresponding note will appear in the table of contents. Example: 3.1.9.1 3.1.9.2 3.1.9.4 3.1.9.6

Before-removal operations (see 3.1.9) Removal (see 3.1.9) Inspection and repair (see 3.1.9) Installation (see 3.1.9)

Quickly finding the sought-after information The manual provides the following aids for assistance in finding the desired section: - The contents listings on the main cover sheets provide references to the tables of contents for the individual sections. - An alphabetical subject index in the first main section provides direct access to the individual sections. - The individual assemblies are listed in the group summary on the cover sheet to the 3rd main section. Basic requirements for maintenance and service work Customers performing their own maintenance must ensure that the following conditions and basic requirements are satisfied: - All safety regulations are observed - Comprehensive assortment of general-purpose tools is provided - Cleaning and testing equipment is provided - Work is performed by trained personnel - Special tools are provided - Service area is adequately equipped For further supplements to this handbook, see 1.6

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.1 3

General assembly instructions are observed D Component cleanness: Areas of all components that come in contact with oil, fuel, engine coolant and combustion air must be kept clean. D

Components requiring “special cleanliness” (e.g. oil- and fuel-carrying components) must be cleaned with suitable cleaning procedures before assembly, checked for particular cleanness and treated accordingly.

D

Component packaging must only be removed immediately before installation.

D

Elastomer components (e.g. rubber parts etc.) must not be washed with diesel fuel, solvents or cold cleaners. Parts dirtied with oil and fuel must be cleaned immediately. The parts should be wiped with a dry cloth. Elastomer components such as engine mounts, damping elements, couplings and V-belts must not be painted. They can only be installed after painting the engine or must be covered before painting work is carried out. Radial-lip shaft seals treated by the manufacturer with oil show as a result definite signs of swelling when delivered. They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.

D

D

The surfaces of parts that slide against each other must be lubricated with SAE30 engine oil when installed, unless otherwise specified.

D

O-rings and surfaces moving against them during installation (bores and shafts) must be coated with petroleum jelly, unless otherwise specified.

D

D

When installing O-rings with counterrings in coolant pumps, always follow the installation instructions. After installing O-rings in shaft grooves, in order to remedy twists caused by installation, pass a rounded marking tool under the sealing ring in the direction of the circumference if the O-ring diameter is sufficiently large. Make sure that the O-ring is not damaged. Before installing shaft seals: On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft running surface with thin-film lubricant or SAE30 engine oil. In the support bore, in the case of a metal outer jacket the outer surface must be coated with surface sealant, unless otherwise specified in the drawing. For elastomer outer jackets or combined metal/elastomer outer jackets, the outer surface must be coated with denaturated ethanol. This symbol applies to radial-lip shaft seals and its significance depends on its position. The arrow indicates the position of the sealing lip.

D

Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on the flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be fitted to the component and then (no more than 20 minutes later) the seal components screwed together. Oil, multi-purpose grease or other materials must not be used to fix the position.

D

Before installing antifriction bearings, lightly lubricate the bearing seats. Only remove the bearings from their original packaging immediately before installation so they do not get dirty. Do not remove the corrosion inhibitor from the bearings in original packaging. Use petroleum spirit or acid-free kerosene to clean the antifriction bearings. After cleaning, relubricate the bearings with engine oil.

D

During assembly, do not apply (axial) forces to rolling elements and do not hit the bearing rings with a hammer (use assembly aids). Do not use an open flame to heat bearing inner races. The temperature should be between 80 °C and 100 °C and must never exceed 120 °C. Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate). Dry bearings must not be oiled.

D

When installing gears, the splines must be lubricated with SAE 30 engine oil.

D

All support and mating surfaces of components (e.g. mating surfaces for centring devices, flange and sealing surfaces, joint surfaces of press fits) must be clean, polished or provided with the specified surface protection and free from warping and damage. Corrosion inhibitors (e.g. oil, grease) must be removed from support and mating surfaces.

M020081/00E - 03.10 -

E MTU

Section Page

1.1 4

General

D

After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate must be removed and the parts coated with SAE 30 engine oil.

D

Sensors must be coated with long-life lubricant before installation in the immersion sleeves.

D

Cable connections with cutting ring threaded connections must be preassembled in a vice and tightened, the thread first being coated with thin-film lubricant.

D

If components are to be marked by etching, after the etching is completed the solution must be removed by means of neutralization agent. The affected parts must then be preserved with SAE30 engine oil.

D

Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes) must be coated at the support and mating surfaces with assembly paste, unless otherwise specified.

D

The assembly surfaces of screws, nuts, washers and of parts to be tensioned must be clean and polished or provided with the specified surface protection and free from warping and damage. Corrosion inhibitors (e.g. oil, grease) must be removed. Threads and screw heads must be coated with lubricant before assembly as per tightening specifications. Unless otherwise specified, the following lubricants should be used: - SAE30 engine oil for general application - Assembly paste in hot part areas.

a) Threaded connections without tightening specifications For threaded connections without tightening specifications, the tightening procedure can be selected as required, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end wrench or box wrench is possible. In the event of mechanical tightening, the tightening torque must be taken from the general tightening specifications according to thread size and property class. b) Threaded connections with tightening specifications - Torque tightening The screw connections must be tightened by hand with a torque wrench or angle-of-rotation torque wrench. The specified torques must be set at the torque wrench without consideration of the specified tolerance. When using an angle-of-rotation torque wrench, the torque indicated must be within the torque specification limit value. Proceed in a similar manner with torsionally protected threaded connections. These instructions apply also to testing torque. Note:

If no tolerance for tightening torque is stated, the tightening tolerance is + 10% of specified torque.

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

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.2

1.2 1

Hazards at the Workplace

These safety instructions must be read and followed by every person who operates, maintains or repairs the machine plant. General Safety and Accident Prevention Regulations D

In addition to the instructions given in this publication, general safety and accident prevention regulations and laws must be taken into consideration; these may vary from country to country.

D

This engine is a state-of-the-art product and conforms to the applicable specifications and regulations. Accidents can still occur, however, causing serious bodily harm or damage to property under the following conditions: Incorrect use Servicing, maintenance and repair carried out by untrained members of staff Modifications or Conversions Noncompliance with the Safety Instructions

-

Correct Use of the Engine D

The engine is designed solely for the contractually-defined purpose. Another use, or a use beyond that defined, is regarded as not being for the purpose intended. The manufacturer accepts no liability for damage resulting from unauthorised use. The responsibility is borne by the operator alone.

D

The contractually-defined use includes the careful reading of the Operating Instructions and Maintenance Manual, and following the maintenance and repair directions.

Personnel Requirements D

Work must be carried out by qualified personnel only. The minimum age required by law must be observed.

D

Only fully-trained or qualified personnel are to be employed. Responsibilities of the operating, maintenance and repair personnel must be specified.

Modifications or Conversions D

Engine modification or conversions carried out by the customer may affect safety. No modifications or conversions must be implemented without prior consent from DDC or MTU.

D

No liability will be accepted for damage resulting from unauthorised modifications or conversions.

Organisational Measures D

This manual is to be given to the maintenance and repair personnel.

D

With assistance from this manual, the personnel must be instructed on the operation and maintenance of the engine, with special emphasis on the safety instructions. This is especially important for personnel who work only occasionally on the engine.

Note:

Amendments to this publication will be sent to you provided the receipt card is returned to MTU. This also applies to in-house use by MTU personnel.

Spare Parts D

Spare parts must at least satisfy the requirements specified by the manufacturer. This is guaranteed when genuine components are used.

Working Clothes and Protective Equipment D

Always wear protective shoes when working on plant.

D

Select protective goggles according to the work to be carried out. Always wear protective goggles when working with mallets, cutting tools, drift punches or similar.

M020081/00E - 03.10 -

E MTU

Section Page

D

1.2 2

General

Work clothing must be tight-fitting so that it does not catch on rotating or projecting components. Do not wear jewellery (rings, chains, etc.).

Welding Operations D

Never use the engine as a ground terminal! (This prevents the welding current from passing through the engine, resulting in burnt or scorched points on the bearings, friction surfaces and tooth flanks which can lead to bearing seizure and/or material damage).

D

Welding on the engine or engine-mounted components is forbidden.

D

Never lay the welding cable over or near the cable harnesses of the DDC/MTU plants. (The welding current could be induced in the cable harnesses which could possibly damage the electrical plant).

D

The ground terminal of the welding unit must be connected to the welding point at a distance of no greater then 60 cm.

D

If welding must be carried out on components (e.g. exhaust pipe), these components must be removed from the engine beforehand.

D

On the DDC/MTU electronics system, it is not necessary to remove the connector and connections to carry out welding operations if the master switch of the power supply is switched from “On” to “Off” and the cable has been disconnected from the negative and positive poles on the battery.

D

During welding operations, always wear welding gloves, headgear, goggles, protective apron and other suitable protective clothing.

Transport D

Lift the engine using only the lifting eyes provided.

D

Use only the transport and lifting equipment approved by DDC/MTU.

D

Take into consideration engine centre of gravity.

D

Transport the engine only in the installation position.

D

In event of special packaging with aluminium foil, attach engine to lifting eyes of bearing pedestal or transport with forklift truck.

D

Before transporting the engine, the crankshaft transportation locking device and engine mount locking device must be installed.

Engine Operation D

When the engine is running, ear protectors must always be worn in the engine room.

D

The engine room must be well ventilated.

D

To avoid injuries caused by falling, leaked or spilt engine oil and coolant must be cleaned up immediately or absorbed with appropriate bonding agents.

D

Exhaust gases from combustion engines are poisonous. They can be injurious to health if inhaled. The exhaust system must be leaktight and discharge the gases to atmosphere.

D

During engine operation, do not touch battery terminals, generator terminals or cables. Inadequate protection of electrical components can lead to electric shocks and serious injuries.

D

If engine is running, never release coolant, oil, fuel, compressed air or hydraulic lines.

Maintenance and Repair D

Compliance with the maintenance and repair instructions is a major safety factor.

D

Unless expressly permitted, no maintenance or repair work is to be carried with the engine running. The engine must be secured against inadvertent starting and the battery disconnected. Attach sign “Do not operate” in operating area or to control equipment. Persons not involved must keep clear.

D

Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required. Maintenance and repair work must only be carried out by authorised and qualified personnel.

D

Use only tools in perfect condition.

E MTU

- 03.10 -

M020081/00E

General

Section Page

1.2 3

D

Do not work on engines or components which are held only by lifting equipment or crane. Always support them on suitable trestles or stands before beginning any maintenance or repair work.

D

Before barring the engine, ensure nobody is within the danger area. After working on the engine, check that all guards have been reinstalled and that all tools and loose components have been removed from the engine.

D

Fluids emerging under high pressure can penetrate clothing and skin and cause serious injury. Before starting work, relieve pressure in systems and H.P. lines which are to be opened.

D

Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal connections with caps or covers if a line is removed or opened.

D

During maintenance or repair work, do not hit fuel lines with wrenches or other tools. To tighten connections when installing lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.

D

Ensure that all fuel injection lines and compressed-oil lines have sufficient play to avoid contact with other components. Do not position fuel or oil lines near hot components.

D

The H.P. lines for hydraulic installation and removal are tested at 3,800 bar.

D

Do not attempt to bend or apply force to lines while under pressure.

D

In order to avoid burning, take special care when handling hot components on products just taken out of use and when working with hot liquids in pipelines, pipes and chambers.

D

Until the engine has cooled, the breather cap must not be opened. Release the breather cap and allow pressure to escape before cap removal.

D

Take special care when removing plugs or vent plugs from engine. In order to avoid being sprayed with highlypressurised 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.

D

Take special care when draining hot liquids - risk of injury. Drain the liquids into a suitable container and wipe up any spillage.

D

When changing engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.

D

When working high up on the engine, always use suitable ladders and work platforms. Make sure components are placed on stable surfaces.

D

To prevent back injury, when lifting components weighing 25 kg (50 lb.) or more, always use suitable lifting gear and equipment. Ensure that all chains, hooks, slings, etc. are in good condition, are sufficiently strong and that hooks are correctly positioned. Lifting eyes are not to be unevenly loaded.

D

When operating electrical equipment, remember that certain components of this equipment are live.

D

Noncompliance with warning notices could result in serious physical injury or damage to property.

D

Work must be carried out by qualified personnel only. Prior to working on electrical equipment, switch off live units.

D

Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acid to come into contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Check polarity before connecting the cables to the battery. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery casing.

D

Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is not damaged by contact with sharp objects, by rubbing against another component or by a hot surface. Never connect wiring to a line carrying hot liquid.

D

On completion of the maintenance and repair work, any cables which have become loose must be correctly secured.

D

Always tighten connectors with connector pliers.

D

If cables are present at mechanical components and there is a risk of wear, the cables must be retained in cable clamps.

D

For this purpose, no cable straps must be used as, during maintenance and/or repair work, the straps can be removed but not installed a second time.

D

Check that all plug-in connections are secure.

M020081/00E - 03.10 -

E MTU

Section Page

D

1.2 4

General

It is not sufficient to tighten the bayonet union connections by hand. There is the risk that the locking unit does not engage correctly and that the connector becomes loose during engine operation. Therefore pliers must be used for turning the bayonet union nut in clockwise direction.

Fire Prevention D

Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires - therefore always keep the engine in a clean condition. Do not leave oil-soaked cloths on the engine. Do not store combustible fluids near the engine. Do not allow dirt or foreign matter to accumulate near the engine, as this constitutes a fire hazard.

D

Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.

D

Never mix petrol (gasoline) with diesel fuel. If petrol/gasoline is added to diesel fuel, there is increased risk of fire.

D

When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of the engine or to the ground terminal of the starter.

D

Always keep a fire extinguisher at hand and learn how to use it.

Noise D

Hearing may be impaired at workplaces where the sound pressure level is in excess of 85 dB(A).

D

Wear earplugs or earmuffs!

Environmental Protection D

Dispose of used fluids and lubricants and filters in accordance with local regulations.

D

Manipulation of the injection or control system can influence the engine performance and exhaust emissions. As a result, compliance with environmental regulations may no longer be guaranteed.

Skin Complaints D

Barrier creams issued for prophylactic use are not suitable for treatment of skin complaints. Seek medical advice on skin rashes of any type, even if symptoms are very slight.

Warning Signs D

Before putting the engine into service and before working on the engine, read and follow all warning signs. Do not paint over warning signs. Replace illegible signs.

Fluids and Lubricants, Auxiliary Materials D

Use only fluids and lubricants that have been tested and approved by DDC and/or MTU.

D

Fluids and lubricants must be kept in properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions applicable to the product. Take special care when using hot and caustic materials. When using inflammable materials, avoid all sparks and do not smoke.

Lead D

When working with lead or pastes that contain lead, take care that the body does not absorb even tiny amounts of lead (from air-borne lead dust, smoke, dirty hands).

-

Adopt suitable measures to avoid the formation of lead dust! Switch on extraction system! - Wash hands before eating and drinking!

Chlorinated Hydrocarbons D

When working with chlorinated hydrocarbons (e.g. perchlorethylene, trichlorethane) or other cold cleaners which contain declared hazardous substances, health-endangering substances may be inhaled.

-

Switch on ventilation and extraction systems! Observe fire-prevention regulations! No smoking and no consumption of alcoholic beverages! Do not permit substances to enter the waste-water system!

E MTU

- 03.10 -

M020081/00E

General

Section Page

1.2 5

Acids and Alkalis D

When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.

-

Immediately remove clothing wetted by acids and alkalis! Rinse injured parts of the body thoroughly with water! Rinse eyes immediately with water from rinsing bottle or clean mains water!

Painting D

When painting in other than spray booths equipped with extractors, ensure good ventilation. Ensure that neighbouring workplaces suffer no detrimental effects.

-

Always wear a mask providing protection against paint and solvent vapours! Observe all fire-prevention regulations! No smoking! No naked flame!

Liquid Oxygen D

Liquid oxygen is highly flammable.

D

Store liquid oxygen only in small quantities and always in regulation containers (without fixed seal)! Do not allow liquid oxygen to come into contact with parts of body (hands); this could cause frostbite and possibly the loss of tissue.

-

No smoking, no naked flame (risk of explosion)! Oxygen enrichment in the air causes flash combustion. Do not store any inflammable substances (e.g. oils and greases) within 5 m of the area of work. Under no circumstances wear oily or greasy clothing! Do not allow vapours to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignite suddenly! After working with liquid oxygen, do not smoke until clothing is free of vapours! Take great care to avoid impacts and shocks when working with liquid oxygen!

-

Liquid Nitrogen D

Store liquid nitrogen only in small quantities and always in regulation containers (without fixed seal)!

D

Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands). Liquid nitrogen causes cold burns and severe frostbite.

-

Always wear protective clothing (e.g. gloves, tight-fitting shoes) and protective goggles! Ensure good ventilation (suffocation if nitrogen enrichment in inhaled air reaches 88%) Do not subject containers, fittings and tools to impact or shock!

M020081/00E - 03.10 -

E MTU

Section Page

1.2 6

General

Compressed Air D

Compressed air is compressed, pressurised air and is stored in pressure vessels from which the compressed air is then extracted.

D

The compressed air pressure can be read off at the pressure indicator (pressure gauge); the pressure vessels and compressed air lines must also be at this pressure.

D

Pressure can cause serious bodily harm, especially if applied suddenly.

D

When working with compressed air, safety precautions must be constantly observed:

-

Pay special attention to the pressure level in the compressed air network and pressure vessel! Connecting devices and equipment must either be designed for this pressure or, if the permitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose couplings and connections must be securely attached! Always wear protective goggles when blowing off tools or extracting chips! The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents air-borne particles being reflected and thereby prevents damage to the eyes. First shut off compressed air lines before compressed air equipment is disconnected from the supply line or before equipment or tool is to be replaced! Unauthorised use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers, results in a “Risk of explosion”! Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks results in a “Risk of explosion”. Removing dirt on soiled clothes while still worn can result in a “Risk of injury”. Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back of the body, the air can enter the anal cavity and cause a potentially fatal rupture of the intestines!

-

Used Oil D

Used oil may contain health-threatening combustion residues.

-

Rub barrier cream into hands! Clean hands thoroughly after contact with used oil!

Warning Notices D

-

Section “3” of this Publication contains especially emphasised safety instructions in accordance with the American standard ANSI Z535, which begin with one of the following signal words according to the degree of danger: Take extreme care in these situations! Read and become acquainted with all warning notices and symbols before operating or repairing this product! Inform operating and maintenance personnel on all Safety Instructions!

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.2 7

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

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

CAUTION An instruction of this type draws attention to a danger which, if ignored, may lead to minor injury.

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

1.2 8

General

- 03.10 -

M020081/00E

General

1.3

Section Page

1.3 1

Designation of Engine Sides and Cylinders

Engine sides are always designated as viewed from the driving end. The cylinders are designated (as per DIN ISO 1204) as viewed from the side opposite the driving end i.e. from the free end. The cylinders are viewed from the left and are designated in consecutive order 1, 2, 3, 4 etc.

Applicable designations and abbreviations Driving end = KS Free end = KGS Left side Right side Top Bottom

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

1.3 2

General

- 03.10 -

M020081/00E

Section Page

General

1.4

1.4 1

Tightening Specifications for Screws, Nuts and Bolts

Designation Engine, crankcase, cylinder head

Tightening specification (Nm)

Crankshaft bearing cap to crankcase Oil separator to crankcase Oil pan to crankcase Oil drain plug on oil pan Oil filler neck to oil pan Oil dipstick guide pipe union to oil pan Gear case cover and crankcase

Details in item (1) 8 Details in item (4) 80 25 50 25 Further details in item (3)

Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil

60 100 25

Engine oil Engine oil Engine oil

180

Engine oil

150

Engine oil

80

Engine oil

50 50

Engine oil Engine oil

50

Engine oil Engine oil

50

Engine oil

50

Engine oil

150

Engine oil

100 25 30

Engine oil Engine oil Engine oil

80 40 25

Engine oil Engine oil Engine oil

100

Engine oil

Gear case to crankcase M10 M12 x1.5 Cover to front of crankcase Plug at front and rear oil channel M30x1.5-10.9 Plug at main oil gallery, fan side M26x1.5-10.9 Plug at auxiliary drive oil supply M18x1.5 Plug at turbocharger oil supply M14x1.5 Plug at oil return oil filter, front Temperature transmitter plug M14x1.5 Plug, coolant supply and return pipe Compressor M14x1.5 Coolant drain plug M14x1.5 Plug at coolant channel, top M26x1.5 Sealing nut, camshaft bore M22x1.5 Friction washer to gear case End cover, compressor opening to gear case Plug, start of delivery inspection port M26x1.5 M38 x 1.5 Cover upper dead centre inspection port to gear case Plug, cylinder head core hole M22x1.5

M020081/00E - 03.10 -

Lubricant

E MTU

Section Page

1.4 2

General

Designation

Tightening specification (Nm)

Lubricant

Cylinder head to crankcase Cylinder head cover to cylinder head (flat gasket) Cylinder head cover to cylinder head (profile gasket) Union, crankcase ventilation Coolant channel, right M14x1.5 Oil dipstick guide pipe to oil pan Tachometer drive front camshaft end Retainer, speed transmitter to gear case Clamping screw to speed transmitter retainer

Details in item (2) 25

Engine oil Engine oil

10

Engine oil Engine oil

50 35 35 25 10

Engine oil Engine oil Engine oil Engine oil Engine oil

Running gear

Counterweight to crankshaft

1st Stage 50 Nm 2nd Stage 140 to 160 Nm 3rdStage 90° to 100° angle of rotation Max. shaft length: 75.5/86.4 mm Belt pulley hub to crankshaft 200 Vibration damper to crankshaft 200 Belt pulley to hub 25 Belt pulley to vibration damper 25 Connecting rod bearing cover to connecting 1st Stage 100 Nm rod 2nd Stage 90° to 100° angle of rotation Max. shaft length: 68.5 mm Flywheel/ring-gear carrier to crankshaft 1st Stage 50 Nm 2nd Stage 200 to 220 Nm 3rd Stage 90° to 100° angle of rotation Max. shaft length: 75/86 mm Viscose vibration damper to hub / belt pulley 40

Molykote G-n plus

Engine oil Engine oil Engine oil Engine oil Engine oil

Engine oil

Valve gear, valves

Rocker shaft support on cylinder head Locknut to adjusting screw for rocker arm

E MTU

75 50

Engine oil Engine oil

- 03.10 -

M020081/00E

Section Page

General

Designation

Adjusting segment to camshaft gear Expansion shaft

Massive shaft

Tightening specification (Nm)

1.4 3

Lubricant

Engine oil 50 Nm Max. shaft length: 25.3 mm 1. Stage 30 to 35 Nm 2. Stage 90° to 100° angle of rotation Max. shaft length: 25.3 mm

Fuel system- engine

Drive gear to injection pump Injection pump to crankcase Injection pressure lines to injection pump and injection nozzle Securing clamp, injection lines Locknut max-speed seal/idle stop injection pump M6 Retaining cap for maximum-speed sealing M6 Connecting cable to charge air manifold Lever to control shaft Control lever to injection pump lever Actuator retainer to crankcase Actuator to retainer Lever to actuator Ball studs/pressure rod on setting lever and injection pump control lever Fuel filter to retainer Fuel filter retainer to gear case/intake pipe cover Filter bowl to fuel filter cover Fuel lines to delivery pump, filter and injection pump Fuel filter vent plug Nozzle in nozzle holder Nozzle holder thrust screw to cylinder head

35 Details in item (5) 25

Engine oil Engine oil Engine oil

10 5

Engine oil Engine oil

5 25 10 10 50 10 10 12

Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil

80 80

Engine oil Engine oil

15 30

Engine oil Engine oil

15 80 70

Engine oil Engine oil Engine oil

Air filter, exhaust turbocharger, charge air line

Charge air manifold to cylinder head 35 Charge air lateral pipe to charge air longitudinal pipe M10 50

Ultratherm MTU

M12 Plug to charge air lateral pipe Turbocharger to exhaust elbow

Ultratherm MTU Ultratherm MTU Ultratherm MTU

M020081/00E - 03.10 -

80 80 50

Ultratherm MTU

E MTU

Section Page

1.4 4

General

Designation

Tightening specification (Nm)

Charge air manifold/air intake pipe mounting M8

25

Ultratherm MTU

50 50

Ultratherm MTU Ultratherm MTU

80

Engine oil

50 20+2 8+1

Engine oil Engine oil Engine oil

30 50 80 35 25

Engine oil Engine oil Engine oil Engine oil Engine oil

15 30 30 50 30 30 30 60

Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil

Exhaust elbow to cylinder head Intake pipe to cylinder head Lateral intake pipe to intake pipe Plug on intake pipe M26x1.5 Intake air pipe to retainer Exhaust system flange to cylinder head Pretighten

50 35 50

Ultratherm MTU Ultratherm MTU Ultratherm MTU

80 50

Ultratherm MTU Engine oil

30+3

Ultratherm MTU

Additional angle of rotation Sliding element to hot parts Exhaust turbocharger to carrier housing

60+5° 55+6 18+2

Ultratherm MTU Ultratherm MTU

M10 Exhaust pipes to exhaust elbow and turbocharger Connection of crankcase ventilation to air intake pipe Measuring probe plug Emergency air shut-off flap, axle in lever Emergency air shut-off flap, screw control cam screw

Lubricant

Belt drive

Plugs/unions to engine/compressor M14x1.5 M22x1.5 M26x1.5 Coolant line to unions Compressor coolant line to turbocharger oil pressure line Pressure diaphragm to spacer plate Spacer plate to cylinder head Bearing bush to gear case Mounting flange for bush bearing Bearing flange to gear case Cylinder head to cylinder liner Cylinder head with cylinder liner to gear case Bearing flange with cap to gear case Exhaust line

Engine electrical system

E MTU

- 03.10 -

M020081/00E

Section Page

General

Designation

Alternator carrier/tension roller to crankcase M14 Alternator carrier to gear case M10 M16 Alternator to carrier M10 M12 x1.5 Clamping element bearing cap stud to alternator Stud to oil pan/carrier Fan belt pulley to alternator M16x1.5 Belt pulley to alternator M27x1.5 Alternator cover Air intake supports to alternator Swivel head alternator to screw M12 Clamping arm to retainer Belt pulley to clamping arm Locknut to clamping nut/stud Starter to gear case

Tightening specification (Nm)

1.4 5

Lubricant

160

Engine oil

60 150

Engine oil Engine oil

50 80 40+4

Engine oil Engine oil Engine oil

50

Engine oil

55

Engine oil

150 50 5

Engine oil Engine oil Engine oil

74+6 80 130 35 80

Engine oil Engine oil Engine oil Engine oil Engine oil

35 35 25 35 35 25 40

Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil

60

Engine oil

60 50 50

Engine oil Engine oil Engine oil

25 25

Engine oil Engine oil

25 25

Engine oil Engine oil

Engine lubrication, engine cooling

Oil pressure relief valve to oil pump Oil pump to crankcase Oil pump cover Oil pump cover (three-gear pump) Oil intake pipe mounting Oil intake pipe to suction basket Oil spray nozzle to crankcase (piston spray) Bulkhead wall to oil cooler housing M10x25 Oil cooler housing to crankcase M10x25 M10x35 M10x40 Oil cooler cover to oil cooler M8x60 M8x35 Oil cooler cover to oil cooler housing M8x60 M10x35

M020081/00E - 03.10 -

E MTU

Section Page

1.4 6

General

Designation

Tightening specification (Nm)

Lubricant

Oil filter bowl to oil cooler cover M10x125 M10x60 M10x100

50 50 50

Engine oil Engine oil Engine oil

25

Engine oil

25 25 25

Engine oil Engine oil Engine oil

Coolant pump

Coolant pump to crankcase and/or distributor housing Union, coolant discharge to coolant pump Union, coolant inlet to coolant pump Belt pulley to coolant pump Raw water pump

Impeller clamping nut to drive shaft 32+3 Nut M8, bearing housing with intermediate el- 20+2 ement to pump housing Plug, pump housing M18x1.5 50+10 G1 1/4 A 140+10

Engine oil Engine oil

Engine oil Engine oil

Coolant cooler (plate-core cooler)

Plate-core pack securing element M12 Tighten diagonally and evenly Pretighten Further tightening but not beyond block dimension (see plate) Intermediate element, coolant temperature transmitter to crankcase Coolant temperature transmitter to crankcase

Engine oil 25+3 45+5

180

Engine oil

25

Engine oil

110

Engine oil

50 330 150

Engine oil Engine oil

Engine suspension/Engine mounting

Front engine carrier to crankcase Front lifting eye front to crankcase M10 M20 Rear lifting eye to gear case

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.4 7

Item 1 Crankshaft bearing cap to crankshaft Central screws (1) - 1st Stage 100 Nm - 2nd Stage 200 Nm - 3rd Stage 300 to 330 Nm - 4th Stage 90° to 100° angle of rotation - Max. shaft length: 156 mm Central screws (2) - Hex screws 80 Nm - Double-hex screws 1st Stage 80 to 90 Nm 2nd Stage 90° 100° angle of rotation Max. shaft length: 86.5 mm Note:

Tighten central screws (1) before the lateral screws (2).

Item 2 Cylinder head to crankcase Sequence for tightening cylinder head screws. Tighten n 6 stages: - 1st Stage 10 Nm - 2nd Stage 50 Nm - 3rd Stage 100 Nm - 4th Stage 140 to 150 Nm - 5th Stage 180 to 190 Nm - 6th Stage 90° to 100° angle of rotation - Max. shaft length 111 / 146 / mm Note:

M020081/00E - 03.10 -

Do not retighten!

E MTU

Section Page

1.4 8

General

Item 3 Tightening sequence for gear case

Item 4 Oil pan to crankcase Tighten corner screws and nuts diagonally and evenly ( A - C ) and ( B - D ) to 35 Nm. Tighten the remaining screws / nuts in peripheral sequence to a torque of 35 Nm (starting from the last corner screw tightened). Retighten corner screws and / or nuts to a torque of 35 Nm.

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.4 9

Item 5 Injection pump to crankcase - 1st Stage 10 Nm all screws - 2nd Stage 50 Nm - 3rd Stage 90° to 100° angle of rotation Max. shaft length: Short screw 72 mm Long screw 102 mm

M020081/00E - 03.10 -

E MTU

Section Page

1.4 10

General

Tightening torques for set screws and stud connections according to MTN 5008 This works standard applies to set screws subjected to little dynamic load as per MMN 384, DIN 912, EN 24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts. It does not apply to heat-proof screws in the hot component area. Tightening torques MA are for screws of strength class 8.8 (bright surface, phosphate coating or galvanised) and 10.9 (bright surface or with phosphate coating). The values in the table are based on a friction coefficient µtot = 0.125. Precondition: Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly. When tightening manually (tightening specifications), an assembly tolerance of + 10% of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g. resulting from inaccurate readings and overtightening during assembly. When tightening mechanically, the permitted assembly tolerance is + 15% Tightening torques = MA Thread

Manually tightened 8.8 MA (Nm)

10.9 MA (Nm)

Machine tightened 8.8 MA (Nm)

10.9 MA (Nm)

M6

9

12

8

11

M8

21

31

20

28

M8x1

23

32

21

30

M10

42

60

40

57

M10x1.25

45

63

42

60

M12

74

100

70

92

M12x1.25

80

110

75

105

M12x1.5

76

105

72

100

M14

115

160

110

150

M14x1.5

125

180

120

170

M16

180

250

170

235

M16x1.5

190

270

180

255

M18

250

350

240

330

M18x1.5

280

400

270

380

M20

350

500

330

475

M20x1.5

390

550

350

520

M22

480

680

450

650

M22x1.5

520

730

490

700

M24

600

850

570

810

M24x1.5

680

950

640

900

M24x2

660

900

620

850

M27

900

1250

850

1175

M27x2

960

1350

900

1275

M30

1200

1700

1100

1600

M30x2

1350

1900

1250

1800

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.4 11

Tightening torques for stress bolt connections according to MTN 5007 This work standard applies to stress pin bolts and stress bolts of strength class 10.9 which are subjected to static and dynamic load, and their associated nuts. Shaft and transition dimensions as to MMN 209 standard and material and machining to MMN 389 (bright surface or phosphate coating). The values in the table are based on a friction coefficient µtot = 0.125. Precondition: Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly. When tightening manually (defined tightening), an assembly tolerance of + 10% of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g. resulting from inaccurate readings and overtightening during assembly. The values in the tables are for manual tightening with torque wrench. Tightening torques = MA Thread M6

Without torsion protection MA (Nm) 9

With torsion protection * MA (Nm) 12

M8

21

28

M8x1

24

30

M10

42

55

M10x1.25

46

60

M12

75

93

M12x1.5

78

99

M14

120

150

M14x1.5

135

160

M16

180

225

M16x1.5

200

245

M18

250

315

M18x1.5

300

360

M20

350

450

M20x1.5

430

495

M22

500

620

M22x1.5

560

675

M24

640

790

M24x2

700

850

M27

900

1170

M27x2

1000

1230

M30

1250

1575

*Protect shank against torsion when tightening.

M020081/00E - 03.10 -

E MTU

Section Page

1.4 12

General

Tightening torques for plugs prescribed in standard MTN 5183-1 This standard applies to plugs as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN 3852, model A (sealed by sealing ring DIN 7603-Cu). DIN 908

DIN 910

DIN 7604A/C

Tightening torques MA are given for plugs made of steel (St) with surface protected by a phosphate coating and oiled or galvanised. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. When tightening manually (defined tightening), an assembly tolerance of + 10% of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g. resulting from inaccurate readings and overtightening during assembly. Tightening torques = MA Tightening torques for plugs DIN 908, DIN 910 and DIN 7604A (with short screwed plug) Inserted in

Thread

M10x1

Steel/gray cast iron MA (Nm) 15

Al-alloy MA (Nm) 15

M12x1.5

35

25

M14x1.5

35

25

M16x1.5

40

30

M18x1.5

50

35

M20x1.5

55

45

M22x1.5

60

50

M24x1.5

70

60

M26x1.5

80

70

M27x2

80

70

100

90

M30x1.5 M30x2

95

85

M33x2

120

110

M36x1.5

130

115

M38x1.5

140

120

M42x1.5

150

130

M45x1.5

160

140

M48x1.5

170

145

M52x1.5

180

150

M56x2

190

160

M64x2

205

175

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.4 13

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

Inserted in Steel/gray cast iron MA (Nm) 10

M8x1

Al-alloy MA (Nm) 10

M22x1.5

80

65

M26x1.5

105

90

M30x1.5

130

130

M38x1.5

140

120

M45x1.5

160

140

Tightening torques for banjo screws according to MTN 5183-2 This works standard applies to banjo screws according to MMN 223 and N 15011 sealed with sealing ring DIN 7603-Cu MMN 223 (4 flow holes)

N 15011 (3 flow holes)

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

M8x1

Inserted in Steel/gray cast iron/Al-alloy MA (Nm) 10

M10x1

15

M12x1.5

20

M14x1.5

25

M16x1.5

25

M18x1.5

30

M22x1.5

60

M26x1.5

90

M30x1.5

130

M38x1.5

140

M45x1.5

160

M020081/00E - 03.10 -

E MTU

Section Page

1.4 14

General

Tightening torques for banjo screws made of copper-aluminium alloys. Thread

Inserted in

M10x1

Steel/gray cast iron/Al-alloy MA (Nm) 15

M16x1.5

30

Tightening torques for male connectors as per MTN 5183-3 This works standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852 model A (sealed by sealing ring DIN 7603-Cu). DIN 2353 Form C

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

Inserted in

M10x1

Steel/gray cast iron MA (Nm) 10

M12x1.5

20

M14x1.5

40

M16x1.5

50

M18x1.5

60

M22x1.5

70

M26x1.5

100

M32x2

160

M42x2

260

M48x2

320

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.5

1.5 1

Settings

Firing order Firing order

1 - 12 -5 -8 -3 -10 - 6 - 7 - 2 -11 - 4 - 9

Direction of rotation viewed on the driving end Crankshaft

c.c.w.

Camshafts

c.w.

Engine oil pump

c.c.w.

Engine coolant pump

c.c.w.

Raw water pump

c.c.w.

Valve clearance, engine cold (20 5C) Inlet

0.40 mm

Exhaust

0.60 mm

Engine timing with valve clearance adjusted Valve clearance adjusted Crank angle_ 1 Inlet valve opens . . . . . . . . . . . . . . 17° before TDC 2 Inlet valve closes . . . . . . . . . . . . . . . . 29° after BDC 3 Exhaust valve opens . . . . . . . . . . . 71° before BDC 4 Exhaust valve closes . . . . . . . . . . . . . 13° after TDC 5 Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° 6 Start of delivery of fuel injection pump, see Engine Acceptance Test Record I . . . . . . . . . . . . . . . . . . . . . . . . Top dead centre (TDC) II . . . . . . . . . . . . . . . . . . . . Bottom dead centre (BDC)

Opening pressure of fuel injectors Setting pressure with new spring

200 bar to 208 bar

Minimum pressure with run-in spring

185 bar

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

1.5 2

General

- 03.10 -

M020081/00E

Section Page

General

1.6

1.6 1

Publication overview

Description and Operating Instructions

M015535/00

Fluids and Lubricants Specification

A001061

Test Procedures and Auxiliary Materials

M070007

Tolerances and Wear Limits List

M070042

Tools List

M004018/20

Specialised information on subjects such as - Engine electronics can be obtained from the acceptance test record of the respective engine.

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

1.6 2

General

- 03.10 -

M020081/00E

Section Page

General

1.7

1.7 1

Repairing threaded bores with threaded inserts (Heli-Coil)

Data Thread M6 M8 M8x1 M 10 M 12 M12x1.5 M 14 M14x1.5 M7x1 M 16 M16x1.5 M7x1 M7x1 M7x1

Core hole bore-dia. (max./min.) 6.31 6.04 8.35 8.04 8.32 8.04 10.40 10.05 12.50 12.05 12.43 12.05 14.53 14.06 14.43 14.05 15.30 15.20 16.53 16.06 16.43 16.05 24.43 24.05 26.43 26.05 30.43 30.05

Twist drill-dia. 6.1-6.2-6.25 8.1-8.2-8.25-8.3 8.1-8.2-8.25-8.3 10.25 12.25-12.5 12.25 14.25-14.5 14.25 15.25 16.25-16.5 16.25 24.25 26.25 30.25

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

L92_23443

M020081/00E - 03.10 -

E MTU

Section Page

1.7 2

General

Insert thread insert (2) into spindle (1) in installation tool. Driver journal of thread insert must be in groove (arrow). 2

1

L92_23443

Use spindle to turn thread insert through snout until it is flush at front (arrow).

L92_23443

Mount installation tool on threaded hole and install thread insert without applying pressure to spindle. Note:

Insert thread insert 1/2 to 1 1/2 turns deeper than threaded bore surface. Use bolt shearer to remove driver journal to M14. In event of threaded inserts over M14, move driver journal up and down with pointed pliers and remove.

L92_23443

E MTU

- 03.10 -

M020081/00E

Section Page

General

1.8

1.8 1

Keyword Index

A Accessories, group

3.88

Air system

3.10.2

C Camshaft

3.6.1

Camshaft axial clearance check

3.6.1.7

Camshaft bearing bush

3.1.5

Carrier housing with exhaust turbocharger and exhaust elbow

3.10.6

Checking engine condition before a major overhaul

2.1

Coolant expansion tank

3.14.5

Coolant pump, group

3.13

Coolant thermostat

3.14.7

Cooling system

3.14

Crankcase bore measurement

3.1.1.4

Crankcase ventilation

3.1.7

Crankcase, group

3.1

Crankshaft

3.3.1

Cylinder designation

1.2

Cylinder head cover

3.6.4

Cylinder head, group

3.5

Cylinder liner

3.1.3

D Designation of engine sides and cylinders

1.3

Distributor housing

3.14.5

Drain lines, intercooler

3.10.14

E Electric starter

3.18.1

Engine assembly

2.5

Engine coolant chamber pressure testing

3.14.9

Engine coolant cooler

3.14.6

Engine coolant lines

3.14.1

Engine coolant pump

3.13.1

Engine disassembly

2.4

Engine disassembly

2.4

Engine governor

3.7

Engine installation and operation

2.7

M020081/00E - 03.10 -

E MTU

Section Page

1.8 2

General

Engine mounting with carrier

3.19.1

Engine mounts, group

3.19

Engine oil cooler

3.16.2

Engine oil filter

3.16.3

Engine oil lines

3.16.1

Engine oil pump

3.15.1

Engine oil system, group

3.16

Engine removal

2.3

Engine removal

2.3

Engine run-in

2.6

Engine, initial operation

2.7

Exhaust system

3.10.3

Exhaust turbocharger, carrier housing

3.10.6

Exhaust turbocharger, group

3.9

F Firing order

1.5

Flywheel

3.3.3

Fuel duplex filter

3.12.3

Fuel injection equipment

3.11

Fuel injection nozzle with nozzle holder

3.11.6

Fuel injection pump

3.11.5

Fuel injection pump drive

3.11.1

Fuel lines

3.12.2

Fuel system

3.12

G Gear case

3.1.8

General assembly instructions are observed

1.1

General, main section

1

Group Summary

3

Group summary

3

H H.P. fuel lines

3.12.1

Hazards at the workplace

1.2

I Important information

1.1

Intake air system/exhaust system, group

3.10

Intercooler

3.10.1

E MTU

- 03.10 -

M020081/00E

General

Section Page

1.8 3

K Keyword index

1.8

M Monitoring system, group

3.84

O Oil bore check

3.1.1.4

Oil dipstick

3.1.11

Oil pan

3.1.6

Oil pump, group

3.15

Oil system, group

3.16

Opening pressure of fuel injectors

1.5

Operation Schedules

2

P Piston-cooling oil spray nozzle

3.1.4

Pistons and conrods

3.3.2

Pistons and conrods

3.3.2

Pressure relief valve

3.15.5

Publication Summary

1.8

Pushrods and rocker arms

3.6.3

R Raw water lines

3.14.3

Raw water pump

3.13.2

Repairing threaded bores with threaded inserts

1.7

Rockers and pushrods

3.6.3

Roller tappets

3.6.2

Run-in program

2.6

Running gear, group

3.3

S Safety Instructions

1.5

Semirotary hand pump for oil extraction

3.15.8

Sensor and transmitter

3.84

Settings

1.5

Spring pin check and replacement

3.1.1.4

Starting system, group

3.18

Summary, groups

3

M020081/00E - 03.10 -

E MTU

Section Page

1.8 4

General

T Task descriptions

3

Three-phase alternator

3.86.1

Tightening sequence for gear case

1.4

Tightening sequence, crankshaft bearing cap to crankshaft

1.4

Tightening sequence, cylinder head to engine block

1.4

Tightening sequence, injection pump to crankcase

1.4

Tightening sequence, oil pan to crankcase

1.4

Tightening specifications for screws, bolts and nuts

1.4

Timing

1.5

V Valve clearance check and adjustment

3.6.3.7

Valve gear, group

3.6

Valve overlap

1.4

Valve tappet

3.6.2

Vent and drain lines

3.14.2

Vibration damper

3.3.4

W W5 maintenance operations

2.2

Wiring

3.84.9

E MTU

- 03.10 -

M020081/00E

Operation Schedules

2

Section Page

2 1

Operation Schedules

Contents 2.1

Checking engine condition before a major overhaul

2.2

W5 maintenance operations

2.3

Engine removal

2.4

Engine disassembly

2.5

Engine assembly

2.6

Engine run-in

2.7

Engine installation and startup

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

2 2

Operation Schedules

- 03.10 -

M020081/00E

Section Page

Operation Schedules

2.1

2.1 1

Engine Condition Check prior to W5 Maintenance Operations and Major Overhaul

Before the engine is removed, a brief test should be conducted to assist in evaluating its condition and running behaviour. Deviations from the Engine Acceptance Test Record Data found during the test run provide valuable information for subsequent overhaul services.

Operations

see

Perform operations preparatory to starting the engine

Operating Instructions

Start engine

Operating Instructions

Perform warm-up run

Operating Instructions

Test engine at highest possible power

-

Check engine speed, temperatures and pressures, where gauges are installed and compare with Acceptance Test Record

-

Check running noises: No noises other than normal operating noise should be audible

Operating Instructions

Check engine and external pipework for leaks during test run (visual inspection)

Operating Instructions

Check exhaust gas colour

Operating Instructions

Run engine at lower adjustable no-load speed

Operating Instructions

Connect fuel line connections for leaks

Operating Instructions

Extract sample of engine oil

Operating Instructions

Analyze engine oil sample (spot test, water content, dilution with fuel)

MTU Test Kit

Extract sample of coolant

Operating Instructions

Analyze coolant sample

MTU Test Kit

Check operation of monitoring system

Operating Instructions

Air filter: Check contamination indicator

Operating Instructions

Shut down engine

Operating Instructions

Check turbocharger rundown

Operating Instructions

Drain coolant

Operating Instructions

Fill system with cleaning solution

Operating Instructions

Start engine

Operating Instructions

Flush cooling system

-

Shut down engine

Operating Instructions

Disconnect H.P. fuel lines

Operating Instructions

Remove fuel injection nozzles with nozzle holders

Operating Instructions

Compression pressure check

Operating Instructions

Work listed here which is not relevant to the respective engine version can be disregarded (see order-specific maintenance schedules).

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

2.1 2

Operation Schedules

- 03.10 -

M020081/00E

Operation Schedules

2.2

Section Page

2.2 1

W5 Maintenance operations

Instructions for carrying out work: No provision is made for W5 maintenance operations with this engine.

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

2.2 2

Operation Schedules

- 03.10 -

M020081/00E

Section Page

Operation Schedules

2.3

2.3 1

Engine Removal

Operations

see

Shut off fuel supply line Close compressed air supply line Shut off raw water supply line

Operating Instructions Operating Instructions Operating Instructions

Drain oil with engine warm when possible Drain oil sludge from engine oil filter Oil sludge metallic residue check Drain engine coolant; coolant temperature must be below 60 °C Drain raw water (sea water)

Operating Operating Operating Operating Operating

Wash machinery plant; do not use chemical solvents

-

Release all connections Install non-fibrous plugs and blanking plates to seal all open connections Remove engine securing screws Remove engine and place on stands Install transportation locking devices (for road or rail transport) Using a lifting device, attach engine only on suspension brackets provided as shown in installation drawing, taking centre of gravity and transportation specifications into consideration.

Operating Instructions Operating Instructions

Instructions Instructions Instructions Instructions Instructions

Engine weight See Operating Instructions

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

2.3 2

Operation Schedules

- 03.10 -

M020081/00E

Operation Schedules

2.4

Section Page

2.4 1

Engine Disassembly

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

see

Mark and disconnect electric cables

3.84.9.9

Remove wiring

3.84.9.9

Remove governor

3.84.11

Remove crankcase vent line

3.1.7.2

Disconnect vent and drain lines

3.14.2.2

Disconnect engine coolant lines

3.14.1.2

Disconnect water lines

3.14.3.2

Remove coolant thermostat

3.14.7.2

Remove coolant expansion tank

3.14.5.2

Remove engine coolant cooler

3.14.6.2

Remove sensor and transmitter

3.84.1.2

Disconnect engine oil lines

3.16.1.2

Remove starter

3.18.1

Remove three-phase alternator

3.86.1

Remove cylinder head covers

3.6.4.2

Remove fuel supply and return lines

3.12.2.2

Disconnect H.P. fuel lines

3.12.1.2

Remove fuel duplex filter

3.12.3.2

Remove exhaust turbocharger with carrier housing and exhaust elbow

3.10.6.2

Disconnect exhaust pipework

3.10.3.2

Remove drain line from intercooler

3.10.14.2

Remove intercooler

3.10.1.2

Remove air intake system

3.10.2.2

Remove engine oil filter

3.16.3.2

Remove engine oil cooler

3.16.2.2

Remove engine coolant pump

3.13.1.2

Remove raw water pump

3.13.2.2

Remove fuel injection pump

3.11.5.2

Remove fuel injection pump drive

3.11.1.2

Remove fuel injector nozzles

3.11.6.2

Remove valve gear housing

3.6.4.2

Remove rockers and pushrods

3.6.3.2

Remove cylinder heads

3.5.1.2

Remove roller tappets

3.6.2.2

Remove flywheel

3.3.3.2

Remove vibration damper

3.3.4.2

M020081/00E - 03.10 -

E MTU

Section Page

2.4 2

Operation Schedules

Operations

see

Remove engine mounts

3.19.1.2

Remove dipstick and oil filler neck

3.1.11.2

Install engine in roll-over assembly dolly

3.1.1.2

Remove oil pan

3.1.6.2

Remove engine oil pump from crankcase

3.15.1.2

Pressure relief valve removal

3.15.8

Remove camshafts

3.6.1.2

Remove pistons and conrods

3.3.2.2

Remove crankshaft

3.3.1.2

Remove oil spray nozzles

3.1.4.2

Remove cylinder liners

3.1.3.2

Remove crankcase from roll-over assembly dolly

3.1.1.6

E MTU

- 03.10 -

M020081/00E

Operation Schedules

2.5

Section Page

2.5 1

Engine Assembly

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

see

Inspect and repair crankcase

3.1.1.4

Install camshaft bearing bushes

3.1.5.6

Install crankcase in roll-over assembly dolly

3.1.1.2

Install end cover, pin, dowel pins and studs in crankcase

3.1.1.4

Install cylinder liners in crankcase

3.1.3.6

Check crankcase for leaks

3.1.1.4

Measure crankcase bore

3.1.1.4

Measuring cylinder liner bore

3.1.3.7

Install and measure crankshaft bearing shells

3.3.1.6

Install oil spray nozzles for piston cooling

3.1.4.6

Install crankshaft in crankcase

3.3.1.6

Install camshafts with drive gear

3.6.1.6

Install piston and conrod in crankcase with intermediate frame

3.3.2.6

Install engine oil pump on crankcase

3.15.1.6

Install oil pan on crankcase

3.1.6.6

Remove engine from roll-over assembly dolly

3.1.1.6

Install valve gear housing

3.1.8.6

Install flywheel

3.3.3.6

Install vibration damper

3.3.3.6

Install roller tappets

3.6.2.6

Install cylinder heads

3.5.1.6

Install rocker arms and pushrods

3.6.3.6

Check and adjust valve clearance

3.6.3.7

Check camshaft timing/valve lift

3.6.1.7

Install fuel injection nozzles

3.11.6.6

Install valve gear housing

3.6.4.6

Install engine oil hear exchanger

3.16.2.6

Install engine oil filter

3.16.3.6

Install fuel injection pump drive

3.11.1.6

Install fuel injection pump

3.11.5.6

Determine crank angle before TDC

3.11.5.7

Adjust injection pump delivery

3.11.5.7

Install air intake system

3.10.2.6

Install intercooler

3.10.1.6

Connect drain lines

3.14.2.6

Install exhaust pipework

3.10.3.6

Install exhaust turbocharger with carrier housing and exhaust elbow

3.10.6.6

M020081/00E - 03.10 -

E MTU

Section Page

2.5 2

Operation Schedules

Operations

see

Install sensor and transmitter

3.84.1.6

Install engine coolant pump

3.13.1.6

Install raw water pump

3.13.2.6

Install engine coolant cooler

3.14.6.6

Install coolant expansion tank

3.14.5.6

Install coolant thermostat

3.14.7.6

Connect engine coolant lines

3.14.1.6

Connect raw water lines

3.14.3.6

Connect vent lines

3.14.2.6

Install fuel duplex filter

3.12.3.6

Install fuel lines

3.12.2.6

Install engine mount on crankcase intermediate frame

3.19.1.6

Install oil supply and return lines

3.16.1.6

Install engine oil lines

3.16.1.6

Install H.P. fuel lines

3.12.1.6

Install fuel supply and return lines

3.12.2.6

Connect leak-off fuel lines

3.12.2.6

Install cylinder head covers

3.6.4.6

Install starter

3.18.1.6

Install crankcase breather

3.1.7.6

Install oil dipstick and oil filler neck

3.1.11.6

Install monitoring instrument

3.84

Install and connect electric wiring

3.84.9.6

Install three-phase alternator

3.84.1.6

Pressure-test engine coolant chambers

E MTU

3.14.9

- 03.10 -

M020081/00E

Operation Schedules

2.6

Section Page

2.6 1

Engine run-in

Run-in program Request instructions on this from MTU Service. After the installation of pistons, piston rings or cylinder liners, the engine must be run in as per the appropriate run-in schedule. A thorough running-in is of critical importance regarding the engine’s durability and operational reliability. Use a dynamometer or generator to absorb the power developed in the braking run. Power must be transmitted from the engine to the dynamometer/alternator by means of a resilient coupling. Settings Set intake-air temperatures before engine according to those given for the engine in its MTU Engine Acceptance Test Record. The engine coolant temperature depends on the operating range of the coolant thermostat. Record readings for power, fuel, lube oil, coolant, charge air and exhaust gas at each test point (time, speed and effective power) of the run-in schedule and enter readings under “Engine Running-In” in “MTU Diesel Engine Factory Test” record. The values stated in the Engine Acceptance Test Record for the respective engine are mandatory. Instructions for carrying out work - A = MTU Acceptance Test Record - B = Operating Instructions - C = MTU Fluids and Lubricants Specification - H = Manufacturer’s Instructions

Operations

see

Install engine on test stand

-

Connect intake air, exhaust gas, starting air, engine coolant, oil and fuel lines

-

Fill expansion tank with coolant with 2% corrosion inhibitor oil up to max. mark

B

Vent coolant lines at vent cock and lines until bubble-free coolant emerges

B

Check that fuel in service or supply tank is to specification

C

Vent fuel system with hand pump

B

Fill up with fresh engine oil to the max. mark

B

Check compressed air supply

-

Before engine start-up, governor and fuel injection pump regulator must be checked

B

Check shutdown position of governor and full-load injection of fuel injection pump at shutdown housing

A

Check function of emergency air shut-off flaps

B

Check function of shutdown equipment

B

Remove cylinder head covers.

B

Always build up oil pressure with priming pump before starting engine

-

Start engine

B

Check lowest adjustable zero-setting speed, adjust at engine governor as necessary

A

After 15 mins running, check valve gear lubrication

-

At zero-load speed, check that oil emerges evenly at sides of all rocker arms and bearings

B

Check oil supply of ball sockets at adjusting screws

-

Check for leaks at coolant, oil and fuel lines, crankcase seals, air system and exhaust pipework

B

M020081/00E - 03.10 -

E MTU

Section Page

2.6 2

Operation Schedules

Operations

see

Run in engine and record measurements in accordance with the running-in schedule

A

Check engine speed and brake load

-

Measure fuel temperature before engine/before measuring glass, fuel density, consumption and control rack travel

-

Measure engine oil pressure before filter and measuring block

-

Measure engine oil temperature before and after engine

-

Measure coolant temperature before engine after coolant pump

-

Measure coolant temperature after engine in air/coolant manifold

-

Measure coolant pressure before pump, after pump and after engine in air/coolant manifold

-

Measure raw water temperature before and after engine

-

Measure raw water pressure before pump and before heat exchanger

-

Check charge air temperature before engine and before cylinder

-

Check intake depression before turbocharger and charge air pressure before cylinder

-

Measure exhaust temperature after exhaust turbocharger, left and right sides

-

Measure exhaust pressure (back pressure) after engine

-

Check exhaust gas colour

-

Check barometer level and enter in record

A

Check engine for abnormal running noises and leaks

-

After running in, check lowest and highest possible zero-power speeds and stop and full-load settings of governor; readjust if necessary

-

Recheck idle-speed and full-load settings

-

Check oil filter

B

After running-in, perform factory test according to the MTU Engine Acceptance Test Record

-

Enter operational values in the enclosed Factory Test Record

A

Compare measured values with those in the Acceptance Test Record

A

Shut down engine

B

In event of an extended out-of-service period, preserve the engine and carry out protective measures appropriate for sea transportation.

B

Remove engine from test stand

-

Install monitoring and measuring units for engine monitoring

B

Spray engine with protective paint

-

E MTU

- 03.10 -

M020081/00E

Operation Schedules

2.7

Section Page

2.7 1

Engine Installation and Startup

Instructions for carrying out work - B = Operating Instructions - D = Special Publication Operations

see

Open all connections, remove covers and plugs

-

Using a lifting device, attach engine only on suspension brackets provided as shown in installation drawing, taking centre of gravity and transportation specifications into consideration.

B

Install engine in machinery plant

-

Join connections appropriately

-

Removing transportation locking device

B

Align engine

D

Fill engine coolant system

B

Fill engine oil system

B

Prepare engine for operation

B

Start engine

B

Perform checks while engine is running

B

Carry out test run

B

Shut down engine

B

Perform after-shutdown services

B

Preservation measures are required if an extended out-of-service period is intended

D

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

2.7 2

Operation Schedules

- 03.10 -

M020081/00E

Section Page

Task Description

3

3 1

Group Summary

Deviation from illustrations possible

3.01

Crankcase

3.14

Coolant system

3.02 3.03 3.04

Gear train * Running gear * End cover, free end

3.15 3.16 3.17

Oil pump * Oil system * Speed monitoring drive *

3.05 3.06 3.07

Cylinder head Valve gear Engine governor *

3.18 3.19 3.20

Starting system Engine mount Fan drive (not installed on this engine)

3.08 3.09 3.10

Governor linkage (not installed on this engine) Exhaust turbocharger * Air/exhaust system

3.27 3.84 3.86

Supplementary control units (not installed on this engine) Monitoring system Accessories (electrical, pneumatic) *

3.11 3.12 3.13

Injection system * Fuel system Coolant pump * *not shown

3.87 3.88

Engine and gearbox controls (not installed on this engine) Accessories (Mechanical)

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

3 2

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.1

3.1 1

Crankcase

Contents 3.1.1

Crankcase 3.1.1.1 3.1.1.2 3.1.1.3 3.1.1.4 3.1.1.5 3.1.1.6

Before-removal operations Removal Disassembly Inspection and repair Assembly Installation

3.1.3

Cylinder liner 3.1.3.1 Before-removal operations 3.1.3.2 Removal 3.1.3.4 Inspection and repair 3.1.3.6 Installation 3.1.3.7 After-installation operations

3.1.4

Piston cooling oil spray nozzle 3.1.4.1 Before-removal operations 3.1.4.2 Removal 3.1.4.4 Inspection and repair 3.1.4.6 After-installation operations 3.1.4.7 After-installation operations

3.1.5

Camshaft bearing bush 3.1.5.1 Before-removal operations 3.1.5.2 Removal 3.1.5.4 Inspection and repair 3.1.5.6 Installation 3.1.5.7 After-installation operations

3.1.6

Oil pan 3.1.6.1 3.1.6.2 3.1.6.4 3.1.6.6

Before-removal operations Removal Inspection and repair Installation

3.1.7

Crankcase breather 3.1.7.1 Before-removal operations 3.1.7.2 Removal 3.1.7.4 Inspection and repair 3.1.7.6 Installation

3.1.8

Valve housing 3.1.8.1 Before-removal operations 3.1.8.2 Removal 3.1.8.3 Disassembly 3.1.8.4 Inspection and repair 3.1.8.5 Assembly 3.1.8.6 Installation

M020081/00E - 03.10 -

EMTU

Section Page

3.1 2

3.1.8

Valve housing 3.1.8.1 Before-removal operations 3.1.8.2 Removal 3.1.8.4 Inspection and repair 3.1.8.6 Installation

3.1.11

Oil filler neck and oil dipstick 3.1.11.1 Before-removal operations 3.1.11.2 Removal 3.1.11.4 Inspection and repair 3.1.11.6 Installation

EMTU

Task Description

- 03.10 -

M020081/00E

Task Description

Section Page

3.1 3

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.1 4

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.1

3.1.1 1

Crankcase

1 Crankcase

12 Cover

2 Sealing cap

13 Sealing ring

3 Sealing rings

14 Gasket

4 Seal

15 Spring washer

5 Plug

16 Hex screw

6 Sealing ring

17 Oil spray nozzle

7 Plug

18 Banjo screw

8 Sealing ring

19 Plug

9 Plug

20 Sealing ring

10 Sealing ring

21 Plug

11 Spring pin

22 Sealing ring

M020081/00E - 03.10 -

EMTU

Section Page

3.1.1 2

1 Dowel pin

Task Description

12 Plug

2 Dowel pin

13 Sealing ring

3 Hex screw

14 Plug

4 Hex screw

15 Sealing ring

5 Camshaft bearing

16 End cover

6 Camshaft bearing

17 Plug

7 End element

18 Sealing ring

8 Plug

19 Dowel pin

9 Sealing ring 10 Plug

20 Dowel pin 21 Ball

11 Sealing ring

EMTU

- 03.10 -

M020081/00E

Task Description

3.1.1.1

Section Page

3.1.1 3

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

x

x

Remove engine Carry out tasks as specified in disassembly plan Removal not planned

2.3

M020081/00E - 03.10 -

EMTU

Section Page

3.1.1.2

3.1.1 4

Task Description

Removal

Set crankcase on assembly pedestal Place crankcase with lifting device on assembly pedestal.

3.1.1.3

Disassembly Removing plugs Remove all plugs (1, 3, 7, 9 and 11) from crankcase (14). Remove sealing rings ( 2, 4, 6, 8, 10). Remove spring pin (13) only if necessary - see Inspection and repair 3.1.1.4.

3.1.1.4

Inspection and repair

Clean all parts, remove paint if necessary. Check crankcase and main oil gallery for cracks using surface crack-testing method with red penetrant dye. Check the mating faces, top and bottom cylinder liner fits and the bores for the crankshaft bearing for wear, damage and cavitation. For advice on matters relating to cracks and crankcase reconditioning, please contact our Product Support service. Use straight edge and feeler gauge to check mating surfaces of crankcase partition walls for evenness. If irregularities of greater than 0.05 mm are detected, recondition the seating surfaces on the partition walls in accordance with MTU specifications. Request the relevant work instructions from MTU Friedrichshafen.

Inspecting oilways Inspecting main oil gallery Endoscopically inspect main oil gallery with cold light source and makesure it is perfectly clean. If necessary, clean oilways with a bristle brush. Do not use wire brushes!

WARNING Test fluid is highly pressurized. Risk of injury! Liquids emerging under high pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. After cleaning, flush oilways with a flushing system that has a minimum working pressure of 10 bar.

EMTU

- 03.10 -

M020081/00E

Task Description

Section Page

3.1.1 5

Closing main oil gallery Before installing plug, check that threads of main oil gallery and plug are in proper condition. Clean and degrease thread and coat with Activator. Fit sealing ring on plug. Coat thread of plug with Loctite 270. Screw plug into main oil gallery, driving end - see Removing plugs. Use torque wrench and Allen key to tighten plug. For torque setting, see Section 1.4. Checking and replacing spring pin Check general condition of spring pin, replace if necessary. Checking and replacing studs Only remove studs if necessary. Coat new studs with Loctite 270. Measuring crankcase bore for cylinder liner Always measure all bores at four points. Check upper and lower locating bores in crankcase for wear or pitting. If badly worn or pitted, recondition bore to next repair stage with suitable boring mill. When reconditioning, always machine both upper and lower locating bores. Adjust bore gauge. Measure upper and lower locating bores for cylinder liners in crankcase. Record measured values in data sheet. For limit values, see Tolerances and Wear Limits List. If wear limits are exceeded, machine locating bores to next repair stage. Mark outside of reconditioned crankcase with numeral punch 6 mm high: Roller tappet guide bush Adjust bore gauge. Measure bore. Record measured values in data sheet. For limit values, see Tolerances and Wear Limits List. Camshaft bearing bush bore Adjust bore gauge. Measure bore for camshaft bearing bush on crankcase. Record measured values in data sheet. For limit values, see Tolerances and Wear Limits List. Check bearing bushes for scoring and damage.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.1 6

3.1.1.5

Assembly

Task Description

Installing plugs Install all plugs (1, 3, 7, 9 and 11) with sealing rings ( 2, 4, 6, 8 and 10) on crankcase (14). Install spring pin (13).

3.1.1.6

Installation

Installing crankcase in assembly dolly Note:

Engine barring when engine is in assembly dolly is allowed only until running gear is installed, i.e. without oil pan, cylinder heads and other installation components. Once the engine has been swivelled, the crankcase must be removed from the roll-over assembly dolly in order to continue the assembly process. Secure crankcase with lifting device. Remove bolts securing crankcase to assembly dolly. Using lifting device, remove crankcase from assembly dolly and set on supports.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.3

3.1.3 1

Cylinder liner

1 Cylinder liner

3 O-rings

2 Tombak ring

M020081/00E - 03.10 -

EMTU

Section Page

3.1.3 2

3.1.3.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Drain engine coolant

Oper. Instr.

-

-

X

Drain or draw off engine oil

Oper. Instr.

-

X

X

Remove crankcase breather (only as required)

3.1.7.2

-

X

X

Remove coolant system vent line

3.14.2.2

-

X

X

Remove engine coolant line

3.14.1.2

-

X

X

Disconnect engine oil lines

3.16.1.2

-

X

X

Remove exhaust pipework (remove screws from respective cylinder head)

3.10.3.2

-

X

X

Disconnect H.P. fuel lines

3.12.1.2

-

X

X

3.10.2.2

-

X

X

Remove intake air pipework (remove screws from respective cylinder head) Disconnect leak-off fuel lines

3.12.2.2

-

X

X

Remove cylinder head covers and gear case

3.6.4.2

-

X

X

Remove rocker arm with pushrods at appropriate cylinder head

3.6.3.2

-

X

X

Remove cylinder head

3.5.1.2

-

X

X

Remove engine oil heat exchanger (only as required)

3.16.2.2

-

X

X

Remove oil pan

3.1.6.2

-

X

X

Remove piston and conrod

3.3.2.2

X

X

X

Measure cylinder liner ID in installed condition

3.1.3.7

EMTU

- 03.10 -

M020081/00E

Task Description

3.1.3.2

Section Page

3.1.3 3

Removal Mark liner position with regard to crankcase (arrow) Fit studs (1). Insert and secure removal/installation tool in cylinder liner up to lower edge of cylinder liner. Turn nut (2) until clamping jaws contact inner diameter of liner.

Install counter-support and tighten spindle of clamping jaws. Hold spindle firmly on hexagon with box wrench. Turn nut (arrow) to withdraw cylinder liner. Turn clamping jaws together. Unscrew counter-support and remove complete installation/removal tool.

Remove cylinder liner. Remove O-ring and Tombak sealing ring.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.3 4

Task Description

3.1.3.4 Inspection and repair Clean parts. Check cylinder liner running surface for scoring and pitting, replace liner if necessary. Using the magnetic crack-testing method and fluorescent magnetic powder, check cylinder liner for cracks, and replace if necessary. Check outer walls of cylinder liner for pitting. In event of minor pitting, install liner turned through 90°. In such cases, rehone the cylinder liner bore and insert new piston rings. Replace the liner if pitting is deeper than 1.5 mm. Measure diameter of cylinder liner fits and thickness of liner collar. Using an electronic engraver, mark collar height and cylinder no. at circumference of seating collar. Adjust bore gauge. Measure bore of bush at appropriate measuring point height turned through 90° twice. Record measured values in data sheet. For limit values, see Tolerances and Wear Limits List. If wear limits are exceeded, replace liner. When using new piston rings, rehone cylinder liner. Check liner collar sealing surfaces for wear, smooth with oilstone if necessary. Replace O-rings and sealing rings (replace in sets only).

3.1.3.6

Installation Note:

The thickness (0.15 mm) of the Tombak sealing ring is balanced by means of liners with a thinner (0.15 mm) collar. A - Cylinder liner protrusion 80.03 to 0.09 mm. 1 - Tombak sealing ring 2 - Fillet (stays free) 3 - O-ring

EMTU

- 03.10 -

M020081/00E

Task Description

Section Page

3.1.3 5

Clean all sealing surfaces in crankcase. Insert new O-ring in crankcase.

Wipe outside of cylinder liner at fits and chamfer. Install new O-ring (3) on cylinder liner. Fit Tobak sealing ring (1) on bush collar. Space (2) remains free. Coat upper and lower fits with petroleum jelly.

Insert cylinder liners into crankcase turned 90° (arrow) with respect to the old installation position.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.3 6

Task Description

Screw studs of installation/removal tool into threaded bores. Place the pressure plate (arrow) on the cylinder liner. Mount installation tool. Keep cylinder liner pretensioned for 5 minutes by turning spindle with 100 Nm.

3.1.3.7

After-installation operations Adjust bore gauge and dial gauge with micrometer or gauge ring to basic size for cylinder liner as per Tolerances and Wear Limits List. Examine four measurement levels, offset by 90° to each other - see Tolerance and Wear Limits List. Record measured values in data sheet. If out-of-roundness is measured: - Remove cylinder liner. - Again measure cylinder liner bore and outer diameter.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.4

3.1.4 1

Piston cooling oil spray nozzle

1 Seal

3 Banjo screw

2 Oil spray nozzle

M020081/00E - 03.10 -

EMTU

Section Page

3.1.4 2

3.1.4.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Drain engine coolant

Oper. Instr.

-

-

X

Drain or draw off engine oil

Oper. Instr.

-

X

X

Remove crankcase breather (only as required)

3.1.7.2

-

X

X

Remove coolant system vent line

3.14.2.2

-

X

X

Remove engine coolant line

3.14.1.2

-

X

X

Disconnect engine oil lines

3.16.1.2

-

X

X

Remove exhaust pipework (remove screws from respective cylinder head)

3.10.3.2

-

X

X

Remove H.P. fuel lines with damping tape

3.12.1.2

-

X

X

3.10.2.2

-

X

X

Remove intake air pipework (remove screws from respective cylinder head) Disconnect leak-off fuel lines

3.12.2.2

-

X

X

Remove cylinder head covers and gear case

3.6.4.2

-

X

X

Remove rocker arm with pushrods at appropriate cylinder head

3.6.3.2

-

X

X

Remove cylinder head

3.5.1.2

-

X

X

Remove engine oil heat exchanger (only as required)

3.16.2.2

-

X

X

Remove oil pan

3.1.6.2

-

X

X

Remove piston and conrod

3.3.2.2

EMTU

- 03.10 -

M020081/00E

Task Description

3.1.4.2

Section Page

3.1.4 3

Removal Take care not to damage the oil spray nozzle (1). Remove screw (2) and oil spray nozzle. Place oil spray nozzle in a suitable transport trestle.

Remove seal (1), from 3rd cylinder.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.4.4

3.1.4 4

Task Description

Inspection and repair WARNING

Fuels are combustible. Risk of burning and explosion. - do not use naked flame, no electric sparks, avoid all sources of ignition

WARNING Compressed air is highly pressurised. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors. Clean oil spray nozzle in fuel. Carefully blow out oilways with dry compressed air. Check that oilways are not obstructed. Using surface crack-testing method and red penetrant dye, check oil spray nozzle for cracks when necessary. If cracks are detected, replace. Check mating faces and spray nozzles for damage, replace if necessary.

3.1.4.6

Installation

Before installing oil spray nozzle, check that mating faces on crankcase and nozzle are smooth. Install oil spray nozzle with screw in crankcase. Tighten screw with socket insert and torque wrench as per Tightening Specifications 1.4.

3.1.4.7

After-installation operations Note:

EMTU

After installing pistons, bar engine and ensure there is clearance between oil spray nozzle and piston.

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.5

3.1.5 1

Camshaft bearing bush

1 Cross handle

7 Centring pipe

2 Shell half

8 Spindle pipe

3 Bearing housing

9 Bearing retainer

4 Locking pin

10 Locking element

5 Bearing flange

11 Locating element

6 Screw

12 Collar bearing fixture

M020081/00E - 03.10 -

EMTU

Section Page

3.1.5 2

3.1.5.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Removal not scheduled

-

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Drain or draw off engine oil

Oper. Instr.

-

X

-

Mark and disconnect cables

3.84.9.2

-

X

-

Remove terminal box and wiring

3.84.9.2

-

X

-

Remove exhaust silencer

3.10.12.2.

-

X

-

Remove engine coolant line

3.14.1.2

-

X

-

Remove coolant expansion tank

3.14.5.2

-

X

-

Disconnect engine oil lines

3.16.1.2

-

X

-

Disconnect engine oil return lines from cylinder head

3.5.1.2

-

X

-

Disconnect fuel lines

3.12.2.2

-

X

-

Disconnect leak-off fuel lines

3.12.2.2

-

X

-

Remove cylinder head covers

3.6.4.2

-

X

-

Remove rocker arm with pushrods at appropriate cylinder head

3.6.3.2

-

X

-

Remove valve gear housing

3.6.4.2

-

X

-

Remove cylinder head

3.5.1.2

-

X

-

Remove roller tappets

3.6.2.2

-

X

-

Remove upper end cover

3.1.9.2

-

X

-

Remove fuel injection pump drive

3.11.1.2

-

X

-

Remove camshaft.

3.6.1.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.5.2

3.1.5 3

Removal Note:

Remove and replace camshaft bearing only if damaged. Unscrew cap nut from end cover.

Remove end cover from crankcase with special tool.

Remove radial-lip oil seal.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.5 4

Task Description

Insert centring pipe (2) into bearing bore and secure bearing flange (1) with two hex screws M10x25 to crankcase.

Insert spindle pipe (3) into bearing flange (2). Turn spindle tube until locking pin (1) engages in groove (arrow).

Insert spindle pipe (1) into cylinder housing and bearing flange (2) behind relevant bearing so that support for bearing (arrow) points in direction of cross handle.

EMTU

- 03.10 -

M020081/00E

Task Description

Section Page

3.1.5 5

Insert bearing retainer (2) into bearing bore and insert stop element (1) into groove behind bearing retainer.

Collar bearing (1) is pressed out at rear. For this purpose, connect cross handle with bearing flange by means of shell half. Remove cross handle and spindle pipe. Remove bearing retainers and collar bearings. Unscrew bearing flange. Clean bearings in crankcase.

3.1.5.4

Inspection and repair

Inspect camshaft bearing bushes for scoring or damage. Remove bushes from crankcase with puller if scoring or damage is identified or if wear limits are exceeded. Measuring camshaft bearing bush locating bore Adjust bore gauge. Measure locating bore in crankcase. Record measured values in data sheet. For limit values, see Tolerances and Wear Limits List. Install next repair-size bush if specified limits are exceeded.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.5.6

3.1.5 6

Task Description

Installation Insert centring pipe (2) into bearing bore and secure bearing flange (1) with two hex screws M10x25 to crankcase.

Insert spindle pipe (3) into bearing flange (2). Turn spindle tube until locking pin (1) engages in groove (arrow).

Fit camshaft bearing (1) on bearing retainer (2), secure (arrows) and lubricate externally. Insert spindle pipe into crankcase and insert bearing retainer with camshaft bearing behind relevant bearing so that camshaft bearing points in direction of cross handle. Note:

EMTU

Install a maximum of two camshaft bearings per operation.

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.5 7

When pulling inner camshaft bearings into bearing bore of collar bearing, install locating ring (1).

Note:

By securing bearing retainer for spindle pipe, oil bore (2) of bearing is simultaneously aligned to oil bore (1) in crankcase. Insert stop element (3) into spindle pipe. Turn cross handle clockwise and pull in bearing until oil bore (2) of bearing is aligned with oil bore (1) in crankcase.

When securing collar bearing to bearing retainer ensure oil bores are aligned (1 aligned with 3 and 2 aligned with 4). Remove bearing insertion tool and measure bearing. For values, see Tolerances and Wear Limits List. Ensure oil ducts are free from obstruction.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.5 8

Task Description

Install end cover with sealant in crankcase.

Install radial-lip oil seal.

Install cap nut on end cover.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.6

3.1.6 1

Oil pan

Oil pan with gaskets

1 Oil pan

5

2 Gasket

6

Stud Hex nut

3 Gasket

7

Washer

4 Stud

M020081/00E - 03.10 -

EMTU

Section Page

1 Thread insert

3.1.6 2

Task Description

4 Sealing ring

2 Thread insert

5 Plug

3 Plug

6 Sealing ring

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.6.1

3.1.6 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Drain or draw off engine oil

Oper. Instr.

-

X

X

Remove elbow with connecting cable from oil pan

3.16.2.2

-

X

X

Remove engine oil return lines from exhaust turbochargers

3.16.1.2

-

X

X

Remove guide tube for oil dipstick from crankcase intermediate frame

3.1.11.2

-

X

X

Remove oil pressure lines and elbow from oil pan to oil heat exchanger

3.16.1.2

-

X

X

Remove bottom securing screws from flywheel housing

3.1.8.2

M020081/00E - 03.10 -

EMTU

Section Page

3.1.6.2

3.1.6 4

Task Description

Removal WARNING

Suspended load. Risk of injury! Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a suspended load. Attach lifting device for complete engine. Unscrew nut and remove with washers - see overview drawing. Carefully raise engine with lifting gear and place on trestles. If necessary and using a plastic mallet, remove oil pan from locating pin. Place oil pan on pallet. Remove gaskets from oil pan.

3.1.6.4

Inspection and repair

Clean oil pan. Carefully remove all cleaning agent residue. Using the surface crack-testing method and red penetrant dye, check the oil pan for cracks. Replace oil pan if cracks are found. Check sealing surfaces of oil pan for irregularities using a steel straightedge and feeler gauge. Smooth sealing surfaces in event of unevenness. Check thread of stud for ease of movement, replace stud if necessary. Replace gaskets.

3.1.6.6

Installation WARNING

Suspended load. Risk of injury! Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a suspended load. Attach lifting device for complete engine. Carefully raise engine with lifting gear. Check sealing surfaces on oil pan and crankcase intermediate frame for cleanliness. Apply a thin coat of sealing paste in dots to gasket. Place gasket on oil pan sealing surface. Coat studs with engine oil. Lower engine with lifting gear down on oil pan until the sealing surfaces are approx. 1 cm apart. Tighten nut with washers - see Fig. 3.1.6. Tighten nut with torque wrench in accordance with Tightening Specifications 1.4.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.7

3.1.7 1

Crankcase breather

1 Gasket

7 Nut

2 Cylinder head cover

8 Vent line

3 Oil separator

9 Clamp

4 Sealing ring

10 Hose

5 Sealing ring

11 Clamp

6 Elbow

12 Hose

M020081/00E - 03.10 -

EMTU

Section Page

3.1.7 2

3.1.7.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

-

x x

Remove engine Perform operations as per Disassembly Plan Disable engine start No preparatory work required

2.3 2.4 Op. Man. -

EMTU

- 03.10 -

M020081/00E

Task Description

3.1.7.2

Section Page

3.1.7 3

Removal

Unscrew vent line, oil separator and cylinder head cover - overview drawing.

3.1.7.4

Inspection and repair

Clean all components. Check vent lines, cylinder head cover and hoses for damage, replace as required.

3.1.7.6

Installation

Install oil separator Install cylinder head cover and oil separator - see overview drawing. Replace sealing rings. Connect vent lines Install vent line - see overview drawing.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.1.7 4

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.8

3.1.8 1

Valve housing

Valve housing with attachments

1 Spacer tube

10 Hex screw

2 Bracket

11 Washer

3 Lifting attachment

12 Gasket

4 Hex screw

13 Hex screw

5 Washer

14 Washer

6 Hex screw

15 Hex screw

7 Bracket

16 Bracket

8 Hex screw

17 Eyebolt

9 Washer

M020081/00E - 03.10 -

EMTU

Section Page

1 Valve housing

3.1.8 2

Task Description

9 Sealing ring

2 End cover

10 Gasket

3 Sealing ring

11 Hex screw

4 Shaft seal

12 Spring washer

5 Screw

13 Cover

6 Screw

14 Hex screw

7 Cover

15 Spring ring

8 Plug

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.8.1

3.1.8 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Drain engine coolant

Oper. Instr.

-

-

X

Drain/draw off engine oil

Oper. Instr.

-

X

X

Remove vent lines

3.14.2.2

-

X

X

Remove intercooler

3.10.1.2

-

X

X

Remove engine flange with driver

3.3.3.2

-

X

X

Remove clamp ring with grooved ball bearing, driving end

3.3.4.2

M020081/00E - 03.10 -

EMTU

Section Page

3.1.8.2

3.1.8 4

Task Description

Removal WARNING

Suspended load. Risk of injury! Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a suspended load. Oil seal removal Using suitable tool, remove radial-lip oil seal (1) from gear case.

Suspend valve housing with lifting device and lifting gear. Remove all screws from valve housing. Remove housing from centring ring and raise from crankcase.

3.1.8.3

Disassembly

Disassembly of valve housing as shown - see overview drawing

3.1.8.4

Inspection and repair

Clean all parts, remove paint if necessary. Crack-test the valve housing using the surface crack-testing method and red penetrant dye. Check mating faces and bores for wear, damage and cavitation. Adjust bore gauge and measure respective bores - see Tolerance and Wear Limits List.

3.1.8.5

Assembly

Assembly of valve housing - see overview drawing. Coat gaskets with sealing paste and install with cover on valve housing. Coat sealing ring with petroleum jelly. Fit on end cover and insert end cover.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.8.6

3.1.8 5

Installation WARNING

Suspended load. Risk of injury! Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a suspended load. Clean mating faces on crankcase and valve housing. Coat sealing surfaces evenly in area of crankcase with surface sealant. Suspend valve housing with lifting device and lifting gear. Install valve housing on crankcase. Fit securing screws and tighten by hand. Remove lifting device. Tighten securing screws with torque wrench to Tightening Specifications 1.4. Installing shaft seal Fit spacer sleeve (arrow) of mandrel on crankshaft.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.8 6

Task Description

Fit shaft seal on mandrel and install in valve housing. Lubricate counter-track ring on flywheel.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.11

3.1.11 1

Oil dipstick

Installation on right side

1 Oil dipstick

6

Hex screw

2 Guide tube

7

Washer

3 Sealing ring

8

Hex nut

4 Adapter

9

Hex screw

5 Bracket

M020081/00E - 03.10 -

EMTU

Section Page

3.1.11 2

Task Description

Installation on left side

1 Oil dipstick

6

Hex screw

2 Guide tube

7

Washer

3 Sealing ring

8

Hex nut

4 Adapter

9

Hex screw

5 Bracket

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.1.11.1

3.1.11 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Drain or draw off engine oil

Oper. Instr.

M020081/00E - 03.10 -

EMTU

Section Page

3.1.11 4

3.1.11.2

Removal

Task Description

Remove oil dipstick as shown in overview drawing.

3.1.11.4

Inspection and repair CAUTION

When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Clean guide tube, oil dipstick and attachments with cold cleaner and check condition. Replace damaged parts. Replace sealing ring. Make sure that a replacement oil dipstick is the correct version.

3.1.11.6

Installation WARNING

Compressed air is highly pressurized. Risk of injury! Test pressure must not be exceeded. Always wear protective clothing, protective gloves and protective goggles/safety mask. Before installation, blow out oil extraction pipe with compressed air and make sure all components are perfectly clean. Install in reverse sequence.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3

3.3 1

Running Gear

Contents 3.3.1

Cranshaft 3.3.1.1 3.3.1.2 3.3.1.3 3.3.1.4 3.3.1.5 3.3.1.6

Before-removal operations Removal Disassembly Inspection and repair Assembly Installation

3.3.2

Piston and connecting rod 3.3.2.1 Before-removal operations 3.3.2.2 Removal 3.3.2.3 Disassembly 3.3.2.4 Inspection and repair 3.3.2.5 Assembly 3.3.2.6 Installation

3.3.3

Flywheel 3.3.3.1 3.3.3.2 3.3.3.3 3.3.3.4 3.3.3.5 3.3.3.6

3.3.4

Before-removal operations Removal Disassembly Inspection and repair Assembly Installation

Vibration damper 3.3.4.1 Before-removal operations 3.3.4.2 Removal 3.3.4.4 Inspection and repair 3.3.4.6 Installation

M020081/00E - 03.10 -

E MTU

Section Page

3.3 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.1 1

3.3.1 Crankshaft Crankshaft

1 Crankshaft

3 Cover plate

2 Crankshaft gear

M020081/00E - 03.10 -

EMTU

Section Page

1 Track ring

3.3.1 2

Task Description

3 Screw

2 Counter weight

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.1.1

3.3.1 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Drain engine coolant

Oper. Instr.

-

-

X

Drain or draw off engine oil

Oper. Instr.

X

X

-

Remove oil pan

3.1.6.4

M020081/00E - 03.10 -

EMTU

Section Page

3.3.1.2

3.3.1 4

Task Description

Removal WARNING

Suspended load. Risk of injury! Only use lifting device provided by manufacturer and observe lifting instructions. Never stand beneath a suspended load. Check marking of main bearing cap to crankcase. If there is no marking: Punch numbers of main bearings in same direction, starting with driving end, making sure they are clearly legible. Height of numeral punches: 6 mm. Remove all screws (1 and 2) and remove crankshaft bearing cap.

Install guide mandel (arrow). Fit sling and lift crankshaft with crane out of crankcase. Make sure crankshaft is positioned horizontally. Remove bearing shells from crankshaft. Place crankshaft on stable supports.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.1.3

3.3.1 5

Disassembly WARNING

Devices may be released suddenly. Fluid is highly pressurised. Risk of injury! Only use specified and tested equipment. It is forbidden to stand in the danger zone. Always wear protective gloves and protective goggles/safety mask. Removing crankshaft gear Mount puller (3) on crankshaft gear and turn it so that locking pin (2) engages between two teeth. Connect and secure hydraulic hand pump (4) and H.P. line to puller. Observe guidelines for using H.P. lines, see 1.5. Fill hydraulic hand pump with SAE10 engine oil. Bleed pump and line until bubble-free oil emerges. Close valve. Operate hand pump until a greater resistance is achieved (approx. 200 to 300 bar) and gear is released from crankshaft. Relieve pressure at oil pressure hand pump. Remove H.P. line. Pull gear off crankshaft. Remove puller. Removing counterweights To remove counterweights (1), install crankshaft in a stable, heavy-duty assembly stand. Ensure that counterweights are numbered consecutively; punch in new numbers if necessary. Install retaining jig and power amplifier to release stress bolts. Unscrew stress bolts with ratchet from counterweight. Remove counterweight, place in appropriate transport trestle.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.1 6

Task Description

Removing track ring Remove face ring (1) with extractor from crankshaft.

3.3.1.4

Inspection and repair

Clean crankshaft surface and bores with cold cleaner. Using the magnetic crack-testing method with fluorescent magnetic powder, check crankshaft for longitudinal and transverse cracks. Include oil bores and journal bores, counterweight mating faces and tapped bores in scope of inspection. Clamp crankshaft longitudinally between jaws of testing device. Required magnetic electric field strength during testing is 20 to 60 A/cm. Instructions for thermal cracks Hot-running cracks are characterised by running almost only parallel to the axis. Transverse cracks sometimes originate from these cracks. Severe thermal cracks are usually as deep as the case-hardening. Replace crankshaft with such cracks. Crankshafts with minor thermal cracking can be repaired, provided that the cracks can be removed by regrinding to the next repair stage or by local grinding. Consult MTU for details. Carefully grind the affected journals until close to a permissible repair size, depending on depth of cracking. Minor cracks can also be repaired by local grinding. Preliminary grinding must be carried out before the after-curing, otherwise there is the danger that the thermal cracks will increase in length and depth. Finish grinding the bearing journals to the specified repair stage only after the hardening process is completed.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.1 7

Remarks on cracks caused by grinding Fine branching is characteristic for grinding cracks. The illustration shows a bearing journal with grinding cracks. Grinding cracks result from inadequate cooling or if rate of feed is too great during the grinding process.

Demagnetising crankshaft. After crack-testing, demagnetise crankshaft; the residual field strength must not exceed 2 to 4 A/cm. Measuring journals Using an outside micrometer, measure crankshaft main bearing journal and crankpin each at four points to check that they are round and even. Record measured values in data sheet. If limit values are exceeded (see Tolerance and Wear Limits List), regrind crankshaft to next repair stage. Marking diameter stages of main bearing journal and crankpin Stage 0 is not marked on crankshaft. If individual main bearings and crankpin bearings are reconditioned on the crankshaft, stamp actual diameter (rated dimension) on crank web next to reconditioned bearings with numeral punch 5 mm high/ 0.5 mm deep, horizontal, as shown in adjacent diagram. Exception: Last main bearing journal, free end. Here, stamp on last web, free end. 1 = Designation of repair stage for crankpin 2 = Designation of repair stage for main bearing journal 3 = Crankshaft

Checking crankshaft journal and taper Check main journal for drive gear on crankshaft for wear. Using an external micrometer, measure main journals. Record values. Check crankshaft taper for damage. If necessary, recondition main journal for drive gear and crankshaft taper as per MTU specifications.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.1 8

Task Description

Measuring crankshaft radial runout Position support bearing at following main bearing journals: 12V on II and VI (see Dynamic balancing). Check main bearing journals for radial runout and mating face for flywheel for face runout. Secure dial gauge on adjustable support and carry out check. When measuring contact face for flywheel, hold crankshaft against axial stop. Check main bearing journals showing uneven wear at circumference only at transition from cylindrical section of journal to web radius, at same time holding crankshaft against axial stop. If radial runout is greater than specified value, crankshaft must be aligned before grinding. If a journal requires rehardening, this must be performed before straightening. Bearing journals must be hardened and crankshaft aligned only after consulting MTU. For radial runout limit values, see Tolerance and Wear Limits List. Checking hardness of journals Check hardness of all journals using the Microdur tester or other suitable hardness tester. Test hardness of each journal at four points at 90° intervals around circumference. Specified hardness = from 49 HRC to 53 HRC A journal that has lost its hardness due to seizure must be rehardened. When checking hardness of bearing journals, note that the curves between the surfaces are not hardened. Rub down all journals with emery cloth. Important: Hardness tests on installed or ready-to-be installed crankshafts are not permitted.

Checking counterweights and screws Check mating faces on counterweights for wear; grind mechanically if necessary. For limit values, see Tolerances and Wear Limits List. Using the magnetic crack-testing method with fluorescent magnetic powder, check screws for counterweights for cracks, replace parts if necessary. Check that threaded bores in crankshaft and counterweight screws are in perfect condition and move freely. For max. permissible screw length, see Section 1.4. Using engineer’s blue, check that screw heads are correctly seated on counterweights; recondition if necessary. Checking track ring ring Using the magnetic crack-testing method with fluorescent magnetic powder, check track ring for cracks; replace if necessary. Checking crankshaft gear Using magnetic crack-testing method and fluorescent magnetic powder, check gear for cracks. Replace if necessary. Examine gear for wear, if necessary smooth with oilstone or Emery cloth, otherwise replace gear. Adjust bore gauge, measure and record gear inner diameter. Checking main bearing shells Inspect crankshaft bearing shells for surface damage and wear; replace worn or spalled shells. Replace crankshaft bearing shells as part of every W6 overhaul.

EMTU

- 03.10 -

M020081/00E

Task Description

Section Page

3.3.1 9

Grinding crankshaft When regrinding, always try to limit operations to next repair size. Adhere strictly to all specifications for sizes and tolerances. This also includes those applicable to fillets and surface condition. For limit values, see Tolerances and Wear Limits List. Necessary checks after grinding: - Check all journals for correct dimensions and surface smoothness. - Check journal fillets. - Check whether oil duct outlets are perfectly rounded and smooth. Take special care when carrying out this task in order to avoid damaging the bearing shells and to ensure perfect lubrication. - Check radial and face runout. - Perform hardness test. - Crack testing Dynamic balancing For dynamic balancing, crankshaft must be assembled with crankshaft gear, sealing components and counterweights.

Seal all oilways against dirt before balancing crankshaft. To balance the crankshaft, position support A and B of the balancing machine at the following main bearing journals: 12V on II and VI Crankshaft gear, counterweights and sealing components must be installed. Balance crankshaft at 200 rpm. Remove material for balancing only from the counterweights by means of radial drilling (max. depth 20 mm). When doing this, the minimum width (between the individual bores, between the bores and side surfaces and/or screw holes) must not be below 5 mm. Permissible residual imbalance at supports: - for initial balancing: 0.02 Nm (200 cmg) each - for check balancing: 0.03 Nm (300 cmg) each On completion of balancing, recheck numbering of counterweights and renumber if necessary.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.1 10

3.3.1.5

Assembly

Task Description

WARNING Fuels are combustible. Risk of burning and explosion. - do not use naked flame, no electric sparks, avoid all sources of ignition

WARNING Compressed air is highly pressurized. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors. Thoroughly clean all crankshaft oil bores with cold cleaner or petroleum spirit and suitable bristle brush and blow through with compressed air.

WARNING Devices may be released suddenly. Fluid is highly pressurised. Risk of injury! Only use specified and tested equipment. It is forbidden to stand in the danger zone. Always wear protective gloves and protective goggles/safety mask. Pressure-testing crankshaft Mount locking device on crankshaft stub at driving end. Seal oilways in crankshaft stub. Insert pressure-test segments into covers of crankshaft stub. Mount blanking brackets on main bearing journal and crankpin in such a way that the oil bores are covered. Tighten clamping levers to secure clamps. Inserting pressure-test segment Insert the pressure-test segment into the end cover in the crankpin so that the position of the eyebolt is approximately equal to the position of the bore, dia.1 mm in end cover. Secure pressure-test segment by tightening threaded pin in centre of segment to 4 Nm. Place O-ring with threaded pin (eccentric) in position at bore dia.1 mm at the end cover and seal the bore by turning the threaded pin. Connect hydraulic pressure-testing device. Pressure-test crankshaft with engine oil (test pressure 30 bar). Check all end covers and core plugs for leaks. Remove hydraulic pressure testing device and blanking bracket. Before removing pressure-test segments, release off-centre threaded pin by approx. one turn and return to original position. Remove pressure-test segment. Seal all oilways with plastic plugs.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.1 11

Counterweight Installation Fit counterweight (1) on crankshaft and tighten slightly with hexagonal socket-head screw (2). Position V-block (3) on respective main bearing cap so that lug (arrow) is between counterweight and main bearing cap.

Insert centring screw (4) into free bore until it is securely positioned. Tighten hex nut (5) to centre counterweight. Tighten hex socket screw (2) with torque wrench to specified torque. For torque setting, see Section 1.4. Remove centring screw (4) and tighten second hex socket screw with torque wrench as per Tightening Specifications 1.4 . Remove V-block (3).

Tighten hex socket screws in the following stages: 1. Stage 140 Nm to 160 Nm 2nd stage 90° to 100° angle of rotation Install remaining counterweights in same sequence as described.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.1.6

3.3.1 12

Task Description

Installation

Installing crankshaft bearing Turn crankcase upside down in assembly dolly. Measure crankshaft bearing main bore. Clean bores and bearing shells with chamois leather. Check repair stage of crankshaft main bearing bore and repair stage of bearing shells, see crankcase data sheet and crankshaft data sheet. Prior to installing crankshaft bearing, measure crankshaft bearing spreading dimension. For dimensions, see Tolerance and Wear Limits List. Bearing shells with no spreading must not be installed. If main bearing bore in crankcase has been machined, it is necessary to increase depth of locating pin bore and crankcase oil groove. Install upper bearing shell with oil groove and oilways in main bearing bore, observing correct location of identification number. Install lower bearing shell without oil groove with one butting face against corresponding face of upper bearing shell. Exert thumb pressure on shell and seat other end in crankcase. Make sure that butting faces of shells are parallel. Mark new bearing shells with 2 mm punch numerals pointing towards driving end. Install crankshaft bearing cap. Measuring crankshaft bearing bore Adjust bore gauge with adjusting ring or micrometer to basic size of bearing bore - see Tolerance and Wear Limits List. Coat running surfaces of crankshaft bearing shells with engine oil. Measure main bearing cap with bore gauge. Record measured values in data sheet. Compare measurement values with Tolerance and Wear Limits List. Replace bearing shells or recondition to next repair stage if limit values are exceeded. After measuring main bearing bore I.D., if necessary mark bearing shell according to bearing shell number.

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

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.1 13

Installing bearing shells Note:

Note: Locking lug (arrow) of bearing shells must sit in grooves of main bores and of crankshaft bearing caps. Insert bearing shell halves in correct sequence into crankcase and crankshaft bearing cap and press firmly into place by hand. Ensure that oil bores in bearing shells and in crankcase are aligned. Install marked crankshaft bearing cap with bearing shell in crankcase.

Crankshaft installation Wipe crankshaft bearing surface. Spray running face of crankcase bearing shells with engine oil. Install guide mandrel (arrow). Fit sling and use crane to fit crankshaft in bearing shells in crankcase. Make sure crankshaft is positioned horizontally.

Install marked crankshaft bearing cap (arrow) with bearing shell into crankcase. Hit the crankshaft bearing cap lightly to settle in final position.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.1 14

Task Description

Coat threads and contact surface of screws (1) with engine oil. Tighten screws in following stages. 1st stage 100 Nm 2nd stage 200 Nm 3rd stage 300 to 400 Nm 4th stage 90° to 100° angle of rotation Tighten side screws (2) with torque wrench as per Tightening Specifications 1.4.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2

3.3.2 1

Piston and connecting rod

1

Snap ring

4

Conrod bearing shells

2

Piston pin

5

Conrod with cap

3

Piston

6

Conrod bolts

M020081/00E - 03.10 -

EMTU

Section Page

3.3.2 2

3.3.2.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Drain or draw off engine oil

Oper. Instr.

-

X

X

Remove terminal box and wiring as required

3.84.9.2

-

X

X

Disconnect engine coolant lines

3.14.1.2

-

X

X

Disconnect engine oil return pipes from cylinder head

3.5.1.2

-

X

X

Disconnect leak-off fuel lines

3.12.2.2

-

X

X

Remove cylinder head covers

3.6.4.2

-

X

X

Disconnect H.P. fuel lines

3.12.1.2

-

X

X

Intake air system: Remove screws from respective cylinder head

3.10.2.2

-

X

X

Exhaust system: Remove screws from respective cylinder head

3.10.3.2

-

X

X

Remove cylinder head

3.5.1.2

-

X

X

Remove oil pan

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2.2

3.3.2 3

Removal Remove combustion residue on bore of cylinder liners at TDC point of piston. Rotate crankshaft sot that piston is at BDC. Rotate crankpin of crankshaft of conrod to be removed towards BDC position. Check marking of conrod cap cover to conrod, mark components if necessary.

Unscrew conrod cap screws (1) approx. 15 mm using a ratchet and socket wrench. Using a plastic mallet, tap conrod cap screws gently to release conrod from conrod cap. Unscrew conrod cap bolts. Remove conrod cap and bearing shell.

Removing conrod with piston With conrod installed, turn piston from working position clockwise so that during further disassembly damage to the oil spray nozzle by the conrod is avoided. Slowly push piston back into cylinder liner until long arm of conrod contacts cylinder liner. Using removal tool, drive out piston and conrod through cylinder liner. Ensure that bearing shell does not fall out of conrod. Remove bearing shell from conrod.

3.3.2.3

Disassembly

Removing snap rings Place piston and conrod on workbench. Remove snap rings with snap ring pliers. CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.2 4

Task Description

Remove piston pin With round piece of wood, press piston pin out of piston pin boss. If too firmly seated, heat the piston on a hot plate to 60 °C. Hold conrod and remove piston pin. Remove conrod from piston. Removing piston rings Remove piston rings with piston ring pliers in sequence from top to bottom. Do not under any circumstances stretch piston rings!

3.3.2.4

Inspection and repair CAUTION

Decarbonizer must be used only in conjunction with a fume extraction system. Pay attention to manufacturer’s safety instructions. Always wear gloves and protective goggles. Cleaning piston Use decarbonizer to remove soot deposits or cleaning jet in area of piston ring grooves with synthetic abrasive agent MTH 608 (rated granulation 16-20). Cover chromium-faced sealing surfaces and top land with masker. Checking piston for cracks Using the magnetic crack-testing method with fluorescent magnetic powder, check piston for cracks. Replace complete piston if cracks are found. Inspecting condition of piston crown. Replace piston if valve pockets or edges of piston are scorched. Remove scoring or scuffing on top land if local and not extending as far as 1st ring groove. Do not remove material to depth of more than 50 mm. If damage is more extensive or if scoring or scuffing extends to 1st ring groove, replace entire piston. Inspecting piston ring grooves If carbon residues cause piston rings to stick or if rings contact carbon residues in groove root, piston crown must be decarbonized. Replace complete piston if cracks are found. Insert new piston ring in groove. Check axial clearance of piston rings with feeler gauge. Check piston ring grooves for cracks Replace complete piston if cracks are found. If limit values are exceeded or if oil control ring has less axial clearance than specified, replace piston. For limit values, see Tolerances and Wear Limits List.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2 5

Inspecting piston rings and measuring piston ring gap Replace rings if first and second rings have sharp upper edges. If slots of oil control ring are clogged by carbon deposits, ring must be decarbonized. Measure piston ring gap by inserting new piston ring (3) in cylinder liner (2) scheduled for installation. Ensure that piston ring is inserted to uniform depth all round. Measure piston ring gap with feeler gauge (1). Replace piston rings if specified limits are exceeded. For limit values, see Tolerances and Wear Limits List. Piston rings must be replaced as a set. The cylinder liner must be rehoned if the piston rings are replaced. Replace piston rings during W6 maintenance. Measure length of piston crown screws. For limit values, see Tolerances and Wear Limits List. Inspecting piston skirt Using surface crack-testing method with fluorescent penetrant dye, check piston skirt for hairline cracks. Replace piston skirt if cracks are identified. Check wear pattern on piston skirt. Using an outside micrometer, measure OD at the non-phosphatised measuring points. Replace piston if clearance exceeds limit value and if piston skirt exhibits large areas worn to a dull sheen. For limit values, see Tolerances and Wear Limits List. Replace pistons exhibiting even minor, localized scuffing or large areas of concentrated scores on piston skirt. Inspecting piston pin bore Adjust bore gauge. Measure piston pin bore. For limit values, see Tolerances and Wear Limits List. Replace piston if specified limits are exceeded. Replace piston if one of press-fitted bronze bushes is slack or exhibits scuffing marks. Inspecting piston pin Using the magnetic crack-testing method with fluorescent magnetic powder, check piston pin for cracks. Replace piston pin if cracked. Remove minor traces of wear and scoring by polishing. Replace pins exhibiting scuffing, indentations and severe wear. Measure piston pin with micrometer and determine pin clearance (see Tolerances and Wear Limits List). If limit values are exceeded, replace piston pin. Inspecting and repairing conrods Uusing magnetic crack-testing method with fluorescent magnetic powder, check conrods, conrod caps and conrod cap bolts for cracks. Replace components exhibiting cracks. Check conrod cap screws - see Tolerances and Wear Limits List. Polish out all traces of nicks in conrod; replace conrod if necessary.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.2 6

Task Description

Checking axial fit of conrod bush WARNING Tools can fall down. Fluid is highly pressurised. Risk of injury! Only use specified and tested equipment. Personnel must stay clear of the danger area. Always wear protective gloves and protective goggles/safety mask.

Check axial fit of conrod bush using mandrel (3) and hydraulic press (1), see Tolerances and Wear Limits List. If limit value is not obtained, force bush out of conrod (2) using mandrel and hydraulic press.

Measuring conrod bush Adjust bore gauge. Measure conrod bush bore, see Tolerance and Wear Limits List. If limit values are exceeded, replace conrod bush. Replace conrod bush exhibiting severe scoring, dirt, wear and hot-running damage. Remove light scoring by polishing with Emery cloth. Replacing conrod bush WARNING Tools can fall down. Fluid is highly pressurised. Risk of injury! Only use specified and tested equipment. Personnel must stay clear of the danger area. Always wear protective gloves and protective goggles/safety mask. Press out worn or loose conrod bushes (4). Adjust bore gauge. Measure small-end bore of conrod (1) at several points, see Tolerances and Wear Limits List. If limit values are exceeded, replace conrod or machine bore to repair size. Check repair sizes of bore and conrod bush prior to installation of conrod bush. See Tolerances and Wear Limits List. Stamp rated dia. in marking field j(5).

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2 7

CAUTION Nitrogen is liquid at (- 200 °C). Danger of freezing and suffocation! Do not allow liquid nitrogen to come into contact with body parts (eyes, hands). Wear protective clothing (including gloves and closed shoes) and goggles. Ensure good ventilation at workplace. Chill new conrod bush in liquid nitrogen and insert without applying force using plastic or wooden mandrel. Install bush in conrod bore so that it is flush with conrod on both sides and ensure that lubricating bores and in bush are aligned with bores in conrod. Check that bush is tightly seated and machine ID to size with precision boring machine. Using a triangular scraper, break edges (x) in the conrod bush and fit with felt disc, dia. 30 to 40. Measure conrod bush with bore gauge. For wear limits, see Tolerances and Wear Limits List. Identification marks for conrod bushes 1 2 1+3 None

Identification mark, stage 1 Conrod bush Identification mark, stage 2 Marking stage 0

WARNING

›‹Compressed air is highly pressurized. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors. Check thread of connecting rod Check conrod and conrod cap screw threads for ease of movement. Threads must not be recut (furrowed thread). Replace damaged conrod cap screws. Thoroughly clean conrod, conrod cap and conrod cap screws.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.2 8

Task Description

Pretightening conrod cap screws with torque wrench Coat threads of conrod cap screws and screw head seating surfaces with engine oil. Carefully insert cap screws by hand until initial contact with thread flanks is made. Screw in bolts three full turns by hand. Initial pretightening: Using torque wrench, pretighten conrod cap screw on short arm until conrod and conrod cap serrations are closed on both short and long arms. For torque setting, see Section 1.4. Then tighten conrod cap screw on long arm. Second pretightening: Using torque wrench, tighten screw on short arm followed by screw on long arm to specified torque. For torque setting, see Section 1.4. Tightening conrod cap screws with angle-of-rotation tightening tool Place angle-of-rotation tightening tool (2) on conrod cap screws. Set pointer (1) to zero. In the order short conrod arm - long conrod arm, tighten conrod screws in accordance with Tightening Specification 1.4. Apply checking torque 100 % in tightening direction as specified in Section 1.4. If bolt turns in tightening direction beyond specified torque: Release and retighten as specified in Section 1.4. Replace conrod screws if necessary.

Checking conrod big-end bore Before measuring, smooth main bore with emery cloth. Adjust bore gauge. Measure conrod big-end bore. If limits specified in Tolerances and Wear Limits List are exceeded, replace conrod or machine big-end bore to repair size. Check big-end bore for wear and scoring. If necessary, replace conrod or machine bore to repair size. If big-end bore is machined to repair size, machine locating bore to appropriate depth and replace locating pin. Marking repair sizes on conrod Stamp conrod cap with numeral punches in area of conrod cap (arrow). For dimensions, see Tolerance and Wear Limits List.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2 9

Checking axial parallelism of conrod bore Arrangement of testing device 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Conrod Alignment mandrel, large conrod eye Locking screw for alignment mandrel V-block Resilient stop Locknut Screw-in housing Adjustable resilient stop Dial gauge for axial twist Locking screw for alignment mandrel Base plate Dial gauge for axial parallelism Adjustable dial gauge carrier Alignment mandrel, small conrod eye

Clean big-end and small-end bores. Insert alignment mandrel (3) in big-end bore. Make sure that mandrel is installed correctly. Wide fit side (1) of alignment mandrel facing conrod shaft; narrow fit side facing conrod cap. Secure mandrel by hand with adjustment screw (2). Take care not to damage test mandrel.

Insert alignment mandrel (3) in small-end bore. Make sure that mandrel is installed correctly. Wide fit side (1) of alignment mandrel facing conrod shaft; narrow fit side facing oil bores of small conrod bore. Secure mandrel by hand with adjustment screw (2). Install mandrels so that narrow fits in big-end and small-end bores lie in a plane. Alignment mandrels are installed in same way for conrod bend and twist checks.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.2 10

Task Description

Checking conrod bend Lay conrod (2) with mandrel (1) installed in big-end bore in both V-blocks (6) of test equipment. Lay conrod (2) with mandrel (1) installed in big-end bore in both V-blocks (6) of test equipment. Position small end (3) against resilient stop (5). Adjust resilient stop so that centreline of mandrel shaft is approx. 2 mm below dial gauge stylus (4). Adjust dial gauges so that their readings indicate approx. 2 mm preload at highest point on small-end mandrel, and set to zero. Turn conrod through 180° and lay carefully in test equipment. Move small-end mandrel through dial gauge styluses at highest point on mandrel. Determine and record deviations from zero on dial gauges. Calculating conrod bend Test equipment is set for measuring axial parallelism over a distance of 200 mm. To obtain correct bend over 100 mm as required for comparison with Tolerances and Wear Limits List, use dial gauge readings to calculate bend as follows: Example: Left dial gauge A= -0.05 mm Right dial gauge A= +0.03 mm 0.08 mm Conrod twist in example: Axial parallelism 0.08 : 4 = 0.02 mm For specified limit, see Tolerances and Wear Limits List. Checking conrod twist Use template (1) to set both dial gauges (3) for conrod twist to zero via styluses (2). Remove template from test equipment.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2 11

Position conrod (2) with installed test mandrels (1) (3) into the two V-blocks (6) of the testing unit. Set rigid stop on adjustable resilient stop (4) so that dial gauge styluses still have travel of approx. 2 mm. Press conrod at small conrod eye on fixed support. Read and record values on dial gauges (5). The difference between the values read off the two dial gauges is the conrod twist. Calculating axial twist To obtain correct bend over 100 mm as required for comparison with Tolerances and Wear Limits List, use dial gauge readings to calculate bend as follows: Example: Dial gauge 1 = 0.00 mm Dial gauge 2 = 0.10 mm Difference = 0.10 mm Conrod twist in example: Axial twist 0.10 : 2 = 0.05 mm For limit values - see Tolerances and Wear Limits List. Release adjustment screws on alignment mandrels. Release adjustment screws on alignment mandrels. Installing bearing shells in conrod New bearing shells must be installed during W6 overhaul. Before installing the conrod bearing shells, observe the diameter stage at conrod and crankshaft journal, see data sheets. Replace bearing shells which are worn, damaged or scored. Prior to installing conrod bearing shells, measure spreading dimension of conrod bearing shell. For dimensions, see Tolerance and Wear Limits List. Install bearing shells (1) in locating bore as marked, paying attention to positions of locating grooves (arrows). Mark any new bearing shells with cylinder number using electric engraver.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.2 12

Task Description

Insert conrod bearing shell (1) into conrod bearing cap. Lug (arrow) must be seated in groove of conrod bearing cap. Coat threads of conrod cap screws and screw head seating surfaces with engine oil. Degrease serrations on conrod and cap. Mount conrod cap. Using torque wrench, tighten conrod screws to specified torque. For torque setting, see Section 1.4. Conrod and conrod cap have same serial number. When assembling, ensure that numbers on components match.

Measuring big-end bearing bore Adjust bore gauge. Measure big-end bearing bore. Measure inner dia. of installed bearing shells at three points (vertical and at a distance of 30° above and below the partition). The values given in the Tolerance and Wear Limits List must be kept to. Record measured values in data sheet. Unscrew conrod cap bolts. Remove conrod cap. Protect components against damage.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2.5

3.3.2 13

Assembly Installing piston rings Note:

The spring-loaded oil control ring has no ”TOP” marking. Turn the spring (2) so that its end (arrow) is 180° to the control-ring end.

Note:

Ensure that piston rings are correctly installed. Oil control ring in groove III Taper face compression ring in groove II. Rectangular-section ring in groove I

M020081/00E - 03.10 -

EMTU

Section Page

3.3.2 14

Task Description

Installing piston rings Note:

To avoid breakage, do not under any circumstances overstretch piston rings! In sequence from bottom to top, insert piston rings with piston ring pliers into annular grooves on piston crown. Stretch piston rings only until they can be fitted over the piston crown. Replace piston rings during W6 maintenance. ”Top” and manufacturer’s designation must be legible on all rings from above.

Installing conrod in piston Using snap ring pliers, insert snap ring into piston boss. Make sure that snap ring is properly seated. Install conrod in matching piston with long arm positioned as shown in adjoining illustration. Long arm (A) of conrod must face in same direction as funnel (B) in piston.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2 15

Wipe piston pin (2) with soft chamois leather and coat with engine oil. Push piston pin into piston and conrod (1) (arrow) until seated against snap ring installed beforehand. Check whether piston pin moves freely in piston boss.

Insert second snap ring. Ensure that snap ring is correctly seated in groove. Note:

M020081/00E - 03.10 -

Position of snap rings - see arrows.

EMTU

Section Page

3.3.2.6

3.3.2 16

Task Description

Installation Note:

If new pistons are to be installed, they should be assigned together with the liners according to the tolerance-group coding. The tolerance-group coding (arrow) is given on the top cylinder liner surface and the piston crown. For coding, see Table.

Code: Piston (group of letters)

Cylinder liner (identification letter)

“BC”

“B”

“BCD”

“C”

“CDE”

“D”

“DE”

“E”

Coat piston and piston rings with engine oil. Position ring butts (arrow) consecutively at 120° intervals.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.2 17

Guide band clamp over piston rings and compress to outside diameter of piston.

Insert conrod bearing shell (1) into conrod. Lug (arrow) must be seated in groove of conrod. Note:

Bore in the conrod bearing shell and conrod must be aligned. Coat running surface of conrod bearing shells with engine oil. Position protective strip on long arm of conrod.

Insert piston in lubricated cylinder liner in direction of arrow to engine centre. Remove protective strip.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.2 18

Task Description

Check code markings on bearing cap and conrod. Use only conrod cap screws up to max. 68.5 mm length. Coat threads of conrod cap screws and screw head seating surfaces with engine oil. Note:

Do not allow conrod screws to drop into bores in conrod cap. Carefully insert conrod cap screws by hand up to initial contact on thread flanks. Without using tools, insert screws into conrod three full turns.

Tightening conrod screws Using torque wrench, tighten conrod cap screw on short arm until conrod and conrod cap serrations are closed on both short and long arms. For torque setting, see Section 1.4. Then tighten conrod cap screw on long arm. When tightening screw, check whether conrod moves freely in axial direction. If conrod cannot move in axial direction, locating pin is not seated in groove of conrod bearing and is stuck. Disassemble conrod and discard damaged bearing shells. Using torque wrench, tighten conrod cap screws to specified torque. For torque setting, see Section 1.4. Tightening sequence: short arm, then long arm. Mount angle-of-rotation tightening tool on conrod cap screw. Beginning with short arm, tighten to specified torque. For torque setting, see Section 1.4. Apply checking torque in tightening direction as specified in Section 1.4. If screw turns beyond specified torque, release both screws and retighten as specified in Section 1.4. Replace screws if necessary. Check conrod bearing axial play with feeler gauge. Disassemble conrod if bearing has no axial play. Discard damaged bearing shells. Measure conrod bore again, see 3.3.2.4.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.3

3.3.3 1

Flywheel

1 Flywheel

M020081/00E - 03.10 -

2 Screw

EMTU

Section Page

3.3.3 2

3.3.3.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

-

x

Remove engine Carry out tasks as specified in disassembly plan Disable engine start

2.3 2.4 Op. Man.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.3.2

3.3.3 3

Removal Remove screws (1).

Insert guide mandrels into two opposing threaded bores. Remove flywheel via guide mandrels.

3.3.3.3

Disassembly CAUTION

Component is hot. Risk of injury! Handle components only when wearing protective gloves.

M020081/00E - 03.10 -

EMTU

Section Page

3.3.3 4

Task Description

Removing ring gear Remove flywheel ring (1).

Heat ring gear (1). Remove ring gear from flywheel (2).

3.3.3.4 Inspection and repair Clean parts. Using the magnetic crack-testing method with fluorescent magnetic powder, check ring gear, flywheel ring and flywheel for cracks. If cracks are found, replace components. Remove burrs and chipping from teeth by grinding or filing. Check mating surface of flywheel for traces of wear and damage; recondition with oilstone as required.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.3.5

3.3.3 5

Assembly Removing ring gear CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Heat ring gear (1) to approx. 200 °C and fit on flywheel (2).

Fit flywheel ring (1).

M020081/00E - 03.10 -

EMTU

Section Page

3.3.3.6

3.3.3 6

Task Description

Installation Insert guide mandrels into two opposing threaded bores. Install flywheel via guide mandrels; the centering pin in the crankshaft gear must be aligned with the centring bore in the flywheel.

Insert screws (1) and tighten with torque wrench to Tightening Specifications 1.4.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.4

3.3.4 1

Vibration damper

1 Vibration damper

3 Hex screw

2 Cover plate

4 Timing pointer

M020081/00E - 03.10 -

EMTU

Section Page

3.3.4 2

3.3.4.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Relieve V-belt tension

3.86.1.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.3.4.2

3.3.4 3

Removal Before removal, mark the position of the vibration damper to the crankshaft with numeral punches (1).

Remove hex screw and remove vibration damper. Remove cover plate and timing pointer - see overview drawing.

3.3.4.4

Inspection and repair

Clean all components. Check vibration damper, cover plate and timing pointer for damage. Check mating surface of vibration damper for traces of wear and damage; recondition with oilstone as required.

3.3.4.6

Installation Before the marked vibration damper (1) is installed, the TDC of cylinder 1 must be set by means of the flywheel marking (2). If a marked part has to be replaced, a new mark must be made using the start-of-delivery TDC setting on the flywheel. Start-of-delivery settings are to be taken from the start-of-delivery plate on the cylinderhead cover. When the vibration damper is re-installed after disassembly, ensure that the markings are aligned. The vibration damper hex screws must not be tightened until the timing pointer is aligned with the mark on the damper (2). Use torque wrench to tighten hex screws to specified torque. For torque setting, see Section 1.4.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.3.4 4

Task Description

- 03.10 -

M020081/00E

Task Description

3.5

Section Page

3.5 1

Cylinder head

Contents 3.5.1

Cylinder head 3.5.1.1 Before-removal operations 3.5.1.2 Removal 3.5.1.3 Disassembly 3.1.5.4 Inspection and repair 3.5.1.5 Assembly 3.5.1.6 Installation

M020081/00E - 03.10 -

EMTU

Section Page

3.5 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1

3.5.1 1

Cylinder head

1 Hex screw

5 Cylinder head screws

2 Rocker arms

6 Cylinder head

3 Cylinder head screws

7 Centring sleeve

4 Cylinder head screws

8 Cylinder head gasket

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 2

Task Description

1 Taper element

6 Valve stem seal

2 Valve spring retainer

7 Washer

3 Valve spring, outer

8 Cylinder head

4 Washer

9 Exhaust valve

5 Valve spring, inner

10 Inlet valve

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1.1

3.5.1 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Remove wiring as required

3.84.9.2

-

X

X

Remove coolant system vent line

3.14.2.2

-

X

X

Disconnect leak-off fuel lines

3.12.2.2

-

X

X

Remove cylinder head covers

3.6.4.2

-

X

X

Disconnect H.P. fuel lines

3.12.1.2

-

X

X

Intake air system: Remove screws from respective cylinder head

3.10.2.2

-

X

X

Exhaust system: Remove screws from respective cylinder head

3.10.3.2

-

X

X

Remove rocker arms and push rods

3.6.3.2

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1.2

3.5.1 4

Task Description

Removal Removing cylinder head screws Unscrew cylinder head screws (1 and 2) with ratchet diagonally and evenly.

With nozzle holder installed: Note:

If the nozzle holder is still installed, the cylinder head screw (arrow) cannot be removed. Remove cylinder head screw with special tool.

WARNING Heavy object. Risk of crushing! Use suitable equipment and lifting gears. Remove cylinder head. If injection nozzle is to remain installed, place cylinder head to the side as the injection nozzle protrudes at the bottom of the cylinder head. Remove centering sleeves - see overview. Remove cylinder head gasket Remove cylinder head gasket. If cylinder head gaskets are to be reused, they must be marked with respective cylinder numbers.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1.3

3.5.1 5

Disassembly CAUTION Spring preload. Risk of injury! Only use specified tool. Removing valves Remove fuel injection nozzle, see 3.11.6. Before removal, use electric engraver to apply identifying marks to valve heads. Position cylinder head on workbench so that valve heads are seated. Insert securing screw (1) of valve spring compressor (2) into tapped bore of cylinder head. Compress valve springs with valve spring compressor and remove valve taper - see also overview drawing. Remove valve springs - see also overview drawing. Remove valve stem seal (1) and washers (2 and 3).

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 6

Task Description

Turn cylinder head on its side. Remove inlet (2) and exhaust valve (1) from valve guides. It is advisable to use a storage rack to protect valves against damage.

3.1.5.4

Inspection and repair CAUTION

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

CAUTION Decarbonizer must be used only in conjunction with a fume extraction system. Pay attention to manufacturer’s safety instructions. Always wear gloves and protective goggles.

CAUTION Heated water, 80 °C - handle components only when wearing protective gloves. Do not exceed the prescribed test pressure. Clean cylinder head base, valve seats, inlet and exhaust valves with cold cleaner. If necessary, pretreat oil carbon deposits on valves and cylinder heads with ”decarbonizer”; for this purpose, place components in a container filled with ”decarbonizer” – dwell time depends on degree of contamination. Add enough solvent to cover valve seats. After completion of the solvent bath, flush or spray cylinder heads valves with water heated to approx. 60 °C to 80 °C. Clean valve seats in cylinder head and valves with a rotary steel-wire brush. Clean bores of inlet and exhaust valve guides with cylinder wiper with brass bristles. Check cylinder head screws for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace screws if cracks are found. Clean cylinder head gaskets. Check for flatness. Check sealing surface for scoring and damage, if necessary nickle-plate and/or replace cylinder head gaskets. Check condition of centring sleeves, replace parts as necessary. Replace valve stem seal.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1 7

Inspecting cylinder head face Check cylinder head face and valve seats for cracks using surface crack-testing method with red penetrant dye. Cracks in cylinder head face can be removed by machining concentrically to limit size. Repeat crack test after machining. Replace cylinder head if further cracks are found. Replace valve seats if cracked. Check cylinder head support surface for flatness and indentations with straight-edge or bridge meter. Indentations can be removed by concentric machining on a lathe. Machine towards centre of cylinder head. Do not remove more material than is necessary in order to obtain a perfect seating face; see Tolerances and Wear Limits List. After reconditioning the cylinder head partitions - Check valve recess, see Valve seat machining. - Checking nozzle projection For limit values, see Tolerances and Wear Limits List. Checking cylinder head for leaks

WARNING Test fluid is highly pressurized. Risk of injury! Liquids emerging under high pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Hydraulic pressure-testing procedure: Install hydraulic pressure testing device. Install nozzle holder. Pump water heated to approx. 80 °C through the cylinder head until the cylinder head warms up. Add 1% corrosion inhibitor oil to water. Close shut-off valve in vent line. Pressure-test cylinder head at 4 bar water pressure. Pressure must be maintained for at least 30 minutes. Pneumatic pressure-testing procedure: Place cylinder head in a water bath heated to 80 °C until cylinder head has warmed up. Pressure-test cylinder head at 0.5 bar air pressure. Check cylinder head for leaks. Pressure must be maintained for at least 30 minutes. Check cylinder head for leaks. Remove removal device. Replace end cover if leaking.

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 8

Task Description

Removing end cover When removing cover (2), take care to prevent it from falling into bore. Do not spot-hole end cover to remove. Using a mandrel (1), carefully knock the edge of one side of the end cover (1) inwards until it tilts in the bore. Take care not to damage bore.

Installing end cover Use only new end covers. Clean and degrease cylinder head bore and seating surface at end cover. Coat seating surface of end cover with Loctite 270. Final strength at 20 °C [12h Using suitable drift (1), drive end cover (2) into cylinder head bore. Rim of end cover must be recessed to a depth of approx. 1 mm in cylinder head bore.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1 9

Inspecting and removing valve guides Clean valve guide bores in cylinder head. Adjust bore gauge. Bore in inlet and exhaust valve guide, according to measurement planes. For measurement planes, see Tolerances and Wear Limits List. Check ends of valve guides protruding into inlet and exhaust ports for cracks using surface crack-testing method with red penetrant dye. Check that inlet and exhaust valve guides are securely seated. Replace damaged valve guides. Check bore with mandrel gauge. Mandrel gauge’s own weight must be enough to cause ”go” end of mandrel to slide through installed valve guide. If ”no-go” end can be inserted, replace valve guide. If measurements of valve guides or clearance between valve and valve guides exceed or drop below wear limits, replace valve guides. Using extractor mandrel, press valve guides out of cylinder head. Removing valve guide Clamp cylinder head in position. From the combustion side, press valve guide out with mandrel. Measuring locating bore for valve guide Using a cylinder wiper, clean the valve guide bore in the cylinder head. Adjust bore gauge. Measure locating bores in cylinder head. If limit values are exceeded, recondition bores to next repair size. For limit values, see Tolerances and Wear Limits List.

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 10

Task Description

Installing valve guide Clean valve guide in cylinder head and valve guide. Coat new valve guide with graphite oil. Drive in with mandrel (A) and spacer sleeve (B). For dimensions, see Tolerance and Wear Limits List. Check bores of valve guides with control mandrel – the ”go”-end length of the mandrel must correspond to the length of the valve guide. Checking valve guides Control mandrel’s own weight must be enough to cause ”go” end of mandrel to slide through installed valve guide. If the ”no-go” end can be inserted, the valve guide must be replaced. Note:

When the finished valve guides are installed, using a control mandrel, check from the compression side and control side of the cylinder head.

Measuring valve seat recess Install new valve into cylinder head. Using depth gauge, measure distance from cylinder head face to valve head. For limit values, see Tolerances and Wear Limits List. Install new valve seat inserts if specified limits are exceeded.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1 11

Removing valve seat inserts Place internal extractor (2) for inlet and exhaust valve seat inserts in annular groove. Place copper plate (arrow) under support surfaces of counter-supports (1). Note:

The internal extractor and counter-holder for inlet and exhaust valve seat inserts differ.

Checking basic bore for valve seat insert Set bore gauge with micrometer to rated dimension. Measure basic bore in cylinder head. Machine to repair size as required. For limit values, see Tolerances and Wear Limits List.

Basic bore reconditioning Insert appropriate pilot (1) into valve guide until slotted rod stop contacts valve guide; if necessary, press down slotted rod with screwdriver. Secure with mandrel inserted at top and bottom of pilot (arrows). Secure turning tool in support.

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 12

Task Description

Release locknut (1), fit rotator (3) over pilot moistened with oil (5). Turn rapid adjustment screw (2) until turning tool (4) has moved to beyond the bore. Push cutting tool downwards until turning tool (15) rests on cylinder head. Note:

Carefully position rotating tool so that carbide tip of cutting tool is not damaged.

Release securing screw (2) on pilot support (1), press pilot support downwards until it contacts the pilot. Retighten locking screw.

Turn knurled washer (1) clockwise until turning tool is just clear. Horizontally clamp cone pin with steady rest clamp; in doing so, working depth ”b” must be set between adjusting ring and cone pin. Measure depth ”b” of bore in cylinder head, see Tolerance and Wear Limits List.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1 13

Calculating setting dimension ”B”: Setting dimension ”B” is basic bore ”a” in cylinder head (see Tolerance and Wear Limits List) and pilot diameter ”A” divided by 2. Example: ”a” = 60 mm ”A” = 14.55 mm (pilot diameter) ”B” =(a + A) :2 ”B” =(60 mm + 14.55 mm) :2 = 37.28 mm

Release locknut (2). Set micrometer to dimension ”B”. Slightly raise rotating tool. Place micrometer on pilot and adjust turning tool with rapid adjusting screw (1) to dimension ”B”. Tighten locknut (2). Note:

It is advisable to set turning tool diameter 0.1 mm smaller for the initial material cut.

Install horizontal stop screw (1) until it makes contact with housing and tighten clamping screw (2); this secures the horizontal stop screw against twisting.

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 14

Task Description

Secure knurled washer (1) with mandrel (arrow) to turning crank.

Turn crank (1) clockwise, simultaneously holding top knurled washer (2) for vertical advance. Recondition bore for valve seat insert until adjusting ring (3) contacts steady rest mount (4). Note:

Readjust turning tool as often as necessary to achieve calculated setting dimension. Then turn again without adjustment to achieve a roughness depth of max. 0.006 mm. Slightly raise rotating tool. Release locknut and using rapid adjusting screw reset turning tool. Turn crank clockwise, simultaneously holding bottom knurled washer for horizontal advance. Grind the end plane and flat until stop screw contacts housing. Remove rotating tool and measure bore.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1 15

Check that the alignment between valve seat insert and bore is in compliance with Tolerance and Wear Limits List.

Installing valve seat inserts Measure OD of valve seat inserts. Check interference against Tolerances and Wear Limits List. CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Head cylinder head in a water bath heated to approx. 80 °C. CAUTION Nitrogen is liquid at (- 200 °C). Danger of freezing and suffocation! Do not allow liquid nitrogen to come into contact with body parts (eyes, hands). Wear protective clothing (including gloves and closed shoes) and goggles. Ensure good ventilation at workplace. Chill new valve seat insert in liquid nitrogen. Fit mandrel into valve seat insert (2) and insert valve seat insert into cylinder head.

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 16

Task Description

Recondition valve seat. Insert appropriate pilot (1) into valve guide until slotted rod stop contacts valve guide; if necessary, press down slotted rod with screwdriver. Secure with mandrel inserted at top and bottom of pilot (arrows). Secure turning tool in support.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1 17

Adjusting valve rotator Clamp cutting tool (6) in support. For angle, see Tolerances and Wear Limits List. Insert valve rotator in pilot. Release locknut (5) on rapid adjuster (4). Turn rapid adjuster until cutting tool (6) is positioned at centre of valve seat face. Secure rapid adjuster with locknut. Carefully push valve tool down onto pilot until turning tool contacts centre of valve seat. Release locking screw (3) on knurled nut (2). Press down pilot rest until it is seated on pilot. Tighten locking screw of knurled nut. Turn knurled nut counterclockwise until cutting tool no longer contacts valve seat face. Mount steady rest on cylinder head. Secure steady rest eye to crutch.

Valve seat surface reconditioning Note:

The valve seat face is machined from the inside outwards. To adjust cutting tool (6): Release locknut (5) on rapid adjuster (4). Turn rapid adjuster until turning tool is positioned at valve seat face ID (7). Tighten locknut on rapid adjuster. To set rate of cut: Set rate of cut with knurled nut (2). Secure with locking screw (3). Grip knurled screw (8) securely. Turn crank (1) clockwise until turning tool moves freely. When refacing valve seats, do not remove more material than is necessary to obtain perfect seats. For limit values, see Tolerances and Wear Limits List. Rework refaced valve seats in cylinder head with turning tool or countersink. Remove valve seat rotating tool, steady rest and pilots. Inspecting valves Measure valve stem with outside micrometer. For limit values, see Tolerances and Wear Limits List. If limit values are exceeded, replace valve. Check valves for damage, pitting, scoring and indentations on stem, plate, neck and pressure surface. Replace valve if chrome plating is damaged or worn through, if indentations are found, if valve stem reveals scores or if pitting is found at transition from valve head to valve stem. Remove severe indentations at pressure face of valve by machining to MTU specifications. Replace valve if necessary.

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 18

Task Description

Regrinding valve head Regrind only to the minimum extent required to produce a perfect valve seat. If a valve grinding machine is not available, machine valve on a valve turning machine. Measure height of outer edge of valve seat. Replace valve if specified limits are exceeded (see Tolerances and Wear Limits List). Check valves for cracks using surface crack-testing method with fluorescent penetrant dye; replace if necessary. Protect valves from damage, store in transportation trestle.

Measuring valve recess Install new valve into cylinder head. Using depth gauge, measure distance from cylinder head face to valve head. For limit values, see Tolerances and Wear Limits List. Install new valve seat inserts if specified limits are exceeded.

Checking valve springs CAUTION Spring preload. Risk of injury! Only use specified tool. Check valve springs with spring testing unit. If limit values are exceeded, replace valve springs. For wear limits, see Tolerances and Wear Limits List. Check valve springs for indentations, flatness, burring and deformation. Flatness deviations of up to 0.2 mm on inner diameter of end coils are permissible. Surface irregularities and burrs on windings can be removed and springs then reused.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1.5

3.5.1 19

Assembly Installing valves WARNING Fuels are combustible. Risk of fire and explosion! - No open flame - No electric sparks - Avoid all sources of ignition Clean valve guides with cylinder wiper and fuel. Clean valves and spray with engine oil. Install exhaust valves (1) and inlet valves (2).

Installing valve stem seals (1) Valve stem seal (2) Washer (3) Cylinder head

Before installing valve stem seal, spray upper valve guide seat (arrow) with denaturated ethanol. Fit assembly sleeve (1) on a valve.

M020081/00E - 03.10 -

EMTU

Section Page

3.5.1 20

Task Description

Press valve stem seal (1) via assembly sleeve (2) onto valve guide.

Installing valve springs Insert washer for inner and outer valve spring -see also overview drawing. Ensure washers for valve springs are correctly seated. Install inner and outer valve springs. Install narrower end of valve springs in direction of cylinder head. CAUTION Spring preload. Risk of injury! Only use specified tool. Insert securing screw of valve spring compressor (1) into tapped bore of cylinder head. Place upper spring retainers (2) on valve springs. Operate valve spring compressor to force springs down. Install valve collets in valve spring retainers. Relieve pressure on valve spring compressor and remove. Place cylinder head on its side and tap valve stem lightly with plastic mallet to settle valve collets correctly on valve stem. Check valve recess.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.5.1.6

3.5.1 21

Installation/Assembly Installing cylinder head Clean threaded bores in crankcase. Clean cylinder head partitions and crankcase end surface. Clean pushrods and insert in crankcase. Place the new cylinder head gasket over the centring sleeve (1) onto the cylinder crankcase end surface. Note:

With replacement engines, the cylinder crankcase partitions and bush collar seat are machined if necessary. With a new cylinder head gasket, the piston protrusion must be measured. If the piston protrusion is less than 0.3 mm, install series cylinder head.

Check threads of cylinder head screws for damage and blow clean with compressed air. Replace damaged cylinder head screws. Coat cylinder head screws (1 and 2) with engine oil, screw into crankcase and tighten lightly. Tighten all cylinder head screws on all cylinder heads with torque wrench in accordance with Tightening Specifications 1.4 and tightening diagram for individual cylinder head.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.5.1 22

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.6

3.6 1

Valve gear

Contents 3.6.1

Camshaft 3.6.1.1 3.6.1.2 3.6.1.4 3.6.1.6 3.6.1.7

Before-removal operations Removal Inspection and repair Installation After-installation operations

3.6.2

Roller tappet 3.6.2.1 Before-removal operations 3.6.2.2 Removal 3.6.2.4 Inspection and repair 3.6.2.6 Installation

3.6.3

Rockers and pushrods 3.6.3.1 Before-removal operations 3.6.3.2 Removal 3.6.3.3 Disassembly 3.6.3.4 Inspection and repair 3.6.3.5 Assembly 3.6.3.6 Installation 3.6.3.7 After-installation operations

3.6.4

Valve housing, cylinder head cover 3.6.4.1 Before-removal operations 3.6.4.2 Removal 3.6.4.4 Inspection and repair 3.6.4.6 Installation

M020081/00E - 03.10 -

EMTU

Section Page

3.6 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.1

3.6.1 1

Camshaft

1 Camshaft

3 Tappet rod

2 Tappet

M020081/00E - 03.10 -

EMTU

Section Page

3.6.1 2

3.6.1.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Removal not scheduled

-

-

X

X

Drain or draw off engine oil

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

-

Disconnecting engine coolant lines

3.14.1.2

-

X

-

Remove coolant expansion tank

3.14.5.2

-

X

-

Disconnect engine oil lines

3.16.1.2

-

X

-

Remove exhaust pipework (as required)

3.10.3.2

-

X

-

Remove air intake system

3.10.2.2

-

X

-

Remove crankcase breather

3.1.7.

-

X

-

Remove fuel injection pump drive

3.11.1.2

-

X

-

Remove valve gear housing

3.6.4.2

-

X

-

Remove rocker arms and push rods

3.6.3.2

-

X

-

Remove cylinder head

3.5.1.2

-

X

-

Remove roller tappets

3.6.2.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.1.2

3.6.1 3

Removal Remove camshaft. Attach rope to camshaft. Withdraw camshaft horizontally out of crankcase.

3.6.1.4

Inspection and repair

Clean camshaft and drive gears.

WARNING Compressed air is highly pressurized. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors. Flush oil bores with as high a pressure as possible and blow out with compressed air. Using the magnetic crack-testing method with fluorescent magnetic powder, check camshaft, drive gear and driver for cracks, replace parts if necessary. Check components for damage or excessive wear; if necessary, recondition in accordance with MTU information and/or replace. Check camshaft alignment bearings for scoring and wear. For wear limits, see Tolerances and Wear Limits List. Measure camshaft bearing and cam with outside micrometer. For limit values, see Tolerances and Wear Limits List. If limit values are exceeded, recondition camshaft in accordance with instructions from MTU; replace camshaft if necessary. Replace damaged dowel pins. Check radial runout of journal with dial gauge. If necessary, straighten camshaft on work bench. For limit values, see Tolerances and Wear Limits List.

M020081/00E - 03.10 -

EMTU

Section Page

3.6.1.6

3.6.1 4

Task Description

Installation Rub journal with chamois leather and spray with engine oil. Insert camshaft into bearing. Bar engine in direction of rotation so that markings of camshaft in relation to crankshaft are aligned (arrows).

3.6.1.7

After-installation operations Axial clearance of camshaft check Press camshaft on camshaft gear (arrow) in direction of gear case. Install dial gauge holder with dial gauge on crankcase. Mount dial gauge with preload on camshaft gear and set scale to ”0”.

EMTU

- 03.10 -

M020081/00E

Task Description

Section Page

3.6.1 5

Press camshaft on camshaft gear against dial gauge and read off axial running clearance of camshaft on dial gauge. For axial clearance, see Tolerances and Wear Limits List If limit values are exceeded, remove drive gear and alignment bearing of camshaft. If axial clearance is too small: Recondition camshaft alignment bearing with fine emery cloth on ink-check plate. If axial clearance is too large, replace camshaft alignment bearing.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.6.1 6

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.2

Valve tappet

3.6.2.1

Before-removal operations

3.6.2 1

A distinction must be made as to whether: The engine is to be completely disassembled

1 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Remove cylinder head covers

3.6.4.2

-

X

X

Disconnect H.P. fuel lines

3.12.1.2

-

X

X

Remove rocker arms and push rods

3.6.3.2

M020081/00E - 03.10 -

EMTU

Section Page

3.6.2.2

3.6.2 2

Task Description

Removal

Remove valve tappet from crankcase.

3.6.2.4

Inspection and repair

Wash valve tappet. Using magnetic crack-testing method and fluorescent magnetic powder, check valve tappet for cracks. Replace if necessary. Measure valve tappet with outside micrometer. Replace component if specified limits are exceeded. For limit values, see Tolerances and Wear Limits List. In event of scoring, wear and indentations, smooth components with emery cloth. Replace components in event of chipping and damage.

3.6.2.6

Installation

Spray valve tappet with engine oil and insert into guide in crankcase.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.3

3.6.3 1

Rockers and Pushrods

1 Snap ring

5 Nut

2 Washer

6 Hex screw

3 Rocker arms

7 Rocker arm bearing

4 Adjusting screw

M020081/00E - 03.10 -

EMTU

Section Page

1 Rocker arms

EMTU

3.6.3 2

Task Description

2 Pushrod

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.3.1

3.6.3 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Remove cylinder head covers

3.6.4.2

M020081/00E - 03.10 -

EMTU

Section Page

3.6.3.2

3.6.3 4

Task Description

Removal

Unscrew stress bolts from rocker shafts. Remove carrier with rocker from cylinder head. Remove locknuts from rocker. Remove adjusting screws. Store rocker in transport trestle and protect against damage. Remove push rods from tappets.

3.6.3.3

Disassembly Disassembling rocker arm Clamp rocker arm bearing (use protective jaws). Release locknuts (2) and remove adjusting screws (2).

Remove snap ring (1).

EMTU

- 03.10 -

M020081/00E

Task Description

Section Page

3.6.3 5

Remove washer (1) and rocker arm (2). Store rockers and rocker shafts in transport trestle and protect against damage.

3.6.3.4 Inspection and repair Clean parts. Using the magnetic crack-testing method with fluorescent magnetic powder, check rocker shafts, rocker arms and pushrods for cracks, replace parts if necessary. Smooth rocker shafts with minor wear and scoring with emery cloth. Remove minor scoring, indentations and wear on bearing bushes with emery cloth; replace as necessary. Measure rocker shafts with outside micrometer. Adjust bore gauge. Measure bores of rocker bearing bushes, see Tolerances and Wear Limits List. Record measurements and determine bearing clearance. If the limit values are exceeded, replace parts. Check threaded bores in rockers and locknuts for ease-of-movement, rechase with tapped bore if necessary. Check nut hexagon for damage, replace if necessary. Check condition of adjusting screw threads and replace if necessary. Check screw slot for damage. Check pushbutton caps for clearance and pitting; replace as necessary. Check ball stud on rocker for wear and damage; press out and replace as necessary. Turn push rod end and top to check if securely seated. Check push rod seat and ball head for wear; replace as necessary. Check push rod for wear; up to max. 0.3 mm permitted. Check carrier for rocker shaft for flatness and damage; smooth with oilstone if necessary.

M020081/00E - 03.10 -

EMTU

Section Page

3.6.3 6

Task Description

Replacing rocker bearing bushes CAUTION Nitrogen is liquid at (- 200 °C). Danger of freezing and suffocation! Do not allow liquid nitrogen to come into contact with body parts (eyes, hands). Wear protective clothing (including gloves and closed shoes) and goggles. Ensure good ventilation at workplace. Use mandrel to press bearing bush out of rocker arm. Ensure that rocker is perfectly seated! Adjust bore gauge and measure bore. For dimensions, see Tolerance and Wear Limits List. Chill new bearing bushes in liquid nitrogen and insert into rocker arms. Oil bores in rocker arm and bearing bush must be aligned. After installation, machine bearing bushes on fine drill to specified dimension - see Tolerance and Wear Limits List. Adjust bore gauge. Measure bore of bearing bush. After processing, carefully clean oil bores and deburr if necessary.

3.6.3.5

Assembly WARNING

Compressed air is highly pressurized. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.3 7

Assembling rocker arm Check oil bores in rocker and shaft for cleanliness and blow through with compressed air. Coat rocker shafts with engine oil. Clamp rocker arm bearing (use protective jaws). Fit rocker arm (2) on rocker shaft. Fit washer (1).

Install snap ring (1).

Make sure adjusting screws (1) move easily! Insert adjusting screws into threaded holes in the rocker arm. Fit locknuts (2) on adjusting screws.

M020081/00E - 03.10 -

EMTU

Section Page

3.6.3.6

3.6.3 8

Task Description

Installation

Coat ball heads of push rods with engine oil. Insert push rods into tappet with ball head end. Check contact surfaces on cylinder head and carrier for evenness; smooth with oilstone as necessary. Set appropriate cylinder to firing TDC. Fit rocker arms on cylinder head. Coat screw thread with engine oil. Install stress bolt in cylinder head and, using torque wrench, tighten as per Tightening Specifications 1.4.

3.6.3.7

After-installation operations Checking and adjusting valve clearance Install engine barring tool on flywheel housing. Turn crankshaft in normal direction of engine rotation until valves of one cylinder are aligned. Note:

Valves on cylinder to be set are closed, rocker arms are completely unloaded and pushrods cannot be turned. The associated piston is now at firing TDC and the valves can now be set.

Check Position feeler gauge between inlet valve and rocker arm and/or between exhaust valve and rocker arm. For valve clearance, see Section 1.5. Note:

EMTU

Valve clearance is set correctly if it is possible to pull the gauge through with slight resistance.

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.3 9

Setting Place valve adjusting wrench on adjusting screw.

Release locknut (2). Set adjusting screw (1) so that feeler gauge can still just be pulled through. In this position, securely hold adjusting screw and tighten locknut. When tightening, the adjusting screw must not turn. After locking locknut, check valve clearance. Remove engine barring tool from flywheel housing. Install cylinder head cover, see 3.6.4.6.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.6.3 10

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.4

3.6.4 1

Cylinder head cover

1 Hex screw

3 Cylinder head cover

2 Spring washer

4 Gasket

M020081/00E - 03.10 -

EMTU

Section Page

3.6.4 2

3.6.4.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Remove cylinder head covers

3.6.4.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.6.4.2

3.6.4 3

Removal Remove screws (1). Remove cylinder head cover (3). Remove gasket (4).

3.6.4.4

Inspection and repair

Crack-test the cylinder head cover using the surface crack-testing method with fluorescent penetrant dye, replace if necessary. Check cylinder head cover for flatness and damage; replace as necessary. Check hex screw for damage and check condition of threads; replace if necessary. Check condition of gasket. If a gasket is damaged, porous or cracked: replace gasket.

3.6.4.6

Installation Smooth cylinder head mating faces with oilstone and clean. Coat cylinder head cover (3) in sealing area with petroleum jelly. Press gasket (4) onto cylinder head cover. Place cylinder head cover on cylinder head. Fit screws with washers and tighten with torque wrench as per Tightening Specifications 1.4.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.6.4 4

Task Description

- 03.10 -

M020081/00E

Task Description

Section Page

3.7 1

3.7 Engine governor Electronic governor; See Special Publication Engine Electronics.

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

3.7 2

Task Description

- 03.10 -

M020081/00E

Task Description

3.9

Section Page

3.9 1

Exhaust turbocharger

Removal, see 3.10.6.2. Installation, see 3.10.6.6. Carry out exhaust turbocharger disassembly and assembly in accordance with Assembly Instructions appropriate to the respective engine model.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.9 2

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.10

3.10 1

Air/exhaust system

Contents 3.10.1

3.10.2

Intercooler 3.10.1.1 3.10.1.2 3.10.1.3 3.10.1.4 3.10.1.5 3.10.1.6

Before-removal operations Removal Disassembly Inspection and repair Assembly Installation

Air system 3.10.2.1 3.10.2.2 3.10.2.4 3.10.2.6

Before-removal operations Removal Inspection and repair Installation

3.10.3

Exhaust system 3.10.3.1 Before-removal operations 3.10.3.2 Removal 3.10.3.3 Disassembly 3.10.3.4 Inspection and repair 3.10.3.5 Assembly 3.10.3.6 Installation

3.10.6

Carrier housing with exhaust turbocharger and exhaust elbow 3.10.6.1 Before-removal operations 3.10.6.2 Removal 3.10.6.3 Disassembly 3.10.6.4 Inspection and repair 3.10.6.5 Assembly 3.10.6.6 Installation

3.10.14

Drain line 3.10.14.1 3.10.14.2 3.10.14.4 3.10.14.6

Before-removal operations Removal Inspection and repair Installation

M020081/00E - 03.10 -

EMTU

Section Page

3.10 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.1

3.10.1 1

Intercooler

Intercooler

1 Intercooler 2 Connector 3 Banjo screw

8 Bracket 9 Hex screw 10 Clamp

4 Sealing ring

11 Hex screw

5 Hose

12 Hex screw

6 Clamp

13 Washer

7 Washer

M020081/00E - 03.10 -

EMTU

Section Page

3.10.1 2

Task Description

Connection components

1 Flange

3 O-ring

2 O-ring

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.1 3

Cover and connection components of air junction on intercooler

1 Air junction

8 Washer

2 O-ring

9 Plug-in pipe

3 O-ring

10 O-ring

4 Hex screw

11 O-ring

5 Hex screw

12 Flange

6 Hex screw

13 Hex screw

7 Sleeve

14 Washer

M020081/00E - 03.10 -

EMTU

Section Page

3.10.1 4

3.10.1.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Disconnect engine coolant lines

3.14.1.2

-

X

X

Remove air intake system, intercooler/exhaust turbocharger

3.10.2.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.1.2

3.10.1 5

Removal DANGER Suspended load Risk of injury! Use suitable tools and lifting equipment. Never stand beneath a suspended load. Screw lifting eyes into intercooler. Attach rope to lifting gear. Remove securing screws for intercooler. Raise intercooler.

3.10.1.3

Disassembly

Removing cover for air inlet and air outlet Mark parts before removal. Remove securing screws from cover, see overview drawing. Remove screws and washers. Remove cover from intercooler, ensuring that the sealing surfaces are not damaged. Remove sealing paste from sealing surfaces. After removal, seal all connections with suitable plugs and covers. Protect intercooler (especially cooling fins) from mechanical damage. Cover cooler nets (e.g. with cardboard).

3.10.1.4

Inspection and repair

Clean all components, check for condition and damage by visual inspection. Replace components as necessary. Check cover for cracks using surface crack-testing method with red penetrant dye. If cracks are detected, replace parts. Check all sealing, mating and contact surfaces for damage and unevenness; smooth with oilstone or emery cloth as necessary. Check thread in intercooler housing for ease of movement; recondition if necessary. Clean intercooler on air and water sides.

WARNING Compressed air is highly pressurised. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors. Cleaning air side: Blow out the cooler with a compressed air jet or spray with a pressurised water jet in the opposite direction of the cooling air. The jet must be directed parallel to the cooling fins in order to prevent the fins being deformed.

M020081/00E - 03.10 -

EMTU

Section Page

3.10.1 6

Task Description

WARNING Hard water jet. Risk of injury! Never direct water jet at other personnel, electric or electronic equipment. Always wear protective clothing, protective gloves and protective goggles/safety mask. If the cooler has a contaminant layer of grease or oil, the cooler must be spray-cleaned with a steam jet in the opposite direction to cooling air. Use nozzle for multi-point water jet. Operating pressure of H.P. cleaning unit should be approx. 80 bar. Use clear water at a temperature of approx. 70 °C (to prevent steam). After cleaning, blow through cooling air ducts with compressed air in vertical direction. Cleaning coolant side: It is essential to examine extent of contamination of water side prior to cleaning. The water side must be cleaned if there is visible encrustation on the water side (inlet area) due to crustations, contamination and oil deposits. Fill cooler with descaling agent.

CAUTION When using these chemical substances, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. An agent which is not aggressive to metal surfaces (e.g. Porodox from Henkel or Porozink from Parobe-Chemie, Basel) must be used to remove deposited material. It is essential to follow the manufacturer’s instructions when preparing the cleaning agent. Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits. After cleaning, flush the cooler with water until pH values of clean water and rinsing water are approximately the same (difference 1 pH). Normal coolant can be used for rinsing. If cooler is not satisfactorily clean, repeat cleaning process. If the cooler is not put into operation immediately afterwards, after this cleaning the water side must be dried and then preserved. Dry in a drying oven between 110 °C and 120 °C. Oven drying time: approx. 3 hours. Spray preservation agent (Branol 32/10 from Brangs and Heinrich) into cooler. The preservation agent condenses and falls to form a protective layer over the inner surfaces. Make sure dosages are correct! 2 ml Branorol 32/10 per litre of coolant. After preservation, seal all openings with suitable end covers air-tight.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.1 7

Intercooler leak check Seal coolant chamber connections on intercooler with suitable flanges (2) and gasket (3). Connect compressed air line to one flange. WARNING Test liquid is hot and highly pressurised. Risk of injury! Liquid emerging under high-pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Use lifting equipment to immerse intercooler into test bath filled with coolant heated to 80 °C . Open compressed air supply and set pressure reducer (1) to 0.5 bar. Pressure-test intercoolers with air in water bath for leaks. Rotate cooler around lateral axis and repeat test. Replace intercooler if leaks are found. WARNING Compressed air is highly pressurised. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors. After checking, blow through cooling air ducts with compressed air in vertical direction.

3.10.1.5

Assembly

Installing cover on air junction Clean sealing surfaces on intercooler and cover, smooth with oilstone if necessary. Coat sealing surfaces evenly with sealing paste. Tighten cover on intercooler air inlet with torque wrench as per Tightening Specifications 1.4.

M020081/00E - 03.10 -

EMTU

Section Page

3.10.1 8

3.10.1.6

Installation

Task Description

DANGER Suspended load Risk of injury! Use suitable tools and lifting equipment. Never stand beneath a suspended load. Check that mating faces on intercooler are clean. Screw in lifting eyes on intercooler and attach with rope to lifting gear. Place intercooler on carrier. Take care not to damage O-rings. Secure intercooler with hex screws.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.2

3.10.2 1

Air system

Charge air line

1 Charge air line

15 Plug

29 Banjo screw

2 Gasket

16 Gasket

30 Sealing ring

3 Hex screw

17 Hex screw

31 Hose

4 Hex screw

18 Hex screw

32 Clamp

5 Washer

19 Washer

33 Clamp

6 Hex screw

20 Hex screw

34 Clamp

7 Hex screw

21 Washer

35 Hex screw

8 Washer

22 Flange

36 Washer

9 Washer

23 O-ring

37 Hex screw

10 Flange

24 Hex screw

38 Clamp

11 O-ring

25 Washer

39 Hex screw

12 Hex screw

26 Plug-in pipe

40 Washer

13 Washer

27 O-ring

14 Charge air manifold

28 Connector

M020081/00E - 03.10 -

EMTU

Section Page

3.10.2 2

3.10.2.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Disconnect engine coolant lines

3.14.1.2

-

X

X

Disconnect H.P. fuel lines

3.12.1.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.2.2

3.10.2 3

Removal

Disconnecting charge air line Remove screws and washers from charge air line on air collecting pipework - see overview drawing. Remove securing screws from flanges - see overview drawing. Remove O-rings, see overview drawing. Disconnect charge air line from cylinder heads - see overview drawing. Remove gaskets from cylinder heads - see overview drawing. Removing connecting line for intercooler/exhaust turbocharger Remove intermediate flanges from intercooler and plug-in pipe from exhaust turbocharger.

3.10.2.4

Inspection and repair CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Wash charge air line for charge air manifold, plug-in pipes and flanges with cleaner. Using the surface crack-testing method and fluorescent penetrant dye, check the charge air line for cracks. Replace component if cracks are found. Check charge air line sealing surfaces and screw interfaces for evenness and damage, smooth with oilstone if necessary. Check bores for sleeves on charge air lines for wear and damage, smooth slight wear and damage with polishing cloth, if necessary line in accordance with MTU regulations. Check condition of threaded inserts and bushes on charge air lines, replace if necessary. Check connecting lines, elbow, sleeves and plug-in pipes for damage and wear, smooth with polishing cloth or oilstone if necessary, replace parts as required.

WARNING Test fluid is highly pressurized. Risk of injury! Liquids emerging under high pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Pressure-test charge air line at room temperature in water bath with air. Test pressure 0.5 bar. Note: The water for pressure testing must be treated with anti-corrosive agent. Replace all gaskets and O-rings.

3.10.2.6

Installation

Installing manifolds Smoothe sealing surfaces on cylinder heads and charge air line with oilstone. Check that charge air line is clean. Coat gaskets with sealing paste and O-rings with petroleum jelly. Fit all gaskets and O-rings. Coat threads of screws with engine oil. Install charge air line with screws and washers. Tighten charge air line on cylinder head with torque wrench as per Tightening Specifications 1.4.

M020081/00E - 03.10 -

EMTU

Section Page

3.10.2 4

Task Description

WARNING Test fluid is highly pressurized. Risk of injury! Liquids emerging under high pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Before installing cover on manifold, pressure-test the engine with water. Install cover with gasket, screws and spring washers on manifold (see overview drawing) and tighten with torque wrench. For torque settings, see Section 1.4. Installing connecting line for intercooler/exhaust turbocharger After installing exhaust turbocharger, insert O-rings into groove on plug-in pipe and on compressor housing of exhaust turbocharger and coat with petroleum jelly. Insert O-ring in groove on flanges and coat with petroleum jelly. Fit flanges on plug-in pipe. Fit plug-in pipe with flanges on compressor housing on exhaust turbocharger. Mount flanges on intercooler with screws and washers and tighten. After installing exhaust turbocharger, insert O-rings into groove on plug-in pipe and on compressor housing of exhaust turbocharger and coat with petroleum jelly. Insert O-ring in groove on flanges and coat with petroleum jelly. Fit flanges on plug-in pipe. Fit plug-in pipe with flanges on compressor housing on exhaust turbocharger. Install flanges on intercooler with screws and washers.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.3

3.10.3 1

Exhaust system

Exhaust elbow Overview drawing 1

1 Exhaust elbow

14 Washer

27 Hex screw

2 Blanking plug

15 ---------

28 Exhaust manifold

3 O-ring

16 O-ring

29 Gasket

4 Adapter

17 Hex screw

30 Hex screw

5 Sealing ring

18 Hex screw

31 Washer

6 Surface sealant

19 Washer

32 ----------

7 Adapter

20 Exhaust elbow

33 O-ring

8 O-ring

21 Plug

34 Hex screw

9 Washer

22 Sealing ring

35 Plug

10 Hex screw

23 Surface sealant

36 Sealing ring

11 Exhaust manifold

24 Adapter

37 Hex screw

12 Gasket

25 O-ring

38 Washer

13 Hex screw

26 Washer

M020081/00E - 03.10 -

EMTU

Section Page

3.10.3 2

Task Description

Attachments on exhaust line Overview drawing 2

1 Cover

14 Plug-in pipe

27 Intermediate element

2 Cover

15 O-ring

28 Plug-in pipe

3 Hex screw

16 Plug-in pipe

29 O-ring

4 Hex screw

17 O-ring

30 Plug-in pipe

5 Socket-head screw

18 O-ring

31 O-ring

6 Washer

19 O-ring

32 O-ring

7 O-ring

20 Hex screw

33 O-ring

8 Cover

21 Washer

34 Hex screw

9 Hex screw

22 O-ring

35 Washer

10 Washer

23 O-ring

36 O-ring

11 ---------

24 Hex screw

37 O-ring

12 Flange

25 Washer

38 Hex screw

13 Intermediate element

26 Flange

39 Washer

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.3 3

Exhaust line with exhaust housing Overview drawing 3

1 Flange

12 Exhaust line

23 Hex screw

2 Gasket

13 Exhaust line

24 Washer 25 Hex screw

3 Socket-head screw

14 Plug-in pipe

4 Flame pipe

15 Gasket

26 Washer

5 Hex screw

16 Grooved pin

27 Sliding element

6 Washer

17 Hex screw

28 Washer

7 Exhaust housing

18 Hex screw

29 Spacer bush

8 Plug

19 Washer

30 Hex screw

9 Sealing ring

20 Clamp

31 Hex screw

10 Exhaust line

21 Dowel pin

11 Exhaust line

22 Hex screw

M020081/00E - 03.10 -

EMTU

Section Page

3.10.3 4

Task Description

Exhaust elbow with transverse connecting pipe Overview drawing 4

1 Exhaust elbow

21 Washer

41 O-ring

2 Bracket

22 Brace

42 O-ring

3 O-ring

23 Hex screw

43 O-ring

4 Hex screw

24 Washer

44 Hex screw

5 Washer

25 Exhaust elbow

45 Washer

6 Protective tube

26 Bracket

46 Hex screw

7 Hex screw

27 O-ring

47 Washer

8 Washer

28 Hex screw

48 Stud

9 --------

29 Washer

49 Hex screw

10 Plug-in pipe

30 Protective tube

50

11 O-ring

31 Hex screw

51 Hex nut

12 O-ring

32 Washer

52 Spacer sleeve

13 O-ring

33 ---------

53 Washer

14 O-ring

34 Plug-in pipe

54 Threaded bush

15 O-ring

35 Exhaust transverse connection

55 Sealing ring

16 O-ring

36 O-ring

56 Plug

17 Hex screw

37 O-ring

57 Sealing ring

18 Hex screw

38 O-ring

19 Washer

39 O-ring

20 Socket-head screw

40 O-ring

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.3.1

3.10.3 5

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Disconnect or remove electrical cable (if necessary)

3.84.

-

X

X

Disconnect engine coolant lines

3.14.1.2

-

X

X

Disconnect drain line

3.10.14.2

M020081/00E - 03.10 -

EMTU

Section Page

3.10.3 6

3.10.3.2

Removal

Task Description

WARNING Heavy object. Risk of crushing! Use suitable equipment and lifting gears. Removing exhaust manifold cover Note: See overview drawing 2. Remove screws securing cover (1 and 2). Remove cover. Removing exhaust manifold Note: See overview drawing 3. Remove screws securing exhaust lines (12 and 13). Withdraw exhaust lines from exhaust housing (7), left and right engine sides simultaneously. Removing exhaust housing Note: See overview drawing 3. Remove screws securing exhaust housing (7), left and right engine sides simultaneously. Remove exhaust housing. Removing exhaust elbow Note: See overview drawing 4. Remove screws for exhaust elbows (1 and 25). Remove exhaust elbow, at the same time withdrawing exhaust transverse connection (35) from exhaust elbow. Remove all O-rings from exhaust elbow, remove exhaust transverse connection and exhaust turbocharger. Removing exhaust elbow Note: See overview drawing 1. Remove screws for exhaust manifold (11 and 28). Remove screws for exhaust elbows (1 and 20). Remove exhaust elbow. Remove all O-rings.

3.10.3.3

Disassembly

Disassembling exhaust elbow Note: See overview drawing 4. Remove screws for carriers (2 and 26 ). Remove carrier and protective tube (6 and 30). Remove plug-in pipes (10 and 34). Remove O-rings. Removing constant-pressure manifold half Note: See overview drawing 3. Remove plug-in pipe (14) from exhaust line. Remove slide element (27) and spacer bush (29).

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.3 7

Disassembling exhaust elbow Note: See overview drawing 1. Remove adapters (7 and 24). Remove O-rings. Remove all plugs and adapters.

3.10.3.4 Inspection and repair CAUTION Decarbonizer must be used only in conjunction with a fume extraction system. Pay attention to manufacturer’s safety instructions. Always wear gloves and protective goggles. Place exhaust line, exhaust housing, cover, exhaust elbow, exhaust transverse connecting pipe, protective tube and plug-in pipe in a tank filled with decarbonizer for approx. 12 to 24 hours. After cleaning, rinse parts until they are free from residues. Stubborn rust deposits can also be treated later by spraying synthetic abrasive MTH (rated grain 16 to 20); coolant inlets and outlets must be sealed for this purpose. Using the surface crack-testing method with red penetrant dye, check the exhaust line, exhaust housing, cover, exhaust elbow, exhaust transverse connecting pipe, protective tube and plug-in pipe for cracks. If cracks are detected, replace parts. Check exhaust line, exhaust housing, cover, exhaust elbow, exhaust transverse connecting pipe, protective tube and plug-in pipe for wear or pitting; recondition or replace as necessary. Check thread and thread inserts for damage. Check sealing surfaces and bores for damage. Replace damaged thread inserts. Smooth sealing surfaces and bores with polishing cloth and oilstone. Replace securing screws and nuts. Clamping element, flame pipe, flange

WARNING Test liquid is hot and highly pressurised. Risk of injury! Liquids emerging under high pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Pressure-test water-carrying components. Pressure-testing regulations: Liquid test pressure = 7.0 bar with water Air test pressure: 0.5 bar in water bath at 80 °C

3.10.3.5

Assembly

Preassembling exhaust line Note: See overview drawing 3. Coat screw thread for sliding element (27) with assembly paste. Coat sliding element with spacer bush (29) with assembly paste and install. Join the two exhaust pipes with plug-in pipe (14).

M020081/00E - 03.10 -

EMTU

Section Page

3.10.3 8

3.10.3.6

Installation

Task Description

Installing left and right exhaust elbow on valve housing Note: See overview drawing 1. Coat O-rings with petroleum jelly and fit on exhaust elbow (1). Coat thread of screws and mating faces of washers with assembly paste. Install exhaust elbows (1 and 20) on valve housing. Fit O-rings (8 and 25) on adapters (7 and 24) and coat with petroleum jelly. Install adapter. Install exhaust manifold (11 and 28) with gaskets (12 and 29). Install all plugs and adapters with new O-rings and sealing rings. Installing left and right exhaust housing Note: See overview drawing 3. Before installing exhaust housing (7), check all cylinder heads on one engine side with a steel ruler for evenness; max. permissible deviation: 0.1 mm. Coat flame pipe (4), flange (1), clamping element (20) with assembly paste and install. Coat gasket (2) with assembly paste and fit. Make sure that gasket is correctly positioned. Coat thread of screws and support surface of washers with assembly paste. Fit exhaust housing and secure. Installing left and right exhaust line Note: See overview drawing 3. Insert preassembled exhaust line into exhaust housing or exhaust elbow. Make sure that sliding elements are correctly positioned (27). Coat thread of screws and mating face of washers securing covers (1 and 20), see overview drawing 1, with assembly paste. Install covers (1 and 20). Installing left and right exhaust elbow Note: See overview drawing 4. Coat all O-rings with petroleum jelly. Coat plug-in pipes (10 and 34) with assembly paste. Install protective tubes (6 and 30) with plug-in pipe. Coat all threads of screws and mating faces of washers with assembly paste. Install exhaust elbows (1 and 25) together with exhaust transverse connection (35). Install carriers (2 and 26) and screw together with protective tube (6) or (30).

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.6

3.10.6 1

Exhaust turbocharger

1 Exhaust turbocharger

3 Bleed valve

2 Exhaust turbocharger

M020081/00E - 03.10 -

EMTU

Section Page

3.10.6 2

3.10.6.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Disconnect engine coolant lines

3.14.1.2

-

X

X

Disconnect vent and drain lines

3.14.2.2

-

X

X

Disconnect or remove electrical cable (if necessary)

3.84.9.2

-

X

X

Remove air intake system, intercooler/exhaust turbocharger

3.10.2.2

-

X

X

Cover for exhaust manifold and constant-pressure manifold half

3.10.3.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.6.2

3.10.6 3

Removal CAUTION Suspended load Risk of injury! Use suitable tools and lifting equipment. Never stand beneath a suspended load. Attach rope to exhaust turbocharger (1) and lifting gear. Remove hex screws (2). Lift off exhaust turbocharger.

3.10.6.3

Disassembly

See Special Publication.

3.10.6.6

Installation CAUTION Suspended load Risk of injury! Use suitable tools and lifting equipment. Never stand beneath a suspended load. Attach rope to exhaust turbocharger (1) and lifting gear. Place exhaust turbocharger (1) on exhaust elbow (2). Tighten hex screws (2).

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.10.6 4

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.14

3.10.14 1

Drain line

Drain line arrangement

1 Intercooler

7 Washer

2 Connector

8 Bracket

3 Banjo screw

9 Hex screw

4 Sealing ring

10 Clamp

5 Hose

11 Hex screw

6 Clamp

M020081/00E - 03.10 -

EMTU

Section Page

3.10.14 2

3.10.14.1

Task Description

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

-

x

Remove engine Carry out tasks as specified in disassembly plan Disable engine start

2.3 2.4 Op. Man.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.10.14.2

3.10.14 3

Removal

Removal as shown in overview drawing.

3.10.14.4

Inspection and repair

No inspection and repair necessary. Replace drain line.

3.10.14.6

Installation

Installation as shown in overview drawing.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.10.14 4

Task Description

- 03.10 -

M020081/00E

Task Description

3.11

Section Page

3.11 1

Fuel injection equipment

Contents 3.11.1

Fuel injection pump drive 3.11.1.1 Before-removal operations 3.11.1.2 Removal 3.11.1.3 Disassembly 3.11.1.4 Inspection and repair 3.11.1.5 Assembly 3.11.1.6 Installation

3.11.5

Fuel injection pump 3.11.5.1 Before-removal operations 3.11.5.2 Removal 3.11.5.4 Inspection and repair 3.11.5.6 Installation 3.11.5.7 After-installation operations

3.11.6

Fuel injection nozzle with holder 3.11.6.1 Before-removal operations 3.11.6.2 Removal 3.11.6.4 Inspection and repair 3.11.6.6 Installation

M020081/00E - 03.10 -

EMTU

Section Page

3.11 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.11.1

3.11.3 1

Fuel injection pump drive

1 Drive gear

3 Washer

2 Hex screw

M020081/00E - 03.10 -

EMTU

Section Page

3.11.3 2

3.11.1.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain raw water

Oper. Instr.

-

X

X

Remove exhaust silencer

3.10.12.2

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Disconnect engine coolant lines

3.14.1.2

-

X

X

Disconnect water lines

3.14.3.2

-

X

X

Remove coolant expansion tank

3.14.5.2

-

X

X

Disconnect engine oil lines

3.16.1.2

-

X

X

Disconnect H.P. fuel lines

3.12.1.2

-

X

X

Remove fuel lines (if necessary)

3.12.2.2

-

X

X

Remove fuel injection pumps

3.11.5.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.11.1.2

3.11.3 3

Removal Remove coupling half. Remove screws (1). Remove drive gear (1).

3.11.1.4

Inspection and repair

Clean all components. Using the magnetic crack-testing method with fluorescent magnetic powder, check coupling half for cracks. If cracks are found, replace coupling half. Check teeth on coupling half for wear. Level with oilstone as required, replace if necessary.

3.11.1.6

Installation Install coupling half. Install drive gear (1) and tighten screw (2) by hand.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.11.3 4

Task Description

- 03.10 -

M020081/00E

Task Description

3.11.5

Section Page

3.11.5 1

Fuel injection pump 12V

M020081/00E - 03.10 -

EMTU

Section Page

3.11.5 2

Task Description

Arrangement of fuel injection lines

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.11.5.1

3.11.5 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain raw water

Oper. Instr.

-

X

X

Remove exhaust silencer

3.10.12.2

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Disconnect engine coolant lines

3.14.1.2

-

X

X

Disconnect water lines

3.14.3.2

-

X

X

Remove coolant expansion tank

3.14.5.2

-

X

X

Disconnect engine oil lines

3.16.1.2

-

X

X

Disconnect H.P. fuel lines

3.12.1.2

-

X

X

Remove fuel lines (if necessary)

3.12.2.2

-

X

X

Remove fuel injection pumps

3.11.5.2

M020081/00E - 03.10 -

EMTU

Section Page

3.11.5 4

3.11.5.2

Removal

Task Description

DANGER Suspended load Risk of injury! Use suitable tools and lifting equipment. Never stand beneath a suspended load. Attach lifting device to H.P. line connections of injection pump. Attach rope to lifting device and lifting gear. Remove screws (1-8). Lift out injection pump. Remove lifting device.

Remove O-rings (1).

3.11.5.4

Inspection and repair

Overhaul fuel injection pump as per Special Publication.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.11.5.6

3.11.5 5

Installation Install barring tool.

Turn crankshaft with barring tool in normal direction of engine rotation until in the compression stroke of the 1st cylinder the mark for start of delivery is aligned with edge (arrow) in inspection port. The engine must not be rotated backwards. Inspection: The valves of the 1st cylinder must be closed, the rocker arms must be unloaded.

Turn injection pump camshaft until mark on drive flange (arrow) is aligned with mark on injection pump. Move injection pump drive gear to central position in elongated holes.

M020081/00E - 03.10 -

EMTU

Section Page

3.11.5 6

Task Description

Coat O-ring with petroleum jelly and insert.

WARNING Heavy object. Risk of injury! Use suitable equipment and lifting gears. Fit assembly gauge on injection pump and secure with knurled-head screw (arrow). Move injection pump to and fro until assembly gauge is in contact with crankcase. Insert injection pump with lifting device in bearing on crankcase. Make sure the injection pump markings are aligned. The gears must engage in the teeth without tension. Remove lifting device.

Coat thread of screws (1) with engine oil. Use torque wrench to tighten screws to specified torque. For torque setting, see Section 1.4.

EMTU

- 03.10 -

M020081/00E

Task Description

Section Page

3.11.5 7

Coat securing screws with engine oil and install with spring washers. Tightening sequence for injection pump securing screws 1. Fit all screws (with battery screwdriver). 2. Pretighten screws in accordance with arrangement opposite. 3. Carry out final tightening in same sequence. For tightening specifications, see 1.4. Adjusting pump timing, see 3.11.5.7.

3.11.5.7

After-installation operations Checking and adjusting start of delivery Connecting supply line (1) from high-pressure pump Remove fuel return line and overflow valve from injection pump. Seal injection pump return with plug (2). Remove injection line to 1st engine cylinder. Connect test line with sight glass (3) to connection of injection pump for the 1st engine cylinder. Set engine approx. 1/2 a rotation before TDC with barring tool. Switch on high-pressure pump.

Bar engine slowly in direction of rotation and observe fuel flow in sight glass until spray pattern shows correct atomisation. A = Good atomisation B = Fuel jet constricted, just before start of delivery. Droplets, start of delivery

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.11.5 8

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.11.6

3.11.6 1

Fuel injection nozzle with holder

1 Nozzle holders

3 Screw, nozzle holder

2 Sealing ring

4 Plug

M020081/00E - 03.10 -

EMTU

Section Page

3.11.6 2

3.11.6.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Disconnect H.P. fuel lines

3.12.1.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.11.6.2

3.11.6 3

Removal Removing nozzle holder Remove thrust screw (1).

Fit puller (1) on injector (2) and withdraw. Remove sealing ring from cylinder head.

3.11.6.4 Inspection and repair For disassembly, cleaning, assembly and inspection of fuel injectors, see Engine Operating Instructions. Replace sealing ring. Check condition of leak-off fuel lines, replace cracked leak-off fuel lines.

M020081/00E - 03.10 -

EMTU

Section Page

3.11.6 4

3.11.6.6

Installation

Task Description

Installing nozzle holder Attach sealing ring on nozzle holder so that, when installing, the gap between nozzle and cylinder head is sufficiently filled with grease. Insert injector into cylinder head. Fit thrust screw (1) over nozzle holder. Coat thrust screw with engine oil. Screw in pin wrench and tighten with torque wrench as per Tightening Specifications 1.4.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.12

3.12 1

Fuel system

Contents 3.12.1

H.P. fuel lines 3.12.1.1 Before-removal operations 3.12.1.2 Removal 3.12.1.4 Inspection and repair 3.12.1.6 Installation

3.12.2

Fuel lines 3.12.2.1 3.12.2.2 3.12.2.4 3.12.2.6

3.12.3

Before-removal operations Removal Inspection and repair Installation

Fuel duplex filter 3.12.3.1 Before-removal operations 3.12.3.2 Removal 3.12.3.3 Disassembly 3.12.3.4 Inspection and repair 3.12.3.5 Assembly 3.12.3.6 Installation

M020081/00E - 03.10 -

EMTU

Section Page

3.12 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.12 3

Fuel system, 12V

1 Engine

12 Leak-of f fuel indicator*

2 Fuel delivery pump

13 Fuel prefilter

3 Fuel duplex filter

14 Drip tray

4 Fuel injection pump

15 Flexible connection

5 Fuel injection nozzle

16 From fuel tank

6 Overflow valve

17 To fuel tank

7 Injection line

18 To leak-off fuel collecting tank

8 Jacket*

*

Order-specific version

9 Leak-of f fuel line

A

Connection on engine

10 Leak-of f fuel from jacket* 11 Leak-of f fuel tank*

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.12 4

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.12.1

3.12.1 1

H.P. fuel lines

H.P. fuel lines

1 Set of injection lines

4 Hex screw

2 Set of injection lines

5 Hex screw

3 Spacer tube

M020081/00E - 03.10 -

EMTU

Section Page

3.12.1 2

Task Description

H.P. fuel line arrangement

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.12.1.1

3.12.1 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

-

-

X

Disable engine start

M020081/00E - 03.10 -

2.4 Oper. Instr.

EMTU

Section Page

3.12.1 4

3.12.1.2

Removal

Task Description

Removing leak-off fuel line Remove leak-off fuel lines (1 and 3) from nozzle holder. Remove plug (2).

Remove H.P. fuel line Remove union nut.

Unscrew H.P. fuel line from fuel injection pump. Remove pipe clamps from charge air manifold.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.12.1.4

3.12.1 5

Inspection and repair

Clean all components. Check injection line for damage and scuffing. Replace damaged injection lines, or lines with dented or corroded tapers. A new, straight injection line must be bent to conform precisely to damaged injection line. Inspect union nuts for damage and, if necessary, replace injection line.

WARNING Compressed air is highly pressurized. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors.

3.12.1.6

Installation Install H.P. fuel line Before installing, blow out injection line with compressed air. Install union nut, ensuring it is free from tension. Arrangement of injection lines - see overview drawing. Tighten union nut on nozzle holder as per Tightening Specifications 1.4.

Screw injection line onto fuel injection pump and tighten with special wrench and torque wrench as per Tightening Specifications 1.4. Remove pipe clamps from charge air manifold.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.12.1 6

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.12.2

3.12.2 1

Fuel lines

Fuel lines to fuel injection pump

1 Fuel line

15 Sealing ring

2 T-piece

16 Banjo union

30 Sealing ring

3 Sealing cone

17 Sealing ring

31 Banjo screw

4 Nut

18 Overflow valve

32 Banjo screw

5 Adapter

19 Adapter

33 Sealing ring

6 Sealing ring

20 Fuel line

34 Plug

7 Fuel line

21 Fuel line

35 Fuel line

8 Banjo screw

22 Fuel line

36 Banjo union

9 Banjo union

23 Fuel line

37 Sealing ring

10 Sealing ring

24 Sealing ring

38 Adapter

11 Fuel line

25 Adapter

39 Plug

12 Banjo screw

26 Banjo screw

40 Fuel line

13 Sealing ring

27 Reduction union

41 Fuel line

14 Adapter

28 Fuel line

M020081/00E - 03.10 -

29 Banjo union

EMTU

Section Page

3.12.2 2

Task Description

Fuel lines, pump, injection nozzle, cylinders 7 to 12

1 Injection line, cylinder 7

10 Sealing ring

2 Injection line, cylinder 8

11 O-ring

3 Injection line, cylinder 9

12 Half-clamp

4 Injection line, cylinder 10

13 Half-clamp

5 Injection line, cylinder 11

14 Half-clamp

6 Injection line, cylinder 12

15 Half-clamp

7 Threaded pin

16 Hex screw

8 Threaded pin

17 Hex screw

9 Cap nut

18 Hex screw

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.12.2 3

Fuel lines, pump, injection nozzle, cylinders 1 to 6

1 Injection line, cylinder 6

10 Sealing ring

2 Injection line, cylinder 5

11 O-ring

3 Injection line, cylinder 4

12 Half-clamp

4 Injection line, cylinder 3

13 Half-clamp

5 Injection line, cylinder 2

14 Half-clamp

6 Injection line, cylinder 1

15 Half-clamp

7 Threaded pin

16 Hex screw

8 Threaded pin

17 Hex screw

9 Cap nut

18 Hex screw

M020081/00E - 03.10 -

EMTU

Section Page

3.12.2 4

Task Description

Leak-off fuel lines

1 Leak-off fuel line

4 Sealing cone

2 Banjo screw

5 Nut

3 Sealing ring

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.12.2 5

Fuel line on fuel cooler, fuel duplex filter

1 Union

13 Clamp

2 Hose line

14 Clamp

3 Elbow

15 Hex screw

4 Union

16 Sealing ring

5 Sealing ring

17 Adapter

6 Hose line

18 Sealing cone

7 Banjo union

19 Nut

8 Sealing ring

20 Washer

9 Banjo screw

21 Hex nut

10 Reduction union

22 Hose line

11 Drip tray

23 Elbow

12 Hose

M020081/00E - 03.10 -

EMTU

Section Page

3.12.2 6

Task Description

Fuel line on distributor

1 Fuel line

10 Washer

2 Fuel line

11 Hex screw

3 Fuel line

12 Sealing ring

4 Banjo screw

13 Plug

5 Banjo screw

14 Sealing ring

6 Banjo union

15 Adapter

7 Sealing ring

16 Union

8 Distributor

17 Sealing cone

9 Spacer sleeve

18 Nut

EMTU

- 03.10 -

M020081/00E

Task Description

3.12.2.1

Section Page

3.12.2 7

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

-

x

Remove engine Carry out tasks as specified in disassembly plan Disable engine start

2.3 2.4 Op. Man.

M020081/00E - 03.10 -

EMTU

Section Page

3.12.2 8

3.12.2.2

Removal

Task Description

WARNING Fuels are combustible. Risk of burning and explosion. - do not use naked flame, no electric sparks, avoid all sources of ignition Before removing the fuel lines, it is advisable to take photos of the engine-mounted fuel pipework, or to mark the fuel lines with tabs, to eliminate the possibility of confusion when reinstalling the fuel lines. After removing fuel lines, seal all connections with suitable plugs.

3.12.2.4 Inspection and repair Clean all fuel lines with cleaner and visually inspect for condition and damage; If necessary, repair or pressure-test fuel lines with air in water bath for leaks.

WARNING Compressed air is highly pressurized. Risk of injury! The pressure must not exceed 0.5 bar. Always wear protective clothing, protective gloves and protective goggles/safety mask. Test pressure: 0.5 bar, coolant temperature: 60 Cº min. 30 °C. Replace damaged, deformed and corroded sealing cones and banjo adapters.

CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Using welding torch, heat lines which do not fit until red-hot. Tighten connections and adapters. Do not cool off lines with water.

WARNING Hydrochloric acid is extremely caustic. Risk of injury and suffocation! Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale. Always wear protective clothing, protective gloves and protective goggles/safety mask. Ensure good ventilation at workplace. After reshaping lines, remove from engine and pickle in a hydrochloric acid solution (9 parts water to 1 part hydrochloric acid).

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.12.2 9

WARNING Compressed air is air which has been compressed under pressure. Fluid is hot. Risk of injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Then wash the pipes in hot water, blow dry with compressed air. Then preserve lines in oil bath and allow to drip dry. Check condition of hoses and for signs of aging; replace if necessary. Check brackets, buffers, grommets, damping strips and securing elements for fuel lines for damage and wear; replace parts if necessary. Check condition of threads of union nut and adapter. Check sealing and screw-on surfaces for damage. smooth with oilstone as necessary. Replace plugs, studs and unions as required.

3.12.2.6

Installation WARNING

Compressed air is highly pressurized. Risk of injury! Never direct a compressed air jet at other people. Always wear protective goggles/safety mask and ear protectors. Before installing, blow fuel lines clear with compressed air. Install fuel lines with fixtures (see overview drawings), take photos or apply markings, ensuring lines are tensionfree.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.12.2 10

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.12.3

3.12.3 1

Fuel duplex filter

Installing fuel duplex filter

1 Hex screw

7 Washer

2 Washer

8 Drip tray

3 Fuel duplex filter

9 Washer

4 Valve

10 Hex nut

5 Sealing ring

11 Washer

6 Hex screw

12 Hex screw

M020081/00E - 03.10 -

EMTU

Section Page

3.12.3 2

Task Description

Fuel duplex filter

1 Fuel duplex filter

7 Sealing ring

2 Filter element

8 Plug

3 Filter head

9 Plug

4 Screw

10 Spring

5 Sealing ring

11 Threaded pin

6 Sealing ring

12 Cover

EMTU

- 03.10 -

M020081/00E

Task Description

3.12.3.1

Section Page

3.12.3 3

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

-

x

Remove engine Carry out tasks as specified in disassembly plan Disable engine start

2.3 2.4 Op. Man.

M020081/00E - 03.10 -

EMTU

Section Page

3.12.3 4

3.12.3.2

Removal

Task Description

Remove fuel duplex filter Remove screws securing fuel duplex filter as per overview drawing. Remove fuel duplex filter. Remove drip tray.

3.12.3.3

Disassembly WARNING

Fuels are combustible. Risk of burning and explosion. - do not use naked flame, no electric sparks, avoid all sources of ignition Disassembling fuel duplex filter: See also fuel duplex filter overview drawing. Unscrew filter element (2). Remove screw (4) and remove sealing ring. Remove plugs (8 and 9). Unscrew threaded pin (11) and remove spring (10).

3.12.3.4

Inspection and repair WARNING

Test fluid is highly pressurized. Risk of injury! Liquid emerging under high-pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Clean all components. Remove corrosion and/or water stains in filter housing with brush. Using red penetrant dye method, crack-test filter head surfaces; replace components as necessary. Pressure-test filter head with diesel fuel at 12 bar. Use emery cloth to polish out slight wear and pitting; replace filter housing if necessary. Check filter head for warping and wear; replace component as necessary. Check condition of securing screw. Check condition of drip tray. Replace filter element. Check condition of springs and replace if necessary.

3.12.3.5

Assembly

Fuel duplex filter assembly: See also fuel duplex filter overview drawing. Screw in filter element (2). Secure screw (4) with sealing ring. Tighten plugs (8 and 9). Fit spring (10) on threaded pin (11) and install.

EMTU

- 03.10 -

M020081/00E

Task Description

3.12.3.6

Section Page

3.12.3 5

Installation

Install fuel duplex filter Install fuel duplex filter as per overview drawing. Install drip tray as per overview drawing.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.12.3 6

Task Description

- 03.10 -

M020081/00E

Task Description

3.13

Section Page

3.13 1

Coolant pump

Contents 3.13.1

Engine coolant pump 3.13.1.1 Before-removal operations 3.13.1.2 Removal 3.13.1.3 Disassembly 3.13.1.4 Inspection and repair 3.13.1.5 Assembly 3.13.1.6 Installation

3.13.2

Raw water pump 3.13.2.1 Before-removal operations 3.13.2.2 Removal 3.13.2.3 Disassembly 3.13.2.4 Inspection and repair 3.13.2.5 Assembly 3.13.2.6 Installation

M020081/00E - 03.10 -

EMTU

Section Page

3.13 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20D

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.13.1

3.13.1 1

Engine coolant pump

Engine coolant pump arrangement

1 V-belt pulley

6 O-ring

2 Spacer ring

7 O-ring

3 Washer

8 Washer

4 Screw

9 Hex screw

5 Engine coolant pump

M020081/00E - 03.10 -

EMTU

Section Page

3.13.1 2

Task Description

1 Coolant pump housing

4 Rotary seal

2 Coolant pump bearing

5 Impeller

3 Snap ring

6 Flange

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

1 Pump housing

6 Impeller

2 Snap ring

7 Flange

3 Pump bearing with shaft

a Reference distance

4 Rotary seal

b Installation dimension, rotary seal 11.9 ± 0.3 mm

5 Rotary seal

s Gap, impeller 0.6 + 0.4 mm

M020081/00E - 03.10 -

3.13.1 3

EMTU

Section Page

3.13.1 4

3.13.1.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

x x

x x x x

Remove engine Carry out services as per disassembly plan Disable engine start Drain engine coolant Remove engine coolant pipework Remove raw water lines

2.3 2.4 Op. Inst. Op. Inst. 3.14.1.2 3.14.3.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.13.1.2

3.13.1 5

Removal Remove hex screws (1) with washers (2). Remove spacer ring (4) and V-belt pulley (4). Remove hex screws (9) with washers (10). Remove engine coolant pump (5) and remove Orings (6 and 7).

3.13.1.3

Disassembly Removing flange Withdraw flange (1) with puller from pump bearing shaft.

Removing coolant pump bearing Remove snap ring (2). Place coolant pump housing on a hollow body. Press coolant pump bearing with shaft (1) out of impeller and coolant pump housing.

M020081/00E - 03.10 -

EMTU

Section Page

3.13.1 6

Task Description

Removing rotary seal Remove rotary seal (2) from coolant pump housing (1).

3.13.1.4

Inspection and repair

Clean all components. Using the surface crack-testing method and red penetrant dye, check the coolant pump housing, impeller and flange for cracks. Using the magnetic crack-testing method with fluorescent magnetic powder, check the coolant pump bearing for cracks. Replace relevant components if cracks are found. Check coolant pump housing and impeller for pitting. Replace parts if pitting is deeper than 1 mm. Always replace coolant pump bearing. Check sealing surfaces on coolant pump housing for wear, smooth with emery cloth as necessary. Replace rotary seal during overhaul .

3.13.1.5

Assembly CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Installing coolant pump bearing Heat coolant pump housing (1) to 80 °C. Note:

Press in pump shaft bearing only on outer race.

Wearing protective gloves, use drift to drive pump shaft bearing (2) into pump housing until seated.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.13.1 7

Installing rotary seal and impeller CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Coat support in coolant pump housing (4) with Loctite. Press dry rotary seal (1) onto shaft (2) and with surface sealant into coolant pump housing. Hold shaft end firmly in position. Projection and installation dimensions - see overview drawing. Installation dimension (position of gasket on impeller) is achieved by shrink-fitting the impeller. Installing flange CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Heat flange (1) to 260 °C. Using protective gloves, push flange flush onto shaft, holding shaft end firmly in position.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.13.1 8

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.13.2

3.13.2 1

Raw water pump

Raw water pump with attachments

1 Raw water pump

12 Clamping nut

2 Gasket

13 Hex screw

3 Hex screw

14 Swivel head

4 Stud

15 Hex screw

5 Nut

16 Washer

6 Washer

17 Hex screw

7 Belt pulley

18 Washer

8 Hex screw

19 Nut

9 Washer 10 V-belts

20 Cover plate 21 Washer

11 Clamping element

M020081/00E - 03.10 -

EMTU

Section Page

3.13.2 2

Task Description

Raw water pump cross-section

1 Pump housing

12 Angular-contact ball bearing

2 Impeller

13 Grooved ball bearing

3 Intermediate element

14 Adjusting shim

4 Bearing housing

15 Adjusting shim

5 Drive shaft

16 Snap ring

6 Clamping nut

17 Snap ring

7 Rotary seal

18 Adjusting screw

8 Shaft seal

19 Plug

9 O-ring

20 Plug

10 Sealing ring

21 Stud

11 Sealing ring

22 Nut

EMTU

- 03.10 -

M020081/00E

Task Description

3.13.2.1

Section Page

3.13.2 3

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

x x

x x x x x

Remove engine Perform operations as per Disassembly Plan Disable engine start Drain engine coolant Drain raw water Remove engine coolant lines Remove raw water lines

2.3 2.4 Op. Inst. Op. Inst. Op. Inst. 3.14.1.2 3.14.3.2

M020081/00E - 03.10 -

EMTU

Section Page

3.13.2 4

3.13.2.2

Removal

Task Description

Removing elbow Remove screws (3) and (5) and remove sleeve (2). Remove hex screw (7).

3.13.2.3

Disassembly Removing pump housing Remove nut (4). Gently tap pump housing (1) with a rubber mallet to remove. Remove O-ring (3). Remove intermediate element (4).

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.13.2 5

Removing cap nut and thrust ring Remove cap nut (3) from impeller (1). Removing impeller Install puller on impeller. Withdraw impeller with thrust screw from drive shaft (2). Remove rotary seals.

Rotary seal removal Remove rotary seal (2) from intermediate element (1).

Removing drive shaft and grooved ball bearing Remove snap rings (2 and 8) with snap ring pliers. Remove shaft seal (4). Remove adjusting shims (1 and 6). Fit bearing housing (3) on a hollow body. Using removal tool and manual press, remove drive shaft (5) together with grooved ball bearing (7) from bearing housing. Remove grooved ball bearing from drive shaft.

M020081/00E - 03.10 -

EMTU

Section Page

3.13.2 6

Task Description

Removing angular-contact ball bearing Remove snap rings (1 and 3) with snap ring pliers. Fit bearing housing (2) on a hollow body. Use removal tool and manual press to remove angular-contact ball bearing (4) from bearing housing.

3.13.2.4

Inspection and repair

Clean all components. Using the surface crack-testing method and red penetrant dye, check the pump housing, impeller, intermediate element and bearing housing for checks. Using the magnetic crack-testing method and fluorescent magnetic powder, check the drive shaft and clamping nut for cracks. If cracks are detected, the respective parts must be replaced. Check pump housing and impeller for pitting. Replace parts if pitting is deeper than 1 mm. Check drive shaft for wear and damage. Smooth minor traces of wear and damage with an emery cloth. Metal-spray sealing surface as per MTU specifications as required. Check thread for ease of movement; rechase or fit thread insert as required. Check stud for damage. Check tapers with taper gauge; replace components as necessary. Check sealing surfaces and bearing bore on bearing flange for wear, smooth with polishing cloth if necessary. Adjust bore gauge and measure bore for grooved ball bearing and angular-contact ball bearing in bearing housing. Using an outside micrometer, measure the bearing seat and fitting diameter on the drive shaft. Replace components if specified limits are exceeded (see Tolerances and Wear Limits List). Replace rotary seals, shaft seal and O-rings at every overhaul. Always replace angular-contact and grooved ball bearings during W6 overhaul.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.13.2.5

3.13.2 7

Assembly Installing grooved ball bearing CAUTION Part is hot. Risk of injury! Handle components only when wearing protective gloves. Clean all components. Heat grooved ball bearing (2) to 180 °C and push onto the drive shaft (1) as far as the stop. Using circlip pliers, insert the snap ring (3) in the groove in the drive shaft. Ensure that the snap ring is correctly fitted in the groove!

Installing drive shaft CAUTION When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Place bearing housing (1) on a hollow body, with flange surface up. Insert drive shaft (3) in direction of drive end into bearing housing up to 10 mm to bearing housing. Insert adjusting shim (4). Clean and degrease bore for shaft seal (2) in bearing housing with denaturated ethanol. Rub down shaft seal seating surface with denaturated ethanol. Press-fit shaft seal with impact bush into the bearing housing until it is in contact. Ensure installation direction is correct.

M020081/00E - 03.10 -

EMTU

Section Page

3.13.2 8

Task Description

Installing intermediate element and rotary seal Place intermediate element (1) on bearing housing. Insert contact surface with boot of rotary seal (3) with petroleum jelly via drive shaft (2) into intermediate element.

Mounting the impeller Clean and degrease taper of drive shaft (2) and impeller (1). Push impeller onto drive shaft. Coat thread of clamping nut (3) and mating face of clamping nut with engine oil. Fit clamping nut and tighten with torque wrench as per Tightening Specifications 1.4.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.13.2 9

Installing angular-contact ball bearing Mount assembled unit on assembly stand. Using a gauge, 0.5 mm, check axial clearance 0.5 ±0.2 mm at a minimum of three positions. Using a suitable tool, clamp impeller and bearing housing together. Using circlip pliers, insert the inside snap ring in the groove in the bearing housing . Ensure that the snap ring is correctly fitted in the groove! Compensate dimension “x” with adjusting shims as required. Dimension “x” = A-B Heat bearing housing in the bearing seat area of the angular-contact ball bearing to 130 + 20°C. Press-fit angular-contact ball bearing into bearing housing. Using circlip pliers, insert the outer snap ring in the groove in the pump shaft. Ensure that the snap ring is correctly fitted in the groove! Compensate dimension “Z” with adjusting shims as required. Using circlip pliers, insert the outer snap ring in the groove in the bearing housing . Ensure that the snap ring is correctly fitted in the groove! Tighten clamping nut with torque wrench according to specifications. For torque settings, see Section 1.4. Again check axial clearance 0.5 ± with gauge. Installing pump housing Coat O-ring (2) with petroleum jelly and insert in pump housing. Install completely assembled unit in pump housing. Fit nut (1) and tighten with torque wrench as per Tightening Specifications 1.4.

3.13.2.6

Installation

Install raw water pump in reverse sequence - see overview drawing: Raw water pump with attachments.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.13.2 10

Task Description

- 03.10 -

M020081/00E

Task Description

3.14

Section Page

3.14 1

Cooling system

Contents 3.14.1

Engine coolant pipework 3.14.1.1 Before-removal operations 3.14.1.2 Removal 3.14.1.4 Inspection and repair 3.14.1.6 Installation

3.14.2

Vent lines/drain lines 3.14.2.1 Before-removal operations 3.14.2.2 Removal 3.14.2.4 Inspection and repair 3.14.2.6 Installation

3.14.3

Raw water lines 3.14.3.1 Before-removal operations 3.14.3.2 Removal 3.14.3.4 Inspection and repair 3.14.3.6 Installation

3.14.5

Coolant expansion tank 3.14.5.1 Before-removal operations 3.14.5.2 Removal 3.14.5.3 Disassembly 3.14.5.4 Inspection and repair 3.14.5.5 Assembly 3.14.5.6 Installation

3.14.6

Engine coolant cooler 3.14.6.1 Before-removal operations 3.14.6.2 Removal 3.14.6.3 Disassembly 3.14.6.4 Inspection and repair 3.14.6.5 Assembly 3.14.6.6 Installation

3.14.7

Coolant thermostat 3.14.7.1 Before-removal operations 3.14.7.2 Removal 3.14.7.3 Disassembly 3.14.7.4 Inspection and repair 3.14.7.5 Assembly 3.14.7.6 Installation

3.14.9

Pressure-testing engine coolant chambers

M020081/00E - 03.10 -

EMTU

Section Page

3.14 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.1

3.14.1 1

Engine coolant pipework

Engine coolant pipework on distribution housing

1 Elbow

15 Coolant line

29 Grommet

2 O-ring

16 Bracket

30 Hex screw

3 Hex screw

17 Hex screw

31 Washer

4 Washer

18 Washer

32 Hex screw

5 Threaded bush

19 Pipe clamp half

33 Washer

6 Threaded bush

20 Hex screw

34 Bracket

7 -

21 Coolant line

35 Sleeve

8 Plug

22 Banjo screw

36 Hex screw

9 Sealing ring

23 Sealing ring

37 Washer

10 Adapter

24 Spacer bushing

38 Spacer bushing

11 Sealing ring

25 Pipe clamp half

39 Pipe clamp half

12 -

26 Grommet

40 Grommet

13 Rubber sleeve

27 Spacer bushing

41 Hex screw

14 Clamp

28 Pipe clamp half

42 Washer

M020081/00E - 03.10 -

EMTU

Section Page

3.14.1 2

Task Description

Coolant distributor housing connections

1 Connector

7 O-ring

2 Adapter

8 Plug

3 Threaded bush

9 Washer

4 Plug

10 Socket-head screw

5 Sealing ring

11 Washer

6 O-ring

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.1 3

Connection on distribution housing

1 Elbow

7 Sealing ring

2 Sealing ring

8 Hex screw

3 Union

9 Hex screw

4 Sealing cone

10 Washer

5 Nut

11 Hex screw

6 Plug

12

M020081/00E - 03.10 -

Washer

EMTU

Section Page

3.14.1 4

Task Description

Engine coolant pipework on coolant distributor housing

1 Rubber sleeve

13 Hex screw

25 Bracket

2 Clamp

14 Washer

26 Hex screw

3 Washer

15 Hex screw

27 Hex screw

4 Clamp

16 Washer

28 Washer

5 Coolant line

17 Spacer bush

29 Pipe clamp half

6 Rubber sleeve

18 Plug

30 Pipe clamp half

7 Clamp

19 Sealing ring

31 Hex screw

8 Coolant line

20 Pipe clamp half

32 Pipe clamp half

9 Coolant line

21 Pipe clamp half

33 Pipe clamp half

10 Bracket

22 Hex screw

34 Spacer bush

11 Pipe clamp half

23 Washer

35 Hex screw

12 Pipe clamp half

24 Washer

36 Washer

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.1 5

Engine coolant pipework between distribution housing and intercooler

1 Elbow

14 Clamp

2 Elbow

15 Engine coolant line

3 O-ring

16 Rubber sleeve

4 Hex screw

17 Clamp

5 Hex screw

18 Double elbow

6 Hex screw

19 O-ring

7 Hex screw

20 O-ring

8 Washer

21 Hex screw

9 Pipeline

22 Washer

10 Rubber sleeve

23 Bracket

11 Clamp

24 Spacer tube

12 Engine coolant line

25 Hex screw

13 Rubber sleeve

26 Washer

M020081/00E - 03.10 -

EMTU

Section Page

3.14.1 6

3.14.1.1

Before-removal operations

Task Description

A distinction must be made as to whether: The engine is to be completely disassembled

1 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Drain raw water

Oper. Instr.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.1.2

3.14.1 7

Removal

Before removing coolant lines, it is advisable to take photographs of engine from all sides or to identify lines with markers so as to avoid confusion during subsequent reassembly. Remove all monitoring devices. After removing coolant lines, seal all connections with suitable plugs.

3.14.1.4

Inspection and repair CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Clean coolant lines with cold cleaner and brushes. Visually inspect plug-in connections and annular grooves on elbows, plug-in pipes, connecting lines and flanges for wear, pitting and cavitation. Provide damaged plug-in connections with bushes in accordance with MTU specifications, replace if necessary. Pressure-test components as required. Recondition damaged sealing surfaces and inspect for irregularities on an ink-check plate. Replace sealing cones and banjo unions that are damaged, indented or corroded.

CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions. Allow lines to cool slowly, do not cool with water.

WARNING Hydrochloric acid is extremely caustic. Risk of injury and suffocation! Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale. Always wear protective clothing, protective gloves and protective goggles/safety mask. Ensure good ventilation at workplace. Pickle lines in hydrochloric acid solution (9 parts water and 1 part hydrochloric acid).

M020081/00E - 03.10 -

EMTU

Section Page

3.14.1 8

Task Description

WARNING Compressed air is air which has been compressed under pressure. Fluid is hot. Risk of injury! The pressure must not exceed 3.0 bar. Always wear protective clothing, protective gloves and protective goggles/safety mask. After pickling, wash the pipes in hot water, blow dry with compressed air, Then immerse lines in an oil bath and allow to drip dry. Check restrictors and strainers for damage, replace as necessary. Check all retaining elements and attaching hardware for damage and wear - replace parts if necessary. Replace grommets as part of every W6 overhaul. Replace sealing rings, O-rings and gaskets. Replace unions if necessary.

3.14.1.6

Installation WARNING

Compressed air is highly pressurized. Risk of injury! Test pressure must not be exceeded. Always wear protective clothing, protective gloves and protective goggles/safety mask. Before installation, blow coolant lines, plug-in pipes and connecting lines clear with compressed air. Note: Do not remove blanking plug until just before installation. Coat O-rings with petroleum jelly and insert into grooves of plug-in pipes and flanges, ensuring they are not twisted. Install coolant lines, plug-in pipes, connecting lines and flanges with new gaskets, O-rings and fixtures so that they are free from strain in accordance with photographs, markers and overview drawing.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.2

3.14.2 1

Vent and drain lines

Drain and vent lines

1 Drain line

15 Hex screw

29 Hex screw

2 Banjo screw

16 Washer

30 Washer

3 Sealing ring

17 Clamp

31 Washer

4 Bracket

18 Hex screw

32 Clamp

5 Pipe clamp half

19 Washer

33 Clamp

6 Grommet

20 T-piece

34 Clamp

7 Hex screw

21 Vent line

35 Hex screw

8 Washer

22 Vent line

36 Hex screw

9 Spacer bush

23 Bracket

37 Vent line

10 Hex screw

24 Hex screw

38 Transition

11 Washer

25 Washer

39 Sealing ring

12 Vent line

26 Clamp

40 Vent line

13 Bracket

27 Hex screw

41 Banjo screw

14 Washer

28 Washer

42 Sealing ring

M020081/00E - 03.10 -

EMTU

Section Page

3.14.2 2

3.14.2.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

-

-

X

Disable engine start

EMTU

2.4 Oper. Instr.

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.2.2

3.14.2 3

Removal

Before removing vent and drain lines, it is advisable to take photographs of engine from all sides or to identify lines with markers so as to avoid confusion during subsequent reassembly. After removing lines, seal all open connections by installing suitable plugs.

3.14.2.4 Inspection and repair CAUTION When using these chemical substances, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Clean vent and drain lines with cold cleaner and brushes. Replace sealing cones and banjo unions that are damaged, indented or corroded.

CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions. Allow lines to cool slowly, do not cool with water.

WARNING Hydrochloric acid is extremely caustic. Risk of injury and suffocation! Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale. Always wear protective clothing, protective gloves and protective goggles/safety mask. Ensure good ventilation at workplace. Pickle lines in hydrochloric acid solution (9 parts water and 1 part hydrochloric acid).

WARNING Compressed air is air which has been compressed under pressure. Fluid is hot. Risk of injury! The pressure must not exceed 3.0 bar. Always wear protective clothing, protective gloves and protective goggles/safety mask. After pickling, wash the pipes in hot water, blow dry with compressed air, Then immerse lines in an oil bath and allow to drip dry. Check all retaining elements and attaching hardware for damage and wear - replace parts if necessary. Replace grommets as part of every W6 overhaul. Replace O-rings and hose sleeve. Replace unions if necessary.

M020081/00E - 03.10 -

EMTU

Section Page

3.14.2 4

Task Description

3.14.2.4 Inspection and repair WARNING Compressed air is highly pressurized. Risk of injury! Test pressure must not be exceeded. Always wear protective clothing, protective gloves and protective goggles/safety mask. Before installation, blow vent and drain lines clear with compressed air. Note: Do not remove blanking plug until just before installation. Fit vent and drain lines with new sealing rings and fixtures so that they are free from strain in accordance with photographs, markers and overview drawing.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.3

3.14.3 1

Raw water line

Raw water line on distribution housing

1 Moulded tubing

18 Raw water line

35 Plug

2 Clamp

19 Rubber sleeve

36 Sealing ring

3 Raw water line

20 Clamp

37 Raw water line

4 Plug

21 Bracket

38 Gasket

5 Sealing ring

22 Pipe clamp halves

39 Hex screw

6 Clamp

23 Pipe clamp halves

40 Hex nut

7 Pipe clamp halves

24 Hex screw

41 Washer

8 Pipe clamp halves

25 Hex screw

42 Plug

9 Hex screw

26 Washer

43 Sealing ring

10 Hex screw

27 Bracket

44 Bracket

11 Washer

28 Pipe clamp halves

45 Hex screw

12 Bracket

29 Pipe clamp halves

46 Washer

13 Bracket

30 Hex screw

47 Hex screw

14 Hex screw

31 Hex nut

48 Sealing cone

15 Washer

32 Washer

49 Nut

16 Hex screw

33 Hex screw

17 Washer

34 Washer

M020081/00E - 03.10 -

EMTU

Section Page

3.14.3 2

Task Description

Raw water line to raw water pump

1 Elbow

6 Washer

2 Sleeve

7 Hex screw

3 Hex screw

8 Plug

4 Washer

9 Sealing ring

5 Hex screw

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.3 3

Engine coolant pipework on distribution housing

1 Elbow

7 Sealing ring

2 Sealing ring

8 Hex screw

3 Union

9 Hex screw

4 Sealing cone

10 Washer

5 Nut

11 Hex screw

6 Plug

12 Washer

M020081/00E - 03.10 -

EMTU

Section Page

3.14.3 4

3.14.3.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

x

x x

Remove engine Perform operations as per Disassembly Plan Disable engine start Drain raw water

2.3 2.4 Op. Man. Op. man.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.3.2

3.14.3 5

Removal

Before removing raw water lines, it is advisable to take photographs of engine from all sides or to identify lines with markers so as to avoid confusion during subsequent reassembly. After removing raw water lines, seal all connections with suitable plugs.

3.14.3.4

Inspection and repair CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Clean raw water lines with cold cleaner and brushes. Make visible inspection of plug-in connections and annular grooves on elbows, plug-in pipes, connecting lines and flanges for wear, pitting and cavitation. Provide damaged plug-in connections with bushes in accordance with MTU specifications, replace if necessary. Pressure-test components as required. Recondition damaged sealing surfaces and inspect for irregularities on an ink-check plate. Replace sealing cones and banjo unions that are damaged, indented or corroded. CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions. Allow lines to cool slowly, do not cool with water. WARNING Hydrochloric acid is extremely caustic. Risk of injury and suffocation! Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale. Always wear protective clothing, protective gloves and protective goggles/safety mask. Ensure good ventilation at workplace. Pickle lines in hydrochloric acid solution (9 parts water and 1 part hydrochloric acid). WARNING Compressed air is air which has been compressed under pressure. Fluid is hot. Risk of injury! The pressure must not exceed 3.0 bar. Always wear protective clothing, protective gloves and protective goggles/safety mask. After pickling, wash the pipes in hot water, blow dry with compressed air, Then immerse lines in an oil bath and allow to drip dry. Check all retaining elements and attaching hardware for damage and wear - replace parts if necessary. Replace grommets as part of every W6 overhaul. Replace all gaskets, sealing rings and O-rings. Replace unions if necessary.

M020081/00E - 03.10 -

EMTU

Section Page

3.14.3 6

3.14.3.6

Installation

Task Description

WARNING Compressed air is highly pressurized. Risk of injury! Test pressure must not be exceeded. Always wear protective clothing, protective gloves and protective goggles/safety mask. Before installing, blow raw water lines clear with compressed air. Before installing, coat O-rings with petroleum jelly. Note: Do not remove blanking plug until just before installation. Fit raw water lines with new sealing rings and O-rings and attaching hardware so that they are free from strain in accordance with photographs and overview drawing.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.5

3.14.5 1

Distribution housing

1 Distribution housing

12 Sealing ring

2 Gasket

13 Plug

3 Hex screw

14 Sealing ring

4 Washer

15 Filler neck

5 Socket-head screw

16 Sheet-metal eye

6 Washer

17 Marker plate

7 Hex screw

18 Gasket

8 Hex screw

19 Gasket

9 Hex screw

20 Hex screw

10 Washer

21 Washer

11 Plug

M020081/00E - 03.10 -

E MTU

Section Page

3.14.5 2

3.14.5.1

Before-removal operations

Task Description

A distinction must be made as to whether: The engine is to be completely disassembled

1 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Op. Man.

-

X

X

Drain engine coolant

Op. Man.

-

X

X

Disconnecting engine coolant lines

3.14.1.2

-

X

X

Disconnect vent lines

3.14.2.2

E MTU

- 03.10 -

M020081/00E

Task Description

3.14.5.2

Section Page

3.14.5 3

Removal Install eyebolt on distribution housing. Attach lifting device to eyebolt.

Remove screws (3; 5; 7; 8 and 11) from distribution housing (2) and remove washers (4; 6; 9 and 10). Lift off distribution housing. Remove gasket (1). Remove lifting device.

M020081/00E - 03.10 -

E MTU

Section Page

3.14.5.3

3.14.5 4

Task Description

Disassembly Removing bracket for three-phase alternator and V-belt tension Release hex screws (1; 7; 9 and 10) from bracket (3) and remove together with washers ( 2; 8 and 11). Remove bracket (3). Releasing hex screws (5 and 6) Remove bracket (4).

Removing filler neck and plug Release hex screw (3) and remove with spring washer (2). Remove sheet-metal eyelet (1) with filler neck (4). Remove gaskets (5 and 7) and marker plate (6). Remove all plugs from distribution housing (8)

3.14.5.4

Inspection and repair CAUTION

When using these chemical substances, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Clean distributor housing and attachments with cold cleaner and brush. Remove scale with a descaling product that does not attack the metal surface (e.g. P3 T288 from Henkel or Euron 1308 amidosulfonic acid from Hoechst). Once cleaning is completed, rinse all parts with water. Check distribution housing for wear and cavitation, smooth sealing surfaces and mating faces with oilstone if necessary, replace as required. Check threaded bores for ease of movement, recut thread if necessary, or install threaded inserts. Check seal on valve cover, replace valve cover if necessary. Replace gaskets and sealing rings. Rub down screw-down and sealing surfaces with oilstone.

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.5.5

3.14.5 5

Assembly Installing filler neck and plug Clean sealing surfaces, smooth with oilstone if necessary. Fit new gaskets (5 and 7) and marker plate on distribution housing (8), making sure they are correctly positioned. Secure sheet-metal eyelet (1) and filler neck (4) with hex screw (3) and washer (3). Tighten hex screws diagonally and evenly. Screw in all plugs with new sealing rings into distribution housing.

Installing bracket for three-phase alternator and Vbelt tension Secure bracket (3) with hex screws (1; 10; 9 and 7) and washers (2; 8 and 11) on distribution housing. Secure bracket (4) with hex screws (5 and 6) to distribution housing.

M020081/00E - 03.10 -

E MTU

Section Page

3.14.5 6

3.14.5.6

Installation

Task Description

Install eyebolt on distribution housing. Attach lifting device to eyebolt.

Clean installation surfaces for gasket (1). Coat gasket with petroleum jelly and fit on distribution housing (2). Install distribution housing with screws (3; 5; 7; 8 and 11) and washers (4; 6; 9 and 11). Remove lifting device and eyelet.

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.6

3.14.6 1

Engine coolant cooler

1 Pin

10 Cooling plate

2 Initial plate

11 End plate

3 Cooling plate

12 Cover

4 Cooling plate

13 Spacer sleeve

5 Intermediate plate

14 Washer

6 Sleeve

15 Hex screw

7 O-ring

16 Warning plate

8 Intermediate plate

17 Round-head grooved pin

9 Intermediate plate

M020081/00E - 03.10 -

EMTU

Section Page

3.14.6 2

Task Description

Example of plate pack arrangement

1 Distributor housing

4 Channel plate

2 Sealing ring

5 Channel plate

3 Initial plate

6 Pressure plate

Number of initial, channel and end plates to be installed: Item 3 = 1x, Item 4 =24x, Item 5 =24x Note: Items 4 and 5 always arranged alternately ! View ”Z2” is a view on gasket side. ”X” component no. for all plates on left side.

EMTU

- 03.10 -

M020081/00E

Task Description

3.14.6.1

Section Page

3.14.6 3

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -x -

x x x

x x x x x

Remove engine Carry out tasks as per Disassembly Plan Disable engine start Drain engine coolant Close raw water supply and return Drain raw water Disconnect raw water outlet line Disconnect raw water outlet line Disconnect drain line to cooler housing

2.3 2.4 Op. Man. Op. Man. Op. Man. 3.14.3.2 3.14.3.2 3.14.1.2

x

M020081/00E - 03.10 -

EMTU

Section Page

3.14.6 4

3.14.6.2

Removal

Task Description

Identify plate pack with a coloured diagonal stroke (arrowed) in correct installation sequence for purposes of subsequent reassembly.

Cover plate removal Insert guide pin (1). Unscrew threaded sleeves (2). Remove pressure plate.

3.14.6.3

Disassembly CAUTION Cooler plates have sharp edges. Risk of injury! Handle plates only when wearing protective gloves. Channel plate removal Beginning at top, remove channel plates in turn. Remove sealing rings for coolant transfer on distribution housing. Remove spacer sleeves from stud bolts.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.6.4

3.14.6 5

Inspection and repair

Cleaning plates

CAUTION Cooler plates have sharp edges. Risk of injury! Handle plates only when wearing protective gloves. Mechanical cleaning Clean cooler plates only with a soft brush and flowing water. Note:

Use only a soft brush to avoid damaging the plates.

Cleaning with steam jet. WARNING Take special care when using high-pressure jet. Risk of injury! Never direct water jet at humans, animals, equipment or electric components. Always wear protective clothing, protective gloves and protective goggles/safety mask. Note:

Maintain specified service pressure and minimum spraying distance to avoid damaging plates. Observe Operating Instructions of equipment manufacturer.

Remove deposits with H.P. spraying jet.

M020081/00E - 03.10 -

EMTU

Section Page

3.14.6 6

Task Description

Chemical cleaning

CAUTION When using these chemical substances, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Note:

Do not use the following solvents: Ketone (e. g. acetone, methyl ethyl ketone, methyl isobutyl ketone), ester (e.g. ethyl acetate, butyl acetate), halogenised hydrocarbon (e.g. chlorothene, carbon tetrachloride, freon), aromatic compounds, benzine, toluene. Note:

After chemical cleaning, flush cooling plates with water and dry with a towel.

Encrustation - scale and sediment (calcium bicarbonate, calcium sulphate, corrosion products, metallic oxides) To clean use: - Nitric acid* - Citric acid* - Phosphoric acid* - Sodium polyphosphate * Concentration max. 4 %; Temperature max. 60° C Note:

Remove scale with a descaling product (e.g. Porodox from Henkel or Euron 1308 from Hoechst, concentration from 5 % to 10 %).

Deposits on carbon-hydrogen basis (oil residue, greases) Use a solution on parafin or naphta basis (z. B. kerosene). Cleaning cover plate Note:

Protect aluminium components from chemicals.

Clean cover plate with cold cleaner and brush. Use only a soft brush to avoid damaging the plates and sealing faces. Inspection and Repair If necessary, use the surface crack-testing method with red penetrant dye or fluorescent penetrant dye to check heat exchanger plates and cover plate for cracks: Replace components as necessary. Check parts for damage; replace if necessary. Check mating faces and sealing surfaces of cover plate for wear and damage; smooth with emery cloth or oilstone as necessary, or replace component. If necessary, replace cover plate thread inserts. Check thread for ease of movement; replace part as necessary. Replace all gaskets and O-rings.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.6.5

3.14.6 7

Assembly Installing distribution housing Coat threads of pins (4) and studs (2) with Loctite 270. Screw pins and studs into distribution housing (1). Note:

3.14.6.6

Final strength at 20 °C ≈ 12h

Installation Channel plate installation CAUTION Cooler plates have sharp edges. Risk of injury! Handle plates only when wearing protective gloves. Insert coolant transfer sealing rings in distribution housing. Insert guide pins (1) and coat with petroleum jelly. Fit channel plates (4) on guide pins in accordance with overview drawings and colour markings. Push spacer sleeves (3) onto studs (2).

Cover plate installation Coat hex screw threads with engine oil. Fit cover plate (3) on guide pins (1). Secure plates in position by tightening threaded sleeve (2) diagonally and evenly. Use torque wrench to tighten hex screws to specified torque. For torque setting, see Section 1.4. Note:

The degree of pretensioning for the profile seal is determined by the spacer sleeves. Remove guide pins.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.14.6 8

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.7

3.14.7 1

Coolant thermostat

1 Coolant distribution housing

11 Washer

2 Restrictor

12 O-ring

3 End cover

13 O-ring

4 -

14 O-ring

5 O-ring

15 Plug

6 O-ring

16 Sealing ring

7 Hex screw

17 Thermostat insert

8 Washer

18 O-ring

9 Thermostat housing

19 Sealing ring

10 Hex screw

M020081/00E - 03.10 -

EMTU

Section Page

3.14.7 2

3.14.7.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Disconnect engine coolant lines

3.14.1.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.7.2

3.14.7 3

Removal Remove hex screws (1). Remove washers (2). Remove coolant distribution housing (3). Remove O-rings (4, 7 and 8). Remove restrictor (6) and end cover (5).

3.14.7.3

Disassembly Remove thermostat insert Remove hex screws (1). Remove washers (2). Remove thermostat elements (6, 8 and 10) from thermostat housing (3). Remove O-rings (3; 4; 7 and 9). Remove sealing ring (5).

M020081/00E - 03.10 -

EMTU

Section Page

3.14.7 4

3.14.7.4

Inspection and repair

Task Description

CAUTION When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Clean all parts with cold cleaner. Check thermostat housing for indentations, wear and cavitation. Smooth mating faces and bores as required with oilstone or polishing cloth, replace as required. Check annular slide running surface for wear; rub down with emery cloth as required and replace if necessary. Check slide in guide bands of thermostat housing for ease of movement. Check condition of tapped bores; recut threads if necessary and install thread inserts as required. Check cover, threaded bush, locking bush, stop pin, washer and pin for wear. Check condition of threads; rechase threads if necessary. Rub down bolt-on and sealing surfaces with oilstone as required; replace components if necessary. Check springs for impact marks, burrs and frictional wear; deburr areas of minor wear and replace springs if necessary. Replace scraper rings during W6 overhaul. Replace thermal element as required. Replace O-rings.

3.14.7.5

Assembly Installing thermostat insert Coat sealing ring (5) with sealing paste. Coat O-rings (3; 4; 7 and 9) with petroleum jelly and fit. Insert thermostat elements (6, 8 and 10) in thermostat housing (3). Secure hex screws (1) with washers (2).

EMTU

- 03.10 -

M020081/00E

Task Description

3.14.7.6

Section Page

3.14.7 5

Installation Insert restrictor (6). Coat end cover (5) with sealing paste and install. Coat O-rings (4, 7 and 8) with petroleum jelly and install. Fit coolant distribution housing (3). Secure hex screws (1) with washers (2).

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.14.7 6

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.14.9

3.14.9 1

Pressure-testing engine coolant chambers

Install hydraulic pressure testing device on distribution housing. Connect connecting hose. Connect vent line to intercooler. Unscrew plug from oil pan.

WARNING Test liquid is hot and highly pressurised. Risk of injury! Liquid emerging under high-pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Install hydraulic pressure testing device on elbow of engine coolant pipework. Connect connecting hose. Fill engine coolant chambers with treated water (coolant). Open cock on vent line until coolant emerges. Close hydraulic pressure testing device on coolant expansion tank. Pressure-test engine with water at 80 °C for at least 20 minutes with max. 7 bar. Check coolant transfer pipes between cylinder heads and charge air/coolant manifolds and constant-pressure manifold housing for leaks. Relieve pressure. Drain or draw off engine coolant. Remove hydraulic pressure testing device. Screw in drain plugs and tighten.

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

3.14.9 2

Task Description

- 03.10 -

M020081/00E

Task Description

3.15

Section Page

3.15 1

Oil pump

Contents 3.15.1

Engine oil pump on crankcase 3.15.1.1 Before-removal operations 3.15.1.2 Removal 3.15.1.3 Disassembly 3.15.1.4 Inspection and repair 3.15.1.5 Assembly 3.15.1.6 Installation

3.15.5

Pressure relief valve 3.15.5.1 Before-removal operations 3.15.5.2b Removal, engine with intermediate frame 3.15.5.4 Inspection and repair 3.15.5.6b Installation, engine with intermediate frame

3.15.8

Semirotary hand pump for oil extraction 3.15.8.1 Before-removal operations 3.15.8.2 Removal 3.15.8.3 Disassembly 3.15.8.4 Inspection and repair 3.15.8.5 Assembly 3.15.8.6 Installation 3.15.8.7 After-installation operations

M020081/00E - 03.10 -

EMTU

Section Page

3.15 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.15.1.1

3.15.1 1

Engine oil pump

Installation on crankcase (12V two intake pipes)

1 Hex screw

3 Washer

2 Hex screw

4 Oil pump with oil extraction pipe

M020081/00E - 03.10 -

EMTU

Section Page

3.15.1 2

3.15.1.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

-

-

X

Disable engine start

Oper. Instr.

-

-

X

Drain engine coolant

Oper. Instr.

-

-

X

Drain or draw off engine oil

Oper. Instr.

-

X

X

Remove oil pressure lines and elbow from oil pan to oil heat exchanger

3.16.2.2

-

X

X

Remove guide tube for oil dipstick

3.1.11.2

-

X

X

Remove oil pan

3.1.6.2

-

X

X

Remove engine oil intake and pressure lines

3.15.1.2

EMTU

2.4

- 03.10 -

M020081/00E

Section Page

Task Description

3.15.1.2

3.15.1 3

Removal WARNING

Heavy object. Risk of crushing! Use suitable equipment and lifting gears Remove intake pipe. Unscrew hex screws (2 and 3) Remove oil extraction pipe (1) and gasket (4).

Removing oil pump and pressure relief valve Unscrew hex screws (2 and 3). Remove pressure relief valve (4) and oil pump (1).

M020081/00E - 03.10 -

EMTU

Section Page

3.15.1.3

3.15.1 4

Task Description

Disassembly Unscrew hex screws (4 and 5) from cover (3). Remove cover. Place oil pump housing with cover installation side on a hollow body. Use manual press to remove oil pump gear (2) from drive gear.

Remove drive gear (1).

3.15.1.4

Inspection and repair

Clean all components. Using the magnetic crack-testing method with fluorescent magnetic powder, check oil pump gears for cracks. Check oil pump housing and intake pipe for cracks using surface crack-testing method with red penetrant dye. If cracks are detected, replace parts. Check oil pump gears and drive gear. Check tooth flanks for wear, indentations and chipping. Check bearings for wear, scoring and indentation. Check oil pump housing for wear, remove slight scoring. In event of wear marks deeper than 0.3 mm in oil chamber of pump housing, replace oil pump housing. Check suction basket on intake pipe for cleanness and damage; replace intake pipe if necessary. Inspect sealing and contact surfaces for irregularities; rub down as required. Inspect contact surface of cover for irregularities and rub down as required. Check thread, recut as required, replace thread inserts if necessary. Replace components as necessary.

EMTU

- 03.10 -

M020081/00E

Task Description

3.15.1.5

Section Page

3.15.1 5

Assembly Ensure that contact surface of pump housing and cover (3) are clean. Coat bearing bushes in cover with engine oil. Fit cover on oil pump housing so that oil pump gear shafts (2 and 3) engage in bearing bore. Insert screws (4 and 5) into cover and screw into oil pump housing. Tighten with torque wrench to specified torque. For torque setting, see Section 1.4. Check ease of movement of oil pump. It must be possible to turn the pump by hand without feeling resistance.

Clean and degrease mating faces on oil pump gear and drive gear. Heat drive gear and press in leaving a clearance of 0.5 mm to shaft.

M020081/00E - 03.10 -

EMTU

Section Page

3.15.1 6

3.15.1.6

Installation

Task Description

WARNING Heavy object. Risk of crushing! Use suitable equipment and lifting gears. Installing oil pump and pressure relief valve Fit oil pump (1) and screw in with hex screws (2). Fit pressure relief valve (4 ) and screw in with hex screws (3). Use torque wrench to tighten hex screws to specified torque. For torque setting, see Section 1.4.

Installing intake pipes Fit oil extraction pipe (1) with gasket (4) on flange. Tighten hex screws (2) Tighten hex screws (3) with torque wrench as per Tightening Specifications 1.4.

EMTU

- 03.10 -

M020081/00E

Task Description

3.15.5

Pressure relief valve

3.15.5.1

Before-removal operations

Section Page

3.15.5 1

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

-

x x

Remove engine Perform operations as per Disassembly Plan Disable engine start Drain or draw off engine oil

2.3 2.4 Op. Man. Op. Man.

M020081/00E - 03.10 -

EMTU

Section Page

3.15.5 2

3.15.5.2

Removal

Task Description

See Section 3.15.1.2

3.15.5.4

Inspection and repair

Clean pressure relief valve. For limit values, see Tolerances and Wear Limits List. Replace pressure relief valve if valve does not open at specified pressure.

3.15.5.6

Installation

See Section 3.15.1.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.15.8.

3.15.8 1

Semirotary hand pump for oil extraction

Semirotary hand pump

1 Lever

5 Suction chamber

2 Pressure chamber

6 Suction valve seat

3 Valve plate

7 Vane

4 Housing

8 Vane pump

M020081/00E - 03.10 -

EMTU

Section Page

3.15.8 2

3.15.8.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x -

x

x x

Remove engine Disable engine start Remove engine oil lines

2.3 Op. Man. 3.16.1.2

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.15.8.2

3.15.8 3

Removal

Removing semirotary hand pump Drain engine oil, catch in a suitable container and dispose of oil in an appropriate manner. Release securing screws on semirotary hand pump. Remove semirotary hand pump.

3.15.8.3

Disassembly Removing lever Remove nuts (1). Remove lever (2) from pump (4). Release union nut (3).

Cover removal Hold hex screws (2) firmly in position and unscrew nuts (1). Remove cover (3) from pump housing (4). Remove gasket. Remove union nut, thrust pad and gland packing. Remove washer from shaft.

M020081/00E - 03.10 -

EMTU

Section Page

3.15.8 4

Task Description

Removing vane Remove vane with shaft (1) from pump housing (3). Remove pressure valve seat (2) from pump housing.

Removing valve plates Unscrew socket-head screws (1) from suction valve seat (3). Remove valve plates (2). Remove gasket. In a similar manner, remove valve plates from the vanes.

3.15.8.4

Inspection and repair

Remove gland packing and gaskets after every disassembly. Check vanes, suction valve seat and housing for cracks using surface crack-testing method with red penetrant dye. If cracks are detected, replace parts. Check sealing surface for flatness and perfect condition.

3.15.8.5

Assembly

Installation in reverse order to disassembly.

3.15.8.6

Installation

Installing semirotary hand pump Install semirotary hand pump, align and secure with securing screws.

EMTU

- 03.10 -

M020081/00E

Task Description

3.16

Section Page

3.16 1

Engine oil system

Contents 3.16.1

Engine oil lines 3.16.1.1 Before-removal operations 3.16.1.2 Removal 3.16.1.3 Disassembly 3.16.1.4 Inspection and repair 3.16.1.5 Assembly 3.16.1.6 Installation

3.16.2

Engine oil cooler 3.16.2.1 Before-removal operations 3.16.2.2 Removal 3.16.2.3 Disassembly 3.16.2.4 Inspection and repair 3.16.2.5 Assembly 3.16.2.6 Installation

3.16.3

Engine oil filter 3.16.3.1 Before-removal operations 3.16.3.2 Removal 3.16.3.3 Disassembly 3.16.3.4 Inspection and repair 3.16.3.5 Assembly 3.16.3.6 Installation

M020081/00E - 03.10 -

EMTU

Section Page

3.16 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.16.1

3.16.1 1

Engine oil lines

Oil return lines from injection pump

1 Oil return

13 Oil return line

2 Sealing ring

14 Sealing cone

3 Banjo screws

15 Nut

4 Oil line

16 Oil return line

5 Pipe clamp half

17 Banjo screw

6 Grommet

18 Sealing ring

7 Hex screw

19 Adapter

8 Washer

20 Sealing ring

9 Threaded bush

21 Pipe clamp half

10 Sealing ring

22 Grommet

11 Sealing ring

23 Washer

12 Adapter

24 Hex screws

M020081/00E - 03.10 -

EMTU

Section Page

3.16.1 2

Task Description

Oil line on turbocharger

1 Oil line

17 Oil line

2 T-piece

18 T-piece

3 Banjo screw

19 Bracket

4 Sealing ring

20 Clamp

5 Bracket

21 Hex screw

6 Clamp

22 Washer

7 Hex screw

23 Hex screw

8 Washer

24 Washer

9 Oil line

25 Oil line

10 Gasket

26 Gasket

11 Hex screw

27 Hex screw

12 Washer

28 Washer

13 Oil line

29 Bracket

14 Clamp

30 Clamp

15 Hex screw

31 Hex screw

16 Washer

32 Washer

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.16.1 3

Oil line on oil filter

1 Hose line

M020081/00E - 03.10 -

2 Elbow

EMTU

Section Page

3.16.1 4

Task Description

Oil line on driving end

1 Oil line

14 Oil line

2 Sealing ring

15 Banjo screw

3 Banjo screw

16 Sealing ring

4 End cover

17 Union

5 Nut

18 Sealing cone

6 Bracket

19 Nut

7 Hex screws

20 Bracket

8 Washer

21 Hex screws

9 Grommet

22 Grommet

10 Pipe clamp halves

23 Pipe clamp halves

11 Pipe clamp halves

24 Washer

12 Washer

25 Hex screws

13 Hex screws

EMTU

- 03.10 -

M020081/00E

Task Description

3.16.1.1

Section Page

3.16.1 5

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Operations

See

x x -

-

x x

Remove engine Perform operations as per Disassembly Plan Disable engine start Drain or draw off engine oil

2.3 2.4 Op. Man. Op. Man.

M020081/00E - 03.10 -

EMTU

Section Page

3.16.1 6

3.16.1.2

Removal

Task Description

Before removing oil lines, it is advisable to photograph the engine from all sides or attach metal tags to the oil lines so that they can be reinstalled in their original positions. Remove oil pipework with gaskets and pipe clamp halves from the engine. After removing oil lines, seal all connections with suitable plugs. Protect thin-walled oil lines against damage.

3.16.1.4

Inspection and repair CAUTION

When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Clean engine oil lines with cold cleaner. Check condition of all lines and inspect for scuffing and damage, repair or remove hydraulically as required. Recondition damaged sealing surfaces and inspect for irregularities on an ink-check plate. Check plug-in connections for wear; smooth wear or replace components as necessary. Replace sealing cones and banjo unions that are damaged, indented or corroded.

CAUTION Component is hot. Risk of injury! Handle components only when wearing protective gloves. Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions. Allow lines to cool slowly, do not cool with water.

WARNING Hydrochloric acid is extremely caustic. Risk of injury and suffocation! Do not allow hydrochloric acid to come into contact with eyes, clothing or skin. Do not inhale. Always wear protective clothing, protective gloves and protective goggles/safety mask. Ensure good ventilation at workplace. Pickle lines in hydrochloric acid solution (9 parts water and 1 part hydrochloric acid).

WARNING Compressed air is highly pressurized. Risk of injury! The pressure must not exceed 3.0 bar. Always wear protective clothing, protective gloves and protective goggles/safety mask. After pickling, wash the pipes in hot water, blow dry with compressed air, Then immerse lines in an oil bath and allow to drip dry. Check all hose lines and attaching hardware for damage and wear - replace parts if necessary. Replace grommets as part of every W6 overhaul. Replace O-rings.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.16.1.6

3.16.1 7

Installation

Ensure that components are particularly clean.

WARNING Compressed air is highly pressurized. Risk of injury! The pressure must not exceed 3.0 bar. Always wear protective clothing, protective gloves and protective goggles/safety mask. Before installing, blow engine oil lines clear with compressed air. Note: Do not remove blanking plug until just before installation. Coat O-rings with petroleum jelly. Install engine oil lines with new gaskets in accordance with photos, markings or overview drawing, ensuring they are tension-free.

M020081/00E - 03.10 -

EMTU

Section Page

EMTU

3.16.1 8

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.16.2

3.16.2 1

Engine oil cooler

1 Engine oil cooler

7 O-ring

2 Gasket

8 O-ring

3 Socket-head screws

9 Hex screw

4 Hex screw

10 Socket-head screw

5 Washer

11 Hex screw

6 Intermediate plate

M020081/00E - 03.10 -

EMTU

Section Page

3.16.2 2

Task Description

Intermediate plate on oil cooler

1 Intermediate plate

6 Sealing rings

2 Adapter

7 Plug

3 Sealing ring

8 Sealing ring

4 Plug

9 Intermediate element

5 Plug

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.16.2.1

3.16.2 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

-

-

X

Disable engine start

Op. Man.

-

-

X

Drain engine coolant

Op. Man.

-

X

X

Remove engine coolant lines and vent line from engine oil heat exchanger

3.14.1.2

-

X

X

Remove elbow for oil supply to oil heat exchanger

3.16.1.2

M020081/00E - 03.10 -

2.4

EMTU

Section Page

3.16.2 4

3.16.2.2

Removal

Task Description

Removing engine cooler WARNING Heavy object. Risk of injury! Use suitable equipment and lifting gears. Remove securing screws (9; 10 and 11). Lift off intermediate plate. Remove O-rings (7 and 8). Remove screws (3 and 4). Remove engine oil cooler (1). Remove gasket.

3.16.2.3

Disassembly

Disassembling intermediate plate See overview drawing: Intermediate plate on oil cooler

3.16.2.4

Inspection and repair

Check engine oil cooler for damage, replace if necessary. Cleaning intermediate washer on coolant side It is essential to examine extent of contamination of coolant chamber prior to cleaning. If greasy scale deposits are found, coolant chamber must first be degreased. Immerse intermediate washer in a cleaning bath containing a cleansing agent solution.

CAUTION When using these chemical substances, it is essential to observe the manufacturer’s instructions for use, safety instructions and waste disposal specifications. Suitable cleaning chemicals are buffered alkaline agents such as a 3 to 5% solution of Henkel P3 FD. The immersion period depends on the condition and temperature of the bath and on the type and degree of contamination. Prepare cleaning bath in accordance with manufacturer’s instructions. To remove scale deposits, use a decalcifying agent which is not harmful to metal surfaces (e.g. P3 T288 manufactured by Henkel or amidosulfonic acid Euron 1308 manufactured by Hoechst). With extremely stubborn deposits, it may be necessary to use a hydrochloric acid solution. In this case, however, the appropriate inhibited acid (e.g. Euron 1144 from Hoechst) must be used. Cleaning process is completed when loosened contaminants can be flushed away with a powerful water jet. After cleaning, system must be flushed with water until pH values of fresh water and flushing water are roughly equal (permissible difference 1 pH).

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.16.2 5

Cleaning and flushing oil side of intermediate plate Note:

If the oil cooler is badly contaminated, e.g. in event of piston scuffing, damage to bearings or chippings in engine oil system, the engine oil cooler must be replaced! Connect oil side to sealed, forced-circulation flushing system. The forced-circulation flushing system must be equipped with a filter (0.05 mm mesh). Note:

Cleaning solution must be pumped through oil cooler in direction opposite to normal oil flow, i.e. opposite to direction of arrow on cooler. Suitable descaling agents are buffered alkaline agents such as a 3 to 5% solution of P3 FD from Henkel. It is essential to follow the manufacturer’s instructions when preparing the cleaning agent. Cleaning can be improved by using ultrasonic equipment. After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are roughly equal (permissible difference 1pH). This releases contaminants, particularly particles from wear parts, from swirl plates, so that they are flushed out with water. Continue cleaning process until flushing medium leaving cooler is same as that entering.

WARNING Test fluid is highly pressurized. Risk of injury! Liquids emerging under high pressure can lead to serious injury! Always wear protective clothing, protective gloves and protective goggles/safety mask. Flushing pressure 3 to 4 bar at 150 to 300 litres/minute. After this cleaning procedure, dry oil side with hot air to remove remaining flushing water from swirl plates and oil ducts. After drying, oil cooler must be rinsed with engine oil or Haku rinsing oil in order to preserve swirl plates. Note:

This preservation is not necessary if engine oil cooler is reinstalled on engine and put into operation immediately after cleaning. Insert protective caps in inlet and outlet bore and protect plate-type oil cooler against damage.

3.16.2.5

Assembly

Assembling intermediate plate See overview drawing: Intermediate plate on oil cooler Coat sealing rings with petroleum jelly before installing.

M020081/00E - 03.10 -

EMTU

Section Page

3.16.2 6

Task Description

Installing engine oil cooler and intermediate plate Check that clean-oil-carrying channels of engine oil cooler (1) and intermediate plate (6) are perfectly clean. Clean mating faces on engine oil cooler and engine. Coat gasket (2) with petroleum jelly and fit on engine oil cooler. Insert screws (3; 4 and 5) and tighten. Coat O-rings (7 and 8) with petroleum jelly and fit on intermediate plate. Fit intermediate plate on engine oil filter. Insert screws (9; 10 and 11) and tighten.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.16.3

3.16.3 1

Engine oil filter

Engine oil filter with filter bowl

1 Filter bowl

7 Plug

2 Gasket

8 Sealing ring

3 Screw

9 Filter element with gaskets

4 Screw

10 Sealing ring

5 Spring washer

11 Sealing ring

6 Oil filter bowl

12 Screw

M020081/00E - 03.10 -

EMTU

Section Page

3.16.3 2

3.16.3.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

-

-

X

Disable engine start

EMTU

2.4 Op. Man.

- 03.10 -

M020081/00E

Section Page

Task Description

3.16.3.2

3.16.3 3

Removal Remove oil filter WARNING Heavy object. Risk of injury! Use suitable equipment and lifting gears. Remove securing screws (3 and 4). Remove engine oil filter (1). Remove gasket (2).

3.16.3.3

Disassembly Disassemble engine oil filter. Unscrew plug (5) and remove sealing ring (4). Drain oil into oil filter bowls (1) via bores. Remove screw (3) and remove sealing ring (2). Remove oil filter bowl from filter bowl (7) and remove sealing ring (6).

++

3.16.3.4

Inspection and repair

Inspecting filter bowl Using the surface crack-testing method with red penetrant dye, check filter bowl for cracks; replace component if cracks are found. Check screw-down surfaces for irregularities and damage; rub down or replace as required. Make sure oilways and oil-carrying parts are particularly clean, clean as required. Replace sealing ring. Check oil filter bowl for damage, replace if necessary.

M020081/00E - 03.10 -

EMTU

Section Page

3.16.3 4

Task Description

Cleaning/rinsing filter bowl Suitable descaling agents are buffered alkaline agents such as a 3 to 5% solution of P3 FD from Henkel. It is essential to follow the manufacturer’s instructions when preparing the cleaning agent. Cleaning can be improved by using ultrasonic equipment. After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are roughly equal (permissible difference 1pH). This releases contaminants, particularly particles from wear parts, from swirl plates, so that they are flushed out with water. Continue cleaning process until flushing medium leaving cooler is same as that entering. After this cleaning procedure, dry hot air to remove remaining cleaning agent.

3.16.3.5

Assembly Assembling engine oil filter Check that clean-oil-carrying channels of filter bowl (6) are perfectly clean. Insert filter element in oil filter bowl (1). Coat sealing ring (6) with petroleum jelly and insert into filter bowl. Fit oil filter bowl. Coat screw (3) with engine oil. Insert screw and sealing ring (2) into oil filter bowl. Secure with torque wrench as per Tightening Specifications 1.4 on filter bowl (7). Screw plug (5) with sealing ring (4) into oil filter bowl and tighten.

3.16.3.6

Installation Install engine oil filter WARNING Heavy object. Risk of injury! Use suitable equipment and lifting gears. Coat gasket (2) with petroleum jelly and fit on engine oil filter (1). Fit engine oil filter. Install securing screws (3 and 4) and tighten.

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.18

3.18 1

Starting system

Contents 3.18.1

Starter 3.18.1.1 3.18.1.2 3.18.1.4 3.18.1.6 3.18.1.7

Before-removal operations Removal Inspection and repair Installation After-installation operations

M020081/00E - 03.10 -

EMTU

Section Page

3.18 2

Task Description

The following tools are required in order to perform the operations described in this section: Tools from the Tool Catalogue M004018/20

EMTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.18.1

3.18.1 1

Electric starter

1 Electric starter

4 Earth wire

2 Hex nut

5 Electrical wire

3 Spring washer

M020081/00E - 03.10 -

EMTU

Section Page

3.18.1 2

3.18.1.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

-

-

X

Disable engine start

EMTU

2.4 Oper. Instr.

- 03.10 -

M020081/00E

Section Page

Task Description

3.18.1.2

3.18.1 3

Removal DANGER

Electric voltage. Risk of serious or even fatal injury - Before starting work, ensure that the engine is not energised. Secure against inadvertent switching on.

Disconnecting starter Before disconnecting, mark all cables with adhesive labels. Disconnect all cables from starter. Protect cables against damage.

Removing starter Unscrew hex nut (3) and remove spring washer (2). Remove starter (1). Protect starter from damage.

3.18.1.4

Inspection and repair

Clean starter only with compressed air. Check tooth flanks of pinion for wear, indentations and chipping; if necessary recondition or replace starter. Check condition of nuts, check thread for ease of movement, replace if necessary. Check condition of studs, check thread for ease of movement. Check mating face on connecting housing for wear.

M020081/00E - 03.10 -

EMTU

Section Page

3.18.1 4

3.18.1.6

Installation

Task Description

Install starter Coat starter pinion with long-life grease. Place starter (1) on connecting housing. Fit nuts (3) with spring washer (2).

Connecting electric starter Connect lines as per marking on starter. Check operation of starter.

EMTU

- 03.10 -

M020081/00E

Task Description

3.19

Section Page

3.19 1

Engine mounting

Contents 3.19.1

Engine mounting with carrier 3.19.1.1 Before-removal operations 3.19.1.2 Removal 3.19.1.3 Disassembly 3.19.1.4 Inspection and repair 3.19.1.5 Assembly 3.19.1.6 Installation

M020081/00E - 03.10 -

E MTU

Section Page

3.19 2

Task Description

The following is a list of tools needed for the assembly operations: Tools from the tool catalogue M004018/20

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.19.1

3.19.1 1

Engine mount with carrier

Engine mount, driving end/free end

1 Carrier, driving end

10 Washer

2 Hex screw

11 Hex screw

3 Hex screw

12 Hex screw

4 Washer

13 Hex screw

5 O-ring

14 Washer

6 Hex screw

15 O-ring

7 Carrier, driving end

16 Engine carrier, free end

8 Hex screw

17 Washer

9 Hex screw

18 Hex screw

M020081/00E - 03.10 -

E MTU

Section Page

3.19.1 2

Task Description

Rubber mounting

1 Rubber mount

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.19.1.1

3.19.1 3

Before-removal operations

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

-

-

X

Disable engine start

-

-

X

Removal of engine mounting not scheduled

M020081/00E - 03.10 -

2.4 Oper. Instr. -

E MTU

Section Page

3.19.1 4

3.19.1.2

Removal

Task Description

Removing free end carrier, right side of engine Remove screws (3; 5; 7; 9; and 10) from carrier (8). Remove washers (2; 4; 6; 11 and 12). Remove carrier. Remove O-ring (1).

Removing free end carrier, left side of engine Remove screws (5 and 7) from carrier (1). Remove washers (4 and 6). Remove carrier (1). Remove O-ring (2).

Removing carrier, free end, left/right engine side Unscrew screws (2) from carrier (3). Remove washers (1). Remove carrier.

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.19.1.3

3.19.1 5

Disassembly Removing rubber mounts Example: carrier, free end Remove nut (1) from carrier (3) and take off washers (2). Remove rubber mount.

3.19.1.4

Inspection and repair

Crack-test the carrier using the surface crack-testing method and red penetrant dye. Replace relevant components if cracks are found. Check mating faces on engine carrier and carrier for evenness, smooth with an oilstone if necessary. Check threads on screw and nut for ease of movement, recut as necessary.

3.19.1.5

Assembly Installing rubber mounts Example: carrier, free end Place rubber mount in position on carrier (3). Screw on nut (1) with washers (2) and tighten.

M020081/00E - 03.10 -

E MTU

Section Page

3.19.1 6

3.19.1.6

Installation

Task Description

Installing free end carrier, right side of engine Coat O-ring (1) with petroleum jelly and fit on carrier (8). Place carrier in position on gear case. Insert screws (3; 5; 7; 9 and 10) with washers (2; 4; 6; 11 and 12) in carrier and tighten.

Installing free end carrier, left side of engine Coat O-ring (2) with petroleum jelly and fit on carrier (1). Place carrier in position on gear case. Insert screws (3; 5 and 7) with washers (4 and 6) in carrier and tighten.

Installing carrier, free end, left/right engine side Place carrier (3) in position on crankcase. Insert screws (2) with washers (1) in carrier and tighten.

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.84

3.84 1

Monitoring system

Contents 3.84.1

Sensor and transmitter 3.84.1.1 Before-removal operations 3.84.1.2 Removal 3.84.1.4 Inspection and repair 3.84.1.6 Installation

3.84.9

Wiring 3.84.9.1 3.84.9.2 3.84.9.4

Before-removal operations Removal Inspection and repair

Governor 3.84.11.1 3.84.11.2 3.84.11.4 3.84.11.6

Before-removal operations Removal Inspection and repair Installation

3.84.11

M020081/00E - 03.10 -

E MTU

Section Page

3.84 2

Task Description

The following is a list of tools needed for the assembly operations: Tools from the tool catalogue M004018/20

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.84.1

3.84.1 1

Sensor and transmitter

P 005 004 b1

1 Pressure sensor

5 Sealing ring

2 Coolant level sensor

6 Temperature sensor PT 1000

3 Probe for oil or fuel

7 Temperature sensor NI1000

4 Sealing ring

8 Speed transmitter

M020081/00E - 03.10 -

E MTU

Section Page

3.84.1 2

Task Description

50700065a

1 Distributor plate

5 Sealing ring

2 Pressure sensor

6 O-ring

3 Plug

7 Nameplate

4 Transition element

8 Nameplate

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.84.1.1

3.84.1 3

Before-removal operations

A distinction must be made as to whether: The engine is to be completely disassembled

1 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

Oper. Instr.

-

X

X

Drain engine coolant

Oper. Instr.

-

X

X

Drain engine oil

Oper. Instr.

M020081/00E - 03.10 -

E MTU

Section Page

3.84.1 4

3.84.1.2

Removal

Task Description

Remove sensor and transmitter.

3.84.1.3

Inspection and repair

Check sensor and transmitter for general condition; replace if necessary.

3.84.1.4

Installation

Install sensor and transmitter.

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.84.9

3.84.9 1

Wiring

1 Wiring harness

7 Pressure sensor

2 Speed transmitter

8 Coolant level sensor

3 Temperature sensor NI 1000

9 -

4 Temperature sensor PT 1000

10 Probe for oil or fuel

5 6 Hose line

M020081/00E - 03.10 -

E MTU

Section Page

3.84.9 2

3.84.9.1

Before-removal operations

Task Description

A distinction must be made as to whether: 1

The engine is to be completely disassembled 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

-

-

X

Disable engine start

-

X

X

Switch off control voltage to engine

E MTU

2.4 Oper. Instr. -

- 03.10 -

M020081/00E

Section Page

Task Description

3.84.9.2

3.84.9 3

Removal GEFAHR

Electrical voltage. Risk of injury. De-energise affected junction box prior to starting work. Note:

During such repair work, partial removal of the electrical equipment may be sufficient, depending on the space available. Make sketches or take photos to record wiring on engine. Mark wiring to terminal boxes and disconnect or unplug. Remove dust caps for sockets. Release wiring on engine as much as necessary and protect from mechanical damage. Note:

Before disconnecting wiring from electrical equipment, check whether the wire and cable numbering is in accordance with the MTU wiring diagram. Provide labels as necessary. For equipment from which the connecting lines can be removed completely with the connecting housing, disconnect only the cables on the equipment and separate the connecting line with connecting housings from the equipment. Otherwise, proceed as follows: - Disconnect conductors. - Carefully cut open and remove thermofil moulded part. - Remove thrust screw from cable gland - Withdrawe line from cable gland - Secure inserts on cable gland on line or - Reinstall inserts in cable glands. - Tighten terminals and seal connection chamber For further removal procedure, see MTU Elektronik Documentation. Release lines and wiring harness from engine, leave wiring harness tied as far as possible. It may be necessary to remove some pipes beforehand. Remove securing screws from terminal box. Remove terminal box with wiring harness from engine and store in a safe place, protected from oil and dirt. Mark securing material of electrical installation and store separately from other securing material.

3.84.9.4

Inspection and repair

Clean all components. Check wires and terminals for damage. Check plug-in contacts for burning and wear through vibration damage. Check resilience of gasket in terminal box. Visually check rubber elements for terminal box mounting for cracks and, deformation; replace components if damaged. Check condition of securing plates and base plates, replace if necessary. Using the surface crack-testing method with red penetrant dye, check securing plates and base plates for cracks; replace components if cracks are found. Check and repair terminal boxes as per MTU Elektronik Documentation.

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

3.84.9 4

Task Description

- 03.10 -

M020081/00E

Section Page

Task Description

3.84.11

3.84.11 1

Governor

1 Bracket

12 Hex screw

23 Hex screw

2 Hex screw

13 Shock damping metal

24 Washer

3 Washer

14 Hex screw

25 Socket-head screw

4 Bracket

15 Washer

26 Socket-head screw

5 Hex screw

16 Hex screw

27 Spacer sleeve

6 Washer

17 Hex screw

28 Socket-head screw

7 Hex screw

18 Washer

29 Spacer sleeve

8 Bracket

19 Shock damping metal

30 Washer

9 Bracket

20 Hex screw

31 Spacer sleeve

10 Hex screw

21 Washer

32 Socket-head screw

11 Washer

22 Shock damping metal

33 Washer

M020081/00E - 03.10 -

E MTU

Section Page

3.84.1 2

3.84.1.1

Before-removal operations

Task Description

A distinction must be made as to whether: The engine is to be completely disassembled

1 2

The engine is to be removed but not disassembled 3

The engine is to remain installed

1

2

3

Operations

see

X

-

-

Remove engine

2.3

X

-

-

Perform operations as per Disassembly Plan

2.4

-

-

X

Disable engine start

E MTU

Oper. Instr.

- 03.10 -

M020081/00E

Task Description

3.84.1.2

Section Page

3.84.11 3

Removal

For securing screws for governor, see overview drawing

3.84.1.4

Inspection and repair

Check governor for external damage.

3.84.1.6

Installation

Install in reverse sequence as shown in overview drawing.

M020081/00E - 03.10 -

E MTU

Section Page

E MTU

3.84.1 4

Task Description

- 03.10 -

M020081/00E

Task Description

3.86

Section Page

3.86 1

Accessories

Contents 3.86.1

Three-phase alternator 3.86.1.1 Before-removal operations 3.86.1.2 Removal 3.86.1.4 Inspection and repair 3.86.1.6 Installation

M020081/00E - 03.10 -

E MTU

Section Page

3.86 2

Task Description

The following is a list of tools needed to carry out the work: Tools from the tool catalogue M004018/20

E MTU

- 03.10 -

M020081/00E

Section Page

Task Description

3.86.1

3.86.7 1

Three-phase alternator

Attachments on engine

1 Bracket

4

Three-phase alternator

2 Washer

5

Washer

3 Nut

6

Hex nut

M020081/00E - 03.10 -

E MTU

Section Page

3.86.7 2

Task Description

Three-phase alternator attachments

1 Alternator

7 Hex nut

2 Adjusting shim

8 Washer

3 Belt pulley

9 Hex nut

4 Washer

10 Grommet

5 Hex nut

11 Protective cap

6 Washer

E MTU

- 03.10 -

M020081/00E

Task Description

3.86.1.1

Section Page

3.86.7 3

Before-removal operations

A distinction must be made as to whether: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3 The engine is to remain installed 1

2

3

Tasks

See

x x -

-

x x

Remove engine Perform operations as per Disassembly Plan Disable engine start Disconnect electrical wires

2.3 2.4 Op. Man. -

M020081/00E - 03.10 -

E MTU

Section Page

3.86.7 4

3.86.1.2

Removal

Task Description

Removing clamping device. Remove nut (2). Remove V-belt (1). Remove nut (8). Remove bush (4), threaded bush (5) and washer (7). Remove hex screws (12 and 16) and take off threaded pin (3). Remove clamping element (14), clamping nut (13) and ball joint (10).

Removing three-phase alternator Remove three-phase alternator as shown in overview drawing (installation).

3.86.1.4

Inspection and repair

Clean all components. Crack-test the bracket using the surface crack-testing method and red penetrant dye. If cracks are detected, replace parts. Remove minor wear, indentation and scoring with emery cloth or oilstone, replace components as necessary. Check threads of screws, nuts and threaded pins for ease of movement. Test and repair three-phase alternator, see special publication.

3.86.1.6

Installation

Installing clamping device. Install clamping device in reverse order. Installing three-phase alternator Install three-phase alternator as shown in overview drawing (installation).

E MTU

- 03.10 -

M020081/00E