Operating Instructions: Diesel Engine 16 V 4000 E20

Operating Instructions
Diesel engine
16 V 4000 E20
M015241/03E
Printed in Germany
© 2011 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, micro‐
filming 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.
Commissioning Note
Important
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 (war‐
ranty, spare parts, etc.).
Table of Contents
1 Safety 6 Troubleshooting
1.1 General conditions 7 6.1 Troubleshooting 41
1.2 Personnel and organizational requirements 8 6.2 DDEC alarms 44
1.3 Transport 9
1.4 Crankshaft transport locking device 10
1.5 Safety regulations for startup and operation 12
7 Task Description
1.6 Explosion hazard when removing
inspection port cover on engine 13 7.1 Engine 64
1.7 Safety regulations for maintenance and 7.1.1 Engine – Barring manually 64
repair work 14 7.1.2 Engine – Barring with starting system 66
1.8 Fluids and lubricants, fire prevention and
environmental protection 17 7.2 Cylinder Liner 67
7.2.1 Cylinder liner – Endoscopic examination 67
1.9 Engine – Barring with starting system 19
7.2.2 Instructions and comments on endoscopic
1.10 Conventions for safety instructions in the
and visual examination of cylinder liners 69
text 20
7.3 Crankcase Breather 71
7.3.1 Crankcase breather – Oil separator check 71
7.3.2 Crankcase breather – Filter element
2 General Information replacement 72
7.3.3 Crankcase breather (open-circuit crankcase
2.1 Engine layout 21 ventilation) – Filter element cleaning 74
2.2 Engine side and cylinder designations 25
2.3 Sensors and actuators – Overview 26 7.4 Valve Drive 75
7.4.1 Valve gear – Lubrication 75
7.4.2 Valve clearance – Check and adjustment 76
7.4.3 Cylinder head cover – Removal and
3 Technical Data installation 80
3.1 16V 4000 E20 engine data 28 7.5 Injection Pump / HP Pump 81
3.2 Firing order 32 7.5.1 HP pump – Relief bore check 81
7.6 Injection Valve / Injector 82

7.6.1 Injector – Replacement 82
4 Operation 7.6.2 Injector – Removal and installation 83
4.1 Putting the engine into operation after 7.7 Fuel System 88
extended out-of-service periods (>3 7.7.1 Fuel system – Venting 88
months) 33
7.8 Fuel Filter 89
4.2 Putting the engine into operation after 7.8.1 Fuel filter – Replacement 89
scheduled out-of-service-period 34 7.8.2 Fuel prefilter – Draining 90
4.3 Engine – Start in manual mode 35 7.8.3 Edge-type fuel filter – Draining 91
4.4 Operational checks 36
4.5 Engine – Shutdown in manual mode 37 7.9 Charge-Air Cooling 92
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4.6 After stopping the engine 38 7.9.1 Intercooler – Check drain for coolant leakage
and obstruction 92
4.7 Plant – Cleaning 39
7.10 Air Intake 93
7.10.1 Service indicator – Check 93
5 Maintenance 7.11 Starting Equipment 94

7.11.1 Starter – Condition check 94
5.1 Maintenance task reference table [QL1] 40
7.11.2 Cold start system with ether injection – Check 95
7.12 Lube Oil System, Lube Oil Circuit 96
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7.12.1 Engine oil level – Check 96 7.17.4 Battery-charging generator drive – Drive belt
7.12.2 Engine oil – Change 97 and belt tensioner replacement 122
7.12.3 Engine oil – Sample extraction and analysis 99 7.17.5 Battery-charging generator drive – Drive belt
tension adjustment 123
7.13 Oil Filtration / Cooling 100
7.13.1 Engine oil filter – Replacement 100 7.18 Fan Drive 124
7.13.2 Centrifugal oil filter – Cleaning and filter 7.18.1 Fan drive belt– Tension check / adjustment 124
sleeve replacement 101 7.18.2 Fan drive – Drive belt replacement 126
7.14 Coolant Circuit, General, High- 7.19 Wiring (General) for Engine/Gearbox/Unit 127
Temperature Circuit 103 7.19.1 Engine wiring – Check 127
7.14.1 Coolant level - Check 103
7.14.2 Engine coolant – Change 104 7.20 Accessories for (Electronic) Engine
7.14.3 Engine coolant – Draining 105 Governor / Control System 128
7.14.4 Engine coolant – Filling 106 7.20.1 DDEC and connectors – Cleaning 128
7.14.5 Engine coolant pump – Relief bore check 108 7.20.2 DDEC – Checking plug-in connections 130
7.14.6 Coolant – Sample extraction and analysis 109
7.15 Low-Temperature Circuit 110

7.15.1 Charge-air coolant – Level check 110
7.15.2 Charge-air coolant – Change 111 8 Appendix A
7.15.3 Charge-air coolant – Draining 112
8.1 Abbreviations 131
7.15.4 Charge-air coolant – Filling 113
7.15.5 Charge-air coolant pump – Relief bore check 116
8.2 MTU contacts/service partners 134
7.16 Belt Drive 117

7.16.1 Drive belt – Condition check 117
9 Appendix B
7.17 Battery-Charging Generator 118
7.17.1 Battery-charging generator – Condition check 118 9.1 Special Tools 135
7.17.2 Battery-charging generator – Check 119 9.2 Index 139
7.17.3 Battery-charging generator – Removal and
installation 120
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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the operating instructions and mainte‐
nance and repair specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel.
Observe the minimum legal age.
Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and
transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐
nel must have read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.
Working clothes and protective equipment

Wear proper protective clothing for all work.
Depending on the kind of work, use the necessary personal protective equipment.
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1.3 Transport
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
Transport the engine/genset in the installation position only, maximum admissible inclination is 10°.
Remove any loose parts on the genset.
Hoist the engine/genset slowly ensuring that lifting cables/chains do not touch the engine or any of its
component parts. Readjust lifting device as necessary.
Pay attention to the center of gravity of the engine/genset.
When specially wrapped in aluminum foil, suspend the engine/genset by the lifting eyes on the bearing
pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.
Fit the crankshaft shipping lock on the engine and fit the engine mount locking devices prior to transport.
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Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip‐
ping and tipping when driving up or down inclines and ramps.
Placement after transport

Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
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1.4 Crankshaft transport locking device
Transport locking device

This locking device protects the crankshaft bearings from shocks and vibration damage during engine
transport.
For removal of the transport locking device, observe the following:
• The transport locking device should remain installed as long as possible during engine installation in
order to avoid damage.
• Starting or barring the engine is allowed only with the transport locking device removed. If the genera‐
tor is already mounted on the engine, ensure that the transport locking device of the generator is re‐
moved.
• Prior to every engine transport (without generator), this transport locking device must be reinstalled
according to the instructions.
Removing the transport locking device from driving end (KS)

• Release the locknuts (6) on both sides of the flywheel housing, remove screws (5) and take off the two
locks (4).
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• Remove screws (2), washers (3), cover plate (8) with label (7) and plates (1).
Store the removed parts of the transport locking device carefully for possible reuse!
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Fitting the transport locking device on driving end (KS)
• Secure the two plates (1) with screws (5) and nuts (6) together with cover plate (8) at the bores on
both sides of the flywheel housing. Tightening torque: 250 Nm + 25 Nm, lubricant: engine oil.
• Screw nut (6) onto screws (5) up to the end of the thread.
• Fit the locks (4) through the openings of plates (1) and fasten with the screws (5).
• Tighten screws (5) in alternating steps on both sides. Tightening torque : 30 Nm + 3 Nm, lubricant: en‐
gine oil.
• Screw on nuts (6) of both screws (5) at plates (1) and secure.
• Mark the engine as "Fitted with transportation locking device".
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1.5 Safety regulations for startup and operation
Safety requirements for initial operation

Prior to initial operation of the unit, install the assembly or unit according to the specifications and check
the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that nobody is in the danger area of moving machine parts.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the signaling and alarm systems work properly.
Safety requirements for operators

The procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
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1.6 Explosion hazard when removing inspection port cover on
engine
DANGER
Explosion hazard due to oil vapors.
Risk of serious injury – danger to life!
• Allow the engine to cool down before opening the crankcase!
• Avoid open flames, electrical sparks and ignition sources.
Safety instructions
u Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion
due to oil vapors).
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1.7 Safety regulations for maintenance and repair work
Safety regulations for maintenance and repair work

Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
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Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
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Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment

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When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
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For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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1.8 Fluids and lubricants, fire prevention and environmental
protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external 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 external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their
use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal

Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and involves the termination of the operating license by the emission authorities. MTU does not accept
any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-
relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐
ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.
Fluids and lubricants

Use only fluids and lubricants that have been tested and approved by MTU.
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
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not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
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Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted 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.
• Wear goggles when blowing off components or blowing away chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Carry out leak test in accordance with the specifications.
Painting
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions

• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective
clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
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• Rinse eyes immediately with eyedrops or clean tap water.
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1.9 Engine – Barring with starting system
Preconditions
☑ External pushbutton “Bar engine without starting” is provided.
DANGER
Unguarded rotating and moving engine components.
• before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
Engine – Barring with starting system

1. Press pushbutton “Bar engine without starting” and keep depressed.
2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.
3. Repeat this procedure after approx. 20 seconds if required.
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1.10 Conventions for safety instructions in the text
DANGER
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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2 General Information
2.1 Engine layout
Engine version with closed-circuit crankcase ventilation
1 Engine lifting eyes 5 Main PTO 10 Engine oil dipstick

2 Cylinder-head cover, cyl‐ 6 Charge-air coolant outlet 11 Engine oil filler neck
inder head 7 Charge-air coolant inlet 12 Starter, engine right-hand
3 Coolant inlet 8 Coolant pump, LT circuit side
4 Intercooler 9 Coolant pump, HT circuit
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1 Engine lifting eyes 8 Oil drain plugs 13 DDEC electronic engine
2 Coolant outlet 9 Engine oil pan control system
3 Fan drive 10 Battery-charging genera‐ 14 Fuel duplex filter (easy-
4 Centrifugal oil filter tor drive change filter)
5 Engine oil filter 11 Starter, engine left-hand 15 Compressor
6 HP fuel pump side
7 Vibration damper 12 Inspection port cover
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1 Battery-charging genera‐ 4 Crankcase breather of 6 Engine oil heat exchang‐
tor closed-circuit crankcase er
2 Combustion-air inlet ventilation (oil separator)
3 Exhaust turbocharger 5 Exhaust outlet
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Engine version with open-circuit crankcase ventilation
1 Crankcase breather, A 3 Crankcase breather 5 Vent line to atmosphere

side mounted on cylinder
2 Crankcase breather, B head cover
side 4 Cylinder head cover
Engine model designation

Key to the engine model designation 16V 4000 E20
16 Number of cylinders
V Cylinder arrangement: V engine
4000 Series
E Application: E=Excavator
2 Application segment
0 Design index
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2.2 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end of
the engine.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
1 KGS = Free end 3 KS = Driving end

2 Right engine side 4 Left engine side
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2.3 Sensors and actuators – Overview
Sensors, actuators
1 Sensor (oil pressure) 5 Sensor (reference mark 9 Sensor (charge-air cool‐

2 Sensor (oil temperature) TDC cylinder 1) ant pressure)
3 Sensor (crankcase pres‐ 6 Sensor (LP fuel) 10 Sensor (coolant pres‐
sure) 7 Sensor (fuel temperature) sure)
4 Sensor (charge-air cool‐ 8 Sensor (HP fuel) 11 DDEC
ant temperature)
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1 Sensor (coolant tempera‐ 3 Sensor (crankshaft angle 4 Sensor (charge-air tem‐
ture) sensor for injection timing perature)
2 Connector power supply / of any cylinder) 5 Sensor (charge-air pres‐
interface to vehicle sure)
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3 Technical Data
3.1 16V 4000 E20 engine data
Explanation:
DL Ref. value: Continuous power (CP)
BL Ref. value: Fuel stop power (FSP)
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
REFERENCE CONDITIONS
Engine model 16V 4000
Application group 5A
Intake air temperature °C 25
Charge-air coolant temperature °C 55
Raw water inlet temperature °C -
Barometric pressure mbar 1000
Site altitude above sea level m 100
POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 16V 4000
Engine rated speed A rpm 1800
Net brake power (without fan) A kW 1600
(fuel stop power ISO 3046)
GENERAL CONDITIONS (for maximum power)

Intake air depression (new filter) A mbar 25
Intake air depression L mbar 50
Exhaust backpressure A mbar 30
Exhaust backpressure, max. L mbar 50
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Fuel temperature at fuel feed connection R °C 30
CONSUMPTION
Specific fuel consumption (be) 100% BL (+5%; EN 590; 42.8MJ/kg) G g/kWh 194
Lube oil consumption after 100 h operation, average (B = fuel con‐ R % of B 0.3
sumption per hour)
28 | Technical Data | M015241/03E 2011-12

MODEL-RELATED DATA (basic design)
Number of cylinders 16
Cylinder configuration: V angle degrees 90
Bore mm 165
Stroke mm 190
Cylinder displacement liter 4.06
Total displacement liter 65.0
Number of inlet valves, per cylinder 2
Number of exhaust valves, per cylinder 2
COMBUSTION AIR / EXHAUST GAS

Charge-air pressure before cylinder (abs.) R bar ABS 2.7
Exhaust temperature after turbocharger R °C 410
COOLING SYSTEM (HT circuit)

Coolant temperature (at engine outlet to cooling equipment; with A °C 92
max. 40% antifreeze)
Coolant temperature after engine, alarm R °C 95
Coolant temperature after engine, shutdown L °C 97
Coolant antifreeze content, max. permissible L % 40
Coolant pump: inlet pressure, min. L bar 0.2
Coolant pump: inlet pressure, max. L bar 2.2
Thermostat, starts to open R °C 77
Thermostat, fully open R °C 85
COOLING SYSTEM (LT circuit)

Coolant temperature (at engine outlet to cooling equipment) R °C 65
Coolant temperature before intercooler (with max. 40% antifreeze) A °C 55
Coolant temperature differential after/before intercooler, max. L °C 15
Coolant antifreeze content, max. permissible L % 40
Thermostat, starts to open R °C 32
TIM-ID: 0000002641 - 001
Thermostat, fully open R °C 44
LUBE OIL SYSTEM

Lube oil operating temperature before engine, from R °C 88
Lube oil operating temperature before engine, to R °C 93
Lube oil operating pressure before engine, from R bar 5.0
M015241/03E 2011-12 | Technical Data | 29

Lube oil operating pressure before engine, to R bar 6,0
Lube oil pressure before engine, alarm R bar 4.5
Lube oil pressure before engine, shutdown L bar 4.0
Lube oil fine filter (main circuit) differential pressure, max. L bar 1.0
FUEL SYSTEM
Fuel pressure at supply connection to engine (when engine is start‐ L bar 0.1
ing), min. admissible
Fuel pressure at supply connection to engine (when engine is start‐ L bar 1.5
ing), max. admissible
Fuel pressure before injection pump, from R bar 4.0
(H.P. pump)
Fuel pressure before injection pump, to R bar 6.0
(H.P. pump)
Fuel pressure before injection pump, min. R bar 3.5
(H.P. pump)
GENERAL OPERATING DATA

Coolant preheating: preheating temperature (min.) R °C 40
INCLINATIONS STANDARD OIL SYSTEM (Ref.: waterline)

Longitudinal inclination, continuous max., driving end down L degrees 22.5
(Option: max. operating inclinations)
Longitudinal inclination, continuous max., driving end up L degrees 10
(Option: max. operating inclinations)
CAPACITIES
Engine coolant capacity (without cooling equipment) R liter 210
Engine oil capacity, initial filling (standard oil system) (Option: max. R liter 520
operating inclinations)
TIM-ID: 0000002641 - 001
Oil pan capacity, dipstick mark min. (standard oil system) (Option: L liter 360
max. operating inclinations)
Oil pan capacity, dipstick mark max. (standard oil system) (Option: L liter 460
max. operating inclinations)
WEIGHTS / MAIN DIMENSIONS

Engine dry weight (basic engine) R kg 7490

FREE-FIELD SOUND PRESSURE LEVEL
Exhaust noise, unsilenced, 1m distance R db(A) 118
TIM-ID: 0000002641 - 001
M015241/03E 2011-12 | Technical Data | 31

3.2 Firing order
Firing order
Number of cylin‐ Firing order
ders
8V A1-B4-A4-A2-B3-A3-B2-B1
12V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8
TIM-ID: 0000002794 - 004

4 Operation
4.1 Putting the engine into operation after extended out-of-
service periods (>3 months)
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting into operation after long out-of-service periods (>3 months)

Item Action
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).
Valve gear Lubricate valve gear every ≥ 6 months (→ Page 75).
Lube oil system Check engine oil level (→ Page 96).
Fuel prefilter Fill with fuel (→ Page 90)(→ Page 91).
Fuel system Vent (→ Page 88).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 104).
Change charge-air coolant (→ Page 111).
Coolant circuit Check engine coolant level (→ Page 103);
Check charge-air coolant level (→ Page 110).
Coolant circuit Preheat coolant with preheating unit, if fitted.
DDEC Check plug-in connections (→ Page 130).
TIM-ID: 0000002201 - 002
M015241/03E 2011-12 | Operation | 33

4.2 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
Startup
Item Action
Lube oil system Check engine oil level (→ Page 96).
Coolant circuit Check engine coolant level (→ Page 103);
Check charge-air coolant level (→ Page 110).
Coolant circuit Preheat coolant with coolant preheating unit (if applicable).
Engine control system Put into operation.
TIM-ID: 0000002683 - 005
34 | Operation | M015241/03E 2011-12

4.3 Engine – Start in manual mode
Preconditions
☑ Engine with no load.
☑ External start interlock is not activated.
DANGER
• Before barring or starting the engine, make sure that nobody is in the danger zone.
WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Measure
Operating mode switch (if Switch to manual mode.
applicable)
Coolant preheating unit (if Switch on.
applicable).
Starting the engine

Item Measure
Switch cabinet, operator If coolant temperature is
station etc. (depending on • > 40 °C (with coolant preheating unit, if applicable)
manufacturer). press start button.
• Automatic starting sequence is executed
• Engine speed display instrument indicates increasing speed
• After the starting sequence is completed, engine is running at idle
speed.
TIM-ID: 0000002233 - 003
M015241/03E 2011-12 | Operation | 35

4.4 Operational checks
DANGER
• Take special care when working on a running engine.
WARNING
Operational checks
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine operation Check engine visually for leaks and general condition;
Check for abnormal running noise, exhaust discoloration and vibrations
(→ Page 41).
HP pump Check relief bore (→ Page 81).
Fuel prefilter Drain water and contaminants via drain cock on fuel prefilter
(→ Page 90)(→ Page 91).
(→ Page 90)Check reading on differential pressure gage of fuel prefilter
(if fitted).
Engine coolant pump Check relief bore (→ Page 108).
Charge-air coolant pump Check relief bore (→ Page 116).
TIM-ID: 0000002264 - 002
36 | Operation | M015241/03E 2011-12

4.5 Engine – Shutdown in manual mode
Preconditions
☑ Engine is not under load
☑ Engine in manual mode
CAUTION
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.
Preparation
Item Measure
Engine Operate engine at idling speed for approx. 5 minutes.
Shutting the engine down

Item Measure
Switch cabinet, operator Press stop button.
station etc. (depending on
• Automatic stopping sequence is executed.
manufacturer)
TIM-ID: 0000002291 - 003
M015241/03E 2011-12 | Operation | 37

4.6 After stopping the engine
Preconditions
☑ MTU Fluids and Lubricants Specification (A001061/..) is available.
After stopping the engine

Item Task
Coolant circuit Drain coolant (→ Page 105)(→ Page 112)if freezing temperatures are ex‐
pected and:
• the engine is to remain out of service for an extended period and cool‐
ant has no antifreeze additive;
• the coolant is not maintained at a suitable temperature;
• antifreeze concentration is 50 % and outside temperature is below
-40°C.
Engine control system Switch OFF.
Air intake and exhaust sys‐ Out-of-service-period > 1 week:
tem
Seal engine's air and exhaust sides.
Out-of-service-period > 1 month:
Preserve engine (→ MTU Fluids and Lubricants Specifications
A001061/.. ).
TIM-ID: 0000002321 - 001
38 | Operation | M015241/03E 2011-12

4.7 Plant – Cleaning
Preconditions
☑ Operating voltage is not applied.
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.
CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
Note: There is a risk of damaging sensors with compressed air.
Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐
tection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
4. Carry out external cleaning as follows:
a) Remove coarse dirt.
b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
c) Use the high-pressure jet to remove the loosened dirt.
d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
TIM-ID: 0000010171 - 018
(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m
must be observed. The temperature of the cleaning medium must not exceed 80 °C.
M015241/03E 2011-12 | Operation | 39

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance tasks
W0500 Check engine oil level (→ Page 96)
W0501 Visually inspect engine for leaks and general condition (→ Page 36)
W0504 Check HP fuel pump weep holes (→ Page 36)
W0505 Check relief bores of coolant pump(s) (→ Page 108)
(→ Page 116)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 36)
and vibrations
W0507 Drain water and dirt from fuel prefilter (if fitted) (→ Page 36)
W0508 Check reading on differential pressure gage of fuel prefilter (if (→ Page 36)
fitted)
W0525 Check battery-charging generator for contamination, clean if (→ Page 119)
necessary
W1001 Replace fuel filter or fuel filter element (→ Page 89)
W1002 Check valve clearance (→ Page 76)
W1003 Check drive belt condition and tension, replace if necessary (→ Page 117)
W1006 Replace fuel injectors (→ Page 82)
W1008 Replace engine oil filter at each oil change or when the time (→ Page 100)
limit (years) is reached, at the latest
W1009 Check layer thickness of oil residue, clean and replace filter (→ Page 101)
sleeve of centrifugal oil filter (if fitted) at every oil change, at
the latest
W1011 Perform endoscopic inspection of combustion chambers (→ Page 67)
W1022 Check engine wiring system externally for damage (→ Page 127)
W1044 Crankcase breather: Clean filter (→ Page 74)
W1209 Remove battery-charging generator and clean thoroughly (→ Page 120)
with compressed air
W1697 Check carbon brushes at flywheel (if fitted), replace if neces‐ -
TIM-ID: 0000034281 - 001
sary
W1698 Replace carbon brushes at flywheel (if fitted) -
Table 1: Maintenance task reference table [QL1]
40 | Maintenance | M015241/03E 2011-12

6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated

Component Cause Action
Battery Low or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are proper‐
ly secured (see manufacturer's docu‐
mentation).
Starter Engine cabling or starter faulty Check if cable connections are proper‐
ly secured, contact Service.
Engine cabling Faulty Check (→ Page 127).
Engine/generator Assemblies or connectors possibly Perform visual inspection (see manu‐
control system loose facturer's documentation).
DDEC Plug-in connections possibly loose Check plug-in connections
(→ Page 130).
Engine Running gear blocked (engine cannot Contact Service.
be barred manually)
Engine turns but does not fire

Starter Poor rotation by starter: Battery low or Charge or replace battery (see manu‐
faulty facturer's documentation).
Fuel system Air in fuel system Vent fuel system (→ Page 88).
DDEC Faulty Contact Service.
Engine fires unevenly

Fuel injection equip‐ Injector faulty Replace (→ Page 82).
ment
TIM-ID: 0000002542 - 002
Engine does not reach rated speed

Fuel supply Fuel prefilter clogged Clean or replace filter element.
Easy-change fuel filter clogged Replace (→ Page 89).
Air supply Air filter clogged Check signal ring position of service in‐
dicator (→ Page 93).
M015241/03E 2011-12 | Troubleshooting | 41

ment
Engine Overloaded Contact Service.
Engine speed not steady

ment
Speed sensor Faulty Contact Service.
Charge air temperature too high

Engine coolant Engine coolant treatment incorrect Check (MTU test kit).
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fans and intake/exhaust lines.
Charge-air pressure too low

Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.
Coolant leaks at intercooler

Intercooler Leaking, major coolant discharge Contact Service.
Black exhaust gas

ment
TIM-ID: 0000002542 - 002
Engine Overloaded Contact Service.
42 | Troubleshooting | M015241/03E 2011-12

Blue exhaust gas
Engine oil Too much oil in engine Drain engine oil (→ Page 97).
Filter element in oil separator is clog‐ Replace (→ Page 72).
ged
Exhaust turbocharg‐ Faulty Contact Service.
er, cylinder head, pis‐
ton rings, cylinder lin‐
er
White exhaust gas

Engine Not at operating temperature Run engine to reach operating temper‐
ature.
Fuel system Water in fuel Drain fuel prefilter (→ Page 90)
(→ Page 91).
Check fuel system.
Intercooler Leaking Contact Service.
TIM-ID: 0000002542 - 002

6.2 DDEC alarms
The DDEC generates alarms which are indicated in different ways depending on the equipment configu‐
ration:
• Two-digit flash code
• Fault code and text on a display or PC screen
To facilitate troubleshooting without additional auxiliary equipment, the two-digit flash codes can be read
out from the DDEC by means of the vehicle-side alarm lamps CHECK ENGINE LIGHT (yellow) and
STOP ENGINE LIGHT (red).
For this purpose, two DIAGNOSTIC REQUEST switches must be provided in the vehicle). The first
switch is used for reading out the flash codes of the master DDEC unit, the second one to read out the
receiver DDEC unit. The flash-code signals from master and receiver are transmitted to the same alarm
lamps.
Active codes: Inactive codes:
indicated by STOP ENGINE LIGHT (red) indicated by CHECK ENGINE LIGHT (yellow)
Activation of flash codes:
1. Operate IGNITION switch to position ON.
2. Operate DIAGNOSTIC REQUEST switch of master or receiver unit.
3. Read off codes.
4. Identify the fault according to the DDC fault code list.
Example:
Active code 23: Inactive code 34:
STOP ENGINE LIGHT lamp CHECK ENGINE LIGHT lamp
is flashing: is flashing:
Flashing phase 1 Flashing phase 2 Flashing phase 1 Flashing phase 2
ОО ООО ООО ОООО
two times flashing three times flashing three times flashing four times flashing
There is a pause of 0.5 seconds between the flashing phases 1 and 2. When a fault code changes from
active to inactive, the pause is 3 seconds.
To terminate flash code indication, switch DIAGNOSTIC REQUEST and IGNITION switches off.
IGNITION is allowed to be switched on again only after 30 seconds.
This method does not allow exact fault diagnostics, since a flash code may indicate faults with several
causes.
The Diagnostic Data Reader (DDR) facilitates more detailed troubleshooting.
The Diagnostic Data Reader (DDR) is intended to:
• Read out alarms from the DDEC electronic system
• Change parameters (limited extent)
TIM-ID: 0000003162 - 001
The DDR provides the possibility to read out active and inactive fault codes via separate menus. Addi‐
tionally, the inactive fault codes stored in the DDEC can be deleted.
For detailed functional description, refer to the description of the DDR.
The DDR (Part No. 5355383601/77) consists of:
• the Pro Link 9000 basic unit
• the MPC Cartridge to integrate a PCMCIA card
• a PCMCIA card
• a connection cable
• an additional adapter cable is required (Part No. J 38500 60A)

Accessory equipment:
• Printer (Part No. J-38699) for direct connection to the DDR
• Spare paper (Part No. J-38480-5) for printer (5 rolls)
The following information will be available by reading out fault codes with the DDR.
Example:
33 MID:128 Engine
TURBO BOOST SENSOR
INPUT VOLTAGE HIGH
▴ A1 PID: 102 FMI:3 ▾
Explanation:
• 33 → Flash code
• MID: 128 →Indicates origin of alarm
• TURBO-BOOST-SENSOR-INPUT-VOLTAGE-HIGH → Fault text
• ▴ ▾ → further faults are present A= active, I= inactive
MID (Message Identification Character)
• Indicates origin of alarm
MID 128 → Master
MID 175 → Receiver 1
MID 183 → Receiver 2
PID (Parameter Identification Character)
• To identify transmitted data: (e. g. engine speed, coolant temperature etc.)
PID 0-127 → 1 data byte
PID 128-191 → 2 data bytes
PID 192-253 → variable
SID (Subsystem Identification Character)
• Identifies the origin of alarms from subsystems, which can be replaced as a complete unit (e.g. injec‐
tors).
FMI (Failure Mode Identifier)
• Identifies the type of fault.
FMI 0 → Measured value exceeds the limit value (monitoring for TOO HIGH), example: Coolant tem‐
perature
FMI 1 → Measured value does not reach the limit value (monitoring for TOO LOW), example: Lube oil
pressure
FMI 3 → Signal path interrupted or signal is exceeds the permissible measuring range (sensor defect)
FMI 4 → Signal path short circuit against (-) supply of sensor or signal does not reach permissible
measuring range (sensor defect)
Flash PID SID FMI Description Tasks
code
11 187 4 Position sensor of variable Contact Service.
speed governor → voltage
too low.
TIM-ID: 0000003162 - 001
11 187 7 Control system / variable Contact Service.

speed governor→ voltage
too high.
12 187 3 Position sensor of variable Contact Service.
speed governor → voltage
too high.

code
13 111 4 Coolant level sensor, input 1. Check coolant condition
voltage too low. (→ Page 109).
2. Check coolant level, top up if
required (→ Page 103).
3. Check wiring.
4. Contact Service.
13 111 6 Sensor "Top up coolant", in‐ 1. Check coolant condition
put voltage too low. (→ Page 109).
3. Check wiring.
4. Contact Service.
14 52 3 Temperature sensor/inter‐ 1. Check wiring.
cooler, input voltage too
2. Contact Service.
high.
14 110 3 Coolant temperature sen‐ 1. Check wiring.
sor, input voltage too high.
2. Contact Service.
14 175 3 Oil temperature sensor, in‐ Contact Service.
put voltage too high.
15 52 4 Temperature sensor/inter‐ 1. Check wiring.
cooler, input voltage too
2. Contact Service.
low.
15 110 4 Coolant temperature sen‐ 1. Check wiring.
sor, input voltage too low.
2. Contact Service.
15 175 4 Oil temperature sensor, in‐ Contact Service.
put voltage too low.
16 111 3 Coolant level sensor, input 1. Check coolant condition
voltage too high. (→ Page 109).
3. Check cooler for contamina‐
tion.
4. Check wiring.
5. Contact Service.
16 111 5 Sensor "Top up coolant", in‐ 1. Check wiring.
TIM-ID: 0000003162 - 001
2. Contact Service.
17 51 3 Throttle sensor, input volt‐ 1. Check wiring.
age too high.
2. Contact Service.
17 72 3 Blower bypass position, in‐ 1. Check wiring.
2. Contact Service.
17 354 3 Humidity sensor, electric 1. Check wiring.
circuit defective / high (ver‐
2. Contact Service.
sion 33.0 or later).

code
age too low.
2. Contact Service.
18 72 4 Blower bypass position, in‐ 1. Check wiring.
2. Contact Service.
18 354 4 Humidity sensor, electric 1. Check wiring.
circuit defective / low (ver‐
2. Contact Service.
age too high.
2. Contact Service.
age too low.
2. Contact Service.
23 174 3 Fuel temperature sensor, 1. Check wiring.
input voltage too high.
2. Contact Service.
23 65 Oxygen concentration cir‐ 1. Check wiring.
cuit, input voltage too high.
2. Contact Service.
24 174 4 Fuel temperature sensor, 1. Check wiring.
2. Contact Service.
24 65 4 Oxygen concentration cir‐ 1. Check wiring.
cuit, input voltage too low.
2. Contact Service.
25 Reserved for "No Codes". No search for faults.
26 25 11 Auxiliary shutdown 1 active. Contact Service.
26 61 11 Auxiliary shutdown 2 active. Contact Service.
27 105 3 Inlet elbow temperature 1. Check wiring.
sensor, input voltage too
2. Contact Service.
high.
27 171 3 Outside temperature sen‐ 1. Check wiring.
2. Contact Service.
27 172 3 Air temperature sensor, in‐ 1. Check wiring.
2. Contact Service.
28 105 4 Inlet elbow temperature 1. Check wiring.
2. Contact Service.
low.
28 171 4 Outside temperature sen‐ 1. Check wiring.
TIM-ID: 0000003162 - 001
2. Contact Service.
28 172 4 Air temperature sensor, in‐ 1. Check wiring.
2. Contact Service.
29 351 4 Circuit exhaust turbocharg‐ 1. Check wiring.
er inlet temperature defec‐
2. Contact Service.
tive / low (version 33.0 or
later).

code
29 404 4 Temperature sensor / ex‐ 1. Check wiring.
haust turbocharger outlet,
2. Contact Service.
input voltage too low (ver‐
31 51 3 Auxiliary output 3, open cir‐ Contact Service.
cuit (side "high") S3.
31 51 4 Auxiliary output 3, ground Contact Service.
short circuit (side "high")
S3.
31 51 7 Auxiliary output 3, fault in Contact Service.
mechanical system S3.
cuit (side "high") S3.
31 52 4 Auxiliary output 4, ground Contact Service.
short circuit (side "high")
T3.
31 52 7 Auxiliary output 4, fault in Contact Service.
mechanical system T3.
32 238 3 SEL, short circuit on battery 1. Check wiring.
circuit (plus).
2. Contact Service.
32 238 4 SEL, open circuit . 1. Check wiring.
2. Contact Service.
32 239 3 CEL, short circuit on battery 1. Check wiring.
circuit (plus).
2. Contact Service.
32 239 4 CEL, open circuit . 1. Check wiring.
2. Contact Service.
33 102 3 Charge-air pressure sensor, 1. Check wiring.
2. Contact Service.
34 102 4 Charge-air pressure sensor, 1. Check wiring.
input voltage too low.
2. Contact Service.
35 19 3 Oil pressure sensor upper 1. Check wiring.
level, input voltage too high.
2. Contact Service.
35 100 3 Oil pressure sensor, input 1. Check wiring.
voltage too low.
2. Contact Service.
36 19 4 Oil pressure sensor upper 1. Check wiring.
TIM-ID: 0000003162 - 001

2. Contact Service.
36 100 4 Oil pressure sensor, input 1. Check wiring.
voltage too low.
2. Contact Service.
37 18 3 Fuel pressure sensor upper 1. Check wiring.
2. Contact Service.
37 94 3 Fuel pressure sensor, input 1. Check wiring.
voltage too high.
2. Contact Service.

code
37 95 3 Fuel- differential pressure 1. Check wiring.
2. Contact Service.
high.
38 18 4 Fuel pressure sensor upper 1. Check wiring.
level, input voltage too low.
2. Contact Service.
38 94 4 Fuel pressure sensor, input 1. Check wiring.
voltage too low.
2. Contact Service.
38 95 4 Fuel differential pressure 1. Check wiring.
2. Contact Service.
low.
39 146 2 EGR system leaking, Contact Service.
charge-air pressure (ver‐
39 146 12 EGR system leaking, ex‐ Contact Service.
haust brake operation (ver‐
39 146 7 EGR valve does not re‐ Contact Service.
spond (version 33.0 or lat‐
er).
39 147 2 VNT nozzles do not re‐ Contact Service.
spond, charge-air pressure
(version 33.0 or later).
39 147 11 VNT nozzles at maximum, Contact Service.
exhaust brake operation
39 147 12 VNT nozzles do not re‐ Contact Service.
spond, brake pressure (ver‐
39 147 14 Exhaust gas recirculation Contact Service.
flow too low, VNT nozzles
do not respond, charge-air
pressure (version 33.0 or
later).
39 147 7 VNT vanes do not respond, Contact Service.
EGR (version 33.0 or later).
39 152 7 No signal from EGR valve 1. Check signal ring position of
(version 29.0 or later). service indicator (→ Page 93).
2. Contact Service.
39 153 7 VNT vanes do not respond, 1. Check signal ring position of
TIM-ID: 0000003162 - 001
(version 29.0 or later). service indicator (→ Page 93).

2. Contact Service.
41 21 0 Too many SRS (TRS miss‐ Contact Service.
ing).
42 21 1 Not enough SRS (SRS Contact Service.
missing).

code
43 111 1 Coolant level too low. 1. Check coolant level, top up if
2. Contact Service.
44 52 0 Intercooler coolant temper‐ 1. Check coolant condition
ature too high. (→ Page 109).
3. Check intercooler for contam‐
ination.
4. Contact Service.
44 105 0 Inlet elbow temperature too 1. Check signal ring position of
high. service indicator (→ Page 93).
2. Contact Service.
44 110 0 Coolant temperature too 1. Check coolant condition
high. (→ Page 109).
tion.
4. Contact Service.
44 172 0 Intake air temperature too 1. Check signal ring position of
high. service indicator (→ Page 93).
2. Contact Service.
44 175 0 Oil temperature too high. 1. Check engine oil level
(→ Page 96).
2. Contact Service.
105 14 Inlet elbow temperature: 1. Check signal ring position of
power reduction. service indicator (→ Page 93).
2. Contact Service.
110 14 Coolant temperature: power 1. Check coolant condition
reduction. (→ Page 109).
tion.
4. Contact Service.
TIM-ID: 0000003162 - 001
45 19 1 High range: Oil pressure 1. Check engine oil level

too low. (→ Page 96).
2. Contact Service.
45 100 1 Oil pressure too low. 1. Check engine oil level
(→ Page 96).
2. Contact Service.
46 168 1 ECM battery voltage too Contact Service.
low.

code
46 214 1 Real-time clock auxiliary Contact Service.
battery, voltage too low
46 232 1 Sensor supply voltage too Contact Service.
low.
47 18 0 High range: Fuel pressure Contact Service.
too high.
47 94 0 Fuel pressure too high. Contact Service.
47 102 0 Charge-air pressure too Contact Service.
high.
47 106 0 Air intake pressure too high. Contact Service.
47 164 0 Injection control pressure Contact Service.
too high.
48 18 1 High range: Fuel pressure 1. Check fuel prefilter
too low. (→ Page 90) and (→ Page 91).
2. Check fuel filter (→ Page 89).
3. Top up tank if required.
4. Contact Service.
48 94 1 Fuel pressure too low. 1. Check fuel prefilter
(→ Page 90) and (→ Page 91).
2. Check fuel filter (→ Page 89).
3. Top up tank if required.
4. Contact Service.
48 106 1 Air intake pressure too low. Contact Service.
too low.
48 351 1 Exhaust turbocharger inlet Contact Service.
temperature below range
48 404 1 Exhaust turbocharger outlet Contact Service.
temperature too low (ver‐
48 411 1 EGR OPD low (version 33.0 Contact Service.
or later).
48 412 1 EGR temperature too low Contact Service.
TIM-ID: 0000003162 - 001
48 154 1 EGR temperature too low. Contact Service.

48 155 1 EGR differential pressure Contact Service.
too low.
49 351 0 Temperature at exhaust tur‐ 1. Check signal ring position of
bocharger inlet above range service indicator (→ Page 93).
2. Check exhaust system.
3. Contact Service.

code
49 404 0 Temperature at exhaust tur‐ 1. Check signal ring position of
bocharger outlet too high service indicator (→ Page 93).
2. Check exhaust system.
3. Contact Service.
404 14 TCO temperature: power Contact Service.
reduction.
51 351 3 Temperature sensor on ex‐ 1. Check wiring.
haust turbocharger inlet, cir‐
2. Contact Service.
cuit defective / high.
51 404 3 Temperature sensor on ex‐ 1. Check wiring.
haust turbocharger outlet,
2. Contact Service.
input voltage too high (ver‐
52 254 12 A/D conversion faulty. Contact Service.
53 253 2 Nonvolatile check sum er‐ Contact Service.
ror.
53 253 12 Write error EEPROM. Contact Service.
53 253 13 Out of calibration. Contact Service.
54 84 12 Vehicle's speed sensor de‐ 1. Check wiring.
fect.
2. Contact Service.
55 216 14 Fault of other control unit Contact Service.
(version 27.0 or later). This
fault is stored in connection
with another fault to refer to
missing information of an‐
other control unit.
55 231 12 Data connection J1939 faul‐ Contact Service.
ty.
55 248 8 System-related data con‐ Contact Service.
nection faulty (master).
55 248 9 System-related data con‐ Contact Service.
nection (repeater).
ty.
ty.
58 92 0 Torque too high. Contact Service.
TIM-ID: 0000003162 - 001
61 xxx 0 Reaction time injection noz‐ Contact Service.

zle xxx too long.
62 26 3 Auxiliary output 1, short cir‐ Contact Service.
cuit on battery circuit (plus)
F3.
cuit F3.

code
62 26 7 Auxiliary output 1, mechani‐ Contact Service.
cal system does not re‐
spond correctly F3.
A2.
cuit A2.
spond correctly A2.
W3.
cuit W3.
spond correctly W3.
X3.
cuit X3.
spond correctly X3.
Y3.
cuit Y3.
spond correctly Y3.
A1.
cuit A1.
TIM-ID: 0000003162 - 001

spond correctly A1.
63 57 0 PWM 1 above normal Contact Service.
range.
63 57 1 PWM 1 below normal Contact Service.
range.

code
63 57 3 PWM 1 short circuit on bat‐ Contact Service.
tery circuit (plus).
63 57 4 PWM 1 open circuit. Contact Service.
range.
range.
range.
range.
range.
range.
64 103 0 Exhaust turbocharger Contact Service.
speed too high.
64 103 8 Exhaust turbocharger Contact Service.
speed sensor, input signal
faulty (irregular period).
65 51 0 Throttle position above nor‐ Contact Service.
mal range.
65 51 1 Throttle position below nor‐ Contact Service.
mal range.
65 51 2 Throttle position not regular. Contact Service.
65 51 7 Throttle does not respond. Contact Service.
65 107 3 Air filter differential pressure 1. Check wiring.
sensor, voltage too high.
2. Contact Service.
TIM-ID: 0000003162 - 001
65 107 4 Air filter differential pressure 1. Check wiring.

sensor, voltage too low.
2. Contact Service.
66 99 3 Oil filter differential pressure 1. Check wiring.
sensor, voltage too high.
2. Contact Service.
66 99 4 Oil filter differential pressure 1. Check wiring.
sensor, voltage too low.
2. Contact Service.

code
66 76 0 Engine knock level above Contact Service.
normal range.
66 76 3 Knock sensor, input voltage Contact Service.
too high.
66 76 4 Knock sensor, input voltage Contact Service.
too low.
66 76 7 Knock sensor does not re‐ Contact Service.
spond.
67 20 3 Coolant pressure sensor, Contact Service.
high range (input voltage
too high).
high range (input voltage
too low).
67 106 3 Air intake pressure sensor, Contact Service.
67 106 4 Air intake pressure sensor, Contact Service.
68 230 5 Idling recognition pedal Contact Service.
travel sensor (TPS), fault in
circuit (circuit open).
68 230 6 Idling recognition pedal Contact Service.
travel sensor (TPS), fault in
circuit (ground short circuit).
71 xxx 1 Reaction time injection noz‐ Contact Service.
zle xxx too short.
72 84 0 Vehicle's speed too high. Contact Service.
72 84 11 Vehicle's speed too high Contact Service.
(absolute).
72 65 0 Oxygen concentration too Contact Service.
high.
72 65 1 Oxygen concentration too Contact Service.
low.
73 107 0 Air filter differential pressure 1. Check signal ring position of
TIM-ID: 0000003162 - 001
too high. service indicator (→ Page 93).

2. Contact Service.
73 77 0 Gas valve position above Contact Service.
normal range.
73 77 1 Gas valve position below Contact Service.
normal range.
73 77 3 Gas valve position input Contact Service.
voltage too high.

code
73 77 4 Gas valve position input Contact Service.
voltage too low.
73 77 7 Gas dosing valve does not Contact Service.
respond.
73 151 14 ESS transmission, engaged Contact Service.
gear step jamming.
73 226 11 Transmission idling switch Contact Service.
defective, (ESS transmis‐
sion).
73 227 2 Analog auxiliary input: data Contact Service.
failing irregularly or defec‐
tive (ESS transmission).
73 227 3 Analog auxiliary input 1, Contact Service.
voltage too high (ESS
transmission).
73 227 4 Analog auxiliary input 1, Contact Service.
voltage too low (ESS trans‐
mission).
74 70 4 Optimized idle security Contact Service.
loop) ground short circuit.
74 99 0 Oil filter plugged. 1. Replace oil filter
(→ Page 100)
2. Contact Service.
75 168 0 ECM battery voltage too Contact Service.
high.
75 214 0 Real time clock backup, Contact Service.
battery voltage too high
75 232 0 Sensor supply voltage too Contact Service.
high.
76 121 0 Engine overspeed with ex‐ Contact Service.
haust brake.
77 3 0 Cylinder head temperature Contact Service.
too high.
77 19 0 High range: oil pressure too Contact Service.
high.
77 20 0 High range: coolant pres‐ Contact Service.
sure too high.
TIM-ID: 0000003162 - 001
77 72 0 Blower bypass position too Contact Service.

high.
77 72 1 Blower bypass position too Contact Service.
low.
77 73 1 Fire pump pressure too low. Contact Service.
77 81 0 Exhaust back pressure too Contact Service.
high.
77 81 1 Exhaust back pressure too Contact Service.
low.

code
77 81 3 Exhaust back pressure sen‐ Contact Service.
sor voltage too high.
77 81 4 Exhaust back pressure sen‐ Contact Service.
sor voltage too low.
77 81 12 Exhaust back pressure near Contact Service.
limit for power reduction.
77 95 1 Fuel filter differential pres‐ Contact Service.
sure too low.
77 99 1 Oil filter differential pressure Contact Service.
too low.
77 100 0 Engine oil pressure too Contact Service.
high.
77 102 1 Charge-air pressure too Contact Service.
low.
77 105 1 Inlet elbow temperature too Contact Service.
low.
77 107 1 Air filter differential pressure Contact Service.
too low.
77 108 0 Atmospheric pressure too Contact Service.
high.
77 108 1 Atmospheric pressure too Contact Service.
low.
77 109 0 Coolant pressure too high. Contact Service.
77 110 1 Coolant temperature too Contact Service.
low.
77 111 0 Coolant level too high. 1. Check coolant level
(→ Page 103).
2. Contact Service.
77 171 0 Outside temperature too Contact Service.
high.
77 171 1 Outside temperature too Contact Service.
low.
77 172 1 Intake air temperature too Contact Service.
low.
77 174 0 Fuel temperature too high. Contact Service.
77 174 1 Fuel temperature too low. Contact Service.
77 175 1 Engine oil temperature too Contact Service.
TIM-ID: 0000003162 - 001
low.
77 222 14 Theft protection faulty. Contact Service.
77 251 10 Clock module with irregular Contact Service.
alteration speed.
77 251 13 Clock module faulty. Contact Service.
77 252 10 Clock module with irregular Contact Service.
alteration speed.
77 252 13 Clock module faulty. Contact Service.

code
77 354 0 Relative air humidity above Contact Service.
range (version 33.0 or lat‐
er).
77 354 1 Relative air humidity under Contact Service.
range (version 33.0 or lat‐
er).
77 446 0 Cylinder head temperature Contact Service.
above range (version 33.0
or later).
77 151 11 Maintenance display lamp, Contact Service.
faulty / service interval ex‐
ceeded (version 32.0 or lat‐
er).
78 86 14 Self-adaptive speed control Contact Service.
faulty (version 27.0 or later).
81 98 3 Oil level sensor, input volt‐ Contact Service.
age too high.
81 101 3 Crankcase pressure sen‐ Contact Service.
81 153 3 Crankcase pressure, input Contact Service.
voltage too high (version
27.0 or later).
high.
81 173 3 Exhaust gas temperature Contact Service.
high.
81 411 3 EGR OPD, circuit defec‐ Contact Service.
tive / high (version 33.0 or
later).
81 412 3 EGR temperature too high Contact Service.
81 129 3 Exhaust duct temperature Contact Service.
1, sensor voltage too high
TIM-ID: 0000003162 - 001


code
81 154 3 EGR temperature, input Contact Service.
voltage too high.
81 155 3 EGR differential pressure, Contact Service.
81 277 9 EGR mass flow, intelligent Contact Service.
sensor does not respond
TIM-ID: 0000003162 - 001
81 277 12 EGR mass flow, intelligent Contact Service.

sensor failure (version 33.0
or later).
82 98 4 Oil level sensor, input volt‐ Contact Service.
age too low.

code
sor, input voltage (version
27.0 or later).
low.
low.
82 411 4 EGR OPD, sensor circuit Contact Service.
defective / low (version 33.0
or later).
82 412 4 EGR temperature too low Contact Service.
1, sensor voltage too low
TIM-ID: 0000003162 - 001


code
82 154 4 EGR- temperature, input Contact Service.
voltage too high.
82 155 4 EGR differential pressure Contact Service.
82 412 9 EGR temperature, intelli‐ Contact Service.
gent sensor does not re‐
spond (version 33.0 or lat‐
er).
82 412 12 EGR temperature, intelli‐ Contact Service.
gent sensor failure (version
33.0 or later).
83 73 0 Pump pressure too high. Contact Service.
83 98 0 Oil level too high. 1. Check engine oil level
(→ Page 96).
2. Contact Service.
83 101 0 Crankcase pressure too Contact Service.
high.
high (version 27.0 or later).
too high.
83 411 0 EGR OPD, high (version Contact Service.
33.0 or later).
83 412 0 EGR temperature too high Contact Service.
TIM-ID: 0000003162 - 001


code
TIM-ID: 0000003162 - 001

84 98 1 Oil level low. 1. Check engine oil level
(→ Page 96).
2. Contact Service.
low.
84 153 1 Crankcase pressure too low Contact Service.

code
85 190 0 Engine idle speed too high. Contact Service.
85 190 14 Engine overspeed signal Contact Service.
86 73 3 Pump pressure sensor, in‐ Contact Service.
86 108 3 Atmospheric pressure sen‐ Contact Service.
87 73 4 Pump pressure sensor, in‐ Contact Service.
87 108 4 Atmospheric pressure sen‐ Contact Service.
88 20 1 High range: coolant pres‐ Contact Service.
sure too low.
88 109 1 Coolant pressure too low. Contact Service.
89 95 0 Fuel differential pressure Contact Service.
too high.
89 111 12 Coolant level, maintenance 1. Check coolant level
note, fault. (→ Page 103).
2. Contact Service.
TIM-ID: 0000003162 - 001

7 Task Description
7.1 Engine
7.1.1 Engine – Barring manually
Preconditions

Barring device F6555766 1
Barring device F6783293 1
Adapter F6558528 1
Ratchet F30006212 1
DANGER
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
Barring engine manually (lateral

installation)
1. Remove guard plate.
2. Engage barring device (2) in ring gear (3)
and install on flywheel housing.
• Use barring device F6555766.
3. Set ratchet (1) onto barring device (2).
4. Rotate crankshaft in engine direction of ro‐
tation. Apart from the normal compression
resistance, there should be no resistance.
5. For barring device removal follow reverse
sequence of working steps.
TIM-ID: 0000002521 - 004
64 | Task Description | M015241/03E 2011-12

Barring engine manually
(installation on lower side)
1. Remove grounding device or guard plate.
2. Engage barring device (2) with ring gear (1)
and mount on flywheel housing.
• For 12/16V engines, use barring device
F6555766 with adapter F6558528.
• For 20V engines, use barring de‐
vice F6783293.
3. Set ratchet (3) onto barring device (2).
4. Rotate crankshaft in engine direction of ro‐
tation. Apart from the normal compression
resistance, there should be no resistance.
5. For barring device removal follow reverse
sequence of working steps.
TIM-ID: 0000002521 - 004
M015241/03E 2011-12 | Task Description | 65

7.1.2 Engine – Barring with starting system
DANGER
Risk of serious injury – Danger to life!
• Before barring the engine, ensure that nobody is in the danger zone.
Engine – Barring with starting

system
1. Remove screws (1, 3) and take off perforat‐
ed plate (2).
2. Withdraw plug (5) from crankshaft angle

sensor for injection timing of any cylinder
(→ Page 26). For this purpose, unlock
latch (4).
3. Bar engine in unloaded condition: Press
START button.
Note: Interrupt engine start after maximum ten
seconds for thirty seconds to prevent starter
from overheating.
4. Let the crankshaft rotate until oil pressure is
indicated.
Note: If no oil pressure is indicated after three
start cycles, contact Service.
5. Slide on connector (5) until lock (4) latches
into position.
6. Fit perforated plate (2) and secure with two
screws (1, 3).
TIM-ID: 0000002786 - 001

7.2 Cylinder Liner
7.2.1 Cylinder liner – Endoscopic examination
Preconditions
☑ Engine is stopped and starting disabled

Endoscope Y20097353
Preparatory steps
1. Remove cylinder head cover (→ Page 80).
2. Remove injector (→ Page 83).
Positioning crankshaft at BDC

1. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached
BDC.
2. Insert endoscope into cylinder liner through injector seat.
Cylinder liner endoscopic examination

Findings Measure
• Thin carbon coating on carbon scraper ring No action required
• Slight localized additive deposits at top edge
• Localized smooth areas at bottom edge
• Carbon deposits on entire circumference between top piston ring
and bottom edge of carbon scraper ring
• First signs of marks left by top piston ring
• Bright mark on entire circumference
• Faultless, even honing pattern
• First signs of marks left by lower cooling bores
• Running pattern seems darker
• Dark areas with even or varying degrees of discoloration Further endoscopic examina‐
• Beginning and end of the discoloration are not sharply defined and tion required as part of main‐
do not cover the entire stroke area tenance work
• Dark areas in the upper section of the cooling bore, remaining cir‐
cumference cannot be faulted
• Piston rings cannot be faulted
• On the entire circumference, apart from light areas of discoloration Cylinder liner must be re‐
(do not impair operation) clearly darker stripes that start at the top placed; Service must be con‐
TIM-ID: 0000003304 - 003
piston ring tacted

• Heat discoloration in the direction of stroke and honing pattern dam‐
age
• Heat discoloration of piston rings
1. Compile endoscopy report using the table.
2. Use technical terms for description of the liner surface (→ Page 69).
3. Depending on findings:
• Do not take any action or
• carry out a further endoscopic examination as part of maintenance work or
• contact Service; cylinder liner must be replaced.

Final steps
1. Install injector (→ Page 83).
2. Install cylinder head cover (→ Page 80).
TIM-ID: 0000003304 - 003

7.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐
nation report.
Findings Measure
Light scoring Minor dirt scores can occur during the assembly of a new engine (honing prod‐
ucts, particles, broken-off burrs). Removed cylinders clearly exhibit such scor‐
ing on the running surface under endoscope magnification. Cannot be felt with
the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC
area and cross through the honing pattern in the direction of stroke.
Scored area These areas consist of scores of different lengths and depths next to one an‐
other. In most cases, they are found at the 6-o'clock and 12-o'clock positions
(inlet/exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are changes to the running surface but almost the whole
honing pattern is still visible. Smoothened areas appear brighter and more bril‐
liant than the surrounding running surface.
Polished area Polished areas are on the running surface and show local removal of the hon‐
ing pattern. Grooves from the honing process are not visible any more.
New cylinder liners must be fitted in the following cases
Polished area:
covers more than 20% of the entire piston running surface,
covers more than 30° of the circumference and extends over more than 50%
of piston stroke,
is wider than 15 mm over the entire piston stroke.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐
perature differences around the liner. It appears rather darker within the honed
structure in contrast to the bright metallic running surface. The honing pattern
is undisturbed. Discolorations extend in stroke direction and may be interrupt‐
ed.
TIM-ID: 0000003285 - 003
Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves in
the overlap (open) position. They are clearly visible due to the dark color of the
honing groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear
discoloration from TDC to BDC in the running surface and the start of localized
damage to the honing pattern.
Cylinders with a number of black lines around the running surface have limited
service life and should be replaced.

Findings Measure
Discolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they
run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring
and becoming more visible from the second TDC-ring onwards and less pro‐
nounced from TDC-ring 1. The honing pattern is usually no longer visible and
displays a clearly defined (straight) edge to the undisturbed surface. The dam‐
aged surface is usually discolored. The circumferential length varies.
Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.
Seizures, Seizure Seizure marks are of irregular circumferential length and depth. Can be
marks caused by either the piston skirt or the piston crown. Material deposits on the
liner (smears) show heavy discoloration and scoring.
Replace liner.
Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in‐
vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un‐
necessary disassembly work, it is recommended that another inspection be carried out after further oper‐
ation of the engine.
TIM-ID: 0000003285 - 003

7.3 Crankcase Breather
7.3.1 Crankcase breather – Oil separator check
Preconditions
☑ Engine is running.
Checking oil separator

Note: A thin oil film is admissible.
1. Check oil separator for damage and exces‐
sive oil discharge (arrow).
2. Replace oil separator if it is defective
(→ Page 72).
TIM-ID: 0000003511 - 005

7.3.2 Crankcase breather – Filter element replacement
Preconditions

Torque wrench 10-60 Nm F30510423 1
Filter element (→ Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Crankcase breather (closed-circuit

crankcase ventilation) – Filter
element replacement
1. Loosen clamps (1), push rubber sleeves (2)
over tubes (3).
2. Operate lever (6) to relieve clamping band
(4).
3. Remove cover (7).
4. Replace filter element (5).
5. Fit cover (7).
6. Operate lever (6) to tension clamping band
(4).
7. Push back rubber sleeve (2) and tighten
clamp (1).
8. Replace further filter elements in the same
way. TIM-ID: 0000003532 - 001

Crankcase breather (open-circuit
crankcase ventilation) – Filter
element cleaning or replacement
1. Clean filter (6) outside.
2. Undo clamp (2) and screw (7).
3. Pull hose (1) off cover (3).
4. Loosen clamp (5).
5. Remove cover (3).
6. Clean filter element (4) (→ Page 74) or re‐
place.
7. Fit cover (3).
8. Use torque wrench to tighten clamp (5) to
specified torque 12 Nm to 14 Nm.
9. Push hose (1) onto cover (3).
10. Tighten clamp (2) and screw (7).
11. Replace further filter elements (2) in the
same way.
TIM-ID: 0000003532 - 001

7.3.3 Crankcase breather (open-circuit crankcase ventilation) – Filter element
cleaning
Preconditions
WARNING
Compressed air
Risk of injury!
CAUTION
Excessive reaction time of cleaning agents on components.
• Observe manufacturer's instructions.
Filter element – Removal / installation .

u (→ Page 72)
Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning

1. Clean filter element with cleaning agent.
2. Remove cleaning agent.
3. Blow out filter element thoroughly with compressed air.
TIM-ID: 0000003508 - 002

7.4 Valve Drive
7.4.1 Valve gear – Lubrication
Preconditions

Engine oil
Valve gear – Lubrication

1. Remove cylinder head covers (→ Page 80).
2. Fill oil chambers of rocker arms and adjust‐
ing screws with oil.
3. Install cylinder head covers (→ Page 80).
TIM-ID: 0000004337 - 004

7.4.2 Valve clearance – Check and adjustment
Preconditions
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.

Feeler gage Y20010128 1
Torque wrench 60-320 Nm F30047446 1
Socket box wrench F30039526 1
Engine oil
Preparatory steps
2. Install barring gear (→ Page 64).
3. Turn crankshaft in direction of engine rota‐
tion with barring gear until “OT-A1” mark
and pointer are aligned.
TIM-ID: 0000004357 - 005

Diagram for 8V – Two crankshaft
positions
1. Crank drive position 1: cylinder A1 in firing
TDC
2. Crank drive position 2: cylinder A1 in over‐
lap TDC
3. Inlet valve (I)
4. Exhaust valve (X)

positions
TDC
lap TDC
3. Inlet valve (I)

positions
TDC
lap TDC
3. Inlet valve (I)
TIM-ID: 0000004357 - 005

positions
TDC
lap TDC
3. Inlet valve (I)
Checking valve clearance in two crankshaft positions

1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet valves (long rocker arm) = 0.2 mm
• Exhaust valves (short rocker arm) = 0.5 mm
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as
per diagram.
4. Use feeler gage to determine the distance between valve bridge and rocker arm.
5. If the deviation from the specified value exceeds 0.1 mm, adjust valve clearance.
Adjusting valve clearance

1. Release locknut (1).
2. Insert feeler gage between valve bridge and
rocker arm.
3. Turn adjusting screw (2) with Allen key until
appropriate valve clearance is set.
4. Feeler gage must just pass through the
gap.
TIM-ID: 0000004357 - 005
5. Tighten locknut (1) to specified torque using a torque wrench holding adjusting screw (2) firmly in so do‐
ing.
Name Size Type Lubricant Value/Standard
Nut M16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.

Final steps
1. Remove barring gear (→ Page 64).
TIM-ID: 0000004357 - 005

7.4.3 Cylinder head cover – Removal and installation
Preconditions
☑ Engine shut down and starting disabled.

Gasket (→ Spare Parts Catalog)
Removing cylinder head cover

1. Clean cylinder head covers prior to removal
if they are heavily soiled.
2. Remove screws.
3. Remove cylinder head cover with gasket
from cylinder head.
Installing cylinder head cover

1. Clean mating face.
2. Check condition of gasket, replace if necessary.
3. Place gasket and cylinder head cover on cylinder head.
4. Install cylinder head cover.
TIM-ID: 0000000923 - 005

7.5 Injection Pump / HP Pump
7.5.1 HP pump – Relief bore check
DANGER
WARNING
Checking HP pump relief bore

1. Check relief bore for oil and fuel discharge
by visual inspection.
2. If relief bore is contaminated, stop the en‐
gine, disable engine start, and clean relief
bore.
3. Note the following in case of fluid dis‐
charge:
• Heavy discharge means continuous dis‐
charge of fluids (leakage). Contact Serv‐
ice.
• Minor discharge of fluids up to 10 drops
per day is normal (moistening) and not
considered a leakage.
TIM-ID: 0000000924 - 004

7.6 Injection Valve / Injector
7.6.1 Injector – Replacement

Injector (→ Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector (→ Page 83).
TIM-ID: 0000000022 - 011

7.6.2 Injector – Removal and installation
Preconditions

Installation and removal tool for injector F6790161 1
Milling cutter F30452739 1
Slotted nut screwdriver F30452578 1
Torque wrench, 0.5-5 Nm 0015384230 1
Torque wrench, 10-60 Nm F30510423 1
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/emulsifier) X00058060 1
Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
• Do not smoke.
CAUTION
Removal of all injectors.
• Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.
CAUTION
Cable damage during operation.
Fire hazard!
• Twist cables when installing.
• Ensure that cables do not touch components.
Preparatory steps
1. Shut off fuel inlet to engine.
TIM-ID: 0000000952 - 004

Removing injector
Note: Always replace the first and last injectors of
one engine side first. Replace the inner in‐
jectors only after the installation of the outer
injectors on this engine side is completed.
1. Undo cable terminal screws (arrow) on in‐
jector and remove cable terminals.
2. Remove screw (2) and take off hold-down

clamp (1).
3. Remove high-pressure fuel line (5).
4. Install installation/removal device on cylin‐

der head.
5. Remove injector with installation/removal
device.
6. Remove installation/removal device.
TIM-ID: 0000000952 - 004

7. Remove sealing ring (1) from injector or use
a self-made wire hook to extract it from the
cylinder head.
8. Remove O-rings (2) from injector.
9. Cover all connections and bores, or seal
with suitable plugs.
Installing injector
1. Remove all plugs before installing.
2. Coat nozzle retaining nut area of injector
with assembly paste.
3. Fit new O-rings on injector and coat with
grease.
4. Fit new sealing ring on injector with grease
ensuring correct installation position of seal‐
ing ring.
5. Clean sealing surface on cylinder head and

protective sleeve with milling cutter.
6. Insert injector into cylinder head ensuring
that the HP line connection is aligned cor‐
rectly.
7. Press in injector with installation/removal
device.
8. Remove installation/removal device.
TIM-ID: 0000000952 - 004

9. Use slotted screwdriver to check thrust ring
at both line ends for secure seating.
10. Tighten loose thrust ring to the specified tightening torque.

Thrust ring Tightening torque 5 Nm to 10 Nm
11. Coat screw head mating face (2) and
thread with engine oil.
12. Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to the
specified initial tightening torque.
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
TIM-ID: 0000000952 - 004
13. Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease.
14. Tighten high-pressure fuel line (5) to the specified initial tightening torque.
HP line Preload torque (Engine oil) 5 Nm to 10 Nm
15. Tighten screw (2) to specified torque using a torque wrench.
Screw M12 Tightening torque 100 Nm + 10 Nm

16. Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench.
Union nut Tightening torque 140 Nm + 10 Nm
17. Tighten union nut of connecting piece (injector) to specified torque using a torque wrench.
Union nut Tightening torque 120 Nm +10 Nm
18. Twist cable several times.
19. Insert cable terminals (arrows) underneath screws on injector and tighten screws to specified torque us‐
ing a torque wrench.
Screw Tightening torque 1.5 Nm
Final steps
2. Open up fuel inlet to engine.
TIM-ID: 0000000952 - 004

7.7 Fuel System
7.7.1 Fuel system – Venting
Preconditions

Filling device B80144852 1
Diesel fuel
WARNING
• Do not smoke.
Venting LP fuel system

1. Connect filling device to connection (3).
2. Disconnect return line at connection (4).
3. Use hand pump to fill fuel system, providing
pressure of min. 0.5 bar / max. 2.0 bar, until
fuel emerges without bubbles at connection
(4).
4. Connect return line to connection (4).
5. Open vent plug (1) on filter housing (2).
6. Use hand pump to fill fuel system, providing
pressure of min. 0.5 bar / max. 2.0 bar, until
fuel emerges without bubbles at connection
(1).
7. Close vent plug (1).
8. Remove filling device and seal connection
(3). TIM-ID: 0000004708 - 001

7.8 Fuel Filter
7.8.1 Fuel filter – Replacement
Preconditions

Filter wrench F30379104 1
Engine oil
Easy-change filter (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Replacing fuel filter

1. Remove easy-change filter using filter
wrench.
2. Clean sealing surface on filter head.
3. Slightly lubricate seal on the easy-change
filter.
4. Screw on easy-change filter by hand until
the seal connects and tighten manually.
5. Vent fuel system (→ Page 88).
6. Replace other easy-change filters in the
same way.
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7.8.2 Fuel prefilter – Draining
Preconditions

Diesel fuel
WARNING
• Do not smoke.
Draining fuel prefilter

1. Shut down the filter unit (5/8) to be changed
at valves (3) and (4) or (9) and (10).
2. Open threaded vent plug (1) or (2) on filter
to be drained.
3. Open drain valve (6) or (7).
4. Drain water and contaminants from the filter
until pure fuel emerges.
5. Close drain valve (6) or (7).
6. Open fuel return line (3) or (10).
7. Open fuel inlet (4) or (9).
8. Close threaded vent plug (1) or (2) on filter
to be drained when clean fuel emerges.
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7.8.3 Edge-type fuel filter – Draining
Preconditions

Diesel fuel
Sealing ring (→ Spare Parts Catalog)
WARNING
• Do not smoke.
Edge-type fuel filter – Draining

1. Rotate edge-type filter (2) with handle (1)
clockwise several times.
2. Do not apply force when rotating handle.
3. Close fuel supply.
4. Remove drain plug (3) from edge-type filter
(2).
5. Drain water and contaminants through drain
plug opening (3) until pure fuel emerges
from filter.
6. Fit drain plug (3) with new sealing ring and
screw in.
7. Open fuel supply.
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7.9 Charge-Air Cooling
7.9.1 Intercooler – Check drain for coolant leakage and obstruction
DANGER
WARNING
WARNING
Compressed air
Risk of injury!
Intercooler – Check drain for

coolant leakage and obstruction
1. Verify that air emerges from condensate
drain bore(s) on left and right engine sides
at driving end when engine is running. If no
air emerges:
• Clean drain bore(s)
• Blow out with compressed air
2. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con‐
tact Service.
Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 83).
2. Bar engine manually (→ Page 64).
3. Crank engine on starting system to blow out combustion chambers (→ Page 66).
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4. Install injectors (→ Page 83).

7.10 Air Intake
7.10.1 Service indicator – Check
See manufacturer's documentation.

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7.11 Starting Equipment
7.11.1 Starter – Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring (→ Page 127).
TIM-ID: 0000000905 - 011

7.11.2 Cold start system with ether injection – Check
Preconditions

Ether cartridge (→ Spare Parts Catalog)
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
Checking filling level and condition

of system
Note: After two successive starting trials with cold
start system, make next starting trial after
10 minutes only. If the next two staring trials
fail, contact Service.
1. If the indicator lamp on the relay module (5)
lights up, fit a new ether cartridge (1).
2. Check the condition of lines (2) and con‐
nections. If damage is found, contact Serv‐
ice.
3. Check the condition of electric lines (4) and
connections. If damage is found, contact
Service.
4. In case of system failure, check the fuses in
the fuse holder (3). If fuses are broken, con‐
tact Service.
TIM-ID: 0000006126 - 001

7.12 Lube Oil System, Lube Oil Circuit
7.12.1 Engine oil level – Check
Preconditions
Checking oil level prior to engine

start
1. Withdraw oil dipstick from guide tube and
wipe it.
2. Insert oil dipstick into guide tube up to stop,
withdraw after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may
exceed the mark (1) by up to 2 cm. This
can be caused by oil flowing from e.g. oil fil‐
ter or heat exchanger back to the oil pan.
3. The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
4. Top up with oil to mark (1) as necessary
(→ Page 97).
5. Insert oil dipstick into guide tube up to the
stop.
Checking oil level after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. Top up with oil to mark (1) as necessary (→ Page 97).
5. Insert oil dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 009

7.12.2 Engine oil – Change
Preconditions
☑ Engine is at operating temperature.

Ratchet adapter F30027341 1
Engine oil
WARNING
Hot oil.
Procedure without pump: Draining oil via drain plug(s) on oil pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug(s) and drain oil.
3. Install drain plug(s) with new sealing ring.
Procedure with pump: Oil extraction

1. Provide a suitable container to collect the oil.
2. Extract all oil from oil pan using the pump.
Draining residual oil at equipment

carrier
1. Provide a suitable container to collect the
oil.
2. Remove drain plug (1) and drain oil (ap‐
prox. 7 liters) from oil heat exchanger and
oil filter.
3. Remove drain plugs (2) and (3) and drain
oil:
TIM-ID: 0000006152 - 003
• at drain plug (2) approx. 12 liters

• at drain plug (3) approx. 5 liters
4. Install drain plug(s) with new sealing ring.

5. Tighten drain plugs (2) and (3) with torque wrench to the specified torque.
Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm
Filling with new oil

1. Open cover on filler neck.
2. Fill oil through filler neck up to "max." mark
at oil dipstick.
3. Close cover on filler neck.
4. Check engine oil level (→ Page 96).
5. After oil change, bar engine with starting
system (→ Page 66).
TIM-ID: 0000006152 - 003

7.12.3 Engine oil – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
Hot oil.
WARNING
Engine oil sample extraction and

analysis
1. With the engine running at operating tem‐
perature, open screw on flange of centrifu‐
gal oil filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals of the
MTU test kit, examine oil for:
• Dispersing capacity (spot test);
• Water content;
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• Fuel dilution.

7.13 Oil Filtration / Cooling
7.13.1 Engine oil filter – Replacement
Preconditions

Engine oil
Oil filter (→ Spare Parts Catalog)
WARNING
Hot oil.
Engine oil filter – Replacement

1. Remove oil filter using the filter wrench.
2. Clean the sealing surface of the filter head.
Note: Use only oil filters with integrated safety
valve.
3. Check condition of the new sealing ring and
coat it with oil.
4. Screw on and tighten new oil filter by hand.
5. Replace further oil filters in the same way.
6. After each oil change and filter replace‐
ment, bar engine with starting system
(→ Page 66).
7. Check oil level (→ Page 96).
TIM-ID: 0000006396 - 001

7.13.2 Centrifugal oil filter – Cleaning and filter sleeve replacement
Preconditions

Cold cleaner (Hakutex 60) 50602 1
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Filter sleeve (→ Spare Parts Catalog)
WARNING
Hot oil.
WARNING
Compressed air
Risk of injury!
TIM-ID: 0000000958 - 003

Cleaning centrifugal oil filter and
replacing filter sleeve
1. Undo screw (1) and remove.
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor (5) from housing.
4. Hold rotor assembly (5) firmly in position
with filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
7. Measure thickness of oil residues on filter
sleeve.
8. If maximum layer thickness of oil residues
exceeds 30 mm, shorten maintenance in‐
terval.
9. Remove standpipe (12) from lower rotor
section (13).
10. Wash hood (2), rotor cap (8), stiffener
plate, (10) standpipe (12), rotor lower sec‐
tion (13) and nozzles (14) with cold cleaner
and blow out with compressed air. Do not
use sharp objects for cleaning.
11. Check nozzles (14) for obstructions.
12. Press standpipe (12) onto rotor lower sec‐
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
smooth surface of filter sleeve (9) faces ro‐
tor cap (8).
14. Check sealing ring (11), replace if necessa‐
ry. Coat sealing ring with grease and insert
in groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position
with filter wrench and tighten knurled
nut (7).
17. Lubricate bearings of rotor (5) with oil, in‐
sert into housing (6) and check for ease of
movement.
18. Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench.
TIM-ID: 0000000958 - 003
Clamp Tightening torque 6 Nm + 1 Nm

Screw Tightening torque 6 Nm + 1 Nm

7.14 Coolant Circuit, General, High-Temperature Circuit
7.14.1 Coolant level - Check
Preconditions
WARNING
Coolant is hot and under pressure.
• Let the engine cool down.
Checking coolant level at filler neck:

1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to
escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Check coolant level (coolant must be visible at the lower edge of the cast-in eye).
Checking coolant level at remote

cooler:
1. Check coolant level (coolant must be visible
at marking plate).
2. Top up coolant if necessary (→ Page 106).
3. Check and clean breather valve.
4. Place breather valve on filler neck and
close.
Coolant level check by means of level sensor:

1. Switch on engine control system and check readings on the display.
TIM-ID: 0000000937 - 010

7.14.2 Engine coolant – Change

Engine coolant
Changing engine coolant

1. Drain engine coolant (→ Page 105).
2. Fill with engine coolant (→ Page 106).
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7.14.3 Engine coolant – Draining
Preconditions
WARNING
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
Engine coolant – Draining

1. Turn breather valve on coolant expansion
tank counterclockwise up to the first stop
and allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
4. Open drain valves and/or drain plugs and
drain coolant at the following points:
• At the preheating unit;
• At the HT coolant pump elbow;
• At the crankcase, left and right side.
5. Additional drain points on 12/16V 4000 M

engines:
• T-piece (3) on engine driving end;
• Intercooler (2), left and right side;
• Carrier-housing cover (1), left and right
side.
6. Close all open drain points.
close.
TIM-ID: 0000006745 - 002

7.14.4 Engine coolant – Filling
Preconditions

Engine coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
TIM-ID: 0000006715 - 001

Filling coolant with pump
1. Connect appropriate pump with hose to
drain valve.
2. Open drain valve and pump coolant into en‐
gine at 0.5 bar minimum.
3. Fill expansion tank until overflow edge is
reached.
4. Close drain valve.
5. Check proper condition of breather valve,
clean sealing faces if required.
6. Set breather valve onto filler neck and close
it.
7. Start engine (→ Page 35).
8. After the engine has run at unloaded condi‐
tion for 10 seconds, stop engine
(→ Page 37).
11. Check coolant level (→ Page 103) and top
up if required:
a) Fill in coolant in expansion tank until the
coolant level at top edge of filler neck
remains constant.
b) Set breather valve onto filler neck and
close it.
c) Repeat the steps from "Start engine"
(→ Step 7) until coolant is no longer
needed to be topped up.
d) Disconnect pump and hose.
Filling coolant through filler neck

1. Alternatively: Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains
constant.
2. Check proper condition of breather valve, clean sealing faces if required.
3. Set breather valve onto filler neck and close until first stop is reached.
5. After the engine has run at unloaded condition for 10 seconds, stop engine (→ Page 37).
6. Turn breather valve counterclockwise and remove.
7. Check coolant level (→ Page 103) and top up if required:
a) Repeat the steps from "Start engine" (→ Step 4) until coolant is no longer needed to be topped up.
b) Check proper condition of breather valve, clean sealing faces if required.
c) Set breather valve onto filler neck and close it.
TIM-ID: 0000006715 - 001
Final steps
1. Start the engine and operate it at unloaded condition for some minutes.
2. Check coolant level (→ Page 103) and top up if required.

7.14.5 Engine coolant pump – Relief bore check
DANGER
WARNING
Checking relief bore on engine

coolant pump
1. Checking relief bore for oil and coolant dis‐
charge.
2. Stop engine (→ Page 37) and disable en‐
gine start, observe general safety instruc‐
tions for maintenance and repair.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to 10
drops per hour.
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000000961 - 007

7.14.6 Coolant – Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
WARNING
Coolant sample extraction and

analysis
1. With the engine running, open drain valve
(1).
2. Flush sample-extraction point by draining
approx. 1 liter coolant.
3. Drain approx. 1 liter coolant into a clean
container.
4. Close drain valve (1).
5. Using the equipment and chemicals of the
MTU test kit, check the coolant for:
• Antifreeze concentration
• Corrosion inhibitor concentration
• pH value.
6. For coolant change intervals, see (→ MTU
Fluids and Lubricants Specifications.)
TIM-ID: 0000000938 - 005

7.15 Low-Temperature Circuit
7.15.1 Charge-air coolant – Level check
Preconditions
WARNING
Checking charge-air coolant level

at filler neck:
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
3. Check coolant level (coolant must be visible
at marking plate).
5. Check proper condition of breather valve,
clean sealing faces if required.
6. Fit breather valve and close it.
Checking charge-air coolant level by means of level sensor:

1. Switch on engine control system and check display (coolant level is automatically monitored by engine
control system).
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7.15.2 Charge-air coolant – Change

Charge-air coolant
Charge-air coolant – Change

1. Drain charge-air coolant (→ Page 112).
2. Fill with charge-air coolant (→ Page 113).
TIM-ID: 0000000041 - 009

7.15.3 Charge-air coolant – Draining
Preconditions

WARNING
Charge-air coolant – Draining

1. Provide an appropriate container to drain
the coolant into.
4. Draw off separated corrosion inhibitor oil in
expansion tank through the filler neck.
5. Open drain valves and/or drain plugs and
drain coolant at the following points:
• At the LT coolant pump;
• At the coolant lines to and from the inter‐
cooler.
6. Draining of residual coolant:

• At the intercooler
7. Close all drain valves and screw in drain
plugs with new sealing rings.
8. Set breather valve onto filler neck and close
it.
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7.15.4 Charge-air coolant – Filling
Preconditions

Coolant
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve of coolant expansion
2. Turn breather valve counterclockwise and
remove.
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Filling with coolant using a pump
1. Connect a suitable pump with a hose to the
drain valve (arrowed).
2. Open vent on intercooler (arrow).

3. Open drain valve and pump coolant into en‐
gine at 0.5 bar minimum.
4. Close venting point when coolant emerges.
5. Fill expansion tank up to overflow.
6. Close drain valve.
7. Check proper condition of breather valve
and clean sealing faces if required.
close.
10. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 37).
11. Turn breather valve of coolant expansion
remove.
up coolant as required:
a) Top up with coolant via expansion tank
until the coolant level is constant at the
overflow.
b) Place breather valve on filler neck and
close.
14. Repeat the steps from "Start engine"
(→ Step 8) until coolant is no longer needed
to be topped up.
TIM-ID: 0000007013 - 002
15. Disconnect pump and hose.

Alternatively: Filling coolant
through filler neck
1. Remove plug screws from filling points (ar‐
rows) on coolant lines from and to the inter‐
cooler.
2. Open air bleed on the intercooler (arrow).

3. Fill coolant via the filling points on the cool‐
ant lines to and from the intercooler and via
the expansion tank up to the overflow.
4. Close venting point when coolant emerges.
5. Install plug screws of filling points with new
sealing rings.
6. Check proper condition of breather valve
and clean sealing faces if required.
7. Set breather valve onto filler neck and turn
to the first stop.
9. After 10 seconds of running the engine
without load, shut down the engine
(→ Page 37).
remove.
up coolant as required:
a) Top up with coolant via expansion tank
until the coolant level is constant at the
overflow.
b) Place breather valve on filler neck and
close.
12. Repeat the steps from "Start engine"
(→ Step 7) until coolant is no longer needed
to be topped up.
Final steps
TIM-ID: 0000007013 - 002
1. Start the engine and run it without load for some minutes.
2. Check coolant level (→ Page 110) and top up coolant as required.

7.15.5 Charge-air coolant pump – Relief bore check
DANGER
WARNING
Charge-air coolant pump – Relief

bore check
1. Check relief bore for oil and coolant dis‐
charge.
2. Stop engine (→ Page 37) and disable en‐
gine start, observe general safety instruc‐
tions for maintenance and repair.
3. Clean the relief bore with a wire if it is dirty.
• Permissible coolant discharge: up to 10
drops per hour.
• Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits:
Contact Service.
TIM-ID: 0000000964 - 003

7.16 Belt Drive
7.16.1 Drive belt – Condition check
Preconditions
☑ Guard is removed.
Drive belt – Condition check
Item Findings Action

Drive belt A Singular cracks None
Drive belt Belt is oily, shows signs of over‐ Replace(→ Page 122)
heating
Drive belt B Cracks on entire circumference
Drive belt C Chunking
TIM-ID: 0000000920 - 008

7.17 Battery-Charging Generator
7.17.1 Battery-charging generator – Condition check
Preconditions
Battery-charging generator – Condition check

1. Check if securing screws of battery-charging generator fit firmly.
2. Tighten any loose threaded connections.
3. Check wiring (→ Page 127).
TIM-ID: 0000007427 - 001

7.17.2 Battery-charging generator – Check
Preconditions
WARNING
Compressed air
Risk of injury!
Checking battery-charging generator

Item Findings Measure
Ventilation area (arrow) Clean None
Ventilation area (arrow) Contaminated Clean
Cleaning battery-charging generator

Note: Dry-clean battery-charging generator only.
1. Remove coarse dirt from battery-charging generator.
2. Blow out ventilation area (arrow) with compressed air until all dust is cleared.
TIM-ID: 0000007378 - 003

7.17.3 Battery-charging generator – Removal and installation
Preconditions

WARNING
Heavy object.
Risk of crushing!
• Use appropriate lifting devices and appliances.
Removing battery-charging
generator
1. Undo screws (1), (2) and (3).
2. Remove protective cover (8).
3. Mark electric cables on battery-charging
generator and remove.
4. Protect all cables from damage.
5. Slacken screws (4) and (5) by half a turn.
6. Place socket adapter or box wrench on
screw (6) and press belt tensioner in the di‐
rection indicated by the arrow as far as it
will go.
7. Tighten screw (4).
8. Remove drive belt (7).
9. Release screws (arrow).

10. Remove battery-charging generator (1).
11. Clean battery-charging generator (1) thor‐
oughly (→ Page 119).
12. Install battery-charging generator (1) follow‐
ing reverse sequence of working steps.
TIM-ID: 0000007425 - 003

Tensioning drive belt
1. Fit drive belt (7).
2. Slacken screw (4) by half a turn.
Result: Belt tensioner moves against the drive belt and tensions it.
3. Use torque wrench to tighten screw (4) to specified tightening torque.
Screw M10x1.5 Tightening torque 60 Nm +5 Nm
Screw M10x1.5 Tightening torque 42 Nm
5. Install protective cover (8).
6. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 123).
TIM-ID: 0000007425 - 003

7.17.4 Battery-charging generator drive – Drive belt and belt tensioner replacement
Preconditions

WARNING
Heavy object.
Risk of crushing!
• Use appropriate lifting devices and appliances.
Replacing drive belt and belt

tensioner
1. Undo screws (1), (2) and (3).
2. Remove protective cover (8).
4. Place socket adapter or box wrench on
screw (6) and press belt tensioner in the di‐
rection indicated by the arrow as far as it
will go.
5. Tighten screw (4).
6. Remove drive belt (7).
7. Screw on screw (5) and replace belt ten‐
sioner.
8. Fit new drive belt (7).
Tensioning drive belt

1. Slacken screw (4) by half a turn.
Result: Belt tensioner moves against the drive belt and tensions it.
TIM-ID: 0000007421 - 004

5. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 123).

7.17.5 Battery-charging generator drive – Drive belt tension adjustment
Preconditions

WARNING
Spring/circlip/tensioning roller preload.
Risk of injury!
• Only use specified tool and equipment.
Adjusting belt tension

1. Undo screw (arrow) and remove protective
cover (3).
Result: Belt tensioner moves against the drive belt
and tensions it.

TIM-ID: 0000007386 - 002

7.18 Fan Drive
7.18.1 Fan drive belt– Tension check / adjustment
Preconditions

Optibell 2 belt tension tester Y4345711 1
Preparatory steps
1. Remove guard cover.
2. Check belt condition visually (→ Page 117).
Result: If required, replace drive belt (→ Page 126).
Checking Vee belt tension

1. Switch on belt tension tester.
2. Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrowed) with a suitable tool.
3. Hold belt tension tester over belt drive until the measured value is indicated.
Initial assembly at MTU Initial operation with fan Belt tension adjustment
36 Hz ± 5 Hz 49 Hz ± 5 Hz 44 Hz ± 5 Hz
TIM-ID: 0000007438 - 001

Adjusting drive belt tension
1. Release screws (2) until fan coupling can
be moved.
2. Tighten stud (1) until the required frequency
is achieved.
3. Tighten screws (2) to 250 Nm ± 25 Nm.
TIM-ID: 0000007438 - 001

7.18.2 Fan drive – Drive belt replacement
Preconditions

Drive belt (→ Spare Parts Catalog)
Preparatory steps
1. Remove protective cover.
2. Remove fan.
Replacing drive belt

1. Release screws (2).
2. Slacken off stud (1) until drive belt can be
removed.
3. Clean belt pulleys.
4. Fit new drive belt on belt pulleys, ensuring
that it is not under tension.
5. Adjust belt tension (→ Page 124).
TIM-ID: 0000007457 - 003

7.19 Wiring (General) for Engine/Gearbox/Unit
7.19.1 Engine wiring – Check
Preconditions

Isopropyl alcohol X00058037 1
Engine wiring – Check

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable ties are firm, tighten loose cable ties.
4. Replace faulty cable ties.
5. Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
6. (→ Contact Service) if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 016

7.20 Accessories for (Electronic) Engine Governor / Control
System
7.20.1 DDEC and connectors – Cleaning
Preconditions

Isopropyl alcohol
DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.
DDEC and connectors – Cleaning

1. Remove coarse dirt from housing surface
using a cloth moistened with isopropyl alco‐
hol.
2. Remove dirt from surface of connectors (1),
connector sockets and shrink sleeves (2)
using a cloth moistened with isopropyl alco‐
hol.
3. Check legibility of cable labels.
• Clean or replace illegible labels.
TIM-ID: 0000008476 - 001

Cleaning severely contaminated
connectors on DDEC
1. Disconnect connectors on both sides of
DDEC. For this purpose, withdraw connec‐
tors (1).
2. Unscrew connectors (3).
3. Remove covers (2).
4. Clean connector housings, connector sock‐
et housings and all contacts with isopropyl
alcohol.
5. When connectors, sockets and all contacts
are dry: Install connectors and check plug-
in connection on DDEC (→ Page 130).
TIM-ID: 0000008476 - 001

7.20.2 DDEC – Checking plug-in connections
Preconditions
Checking plug-in connections on

DDEC
1. Check all plug-in connections on both sides
of DDEC for secure seating.
2. Slide connectors (1) on until they latch into
position.
3. Screw in connectors (3) securely.
4. Seal non-assigned connector bases with
covering caps (2).
5. If plug-in connection is defective, contact
Service.
TIM-ID: 0000008478 - 001

8 Appendix A
8.1 Abbreviations
Abbreviation Meaning Explanation

A/D Analog/Digital Transformer: transforms sensor voltages into
numeric values
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
ANSI American National Standards Institute Association of American standardization or‐
ganizations
ATL Abgasturbolader Exhaust turbocharger (ETC)
ATS Air Temperature Sensor
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications,
Publication No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting of drift compensation in engine gov‐
ernor with DiaSys
CEL Stop Engine Light 1st function: Warning lamp (rectify fault as
soon as possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant Level Sensor Monitors coolant level
CPS Coolant Pressure Sensor Monitors coolant pressure
CTS Coolant Temperature Sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Die‐
sel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
DIN Deutsches Institut für Normung e. V. At the same time identifier of German stand‐
ards (DIN = “Deutsche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel
particulate filter
TIM-ID: 0000000858 - 008
DPF Diesel Particulate Filter

DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EEPROM Electrically Erasable Programmable
Read Only Memory
EFPA Electronic Foot Pedal Assembly
M015241/03E 2011-12 | Appendix A | 131

EGR Exhaust Gas Recirculation
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
EUI Electronic Unit Injector
FPS Fuel Pressure Sensor Monitors fuel pressure
FRS Fuel - Differential Pressure Sensor
FTS Fuel Temperature Sensor Monitors fuel temperature
FWCP Fire Water Control Panel Control cabinet
GND Ground
HD Hochdruck High Pressure (HP)
HI High Alarm: Measured value exceeds 1st maxi‐
mum limit
HIHI High High Alarm: Measured value exceeds 2nd maxi‐
mum limit value
HT High Temperature
IDM Interface Data Module Memory module for interface data
INJ Injector
ISO International Organization for Stand‐ International umbrella organization for all na‐
ardization tional standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO
1204
KS Kraftseite Engine driving end in accordance with DIN
ISO 1204
LED Light Emitting Diode
LO Low Alarm: Measured value lower than 1st mini‐
mum limit value
LOLO Low Low Alarm: Measured value lower than 2nd mini‐
mum limit value
LSG Limiting Speed Governor
N/A Not Applicable
LP Low Pressure
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor Monitors oil level
OPS Oil Pressure Sensor Monitors oil pressure
TIM-ID: 0000000858 - 008
OTS Oil Temperature Sensor Monitors oil temperature

OT Oberer Totpunkt Top Dead Center (TDC)
PAN Panel Control panel
PIM Peripheral Interface Module
PWM Modulated signal
P-xyz Pressure-xyz Pressure measuring point, xyz specifies the
measuring point designation
RL Redundancy Lost Alarm: Redundant CAN bus failure
132 | Appendix A | M015241/03E 2011-12

SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SEL Stop Engine Light 1st function: Warning lamp (stop engine and
rectify fault)
2nd function: Read out fault codes
SID System Identifier
SRS Synchronous Reference Sensor TDC cylinder 1
SS Safety System Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Deviation in transmitter values
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point, xyz specifies
the measuring point designation
UT Unterer Totpunkt Bottom Dead Center (BDC)
VNT Variable Nozzle Turbine
VSG Variable-Speed Governor
VSS Vehicle Speed Sensor
WZK Werkzeugkatalog Tool Catalog (TC)
TIM-ID: 0000000858 - 008
M015241/03E 2011-12 | Appendix A | 133

8.2 MTU contacts/service partners
Service
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
- either during operation, for preventive maintenance, corrective work in case of malfunction or changed
operating conditions, or for spare parts supply.
Your contact at Headquarters:Service-support@mtu-online.com
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system
- a central depot at Headquarters, as well as decentralized depots among our subsidiaries, representa‐
tives and contractual workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 010
134 | Appendix A | M015241/03E 2011-12

9 Appendix B
9.1 Special Tools
Adapter
Part No.: F6558528
Qty.: 1
Used in: 7.1.1 Engine – Barring manually (→ Page 64)
Barring device
Part No.: F6555766
Qty.: 1
Barring device
Part No.: F6783293
Qty.: 1
Endoscope
Part No.: Y20097353
Qty.:
Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 67)
Feeler gage
Part No.: Y20010128
Qty.: 1
Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 76)
Filling device
Part No.: B80144852
Qty.: 1
Used in: 7.7.1 Fuel system – Venting (→ Page 88)
Filter wrench
Part No.: F30379104
Qty.: 1
DCL-ID: 0000015148 - 001
Used in: 7.8.1 Fuel filter – Replacement (→ Page 89)

Qty.: 1
Used in: 7.13.1 Engine oil filter – Replacement (→ Page 100)
Qty.: 1
Used in: 7.13.2 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 101)
M015241/03E 2011-12 | Appendix B | 135

Installation and removal tool for injector
Part No.: F6790161
Qty.: 1
Used in: 7.6.2 Injector – Removal and installation (→ Page 83)
Milling cutter
Part No.: F30452739
Qty.: 1
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.12.3 Engine oil – Sample extraction and analysis (→ Page 99)
Qty.: 1
Used in: 7.14.6 Coolant – Sample extraction and analysis (→ Page 109)
Optibell 2 belt tension tester

Part No.: Y4345711
Qty.: 1
Used in: 7.18.1 Fan drive belt– Tension check / adjustment (→ Page 124)
Ratchet
Part No.: F30006212
Qty.: 1
Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 7.12.2 Engine oil – Change (→ Page 97)
Ratchet adapter
Part No.: F30027339
Qty.: 1
Ratchet adapter
DCL-ID: 0000015148 - 001
Part No.: F30027340

Qty.: 1
Used in: 7.17.3 Battery-charging generator – Removal and installation (→ Page 120)
Qty.: 1
Used in: 7.17.4 Battery-charging generator drive – Drive belt and belt tensioner replacement (→
Page 122)
Qty.: 1
Used in: 7.17.5 Battery-charging generator drive – Drive belt tension adjustment (→ Page 123)
136 | Appendix B | M015241/03E 2011-12

Slotted nut screwdriver
Part No.: F30452578
Qty.: 1
Socket box wrench

Part No.: F30039526
Qty.: 1
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.7 Plant – Cleaning (→ Page 39)
Torque wrench 10-60 Nm

Part No.: F30510423
Qty.: 1
Used in: 7.3.2 Crankcase breather – Filter element replacement (→ Page 72)
Torque wrench 60-320 Nm

Part No.: F30047446
Qty.: 1
Torque wrench, 0.5-5 Nm

Part No.: 0015384230
Qty.: 1
Torque wrench, 10-60 Nm

Part No.: F30510423
Qty.: 1

Part No.: F30026582
Qty.: 1
DCL-ID: 0000015148 - 001
Used in: 7.17.3 Battery-charging generator – Removal and installation (→ Page 120)
Qty.: 1
Used in: 7.17.4 Battery-charging generator drive – Drive belt and belt tensioner replacement (→
Page 122)
Qty.: 1
Used in: 7.17.5 Battery-charging generator drive – Drive belt tension adjustment (→ Page 123)
M015241/03E 2011-12 | Appendix B | 137

Part No.: F30027337
Qty.: 1
Used in: 7.12.2 Engine oil – Change (→ Page 97)

Part No.: F30027336
Qty.: 1

Part No.: F30047446
Qty.: 1
DCL-ID: 0000015148 - 001
138 | Appendix B | M015241/03E 2011-12

9.2 Index
16V 4000 E20 engine data 28 E
Edge-type fuel filter – Draining 91
A
Engine
Abbreviations 131 – Barring manually 64
After stopping the engine 38 – Shutdown in manual mode 37
– Start in manual mode 35
B
– Wiring check 127
Battery-charging generator Engine coolant
– Check 119 – Change 104
Battery-charging generator drive – Drive belt and belt Engine coolant pump
tensioner replacement 122 – Relief bore check 108
Battery-charging generator drive – Drive belt tension ad‐ Engine coolant – Draining 105
justment 123 Engine coolant – Filling 106
Battery-charging generator – Condition check 118 Engine layout 21
Battery-charging generator – Removal and installation Engine oil
120 – Change 97
C – Sample extraction and analysis 99
Engine oil filter – Replacement 100
Centrifugal oil filter
Engine oil level
– Cleaning and filter sleeve replacement 101
– Check 96
Charge-air coolant
Engine side and cylinder
– Change 111
– Designations 25
– Draining 112
Engine wiring
– Filling 113
– Check 127
– Level check 110
Engine – Barring with starting system 66
Charge-air coolant level
– Check 110 F
Charge-air coolant pump Fan drive
– Relief bore check 116 – Drive belt replacement 126
Cold start system with ether injection – Check 95 Fan drive belt– Tension check / adjustment 124
Contact persons 134 Fire prevention and environmental protection 17
Coolant Firing order 32
– Sample extraction and analysis 109 Fluids and lubricants 17
Coolant - charge air Fuel filter
– Level check 110 – Replacement 89
Coolant - charge-air Fuel prefilter - Draining 90
– Change 111 Fuel system – Venting 88
Coolant level
– Check 103 G
Crankcase breather General conditions 7
– Oil separator check 71
Crankcase breather (open-circuit crankcase ventilation) – H
Filter element cleaning 74 HP pump
Crankcase breather – Filter element replacement 72 – Relief bore check 81
Crankshaft transport locking device 10
DCL-ID: 0000015148 - 001
Cylinder head cover I

– Removal and installation 80 Injector
Cylinder liner – Removal and installation 83
– Endoscopic examination 67 – Replacement 82
Inspection port cover
D
– Explosion hazard 13
DDEC alarms 44 Instructions and comments on endoscopic and visual ex‐
DDEC and connectors – Cleaning 128 amination of cylinder liners 69
DDEC – Checking plug-in connections 130 Intercooler
Drive belt – Drain, coolant leakage 92
– Condition check 117
M015241/03E 2011-12 | Appendix B | 139

M
Maintenance and repair work
– Safety regulations 14
MTU contact persons 134
O
Operational checks 36
P
Personnel and organizational requirements 8
Plant
– Cleaning 39
Putting the engine into operation
– Preparation after scheduled out-of-service-period
34
Putting the engine into operation after extended out-of-
service periods (>3 months) 33
S
Safety instructions 20
Sensors and actuators – Overview 26
Service indicator
– Check 93
Service partners 134
Starter
– Condition check 94
Startup and operation
– Safety regulations 12
T
Transport 9
Troubleshooting 41
V
Valve clearance
– Adjustment 76
– Check and adjustment 76
Valve gear
– Lubrication 75
W
Wiring - engine
– Check 127
DCL-ID: 0000015148 - 001
140 | Appendix B | M015241/03E 2011-12

Operating Instructions: Diesel Engine 16 V 4000 E20

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Operating Instructions: Diesel Engine 16 V 4000 E20

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Operating Instructions

7.6 Injection Valve / Injector 82

5 Maintenance 7.11 Starting Equipment 94

7.12 Lube Oil System, Lube Oil Circuit 96

M015241/03E 2011-12 | Table of Contents | 5

7.15 Low-Temperature Circuit 110

7.16 Belt Drive 117

DCL-ID: 0000015148 - 001

6 | Table of Contents | M015241/03E 2011-12

M015241/03E 2011-12 | Safety | 7

Working clothes and protective equipment

TIM-ID: 0000000874 - 016

8 | Safety | M015241/03E 2011-12

Placement after transport

M015241/03E 2011-12 | Safety | 9

Transport locking device

Removing the transport locking device from driving end (KS)

10 | Safety | M015241/03E 2011-12

M015241/03E 2011-12 | Safety | 11

Safety requirements for initial operation

Safety requirements for operators

Operation of electrical equipment

12 | Safety | M015241/03E 2011-12

M015241/03E 2011-12 | Safety | 13

Safety regulations for maintenance and repair work

14 | Safety | M015241/03E 2011-12

Hydraulic installation and removal

Working on electrical/electronic assemblies

Working with laser equipment

M015241/03E 2011-12 | Safety | 15

TIM-ID: 0000000879 - 022

16 | Safety | M015241/03E 2011-12

Environmental protection and disposal

Fluids and lubricants

M015241/03E 2011-12 | Safety | 17

Acids and alkaline solutions

• Rinse eyes immediately with eyedrops or clean tap water.

18 | Safety | M015241/03E 2011-12

Engine – Barring with starting system

M015241/03E 2011-12 | Safety | 19

TIM-ID: 0000000881 - 015

20 | Safety | M015241/03E 2011-12

Engine version with closed-circuit crankcase ventilation

1 Engine lifting eyes 5 Main PTO 10 Engine oil dipstick

M015241/03E 2011-12 | General Information | 21

TIM-ID: 0000002075 - 002

22 | General Information | M015241/03E 2011-12

M015241/03E 2011-12 | General Information | 23

1 Crankcase breather, A 3 Crankcase breather 5 Vent line to atmosphere

Engine model designation

24 | General Information | M015241/03E 2011-12

1 KGS = Free end 3 KS = Driving end

M015241/03E 2011-12 | General Information | 25

1 Sensor (oil pressure) 5 Sensor (reference mark 9 Sensor (charge-air cool‐

26 | General Information | M015241/03E 2011-12

M015241/03E 2011-12 | General Information | 27

GENERAL CONDITIONS (for maximum power)

Fuel temperature at fuel feed connection R °C 30

28 | Technical Data | M015241/03E 2011-12

COMBUSTION AIR / EXHAUST GAS

COOLING SYSTEM (HT circuit)

COOLING SYSTEM (LT circuit)

Thermostat, fully open R °C 44