Manual de Manutenção 16V, 12V 4000

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

MS25012/00E
Printed in Germany
© 2008 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the
prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution,
translation, microfilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or
damage during operation.
Subject to alterations and amendments.
Table of Contents 01
1 General Information ............................................................ 11

1.1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1.1 Prerequisites for maintenance tasks and general assembly instructions . . . . . . . 11
1.2 General Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.2 Personnel and organizational requirements ............................ 14
1.2.3 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.4 Auxiliary materials, fire prevention and environmental protection . . . . . . . . . . . . . 18
1.2.5 Standards for warning notices in the publication . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.6 General information regarding the Tolerances and Wear Limits List . . . . . . . . . . . 21
1.2.7 Engine side and cylinder designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.8 Torque specifications for screws, nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.2.10 Conversion tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil) . . . . . . . . . . . . . . . . . 47
1.2.12 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2.13 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Maintenance .................................................................. 53
2.1 Preface ................................................................ 53
2.2 Maintenance schedule matrix .............................................. 54
2.3 Maintenance tasks ....................................................... 56
3 Task Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.1 Engine – Checking condition before a major overhaul .......................... 59
3.2 Engine – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.3 Engine – Disassembly .................................................... 61
3.4 Engine – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.5 Engine – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.6 Engine – Running-in procedure ............................................ 66
3.7 Initial engine operation ................................................... 68
4 Work Descriptions ............................................................. 69
4.1 Engine Casing and Add-on Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1.2 Crankcase and attachments – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1.3 Crankcase – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.1.4 Crankcase – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1.5 Crankcase – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.1.6 Crankcase – Checking upper and lower cylinder liner fit . . . . . . . . . . . . . . . . . . . 80
4.1.7 Crankcase – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.1.8 Crankcase – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.1.9 Crankcase – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.1.10 Cylinder liner – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.1.11 Cylinder liner – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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02 Table of Contents
4.1.12 Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4.1.13 Cylinder liner – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.1.14 Cylinder liner – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.1.15 Cylinder liner – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.1.16 Oil pan – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.1.17 Oil pan – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.1.18 Oil pan – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.1.19 Oil pan – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.1.20 Oil pan – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.1.21 Tightening sequence for oil pan GGG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1.22 Engine lifting equipment - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.1.23 Engine lifting equipment – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.1.24 Engine lifting equipment – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.1.25 Engine lifting equipment – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.1.26 Engine lifting equipment – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.1.27 End housing driving end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.1.28 End housing, driving end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.1.29 End housing, driving end disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.1.30 End housing, driving end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.1.31 End housing, driving end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.1.32 End housing , driving end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.1.33 End housing, driving end – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.1.34 End housing, driving end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.1.35 Crankcase breather – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.1.36 Crankcase ventilation – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.1.37 Crankcase breather – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.1.38 Crankcase breather – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.1.39 Hengst oil separator – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.1.40 Hengst oil separator – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.1.41 Hengst oil separator – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.1.42 Crankcase ventilation – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.2 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.2.1 Gearcase, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.2.2 Gearcase, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.2.3 Gearcase, free end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.2.4 Equipment carrier free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.2.5 Gearcase, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.2.6 Gearcase, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.2.7 Gearcase, free end – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.2.8 Gearcase, free end – Tightening sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.2.9 Gearcase, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.2.10 Gear train, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.2.11 Gear train, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.2.12 Gear train, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.2.13 Gear train, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.2.14 Gear train, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.2.15 Gear train, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.2.16 Bearing bushing of idler gear – Removal and installation . . . . . . . . . . . . . . . . . . . 190
4.3 Crank Drive ............................................................. 192
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4.3.1 Crank drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

4.3.2 Crankshaft – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.3.3 Crankshaft – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.3.4 Crankshaft – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3.5 Crankshaft - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.3.6 Crankshaft – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.3.7 Crankshaft – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.3.8 Crankshaft – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.3.9 Crankshaft – Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.3.10 Crankshaft bearing bore – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
4.3.11 Crankshaft – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.3.12 Flywheel on PTO flange, driving end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.3.13 Flywheel on PTO flange, driving end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.3.14 Radial-lip shaft seal, driving end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
4.3.15 Flywheel on PTO flange, driving end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.3.16 Flywheel on PTO flange, driving end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.3.17 Radial-lip shaft seal, driving end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.3.18 Flywheel on PTO flange, driving end – Installation . . . . . . . . . . . . . . . . . . . . . . . . 239
4.3.19 Crankshaft PTO, free end – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.3.20 Vibration damper on PTO, free end – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.3.21 Vibration damper on PTO, free end – Disassembly . . . . . . . . . . . . . . . . . . . . . . . 250
4.3.22 Vibration damper on PTO, free end – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4.3.23 Vibration damper on PTO, free end – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.3.24 Vibration damper on PTO, free end – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.3.25 Vibration damper on PTO, free end – Installation . . . . . . . . . . . . . . . . . . . . . . . . . 254
4.3.26 Piston and conrod – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.3.27 Piston and conrod – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
4.3.28 Piston and conrod – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
4.3.29 Piston – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.3.30 Piston – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4.3.31 Piston – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.3.32 Conrod – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.3.33 Piston rod – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.3.34 Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
4.3.35 Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.3.36 Conrod – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.3.37 Piston and conrod – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
4.3.38 Piston and conrod – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4.4 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
4.4.1 Cylinder head and attachments – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
4.4.2 Valve-seat turning machine for cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
4.4.3 Cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
4.4.4 Cylinder head – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
4.4.5 Cylinder head – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.4.6 Cylinder head – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
4.4.7 Cylinder head – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.4.8 Cylinder head – Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
4.4.9 Cylinder head – Plug repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
4.4.10 Cylinder head – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
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4.4.11 Cylinder head – Installation ......................................... 344

4.5 Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.5.1 Valve gear – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.5.2 Camshaft – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
4.5.3 Camshaft – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
4.5.4 Camshaft – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
4.5.5 Camshaft running surfaces and swing followers – Visual inspection . . . . . . . . . . 353
4.5.6 Camshaft – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
4.5.7 Camshaft – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
4.5.8 Camshaft – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.5.9 Camshaft drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
4.5.10 Camshaft drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4.5.11 Camshaft drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
4.5.12 Camshaft drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
4.5.13 Camshaft drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
4.5.14 Camshaft thrust bearing – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4.5.15 Camshaft thrust bearing – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
4.5.16 Camshaft thrust bearing – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
4.5.17 Camshaft thrust bearing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
4.5.18 Valve drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
4.5.19 Valve drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
4.5.20 Valve drive – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
4.5.21 Valve drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
4.5.22 Valve drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
4.5.23 Valve drive – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
4.5.24 Valve drive – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
4.5.25 Valve drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
4.5.26 Cylinder head cover – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
4.5.27 Cylinder head cover – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
4.5.28 Cylinder head cover – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
4.5.29 Cylinder head cover – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4.5.30 Cylinder head cover – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4.6 High-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4.6.1 HP fuel system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4.6.2 High-pressure pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4.6.3 High-pressure pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4.6.4 High-pressure pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4.6.5 High-pressure pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
4.6.6 HP pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4.6.7 H.P. fuel pump – Control block replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
4.6.8 Injector – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4.6.9 Injector – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
4.6.10 Fuel injector disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
4.6.11 Injector – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
4.6.12 Injector – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
4.6.13 Injector – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
4.6.14 HP fuel line – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
4.6.15 High-pressure line – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
4.6.16 High-pressure fuel line – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
MS25012/00E 08-06 © MTU

4.6.17 High-pressure fuel line – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

4.6.18 HP line – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
4.6.19 Pressure relief valve on fuel distributor – Removal . . . . . . . . . . . . . . . . . . . . . . . . 427
4.6.20 Pressure relief valve on fuel distributor – Installation . . . . . . . . . . . . . . . . . . . . . . 428
4.7 Low-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
4.7.1 Low-pressure fuel system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
4.7.2 Fuel delivery pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
4.7.3 Fuel delivery pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
4.7.4 Fuel delivery pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
4.7.5 Fuel delivery pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
4.7.6 Fuel delivery pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
4.7.7 Fuel delivery pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
4.7.8 Fuel pipework from fuel delivery pump to fuel filter – Overview . . . . . . . . . . . . . . 438
4.7.9 Fuel lines from fuel delivery pump to fuel filter – Removal . . . . . . . . . . . . . . . . . . 439
4.7.10 Fuel lines from fuel delivery pump to fuel filter – Cleaning . . . . . . . . . . . . . . . . . . 440
4.7.11 Fuel lines from fuel delivery pump to fuel filter – Check . . . . . . . . . . . . . . . . . . . . 441
4.7.12 Fuel lines from fuel delivery pump to fuel filter – Installation . . . . . . . . . . . . . . . . . 442
4.7.13 Fuel duplex filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
4.7.14 Fuel duplex filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
4.7.15 Fuel duplex filter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
4.7.16 Fuel filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
4.7.17 Fuel filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
4.7.18 Fuel duplex filter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
4.7.19 Fuel duplex filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
4.7.20 Fuel pipework from fuel filter to HP pump – Overview . . . . . . . . . . . . . . . . . . . . . 450
4.7.21 Fuel pipework from fuel filter to HP pump – Removal . . . . . . . . . . . . . . . . . . . . . 451
4.7.22 Fuel pipework from fuel filter to high-pressure pump – Cleaning . . . . . . . . . . . . . 452
4.7.23 Fuel pipework from fuel filter to high-pressure pump – Check . . . . . . . . . . . . . . . 453
4.7.24 Fuel pipework from fuel filter to HP pump – Installation . . . . . . . . . . . . . . . . . . . . 454
4.7.25 Leak off fuel pipework – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
4.7.26 Leak-off fuel line – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
4.7.27 Leak-off fuel pipework – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
4.7.28 Leak-off fuel pipework – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
4.7.29 Leak-off fuel line – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
4.8 Exhaust Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
4.8.1 Exhaust turbocharger – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
4.8.2 Exhaust turbocharger – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4.8.3 Exhaust turbochargers – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
4.8.4 Exhaust turbocharger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
4.8.5 Exhaust turbocharger – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
4.9 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
4.9.1 Intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
4.9.2 Intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
4.9.3 Intercooler – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
4.9.4 Intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
4.9.5 Intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
4.9.6 Intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
4.10 Air Intake / Air Supply .................................................... 475
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4.10.1 Air intake / air supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

4.10.2 Air filter with retainers – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
4.10.3 Air filter with bracket – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
4.10.4 Air filters and retainers – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
4.10.5 Air filters and retainers – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
4.10.6 Air filter with retainers – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
4.10.7 Intake air system to cylinders, left – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
4.10.8 Air supply to cylinders, LHS – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
4.10.9 Air supply system to cylinders, left – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
4.10.10 Air supply to cylinders, left side – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
4.10.11 Air pipework to cylinders, left side – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 486
4.10.12 Air supply system to cylinders, right – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 487
4.10.13 Air supply to cylinders, RHS – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488
4.10.14 Air supply system to cylinders, right – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 489
4.10.15 Air supply to cylinders, RHS – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4.10.16 Air pipework to cylinders, right side – Installation . . . . . . . . . . . . . . . . . . . . . . . . . 491
4.10.17 Air supply from turbocharger to intercooler – Overview . . . . . . . . . . . . . . . . . . . . 492
4.10.18 Air supply from turbocharger to intercooler – Removal . . . . . . . . . . . . . . . . . . . . . 493
4.10.19 Air supply from turbocharger to intercooler – Cleaning . . . . . . . . . . . . . . . . . . . . . 494
4.10.20 Air supply from turbocharger to intercooler – Check . . . . . . . . . . . . . . . . . . . . . . . 495
4.10.21 Air supply from turbocharger to intercooler – Installation . . . . . . . . . . . . . . . . . . . 496
4.11 Exhaust Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
4.11.1 Exhaust pipework after cylinder head – Overview . . . . . . . . . . . . . . . . . . . . . . . . 497
4.11.2 Exhaust pipework after cylinder head – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 498
4.11.3 Exhaust pipework after cylinder head – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
4.11.4 Exhaust pipework after cylinder head – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
4.11.5 Exhaust pipework after cylinder head – Installation . . . . . . . . . . . . . . . . . . . . . . . 501
4.11.6 Exhaust pipe bellows after engine – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
4.11.7 Exhaust pipe bellows after engine – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
4.11.8 Exhaust pipe bellows after engine – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
4.11.9 Exhaust pipe bellows after engine – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
4.11.10 Exhaust pipe bellows after engine – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 508
4.12 Starting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4.12.1 Starter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4.12.2 Starter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
4.12.3 Starter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
4.12.4 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
4.12.5 Starter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
4.12.6 Starter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
4.12.7 Starter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
4.12.8 Starter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
4.12.9 Starter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
4.12.10 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
4.12.11 Starter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
4.12.12 Starter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
4.12.13 Starter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
4.13 Lube-oil System, Lube-oil Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
4.13.1 Lube oil system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
MS25012/00E 08-06 © MTU

4.13.2 Lube-oil pump with drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

4.13.3 Lube-oil pump with drive – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
4.13.4 Lube-oil pump with drive – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
4.13.5 Lube oil pump with drive – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
4.13.6 Lube-oil pump with drive – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
4.13.7 Lube-oil pump with drive – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
4.13.8 Oil filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
4.13.9 Oil filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
4.13.10 Oil filter housing – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
4.13.11 Oil filter housing – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
4.13.12 Oil filter housing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
4.13.13 Oil filter housing – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
4.13.14 Oil filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
4.13.15 Centrifugal oil filter – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
4.13.16 Centrifugal oil filter – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
4.13.17 Centrifugal oil filter – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
4.13.18 Centrifugal oil filter – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
4.13.19 Centrifugal oil filter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
4.13.20 Centrifugal oil filter – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
4.13.21 Centrifugal oil filter – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
4.13.22 Oil cooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
4.13.23 Oil cooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
4.13.24 Oil heat exchanger – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
4.13.25 Oil heat exchanger – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
4.13.26 Oil cooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
4.13.27 Oil system in crankcase – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
4.13.28 Oil system in crankcase – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
4.13.29 Oil pipework in crankcase – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
4.13.30 Oil pipework in crankcase – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
4.13.31 Oil pipework in crankcase – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
4.13.32 Turbocharger oil supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
4.13.33 Turbocharger oil supply – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
4.13.34 Turbocharger oil supply – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
4.13.35 Turbocharger oil supply – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
4.13.36 Turbocharger oil supply – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
4.14 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
4.14.1 Coolant system – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
4.14.2 Engine coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
4.14.3 Engine coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
4.14.4 Engine coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
4.14.5 Engine coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
4.14.6 Engine coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
4.14.7 Engine coolant pump – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596
4.14.8 Engine coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
4.14.9 Engine coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
4.14.10 Coolant supply for engine coolant pump, intake side – Overview . . . . . . . . . . . . 607
4.14.11 Coolant pipework for engine coolant pump, intake side – Removal . . . . . . . . . . . 609
4.14.12 Coolant supply for engine coolant pump, intake side – Clean . . . . . . . . . . . . . . . 610
4.14.13 Coolant pipework to engine coolant pump, intake side – Check . . . . . . . . . . . . . 611
MS25012/00E 08-06 © MTU

4.14.14 Coolant pipework for engine coolant pump, intake side – Installation . . . . . . . . . 612
4.14.15 Coolant pipework after cylinder – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
4.14.16 Coolant pipework after cylinder – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
4.14.17 Coolant pipework after cylinder – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
4.14.18 Coolant pipework after cylinder – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
4.14.19 Coolant pipework after cylinder – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
4.14.20 Preheating unit – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
4.14.21 Preheating unit – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
4.14.22 Preheating unit, screw-in heating element – Replacement . . . . . . . . . . . . . . . . . . 620
4.14.23 Preheating unit, coolant pump – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
4.14.24 Preheating unit, thermostat – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
4.14.25 Preheating unit – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
4.14.26 Engine coolant and charge-air coolant ventilation – Overview .............. 625
4.14.27 Engine coolant and charge-air cooling vent – Removal . . . . . . . . . . . . . . . . . . . . 629
4.14.28 Engine coolant and charge-air coolant ventilation – Cleaning . . . . . . . . . . . . . . . 630
4.14.29 Engine coolant and charge-air coolant ventilation – Check . . . . . . . . . . . . . . . . . 631
4.14.30 Engine coolant and charge-air cooling vent – Installation . . . . . . . . . . . . . . . . . . . 632
4.14.31 Charge-air coolant pump – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
4.14.32 Charge-air coolant pump – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
4.14.33 Charge-air coolant pump – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
4.14.34 Charge-air coolant pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
4.14.35 Charge-air coolant pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
4.14.36 Charge-air coolant pump – Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
4.14.37 Charge-air coolant pump – Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647
4.14.38 Charge-air coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
4.14.39 Coolant system from/to intercooler – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 655
4.14.40 Coolant pipework from/to intercooler – Removal . . . . . . . . . . . . . . . . . . . . . . . . . 656
4.14.41 Coolant system from/to intercooler – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657
4.14.42 Coolant system from/to intercooler – Check ............................ 658
4.14.43 Coolant system from/to intercooler – Installation . . . . . . . . . . . . . . . . . . . . . . . . . 659
4.14.44 Coolant pipework – Overview ....................................... 660
4.14.45 Coolant distribution housing – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
4.14.46 Coolant distribution housing – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
4.14.47 Coolant distribution housing – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
4.14.48 Coolant distribution housing – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
4.14.49 Thermostat – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667
4.14.50 Thermostat – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670
4.14.51 Thermostat – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
4.14.52 Thermostat – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672
4.14.53 Thermostat – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
4.14.54 Thermostat – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
4.15 Power Supply, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
4.15.1 Battery-charging generator – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
4.15.2 Battery-charging generator – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
4.15.3 Battery-charging generator – Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
4.15.4 Battery-charging generator – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
4.15.5 Battery-charging generator – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
4.15.6 Battery-charging generator – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
4.16 Mounting/Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
MS25012/00E 08-06 © MTU

4.16.1 Engine mounting / support – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683

4.16.2 Engine mounting – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685
4.16.3 Engine mount – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
4.16.4 Engine mounts – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690
4.16.5 Engine mounts – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
4.16.6 Engine mounting – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
4.17 Monitoring, Control and Regulation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
4.17.1 Monitoring, control and regulation devices – Overview . . . . . . . . . . . . . . . . . . . . . 693
4.17.2 Engine wiring harnesses and brackets – Overview . . . . . . . . . . . . . . . . . . . . . . . 694
4.17.3 Engine wiring harnesses – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
4.17.4 Engine wiring harness – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
4.17.5 Engine wiring harness – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706
4.17.6 Engine wiring harnesses – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
4.17.7 Sensors, actuators and injectors – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
4.17.8 Sensors, actuators and injectors – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
4.17.9 Sensors, actuators and injectors – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
4.17.10 Sensors, actuators and injectors – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
5.1 Standard tools – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
5.2 Special tools – Overview .................................................. 722
5.3 General workshop equipment – Overview .................................... 843
5.4 Measuring tools – General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 849
6 Appendix ..................................................................... 855
6.1 Manufacturer’s documentation ............................................. 855
6.2 MTU contact/service partner ............................................... 856
6.3 Index .................................................................. 866
MS25012/00E 08-06 © MTU

MS25012/00E 08-06 © MTU

General Information 11
1 General Information
1.1 Important Information
1.1.1 Prerequisites for maintenance tasks and general

assembly instructions
This Workshop Manual is for technicians responsible for maintenance.
Contents: Extended component maintenance
Observe the following sequences:
• Engine disassembly (→ Page 61).
• Engine assembly (→ Page 63).
Prerequisites for maintenance tasks

Customers performing their own maintenance must ensure that the following conditions are fulfilled:
• All safety regulations are observed.
• Use of trained and qualified personnel.
• Suitable workshop equipment with general tools.
• Suitable test equipment.
• Approved special tools.
General assembly instructions

For assembly work, use new sealing and securing elements.
Assemblies that are exposed to contact with oil, fuel, coolant and combustion air must be clean. Assemblies with
the requirement ”Specially clean” (e.g. components carrying oil and fuel) should be cleaned in the appropriate
manner and checked for cleanness. Remove packaging of components immediately before assembly.
Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners.
• Remove oil or fuel coatings. The parts should be wiped with a dry cloth.
• Elastomer components such as engine mountings, damping elements, couplings and
V-belts must not be painted. They may only be installed after painting the engine or
must be covered before painting work is carried out.
Radial-lip shaft seals treated by the manufacturer with oil show, as a result, definite signs of swelling when delivered.
They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.
The surfaces of parts that slide against each other must be lubricated with SAE30 engine
oil when installed, unless otherwise specified.
O-rings and surfaces moving against them during installation (bores and shafts) must be coated with grease, unless
otherwise specified. When installing O-rings with counterrings in coolant pumps, always follow the installation
instructions. After installing O-rings in shaft grooves, pass a rounded marking tool under the O-ring in the direction
of the circumference if the O-ring diameter is sufficiently large. Make sure that the O-ring is not damaged.
Before assembling shaft seals:
• On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft
running surface with thin-film lubricant or SAE 30 engine oil.
• In the support bore, in the case of a metal outer jacket the outer surface must be coated with surface
sealant, unless otherwise specified in the drawing. For elastomer outer jackets or combined metal/elastomer
outer jackets, the outer surface must be coated with denatured ethanol.
TIM ID: 0000000390 – 007
This symbol applies to radial-lip shaft seals and its significance depends on its position. The
arrow indicates the position of the sealing lip.
MS25012/00E 08-06 © MTU

Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on the
flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be fitted
to the component and then (no more than 20 minutes later) the seal components screwed together.
Before installing antifriction bearings, lubricate the bearing seats. Only remove the bearings from their
original packaging immediately before installation. Do not remove the corrosion inhibitor from the
bearings in the original packaging. Use petroleum spirit or acid-free kerosene to clean the antifriction
bearings. After cleaning, lubricate the bearings with engine oil SAE 30.
• During assembly, do not apply (axial) forces to rolling elements and do not hit the bearing
rings with a hammer (use assembly aids).
• Do not use an open flame to heat bearing inner races.
• The temperature must be between 80 °C and 100 °C and never exceed 120 °C.
• Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
Do not oil dry bearings.
When assembling gears, the splines must be lubricated with SAE 30 engine oil.
All support and mating surfaces of components (e.g. mating surfaces for centering devices, flange
and sealing surfaces, joint surfaces of press fits) must be clean, polished or provided with the specified
surface protection and free from surface irregularities and damage. Corrosion inhibitor (e.g. oil,
grease) must be removed from the contact and mating faces.
After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate
must be removed and the parts coated with SAE 30 engine oil.
Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
Cable connections with cutting ring unions must be preassembled and tightened in a vice, after
the threads have been previously coated with thin-film lubricant.
If components are marked by etching, after the etching is completed the solution must be removed by means
of neutralization agent. The affected parts must then be preserved with SAE 30 engine oil.
Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes) must be coated at the support
and mating surfaces with assembly paste, unless otherwise specified.
The assembly surfaces of screws, nuts, washers and of parts to be tensioned must be clean and polished or
provided with the specified surface protection and free from surface irregularities and damage. Corrosion
inhibitors (e.g. oil, grease) must be removed. Thread and screw contact surfaces must be coated with
lubricant before installation in accordance with tightening specifications.
Unless otherwise specified, use engine oil SAE 30 as a lubricant and assembly paste in hot-component areas.
For threaded connections without tightening specifications, the tightening procedure can be selected
as required, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end
wrench or box wrench is possible. When machine-tightening is carried out, look up tightening torque
of thread size and strength class in the general tightening specifications.
Threaded connections with tightening specifications:
• The threaded connections must be tightened manually with a click wrench or angle-of-rotation torque
wrench. The specified tightening torques must be set without considering the specified tolerance
at the click wrench. When using an angle-of-rotation torque wrench, the torque indicated must be
within the torque specification limit value. Proceed in a similar manner with torsionally protected
threaded connections. This information also applies to checking torques.
• If no tolerance is specified for tightening torque, the tightening tolerance is + 10% of specified torque.
• Angleofrotation tightening:
The angles of further rotation specified in the tightening specifications must be achieved and may be
exceeded within the specified tolerance. If no tightening tolerance is specified, the following tolerances
must be observed: +5° for additional angle of rotation less than or equal to 90° +10° for additional
angle of rotation greater than 90°. Before angleofrotation tightening, each screw head must be
colormarked so that after tightening it is possible to check that the angle of rotation is correct (exception:
colormarking is not necessary in the case of a selfmonitoring NC screwdriver).
• Elongated tightening:
TIM ID: 0000000390 – 007
Carry out tightening according to tightening specifications, taking tightening tolerance into consideration.
MS25012/00E 08-06 © MTU

1.2 General Conditions
1.2.1 General Instructions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized engine modifications compromise safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.
Reworking components
During repair or engine overhaul reworking can be carried out in workshops authorized by MTU.
However, no generally valid instructions can be issued for the reworking of components as
the machining tools available on site may differ.
TIM ID: 0000000385 – 003
MS25012/00E 08-06 © MTU

1.2.2 Personnel and organizational requirements
Personnel requirements
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).
TIM ID: 0000000509 – 001
MS25012/00E 08-06 © MTU

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

Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Safety requirements for operators
Procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the displays and monitoring units must be permanently observed with regard to present
operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Compliance with maintenance and repair specifications is an important safety factor.
Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. Secure
the engine against inadvertent starting. With electric starter, disconnect the battery. With pneumatic starter, close
main shut-off valve of compressed-air system and release pressure from compressed-air supply line. Attach sign
"Do not operate" in operating area or to control equipment. Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance and repair work must only be carried out by authorized, qualified personnel.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane.
Always support these components in accordance with regulations on suitable frames or stands
before beginning any maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check
that all guards have been installed and that all tools and loose components have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
TIM ID: 0000000542 – 003
Always seal connections with caps or covers if a line is removed or opened.

During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections when
installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
MS25012/00E 08-06 © MTU

Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. When subjected to fire
or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. Hydrogen fluoride
vapors are released in this case. The resulting acid leads to serious burning if it contacts the skin. Do not touch
elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Do not touch hot components of the compressor and the exhaust system ⇒ Risk of injury!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable bonding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Observe special cleanness when conducting maintenance and repair work on the engine plant. After completion
of maintenance and repair work, make sure that no loose objects are in/on the engine plant.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. The welding
current could be induced in the cable harnesses and could possibly damage the electrical plant.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
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into shaft end until correct sealing is achieved.

During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
MS25012/00E 08-06 © MTU

Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
Prior to working on assemblies, the power of the appropriate areas must be switched off. Any measures
requiring power supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
Always tighten connectors with connector pliers.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when despatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.
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MS25012/00E 08-06 © MTU

1.2.4 Auxiliary materials, fire prevention and environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible fluids near the engine.
Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
noises indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applicable, which
means work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling
hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke.
Lead
• When working with lead or lead-containing pastes, avoid direct contact with the
skin and do not inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust!
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
Painting
• When painting in other than spray booths equipped with extractors, ensure good ventilation.
Make sure that adjacent work areas are not affected.
• No naked flames!
• No smoking.
• Observe fire prevention regulations!
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• It is absolutely necessary to wear masks providing protection against paint and solvent fumes.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing.
• Wear protective clothing, gloves, closed shoes and protective goggles!
• Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
MS25012/00E 08-06 © MTU

Compressed air
Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air tanks and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Connecting devices and equipment must either be designed for this pressure or, if the permitted
pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
• Always wear protective goggles when blowing off tools or extracting chips!
• The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents
air-borne particles being reflected and thereby prevents injury to eyes.
• First shut off compressed air lines before compressed air equipment is disconnected from the
supply line or before equipment or tool is to be replaced!
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII
and B) out of containers, results in a risk of explosion!
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of explosion!
• Do not blow dirty clothing with compressed air when being worn on the body.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.
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MS25012/00E 08-06 © MTU

1.2.5 Standards for warning notices in the publication

In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures
Note: This Publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:
Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!
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MS25012/00E 08-06 © MTU

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

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

dimensional deviation
Deviation Permissible tolerance of toleranced/basic size.

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

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

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

specification, the components concerned must be
reworked as per reworking instructions or replaced.
Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limits unless
specifically indicated. All dimensions are given in "mm" unless otherwise specified.
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MS25012/00E 08-06 © MTU

1.2.7 Engine side and cylinder designations

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

2 Right side 4 Left side
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MS25012/00E 08-06 © MTU

1.2.8 Torque specifications for screws, nuts and bolts
Crankcase
Designation Tightening specification Lubricant
Newly fitted studs must be elongated before initial tightening. Engine oil
Studs for crankshaft bearing cap in crankcase 80 Nm

(to blind hole base)
Studs (Nominal length: 347.5 mm to 348.5 mm):
Stud elongation for crankshaft bearing cap ΔI = 1.15 mm +0.05 mm
Residual screw elongation ΔI = 0.9 mm +0.05 mm
Lateral fillister head screws:
1 Starting, driving end: Left side all 80 Nm

screws.
2 Starting, driving end: Right side all 80 Nm

screws.
3 Final tightening torque, left side 280 Nm +20 Nm
4 Final tightening torque, right side 280 Nm +20 Nm
Oil pan
Threaded connections for oil pan GGG.
Screws “A” 42 Nm +4 Nm Engine oil
Screws “B” 42 Nm +4 Nm
Screws “C” 74 Nm +7 Nm
Gearcase
Screw M12x80 75 Nm +8 Nm Engine oil
Screw M12x170 75 Nm +8 Nm
Screw 10.9 M16x160
Pretightening torque: 200 Nm +20 Nm

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Angle of further rotation: 90° +5°
MS25012/00E 08-06 © MTU

End housing driving end

End housing screws
Pretightening torque 25 Nm Engine oil
Tightening torque 100 Nm +10 Nm
Crank drive
Screws for counterweight Engine oil

• Nominal length: 129.6 mm to 130 mm
• Max. length: 132 mm
1 Pretightening torque 320 Nm +30 Nm
2 Angle of further rotation 120° +10°
3 Checking torque 800 Nm +50 Nm
Vibration damper oil feed plug screw 15 Nm +2 Nm Engine oil
Conrod screws Engine oil

• Nominal length: 102.6 mm to 103.2 mm
• max. elongation: 104.5 mm

Sequence:
a Short arm
b Long arm

Sequence:
a Short arm
b Long arm
3 Checking torque 450 Nm +20 Nm

Sequence:
a Short arm
b Long arm
Screws for seal carrier, free end 74 Nm +7 Nm
Screws for timing wheel on flywheel 21 Nm +2 Nm
Crankcase breather
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Screws on oil separator cover 10 Nm +2 Nm
MS25012/00E 08-06 © MTU

Cylinder head
Sleeve for injector 60 Nm +6 Nm Engine oil
Plug screws 60 Nm +6 Nm
Screws for cylinder head

• Nominal length: 282.7 mm to 283.3 mm
• Nominal length: 332.7 mm 333.3 mm with engine lifting eye
Tightening sequence of screws: 1 to 6
1 Hand tightening 25 Nm
4 Checking torque 400 Nm
A Exhaust side
B Inlet side
Valve gear
Screws for camshaft gear 100 Nm +10 Nm Engine oil
Screws for rocker shaft support 250 Nm +25 Nm

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max. shaft length: 180.8 mm
Locknut on adjusting screw for rocker arm 90 Nm +9 Nm
Screw for cylinder head cover 42 Nm
MS25012/00E 08-06 © MTU

HP fuel system
Screw for rail on crankcase 60 Nm +6 Nm Engine oil
Screw for distributor on mount 60 Nm +6 Nm
Screw for hold-down clamp at injector
1. Pretightening torque 5 Nm +10 Nm
2. Final tightening torque 100 Nm +10 Nm
Adapter on injector
1. Pretightening torque 5 Nm +10 Nm
Tighten screw connections of pressure relief valve on

distributor in the following order:
1. Screw 1
2. Screw 2
1. Pretightening torque 5 Nm
Tighten screw connections on HP line in the following 30 Nm +5 Nm

order:
1. Rail,
2. injector adapter
Tighten screw connections on HP line in the following

order:
1. A (HP pump only to 100 Nm)
2. B (A-side of distributor)
3. C (B-side of distributor)
4. D (HP pump distributor)
5. E (rail, A-side)
6. F (rail, B-side)
3. Pretightening torque (not HP pump) 220 Nm
Tighten screw connections on HP line to their final

tightening torque in the following order:
1. A (HP pump only to 100 Nm) 150 Nm ±5 Nm
2. B (A-side of distributor) 290 Nm +10 Nm
3. C (B-side of distributor) 290 Nm +10 Nm

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4. D (HP pump distributor) 290 Nm +10 Nm
5. E (rail, A-side) 290 Nm ±5 Nm
6. F (rail, B-side) 290 Nm +10 Nm
Temperature sensor on distributor 30 Nm +3 Nm
HP sensor on distributor 30 Nm +3 Nm
Screw for control block at HP pump 30 Nm

MS25012/00E 08-06 © MTU
Exhaust turbocharger, 12V/16V

Screws for ETC on ETC exhaust M10 x 40 26 Nm +2 Nm Engine oil

manifold M10 x50
Screw for v-belt clamp of turbine housing on bearing 17 Nm +2 Nm

housing
Screw for v-belt clamp of compressor casing on bearing 12.4 Nm +2.3 Nm

housing
Exhaust pipework, 12V/16V

Screws for exhaust line on cylinder head M10 42 Nm + 4 Nm Ultra-Therm MTU

x 120
Starting equipment, electrical – Prestolite S152 starter

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

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

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MS25012/00E 08-06 © MTU

Starting equipment, pneumatic

Screw for disc in turbine housing 3.4 Nm
Screw for nozzle on turbine housing 3.4 Nm
Screw for rotor fixing, stage 2 to shaft 11.3 Nm
Screw for fixing housing to nozzle ring and 9 Nm Screw locking compound
turbine housing (Loctite 270)
Screw for fixing flange to turbine housing 19 Nm
Slotted nut 67.8 Nm to 90.4 Nm
Screw for gearcase on turbine housing 10.2 Nm to 13.6 Nm
Threaded connection for drive housing to 10.2 Nm to 13.6 Nm

gearcase
Lube oil system

Pressure reducing valve in equipment carrier 60 Nm +20 Nm Engine oil
Screws for oil pump 60 Nm +6 Nm
Nuts for oil cooler core 100 Nm +10 Nm
Oil spray nozzle 21 Nm +2 Nm
Screw to secure cover of centrifugal oil filter 5 Nm +2 Nm
Clamp to secure cover of centrifugal oil filter 8 Nm +2 Nm
Generator/drive
Nut for belt pulley on generator 94 Nm +14 Nm
Belt pulley on drive (flush) Mounting force max. 68 kN Engine oil
Gear on drive (flush) Mounting force max. 70 kN Engine oil
Screw for belt tensioning roller 60 Nm + 5 Nm Engine oil

on retainer, M12 x 40
Screw for belt tensioning roller 60 Nm + 5 Nm Engine oil

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MS25012/00E 08-06 © MTU

Mounting/Support
Variant Designation Tightening specification Lubricant
A Screw (M10) for engine mounting bracket on 42 Nm +4 Nm Engine oil

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

crankcase
Nut for damper mount on engine mounting 580 Nm +50 Nm

bracket
B Screw (M20) for engine mounting bracket on 500 Nm +50 Nm

crankcase
Screw (M20) for damper mount on engine 350 Nm +35 Nm

mounting bracket
Screw (M12) for damper mount on baseframe 74 Nm +7 Nm
Screw (M12) for engine support on crankcase 74 Nm +7 Nm
Screw (M20) for engine support on crankcase 180 Nm +18 Nm

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MS25012/00E 08-06 © MTU

Monitoring, control and regulation devices

Sensor Type Remarks Tightening Lubricant
specification
B01 Speed sensor Camshaft speed – Engine oil
B04.xx Temperature sensor: Exhaust gas temperature of

each cylinder
Union nut 35 Nm ±5 Nm
Sensor (threaded 40 Nm ±5 Nm
connector)
B05 Pressure sensor Lube oil pressure 20 Nm to 45 Nm
B05.3 Pressure sensor Lube oil pressure 20 Nm to 45 Nm
B06 Pt1000 temperature sensor Engine coolant temperature 15 Nm to 30 Nm
B07 Pt1000 temperature sensor Lube oil temperature 15 Nm to 30 Nm
B09 Pt1000 temperature sensor Charge-air temperature 15 Nm to 30 Nm
B10 Pressure sensor Charge-air pressure 20 Nm to 70 Nm
B13 Speed sensor Engine speed –
B16 Pressure sensor Coolant pressure 20 Nm to 70 Nm
B26 Pt1000 temperature sensor Charge-air coolant temperature 15 Nm to 30 Nm
B33 Pt1000 temperature sensor Fuel temperature 15 Nm to 30 Nm
B34 Pressure sensor Fuel pressure after filter 20 Nm ±3 Nm
B43 Pressure sensor Coolant pressure 20 Nm to 70 Nm
B48 Pressure sensor Fuel high pressure 30 Nm ±3 Nm
B50 Pressure sensor Crankcase pressure 20 Nm to 45 Nm
F33 Level probe Coolant max. 30 Nm
F53 Level probe Charge air coolant max. 30 Nm
Tightening torques for setscrew and stud connections to works standard MTN 5008
This works standard applies to setscrews subjected to little dynamic load as per MMN 384, DIN 912, EN
24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.
It does not apply to heat-resistant screws in the hot component area.
Tightening torques MA are for screws of strength class 8.8 (bright surface, phosphate coating or
galvanized) and 10.9 (bright surface or with phosphate coating).
The values in the table are based on a friction coefficient µtot.= 0.125. Precondition: Thread and mating
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faces of screws and nuts must be coated in engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values
is permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process - e.g. resulting from inaccurate readings and overtightening during assembly.
MS25012/00E 08-06 © MTU

When tightening mechanically, the permitted assembly tolerance is +15 %.
Hand-tightened Machine-tightened
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M2 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA = tightening torques
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Tightening torques for stress bolt connections prescribed in standard MTN 5007
This standard applies to stress pin bolts and stress bolts which are subjected to static and
dynamic load of strength class 10.9 and the associated nuts.
Shaft and transition dimensions as to MMN 209 standard and material and machining to MMN
389 standard (bright surface or with phosphate coating).
The values in the table are based on a friction coefficient µtot.= 0.125. Precondition: Thread and mating
faces of screws and nuts must be coated in engine oil prior to assembly.
MS25012/00E 08-06 © MTU

When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
The values in the tables are for manual tightening with torque wrench.
Thread not torsionally protected MA(Nm) torsionally protected MA(Nm)
M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*Protect shank against torsion when tightening.

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

This standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with threaded shank
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DIN 3852, model A (sealed by sealing ring DIN 7603-Cu).
MS25012/00E 08-06 © MTU

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MS25012/00E 08-06 © MTU

Tightening torques MA are given for banjo screws made of steel (St) with surface protected by a phosphate coating
and oiled or galvanized and for banjo screws made of copper-aluminum alloys. Thread and mating faces beneath
heads must be coated in engine oil prior to assembly. When tightening manually (defined tightening), an assembly
tolerance of +10 % of the table values is permitted for unavoidable deviations of the tightening torque from the table
value during the tightening process - e.g. resulting from inaccurate readings and overtightening during assembly.
Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed plug)
Inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 35 25
M14 x 1.5 35 25
M16 x 1.5 40 30
M18 x 1.5 50 35
M20 x 1.5 55 45
M22 x 1.5 60 50
M24 x 1.5 70 60
M26 x 1.5 80 70
M27 x 2 80 70
M30 x 1.5 100 90
M30 x 2 95 85
M33 x 2 120 110
M36 x 1.5 130 115
M38 x 1.5 140 120
M42 x 1.5 150 130
M45 x 1.5 160 140
M48 x 1.5 170 145
M52 x 1.5 180 150
M56 x 2 190 160
M64 x 2 205 175
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MS25012/00E 08-06 © MTU

Tightening torques for plug screws as per DIN 7604C (with long screwed plug)
Inserted in
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
Tightening torques for banjo screws as per MTN 5183-2 standard

This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603-Cu
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MS25012/00E 08-06 © MTU

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

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

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MS25012/00E 08-06 © MTU

Tightening torques for banjo screws made of copper/aluminum alloys

Inserted in steel/gray cast iron/Al alloy MA
Thread
(Nm)
M10 x 1 15
M16 x 1.5 30
Tightening torques for male connector as per MTN 5183-3 standard

This standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852,
model A (Sealed by sealing ring DIN 7603-Cu).
Tightening torques MA are given for male connectors made of steel (St) with surface protected
by a phosphate coating and oiled or galvanized.
Thread and mating faces beneath heads must be coated in engine oil prior to assembly.
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MS25012/00E 08-06 © MTU

inserted in steel/gray cast iron MA

Thread
(Nm)
M10 x 1 10
M12 x 1.5 20
M14 x 1.5 40
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
Tightening torques for union nuts on screwed plugs ISO 6149-3
1 Union nut
2 Union body
3 O-ring
4 Ball bush
Union nut: When installing the linear ball bearing, the union nut should be tightened firmly by hand
TIM ID: 0000029818 – 001
(noticeable increase in force) a quarter of a turn (90°) beyond this point.
MS25012/00E 08-06 © MTU

1.2.9 Settings
Firing order
12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
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
Direction of rotation, viewed on driving end

Component Direction of rotation
Crankshaft Anticlockwise
Camshaft Clockwise
HP fuel pump Anticlockwise
Oil pump Anticlockwise
Engine coolant pump Anticlockwise
Raw water pump Anticlockwise
Battery-charging generator Anticlockwise
Valve clearance with cold engine

Inlet 0.20 mm
Exhaust 0.50 mm
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Valve timing with valve clearance adjusted (view on free end)
No. Valve position Crank angle
1 Inlet opens 42.6° before TDC
2 Inlet closes 66.6° after BDC
3 Exhaust opens 57.6° before BDC
4 Exhaust closes 30.4° after TDC
5 Overlap 73 °
Start of delivery Performance-map controlled
I Top dead center (TDC)
II Bottom dead center (BDC)
Cam and valve lift for camshaft adjustment

Inlet Exhaust
Cam lift at TDC 1.43 mm 1.43 mm
Valve lift at TDC (zero valve 2.10 mm 1.9 mm

clearance)
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MS25012/00E 08-06 © MTU

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

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

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

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

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MS25012/00E 08-06 © MTU

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

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

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MS25012/00E 08-06 © MTU

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

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

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MS25012/00E 08-06 © MTU

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

ft lb s2 1.3563 = kg m2
kg m2 0.7373 = ft lb s2
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MS25012/00E 08-06 © MTU

Energy
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J
J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
Power
HP (horse power) 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 =W
HP 550 = ft lb/s
kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
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MS25012/00E 08-06 © MTU

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

K
x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F
Fuel consumption
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km
km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
TIM ID: 0000000413 – 005
MS25012/00E 08-06 © MTU

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

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

tool from bore (left).
2. Bore core hole with suitable twist drill - see table.
3. Cut thread with special tap.
4. Do not countersink hole!
5. Mount spindle (2) and snout (1) corresponding
with thread.
6. Groove on snout must be aligned with markings on
installation tool (arrows).
1 Snout
2 Spindle
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MS25012/00E 08-06 © MTU

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

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

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

thread insert without applying pressure to spindle.
11. Insert thread insert 1/2 to 1 1/2 turns deeper than
the threaded hole surface.
12. Use screw shearer to remove driver journals up
to M 14. With threaded inserts over M14, use
pointed pliers to move driver journal up and
down and remove.
TIM ID: 0000000499 – 002
MS25012/00E 08-06 © MTU

1.2.12 Transport
Transport
Lift the engine only with the lifting eyes provided.
Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
In the case of special packaging with aluminium foil, suspend the engine on the lifting eyes of the
transport pallet or transport with equipment for heavy loads (forklift truck).
Prior to transporting the engine, it is imperative to install transport locking devices for crankshaft and engine mounts.
Secure the engine against tilting during transportation. The engine must be especially secured
against slipping or tilting when going up or down inclines and ramps.
Setting the engine down after transport
Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.
TIM ID: 0000009458 – 001
MS25012/00E 08-06 © MTU

1.2.13 Abbreviations
Abbrevia- Meaning Explanation

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

TIM ID: 0000000383 – 004
ISO International Organization for

Standardization
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
MS25012/00E 08-06 © MTU

Abbrevia- Meaning Explanation

tion
LCD Liquid Crystal Display, Liquid Crystal

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

Unit
OT Oberer Totpunkt Top dead center (TDC()
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
UPS Unit Pump System
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps
SPC Spare Parts Catalog
SS Safety System Alarm initiated by safety system
SSK Schnellschlussklappe(n) Emergency Air Shutoff Flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TC Tools Catalog
TIM ID: 0000000383 – 004
TD Transmitter Deviation Alarm: Deviation in transmitter values
UT Unterer Totpunkt Bottom dead center (BDC)
VS Voith Schneider Voith Schneider drive
WJ Water Jet Waterjet drive
MS25012/00E 08-06 © MTU

TIM ID: 0000000383 – 004
MS25012/00E 08-06 © MTU

Maintenance 53
2 Maintenance
2.1 Preface
MTU maintenance concept

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

Specifications for fluids and lubricants, guideline values for their maintenance and change intervals and lists of
recommended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications A001061 and in
the fluids and lubricants specifications produced by the component manufacturers. They are therefore not listed in
the maintenance schedule (exception: deviations from the Fluids and Lubricants Specifications). Only use fluids
and lubricants which meet MTU specifications or are approved by the component manufacturer concerned.
Amongst other items, the operator/customer must perform the following additional maintenance work:
• Protect components made of rubber or synthetic material from oil. Never treat them
with organic detergents. Wipe with a dry cloth only.
• Fuel prefilter:
The maintenance interval depends on how dirty the fuel is. The paper inserts in fuel prefilters
must be replaced every 2 years at the latest (Task 9998).
• Battery:
Battery maintenance depends on use and ambient conditions. The battery
manufacturer’s instructions must be obeyed.
The relevant manufacturer’s instructions apply with respect to the maintenance of any components
which do not appear in this maintenance schedule.
Items that are listed in this maintenance schedule but that do not refer to the respective engine model, can be ignored.
Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures in
accordance with the MTU Fluids and Lubricants Specifications, Publication No. A001061/.
TIM ID: 0000029566 – 001
Application group
3B Continuous operation, variable
3D Standby operation
MS25012/00E 08-06 © MTU

54 Maintenance
2.2 Maintenance schedule matrix
Maintenance schedule matrix for application group 3B, 0-10,000 operating hours
Item Operating hours [hrs]
Limit years
10,000
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
7,500
8,000
8,500
9,000
9,500
Daily
500
Engine oil filter 2
Engine operation - X
Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X X X
Valve gear - X X X X X X X X X X
Fuel filter 2 X X X X X X X X X X
Belt drive 2 X X X X X X
Air filter 3 X X X
Fuel injector - X X
Cylinder chambers 4 X X
Rubber sleeves 5 X X
Crankcase breather - X
Exhaust turbocharger - X
Component maintenance - X
Fuel delivery pump - X
Cylinder head - X
Extended component maintenance 18 X
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Maintenance 55
Maintenance schedule matrix for application group 3C, 0-6,000 operating hours
Item Operating hours [hrs]
Limit years
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
5,500
6,000
Daily
500
Engine oil filter 2
Engine operation - X
Centrifugal oil filter 2 X X X X X X X X X X X X
Valve gear - X X X X X X
Fuel filter 2 X X X X X X
Belt drive 2 X X X X X X
Air filter 3 X X
Rubber sleeves 6 X X
Fuel injector - X
Cylinder chambers 4 X
Crankcase breather - X
Exhaust turbocharger - X
Component maintenance - X
Cylinder head - X
Extended component maintenance 18 X

TIM ID: 0000029567 – 001
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56 Maintenance
2.3 Maintenance tasks

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

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

TIM ID: 0000029568 – 001
Clean intercooler and check for leaks (→Maintenance Manual). W2003
Replace fuel HP sensor (→Maintenance Manual). W2004
Check engine coolant thermostat and replace thermostat insert W2006

(→Maintenance Manual).
Check charge-air coolant thermostat and replace thermostat insert W2007

(→Maintenance Manual).
MS25012/00E 08-06 © MTU

Maintenance 57
Qual- Interval Item Maintenance tasks Task

ifica-
tion [h] [a]
Overhaul engine coolant preheating (if fitted) (→Maintenance W2008

Manual).
Check centrifugal oil filter for wear (if fitted) (→ Maintenance Manual). W2009
Overhaul starter (→Maintenance Manual). W2010
Overhaul charge-air coolant pump (→Maintenance Manual). W2070
Replace sealing materials of all disassembled components. W2062
Overhaul engine coolant pump (→Maintenance Manual). W2110
QL3 Fuel delivery pump Replace fuel delivery pump (→Maintenance Manual). W1051
QL3 Cylinder head Overhaul cylinder heads (→Maintenance Manual). W1134
QL4 Extended component Disassemble engine completely. Inspect engine components acc. to W3000
maintenance assembly Instructions; repair or replace as necessary (→ Page 60).
Replace all elastomer parts and seals. W3001
Replace piston rings (→ Page 262). W3002
Replace conrod bearings (→ Page 262). W3003
Replace crankshaft bearings (→ Page 195). W3004
Replace cylinder liners (→ Page 108). W3005
Replace auxiliary PTO antifriction bearing (→ Page 677). W3006
Replace high-pressure fuel pump (→ Page 403). W3007
Overhaul battery-charging generator (→ Page 677). W3042

TIM ID: 0000029568 – 001
MS25012/00E 08-06 © MTU

58 Maintenance
TIM ID: 0000029568 – 001
MS25012/00E 08-06 © MTU

Task Schedules 59
3 Task Schedules
3.1 Engine – Checking condition before a major overhaul

In order to assess engine performance and engine condition, a short test run should be carried out, prior to removal.
The determined deviations from the Acceptance Test Record are important information for later overhaul work.
Operations to be performed See
Put the engine into operation after a scheduled (→Operating Instructions)

out-of-service period.
Start engine. (→Operating Instructions)
Warm up engine. (→Operating Instructions)
Test engine at highest possible power. (→Acceptance Test Record)

If this is not possible, operate the engine at adjustable
upper and lower no-load speed.
Perform operational checks. (→Operating Instructions)
Take engine oil sample and analyze. (→Operating Instructions)
Take engine coolant sample and analyze. (→Operating Instructions)
Take charge-air coolant sample and analyze. (→Operating Instructions)
Switch off engine. (→Operating Instructions)
Drain engine coolant. (→Operating Instructions)
Drain charge-air coolant. (→Operating Instructions)
If engine coolant sample shows contamination, add (→Fluids and Lubricants Specification)
cleaning solution.
If charge-air coolant sample shows contamination, add (→Fluids and Lubricants Specification)
cleaning solution.
Flush engine coolant circuits. (→Fluids and Lubricants Specification)
Switch off engine. (→Operating Instructions)

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

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

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

transportation regulations.
TIM ID: 0000004043 – 001
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Task Schedules 61
3.3 Engine – Disassembly

The sequence of the work steps stated below corresponds to practical assembly procedure.
Before disassembling the engine, it is advisable to take photographs from all engine sides or to
make a record of all components installed on the engine.
The exact task description must be taken from the respective functional group.
Remove PTO system. –
Mark and disconnect wiring harness. (→ Page 704)
Mark and disconnect electric cables. –
Remove engine governor. –
Remove air intake. (→ Page 475)
Remove air pipework from exhaust (→ Page 493)

turbocharger to intercooler.
Remove exhaust turbocharger. (→ Page 462)
Remove exhaust pipework. (→ Page 498)
Remove coolant pipework from/to (→ Page 656)

intercooler.
Remove crankcase breather. (→ Page 151)
Remove charge-air pipes. (→ Page 483)and (→ Page 488)
Remove intercooler. (→ Page 469)
Remove engine coolant and charge-air (→ Page 629)

cooling breather.
Remove coolant pipework. (→ Page 614)
Remove centrifugal oil filter. (→ Page 551)
Remove oil filter with oil filter housing. (→ Page 544)
Remove oil cooler. (→ Page 562)
Remove coolant pipework with (→ Page 662)

thermostat.
Remove charge-air coolant pump. (→ Page 635)
Remove engine coolant pump. (→ Page 587)
Remove fuel supply pipework from fuel (→ Page 451)

filter to HP pump.
Remove leak-off fuel line (→ Page 456)

TIM ID: 0000004814 – 007
Remove HP fuel pump. (→ Page 403)
Remove fuel delivery pump. (→ Page 433)
Remove HP fuel lines. (→ Page 421)
Remove fuel filter. (→ Page 444)
MS25012/00E 08-06 © MTU

62 Task Schedules
Remove starter. (→ Page 510)
Remove engine mounting (→ Page 689)
Remove oil pan. (→ Page 119)
Install crankcase in crankcase rotation (→ Page 75)

device.
Remove engine lifting attachment. (→ Page 129)
Remove cylinder head covers. (→ Page 397)
Remove valve drive. (→ Page 380)
Remove fuel injector. (→ Page 410)
Remove cylinder heads. (→ Page 312)
Remove vibration damper. (→ Page 247)
Remove flywheel. (→ Page 233)
Disassemble crankcase. (→ Page 75)
Remove end housing, driving end. (→ Page 136)
Remove lube-oil pump with drive. (→ Page 535)
Remove gearcase, free end. (→ Page 164)
Remove piston and conrod. (→ Page 262)
Remove crankshaft. (→ Page 195)
Remove cylinder liners. (→ Page 108)
Remove oil pipework and oil spray (→ Page 569)

nozzles.
Remove camshaft drive. (→ Page 368)
Replace camshaft thrust bearing. (→ Page 374)
Remove camshaft. (→ Page 350)
Remove end cover. (→ Page 75)
Remove studs. (→ Page 75)
Remove camshaft bearing bush. (→ Page 75)

TIM ID: 0000004814 – 007
MS25012/00E 08-06 © MTU

Task Schedules 63
3.4 Engine – Assembly

The sequence of the work steps stated below corresponds to practical assembly procedure.
The exact task description must be taken from the respective functional group.
Clean crankcase. (→ Page 78)
Check crankcase. (→ Page 83)
Assemble crankcase. (→ Page 98)
Install camshaft. (→ Page 360)
Install crankcase in crankcase rotation device. (→ Page 75)
Install camshaft drive. (→ Page 372)
Install oil system in crankcase. (→ Page 574)
Install cylinder liners. (→ Page 115)
Install crankshaft. (→ Page 222)
Install piston with conrod. (→ Page 299)
Install gearcase, free end. (→ Page 175)
Install lube-oil pump with drive. (→ Page 540)
Install oil pan. (→ Page 122)
Install end housing, driving end. (→ Page 144)
Remove crankcase from crankcase rotation device. (→ Page 98)
Install camshaft thrust bearing. (→ Page 374)
Install PTO flange, flywheel driving end. (→ Page 239)
Install cylinder heads. (→ Page 344)
Install engine lifting attachment. (→ Page 132)
Install fuel injector. (→ Page 415)
Install valve gear. (→ Page 393)
Install cylinder head cover. (→ Page 400)
Install main oil gallery. (→ Page 98)
Install engine mounting. (→ Page 692)
Install coolant distribution housing. (→ Page 665)
Install starter. (→ Page 514)

TIM ID: 0000004817 – 004
Install fuel filter. (→ Page 449)
Install H.P. fuel line. (→ Page 424)
Install fuel delivery pump. (→ Page 437)
Install HP fuel pump. (→ Page 406)
MS25012/00E 08-06 © MTU

64 Task Schedules
Install leak-off fuel pipework. (→ Page 459)
Install fuel pipework from fuel filter to HP pump. (→ Page 454)
Install engine coolant pump. (→ Page 605)
Install charge-air coolant pump. (→ Page 653)
Install coolant pipework with thermostat. (→ Page 665)
Install vibration damper on PTO, free end. (→ Page 254)
Install oil cooler. (→ Page 566)
Install oil filter with oil filter housing. (→ Page 549)
Install centrifugal oil filter. (→ Page 559)
Install coolant pipework. (→ Page 617)
Install engine coolant and charge-air coolant breather. (→ Page 632)
Install intercooler. (→ Page 474)
Install charge-air pipes. (→ Page 486)
Install crankcase breather. (→ Page 159)
Install coolant pipework from/to intercooler. (→ Page 659)
Install exhaust pipework. (→ Page 501)
Install exhaust turbocharger. (→ Page 465)
Install air pipework to intercooler. (→ Page 496)
Install air intake. (→ Page 475)
Install engine governor. –
Connect electrical lines. –
Install PTO system. –
TIM ID: 0000004817 – 004
MS25012/00E 08-06 © MTU

Task Schedules 65
3.5 Engine – Installation
Open all connections, remove caps and rubber plugs. –
Attach engine at lifting eyes only and install as per (→Operating instructions)
transportation instructions.
Connect coolant lines, fuel lines and engine monitoring –

system.
Fill with engine coolant. (→Operating instructions)
Fill with charge-air coolant. (→Operating instructions)
Change/fill with engine oil. (→Operating instructions)
Align engine. –
TIM ID: 0000004824 – 002
MS25012/00E 08-06 © MTU

66 Task Schedules
3.6 Engine – Running-in procedure

Running in engine after component replacement
• After replacing pistons, piston rings or cylinder liners, run-in the engine in compliance to
the respective run-in program. Conscientious running-in has a significant influence on the
useful life and operational reliability of the engine.
• To destroy the braking energy, use the generator or dynamometer.
• Power must be transmitted from the engine to the dynamometer by means of a resilient coupling.
Setting engine operational values
• Set temperatures, fuel and intake air according to the temperature values specified in the
MTU acceptance test record. Please note that:
• The coolant temperature depends on the operating range of the coolant thermostat.
• The fuel temperature depends on the volume of the day tank insofar as there is no
fuel-cooling device on the test stand.
• Record operational data for power, fuel, oil, coolant, charge air, and exhaust gas at each test point (time, speed,
and effective power) and enter the data under ENGINE RUN-IN in “MTU Diesel Engine Factory Test” record.
Install engine on test stand. –
Connect engine to dynamometer or generator. –
Connect lines for exhaust gas, coolant, and fuel. –
Connect dialog unit to engine governor. –
Check engine coolant level. (→Operating instructions)
Check charge-air coolant level. (→Operating instructions)
Check that fuel in supply or day tank is to specification. (→Fluids and Lubricants Specifications)
Vent fuel system. (→Operating instructions)
Check oil level. (→Operating instructions)
Lubricate valve gear. (→Operating instructions)
Check function of engine governor before starting –

engine.
Check emergency shutdown system. –
Start engine. (→Operating instructions)
After approx. 1 minute no-load operation, shut down (→Operating instructions) (→Operating instructions)
engine and:
• Check oil level. Top up with oil if necessary.
• Check lubrication of valve gear.
Start engine and check idling speed. –
Check water, oil and fuel lines, sealings on crankcase, –

and air inlet and exhaust gas lines for tightness.
TIM ID: 0000004875 – 003
Run in engine in accordance with run-in program and (→Acceptance Test Record)
record measured values.
Compare fill level, temperatures, pressures and speeds –

to acceptance test record according to display on dialog
unit.
MS25012/00E 08-06 © MTU

Task Schedules 67
Check color of exhaust gas and enter details. –
Enter barometric pressure and relative air humidity in (→Acceptance Test Record)
Test Record.
Check engine for abnormal running noises and leaks. –
Check engine monitoring. –
After completion of the run-in program, run down engine (→Operating instructions)
and switch off.
Cut open one oil filter and check for residues. –
Carry out acceptance test in accordance with MTU –

Acceptance Test Record.
Enter operational data in Acceptance Test Record. (→Acceptance Test Record)
Compare values with measured values in MTU (→Acceptance Test Record)

Acceptance Test Record and evaluate.
After completion of acceptance test, run down engine (→Operating instructions)

and switch off.
Preserve engine during longer standstills. (→Operating regulations)
Remove measuring sensors and measuring lines and –

seal measuring points.
Remove engine from test stand. –
Prepare the engine for painting and coat with protective –

paint.
TIM ID: 0000004875 – 003
MS25012/00E 08-06 © MTU

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

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

• Carry out external preservation
• Disable engine start
• Seal air inlet and exhaust outlet
• Carry out internal preservation (air, oil, fuel)
TIM ID: 0000004825 – 001
MS25012/00E 08-06 © MTU

Work Descriptions 69
4 Work Descriptions
4.1 Engine Casing and Add-on Components
4.1.1 Engine layout
Illustration is also valid for 12V 4000 Gx3 engines
010 Crankcase and attachments 140 Exhaust system

020 Gear train 170 Starting equipment
030 Running gear 180 Lube oil system
040 Cylinder head 200 Coolant system
050 Valve gear 210 Power supply
070 Fuel system (high pressure) 230 Mounting / support
080 Fuel system (low pressure) 250 PTO systems, driving end and
100 Exhaust turbocharger free end (coupling)
110 Intercooler 500 Monitoring and control systems,
120 Air intake / air supply general electrical systems
TIM ID: 0000029817 – 001
MS25012/00E 08-06 © MTU

70 Work Descriptions
Engine model designation

Key to the engine model designations 12/16V 4000 Gx3
12/16 Number of cylinders
V Cylinder arrangement: Vee configuration
4000 Series
G Application
x Application segment (2, 4, 6, 8)
3 Design index
TIM ID: 0000029817 – 001
MS25012/00E 08-06 © MTU

4.1.2 Crankcase and attachments – Overview
Crankcase and attachments – Overview
1 Crankcase 8 Block
2 Camshaft bearing 9 Nut for crankshaft bearing cap
3 Crankshaft bearing 10 Socket-head screws
TIM ID: 0000000563 – 001
4 Stud 11 Crankshaft bearing cap

5 Crankshaft alignment bearing 12 Cylinder liner
6 Crankshaft alignment bearing cap 13 Oil filler neck
7 Oil pan 14 Oil dipstick
MS25012/00E 08-06 © MTU

4.1.3 Crankcase – Overview
Crankcase with cover
11 Strip 33 O-ring
13 Screw 34 Screw
15 Drain valve 35 Washer
22 Stud 36 O-ring
24 Plug 38 O-ring
25 O-ring 47 Inspection port cover
26 Strap 48 Gasket
28 Screw 49 Screw
30 Washer 50 Cover
31 Screw 51 Crankcase
Elongate new studs prior to initial tightening.

TIM ID: 0000027973 – 001
MS25012/00E 08-06 © MTU

Inspection port cover
3 Inspection port cover 8 O-ring

4 Sealing ring 10 Cover
5 Threaded adapter 12 Gasket
6 Oil dipstick 13 Screw
TIM ID: 0000027973 – 001
MS25012/00E 08-06 © MTU

15 Inspection port cover 17 Gasket 18 Screw
TIM ID: 0000027973 – 001
MS25012/00E 08-06 © MTU

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

Hydraulic kit F6557935 1
Hydraulic kit F6557936 1
Camshaft bearing removal device F6783824 1
Hand pump kit B80146893 1
Swivel frame F6786993 1
Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Components have sharp edges.

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

1. Remove cover (→ Page 72).
2. Remove guide tube (→ Page 72).
3. Remove oil filler neck, (not applicable to gas engines) (→ Page 72).
4. Remove inspection port cover (→ Page 72).
5. Remove all seals and O-rings.
Installing crankcase in crankcase rotation device

1. Attach supports (1) for swivel frame (2) on left
and right sides of crankcase.
2. Lift crankcase with lifting device and ropes.
3. Insert crankcase in swivel frame and secure.
TIM ID: 0000003556 – 007
MS25012/00E 08-06 © MTU

Removing crankshaft bearing cap and studs

1. Remove crankshaft bearing caps (→ Page 195).
Note: Remove studs only if damaged or
over-elongated. When removing, replace
studs in pairs.
2. Place installation/removal tool (arrow) on studs.

3. Remove respective studs using the
installation/removal tool.
Removing camshaft bearings

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

housing attached
1. Cover bottom of camshaft chamber to prevent
camshaft bearings from falling into the crank drive.
2. Removal is the same as for removal of the
camshaft bearings, with the difference that jig (1)
is used → 3. .
TIM ID: 0000003556 – 007
MS25012/00E 08-06 © MTU

Removing end cover

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

edge of one side of the end cover inwards until
it tilts into the bore.
2. Use pliers to withdraw plug, taking care that end
cover does not fall into the bore.
TIM ID: 0000003556 – 007
MS25012/00E 08-06 © MTU

4.1.5 Crankcase – Cleaning
Material

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

• Wear protective clothing, gloves, and goggles / safety mask.
Unsuitable cleaning tools.

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

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

1. Remove sealant from crankcase cover.
2. Clean oil bores thoroughly with a hole brush.
3. After cleaning, flush bores (under pressure if
possible) and blow clear with compressed air.
TIM ID: 0000003179 – 003
MS25012/00E 08-06 © MTU

Cleaning oil bores in crankcase

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

suitable hole brush. Never use a wire brush!
2. After cleaning, flush bores (under pressure if
possible) and blow clear with compressed air.
Cleaning crankshaft bearing cap

1. Wipe bearing shell mating faces on crankshaft
bearing cap with chamois leather.
2. Clean mating faces on crankshaft bearing cap and
crankcase and blow clear with compressed air.
TIM ID: 0000003179 – 003
MS25012/00E 08-06 © MTU

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

Crankcase
Checking area I of upper and lower fits

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

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

TIM ID: 0000024866 – 001
MS25012/00E 08-06 © MTU

Exemplary illustrations showing corrosive pitting in

upper and lower fits
1. Upper fit
2. Upper fit
TIM ID: 0000024866 – 001
MS25012/00E 08-06 © MTU

3. Lower fit
4. Lower fit
5. Lower fit
6. If the assessment of the findings should be
unclear or extreme corrosive pitting was found,
(→Contact Service.). TIM ID: 0000024866 – 001
MS25012/00E 08-06 © MTU

4.1.7 Crankcase – Check
Special tools

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

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

Crankshaft bearing cap
Studs for main bearing
Socket-head screws for crankshaft bearing cap
Camshaft bearing
Oil filler neck, (not applicable to gas engines)
Oil dipstick
Cover
TIM ID: 0000003180 – 008
Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.
MS25012/00E 08-06 © MTU


Risk of injury!
TIM ID: 0000003180 – 008
MS25012/00E 08-06 © MTU

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

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

to check crankshaft bearing caps for
cracks.
Check contact surface and upper and lower cylinder liner fits in crankcase (→ Page 80).
Check crankcase top for stress • Stress marks To be carried out only in workshops
marks, damage and cavitation. • Damage authorized by MTU. Rework
• Cavitation crankcase top.
visible
Check main bearing studs for Damaged Replace component.

damage.
Check socket-head screws for Damaged Replace component.

lateral fixation of crankshaft bearing
cap for damage.
Check camshaft bearing and guide Damaged Replace component (→ Page 98).
bushings for wear and damage.
Check all mating and sealing faces Stress marks • Corrective work: Smooth with
and fits. oilstone or emery cloth.
• Replace
Check all threads for damage. Damaged Recut threads.
Check oil filler neck for damage (not Damaged • Corrective work
applicable to gas engine). • Replace
Check that oil dipstick fits correctly Damaged Replace component. Make sure
in guide tube and check for damage. that replacement oil dipstick is the
correct version.
Check cover for stress marks and • Stress marks • Corrective work
damage. • Damage • Replace
visible • Use a plastic plug to prevent
each bore from being soiled
until the crankcase has been
assembled.
Use a C-frame micrometer to Values exceeded. Replace cap.

measure width of crankshaft bearing
cap at upper and lower fits. Values
(→ Page 89)
Check stud for damage; measure • Damaged Replace (→ Page 98)

length of stud. Values (→ Page 89) • Values exceeded
TIM ID: 0000003180 – 008
MS25012/00E 08-06 © MTU

Checking oil bores in crankcase

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

crankcase, sides A and B.
2. Check main oil supply bores for camshaft and

main bearing in crankcase V.
3. Check oil bores (arrow) in camshaft chamber.
TIM ID: 0000003180 – 008
MS25012/00E 08-06 © MTU

4. Check oil bores in crankshaft bearing pedestal

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

Note: Bearing cap guides not in swivel
frame (results in measuring errors).
1. Remove crankcase from swivel frame and place

on a flat surface.
2. Using a bore gauge (1), measure bearing
cap guides at upper and lower fits. Values
(→ Page 89).
Note: To be carried out only in workshops
authorized by MTU.
3. If values are exceeded: Machine respective

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

1. Install and tighten crankshaft bearing cap
according to specifications (→ Page 98).
2. Adjust bore gauge.
3. Using a bore gauge (2), measure the crankshaft
bearing bore (1).
4. Record measured values in data sheet. Measuring
planes as well as values (→ Page 89).
authorized by MTU.
TIM ID: 0000003180 – 008
5. If values are exceeded: Machine respective bore

to next repair size using a boring mill.
6. Mark repair stages of a crankcase main bore
with numeral punches.
7. When installing a new crankshaft bearing cap:
mark position of new crankshaft bearing cap
accordingly.
MS25012/00E 08-06 © MTU

Measuring camshaft bearing bushing bore.

1. Measure diameter of camshaft bearing bushing
bore (Ø B) with bore gauge. Values (→ Page 89).
2. If values are exceeded: Remove camshaft bearing
bushing (2) (→ Page 75).
3. After removal of camshaft bearing bushing:
Measure diameter (dia. A) of the main camshaft
bearing bore in the crankcase (1). Record
measured values in data sheet. Values
(→ Page 89).
authorized by MTU.

main camshaft bearing bore to next repair size
using a boring mill.
5. Mark repair stages with numeral punches.
6. Install camshaft bearing bushing (→ Page 98).
Measuring crankcase bores for cylinder liners

1. Measure crankcase bore for cylinder liner in upper
and lower fits with bore gauge.
2. Record measured values in data sheet. Values
(→ Page 89).
authorized by MTU.

crankcase bore to next repair size using a
boring mill.
4. Mark repair stages with numeral punches.
TIM ID: 0000003180 – 008
MS25012/00E 08-06 © MTU

4.1.8 Crankcase – Tolerances
Crankcase bore for crankshaft
No. Designation Stage Tol. size Deviation Clearance Interference Limit

Basic value
size
Lower Upper Min. Max. Min. Max.
1 Crankcase bore 0 171.000 H6 0 +0.025 171.035

for crankshaft Trans-
bearing verse
ovality
max. 0.050
1 171.500 H6 171.535
Trans-
verse
TIM ID: 0000016559 – 001
ovality
max. 0.050
2 172.000 H6
a After refinishing the crankcase bore, during re-assembly, the crankcase bore in a-direction may be fallen
short of by 0.015 mm.
MS25012/00E 08-06 © MTU

Crankcase bore for camshaft

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

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

bearing, outer
Ø 1 97.580
not installed
2 Camshaft 92.012 0 +0.052 0.084 0.171

bearing bushing
bore,
installed
Camshaft outer 92.000 e7 –0.107 –0.072

Ø
a Concentricity of left and right bearings
TIM ID: 0000016559 – 001
b Between camshaft bearing bores 1 and 2
MS25012/00E 08-06 © MTU

Top deck and mating face of cylinder liner
No. Designation Stage Toler- Deviation Clearance Interference Limit

anced value
size
Basic Lower Upper Min. Max. Min. Max.
size
1 Cylinder liner 0 562.000 −0.150 +0.050

mating face
1 561.700
2 561.400
2 Top deck 0 562.500 −0.200 +0.200
1 562.200 −0.100 +0.100
2
TIM ID: 0000016559 – 001
MS25012/00E 08-06 © MTU

Crankcase bore for cylinder liner

Basic value
size
1 Crankcase bore 0 196.000 0 +0.046 0.059 0.016

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

upper fit
1 196.500 j6
TIM ID: 0000016559 – 001
2 197.000 j6
MS25012/00E 08-06 © MTU


Basic value
size
2 Crankcase bore 0 193.000 0 +0.046 0.050 0.125

lower fit H7
1 193.500
H7
2 194.000
H7
Cylinder liner 0 193.000 f6 -0.079 -0.050

lower fit
1 193.500 f6
2 194.000 f6
Stage marking see reconditioning drawing
Reconditioning notes:
• In case of cavitation at upper or lower fit, rework crankcase bore to next stage and
install cylinder liner of respective stage.
• Punch number of stage (height of numeral punch 6 mm). (stage 1 +0.5) (stage 2 +1.0)
TIM ID: 0000016559 – 001
MS25012/00E 08-06 © MTU

Crankshaft bearing cap

Basic value
size
1 Bearing cap bed 0 298.000 E9 +0.110 +0.240 0.022 0.184

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

bearing cap
lower fit 1 298.500 p6
2 299.000 p6
2 Bearing cap bed 0 298.000 0 +0.052 0.004 0.088

upper fit H7
1 298.500
H7
2 299.000
H7
TIM ID: 0000016559 – 001
Crankshaft 0 298.000 p6 +0.056 +0.088

bearing cap
upper fit 1 298.500 p6
2 299.000 p6
3 Screw length 348.000 –0.500 +0.500
MS25012/00E 08-06 © MTU

Crankshaft bearing bore
Install crankshaft bearing cap in crankcase as per installation instructions.

Measure crankshaft bearing bores:
• Determine diameters a, b1 and b2 in two measuring planes and calculate the averages for a, b1 and b2.
Check bore roundness:
• Possible deviations from roundness are a result of the average values for a, b1 and
b2 according to the formula: (b1+b2) /2 −a
Vertical ovality greater than (b1+b2) /2 is not permissible.
TIM ID: 0000016559 – 001
MS25012/00E 08-06 © MTU

Crankcase crankshaft bore concentricity
No. Max. permissible deviation from concentricity New Limit value

a left/right bearings Ø 0.040 Ø 0.050
b 8V: from crankshaft bearing 1 to 5 Ø 0.060 Ø 0.100

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

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

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

TIM ID: 0000016559 – 001
MS25012/00E 08-06 © MTU

Crankcase camshaft bore concentricity
No. Max. permissible deviation from concentricity New Limit value

a left/right bearings Ø 0.040 Ø 0.050
b 8V: from camshaft bearing 1 to 5 Ø 0.060 Ø 0.100

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

e 20V: from camshaft bearing 1 to 11 Ø 0.160 Ø 0.200
TIM ID: 0000016559 – 001
MS25012/00E 08-06 © MTU

4.1.9 Crankcase – Assembly
Special tools

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

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

Gasket
O-ring
O-ring
End cover
Camshaft bearing
Stud
Suspended load.
TIM ID: 0000003181 – 008
Danger to life!
Nitrogen is liquid (at -200°C).

Risk of freezing and suffocation!
DANGER • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands).
• Ventilate working area well.
MS25012/00E 08-06 © MTU


Risk of injury!
Contamination in blind hole.

CAUTION • Inspect and clean blind hole.
Installing end cover

1. End cover and crankcase bore must be free
of grease and dry.
2. Coat end cover seat with Loctite screw locking
compound.
3. Using a mandrel, drive end cover into the
crankcase bore.
4. In case of leaks or sealing surface damage, the
end cover can be swaged in after it has been
driven in with a mandrel.
TIM ID: 0000003181 – 008
MS25012/00E 08-06 © MTU

Installing camshaft bearings

1. Screw camshaft bearing stop and alignment
device (1) on to locating bore of swing-follower
shafts. Installation sequence: Start at driving end
and continue in succession towards free end.
2. Fit plastic installation mandrel (1) on assembly tool.

3. Chill camshaft bearing bushing in liquid nitrogen.
4. Fit chilled camshaft bearing bushing on assembly
tool so that the spring-loaded locating mandrel
(3) of the assembly tool engages in the oil bore
(arrow) of the camshaft bearing bushing.
5. Withdraw installation mandrel from camshaft

bearing assembly tool.
6. Check position of camshaft bearing oil bore in
assembly tool (arrowed). TIM ID: 0000003181 – 008
MS25012/00E 08-06 © MTU

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

bushing (2) from outside in main bore as far as
it will go. At the same time, the assembly tool
is positioned by the centering and positioning
mandrel.
8. Check that oil bores in bearing bushing and
crankcase are aligned.
Installing last camshaft bearing

1. Install camshaft bearing stop and alignment device
from outside on free end of crankcase (2) when
installing last camshaft bearing.
2. Use assembly tool (1) to insert camshaft bearing

bushing in main camshaft bore up to stop. At the
same time, the assembly tool is positioned by the
centering and positioning mandrel.
3. Check that the oil bores in bearing bushing and
TIM ID: 0000003181 – 008
MS25012/00E 08-06 © MTU

Inserting studs for crankshaft bearing caps

1. Coat thread of stud (1) on shoulder side with
engine oil.
2. Insert stud (1) with the journal side in the threaded
bore.
3. Insert stud (1) up to stop with installation/removal
device (2) and torque wrench. Tightening torque,
see (→ Page 23).
Note: Replace studs only in pairs.
4. For initial fitting of studs, carry out the following

steps:
4.1. Tighten nut up to contact.
4.2. Tighten studs with hydraulic tensioner.
Tightening method: elongation.
4.3. Tighten studs with hydraulic tensioner.
Hydraulic pressure: 1500 bar.
4.4. Release studs.
4.5. Tighten studs again with hydraulic tensioner.
Hydraulic pressure: 1500 bar.
4.6. Release studs.
Installing crankshaft bearing cap
1. Install bearing cap (→ Page 222).
2. Crankcase mating face (1) for strip (driving end)
must be dry and free of grease.
3. Coat contact surface with sealing paste (arrows)
and do not forget the end sides.
TIM ID: 0000003181 – 008
MS25012/00E 08-06 © MTU

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

crankcase (2).
5. Place strip (1) on surface coated with sealing
paste on crankcase.
6. Use socket-head screws (2) to fasten strip (1) on

crankcase (3).
7. Using a straightedge, check the alignment of the
strip to the crankcase. The strip surface must form
a single plane with the crankcase joint so that the
oil pan will fit perfectly.
Installing cover
1. Mating faces on crankcase and cover (2) must be
dry and free of grease.
2. Coat new O-ring (1) with grease and insert
in groove.
TIM ID: 0000003181 – 008
MS25012/00E 08-06 © MTU

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

4. Coat mating surface (1) on crankcase with surface
sealant.
5. Coat new O-rings (arrowed) with grease and insert
in oil transfer bores.
6. Insert assembly pins (2) in the crankcase at two
diagonally opposite corner points.
7. Use lifting device to connect cover to assembly
pins and lower.
8. Align cover to assembly jig stop.
9. Tighten screws in accordance with tightening

sequence.
• 8V 1-18
• 12V 1-26
• 16V 1-34
• 20V 1-42
10. Remove assembly device.
11. Coat O-ring with grease and fit on plug (1).

12. Insert plug in oil gallery and secure with lug (2).
TIM ID: 0000003181 – 008
MS25012/00E 08-06 © MTU

Removing crankcase form swivel frame

1. Attach lifting appliance and lifting ropes to
crankcase. Make sure that lifting ropes are
tensioned evenly.
2. Release crankcase from swivel frame and lift out.
TIM ID: 0000003181 – 008
MS25012/00E 08-06 © MTU

4.1.10 Cylinder liner – Overview
Overview of cylinder liner with scraper ring
1 Cylinder liner 2 Carbon scraper ring 3 Sealing ring
TIM ID: 0000003182 – 001
MS25012/00E 08-06 © MTU

Cylinder liner with scraper ring in crankcase
1 Carbon scraper ring

2 Cylinder liner
3 Crankcase
4 Sealing ring
5 Sealing ring
TIM ID: 0000003182 – 001
MS25012/00E 08-06 © MTU

4.1.11 Cylinder liner – Removal
Special tools

Removal tool for carbon scraper ring F6785078 1
Removal tool for cylinder liner F6557114 1
Heavy object.
Risk of crushing!

Risk of injury!
Removing carbon scraper ring

1. Mount removal tool (3) on cylinder liner (1).
2. Remove carbon scraper ring (2) with removal tool
(3) from cylinder liner fit (1).
3. Remove removal tool (3).
4. Remove piston and conrod (→ Page 262).
TIM ID: 0000016118 – 002
MS25012/00E 08-06 © MTU

Cylinder liner – Removal

1. Mark installation position of cylinder liner in relation
to crankcase (arrow) with a marking pen.
2. Insert removal tool in cylinder liner.

3. Position removal tool at lower collar of cylinder
liner. Take care not to damage the oil spray nozzle.
4. To avoid tensioning the liner, only place fork in
position gently.
5. Rotate the removal tool spindle until the cylinder
liner is released from the crankcase bore.
6. Remove removal tool.
7. Pull cylinder liner out of crankcase.
8. Remove sealing rings from cylinder liner.
TIM ID: 0000016118 – 002
MS25012/00E 08-06 © MTU

4.1.12 Cylinder liner – Cleaning
Material

Cleaner is extremely caustic.

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

Cylinder liner – Cleaning

2. Blow out all parts with compressed air.
TIM ID: 0000003184 – 002
MS25012/00E 08-06 © MTU

4.1.13 Cylinder liner – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Material

Crack detection oil (No. 63 40475 1
Spare parts

Cylinder liner
Carbon scraper ring
Heavy object.
Risk of crushing!
TIM ID: 0000003185 – 006
MS25012/00E 08-06 © MTU

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

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

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

scoring and pitting. • Pitting
visible
Check floating mount of the carbon Signs of jamming • Measure cylinder liner.
scraper ring in the cylinder liner. • Replace carbon scraper ring.
Check cylinder liner running surface • Scores Replace

for scores and pitting. • Pitting
visible
Check reversal point of first piston Wear visible. Replace cylinder liner.
ring for wear.
Measure cylinder liner bore with Values exceeded. Replace

bore gauge and dial gauge.
Measurement plane and values
(→ Page 113)
TIM ID: 0000003185 – 006
MS25012/00E 08-06 © MTU

4.1.14 Cylinder liner – Tolerances

anced value
size
size
1 Crankcase bore 0 196.000 0 +0.046 0.059 0.016

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

- upper fit
1 196.500 j6
2 Crankcase bore 0 193.000 0 +0.046 0.050 0.125

H7
- lower fit
1 193.500
H7
Cylinder liner 0 193.000 f6 -0.079 -0.050

- lower fit
TIM ID: 0000024840 – 001
1 193.500 f6
3 Liner bore 175.000 0 +0.040 0.014 0.094

H7
Scraper ring 175.000 -0.054 -0.014

OD g7
MS25012/00E 08-06 © MTU


anced value
size
size
4 Scraper ring ID 169.400 0 +0.063

H8
5 Liner bore 170.000 0 +0.040

H7
- installed
Reconditioning instructions:
Re 1 and 2: If there is cavitation on the upper and/or lower fit of the crankcase bore:
• Introduce next repair stage and install cylinder liner of corresponding stage.
• To be carried out only in workshops authorized by MTU.
Re 3 and 4: Check scraper ring OD and ID when fitted.
TIM ID: 0000024840 – 001
MS25012/00E 08-06 © MTU

4.1.15 Cylinder liner – Installation
Special tools

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

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

Sealing ring
Heavy object.
Risk of crushing!

Risk of injury!
Installing cylinder liner

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

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

TIM ID: 0000003188 – 009
prior to removal in accordance with the marking on

liner and crankcase.
MS25012/00E 08-06 © MTU

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

tool into threaded bores for cylinder head screws.
6. Fit pressure plate (3) on cylinder liner.
7. Rotate spindle (2) clockwise to insert cylinder liner
in crankcase bore.
Measuring cylinder liner ID

1. Adjust bore gauge and dial gauge with micrometer
to basic cylinder liner bore dimension. Value and
measurement planes (→ Page 113).
2. Measure cylinder liner bore with bore gauge.
3. Record measured values in data sheet.
4. If out-of-round is measured:
4.1. Remove cylinder liner.
4.2. Remeasure cylinder liner bore and outer
diameter.
TIM ID: 0000003188 – 009
MS25012/00E 08-06 © MTU

Installing carbon scraper ring

Note: Insert carbon scraper ring after installing
piston (→ Page 299).
1. Spray cylinder liner and carbon scraper ring

with engine oil.
2. Insert carbon scraper ring into fit of cylinder liner.
TIM ID: 0000003188 – 009
MS25012/00E 08-06 © MTU

4.1.16 Oil pan – Overview
1 Oil pan 8 Washer 15 Screen

2 Rubber profile 9 Plug screw 16 Screw
3 Screw 10 Sealing ring 17 Washer
4 Washer 11 Cover 18 Plug-in pipe
5 Screw 12 Gasket 19 O-ring
6 Washer 13 Screw
7 Screw 14 Suction basket
TIM ID: 0000016100 – 001
MS25012/00E 08-06 © MTU

4.1.17 Oil pan – Removal
Special tools

Eyebolt T80092075 4
Suspended load.
Danger to life!
Remove oil pan

1. Install engine in the assembly dolly and rotate
by 180°.
2. Remove screws (1) for oil pan.
3. Remove plug screws at end faces.
4. Screw in suitable eyebolts (arrow).
5. Lift oil pan with lifting ropes and crane.
6. Place oil pan on to adequate surface.
7. Remove flange at end faces.
8. Remove rubber profile.
Removing suction basket

1. Unscrew screws on suction basket (→ Page 118).
2. Remove suction basket.
3. Remove O-rings.
TIM ID: 0000027975 – 001
MS25012/00E 08-06 © MTU

4.1.18 Oil pan – Cleaning
Material

Compressed air.
Risk of injury!

Oil pan – Cleaning

2. Thoroughly blow out oil pan and all threaded bores with compressed air.
TIM ID: 0000003557 – 002
MS25012/00E 08-06 © MTU

4.1.19 Oil pan – Check
Special tools

Dye penetrant (standard check) 40488 1
Spare parts

Oil pan
Gasket
Suction basket
Screen
Flange
Plug screw
Hex screw
O-ring
Plug-in pipe
Heavy object.
Risk of crushing!
Oil pan – Check
Item Findings Action
Check oil pan for Signs of cracks • Corrective work: Contact Service.
cracks using surface • Replace
crack-testing method and
red dye penetrant.
Check oil pan mating Unevenness greater Recondition mating face.

face on crankcase for than 0.2 mm
evenness
Check sealing surfaces Damaged • Corrective work

and groove of rubber • Replace
profile.
Check suction basket for Damaged Replace

TIM ID: 0000027976 – 001
damage.
Check threaded holes for Sluggish Replace thread inserts.

freedom of movement.
MS25012/00E 08-06 © MTU

4.1.20 Oil pan – Installation
Special tools

Eyebolt T80092075 4
Material

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

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

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

2. Insert O-rings into groove as shown in overview drawing (→ Page 118).
3. Install suction basket with screws.
TIM ID: 0000003559 – 008
MS25012/00E 08-06 © MTU

Preparing oil pan for installation

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

3. Coat the rubber profile with grease on the end
face of the free end (arrows).
4. Fit flanges for plug screws at both end faces.
5. Apply surface sealant to equipment carrier.

6. Spray lint-free rag with express dry cleaner and
wipe off excess surface sealant on the exposed
flange faces.
7. Coat slit between front cover/crankcase with

silicone rubber on both sides of the front cover
(arrow), laying down a bead of approx. 5 mm.
TIM ID: 0000003559 – 008
MS25012/00E 08-06 © MTU

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

silicone rubber, laying down a bead of approx.
5 mm.
9. Screw eyebolts into bores for plugs on the oil pan.

10. Lift oil pan with lifting ropes and crane.
11. Lower oil pan onto contact surface of crankcase.
12. Align oil pan to bores in the contact surface
of crankcase.
Note: Washers for screw connections A, B and
C are different.
13. Screw in screws (1).

14. Tighten oil pan per tightening sequence
(→ Page 125).
15. Install flanges with new gaskets.
TIM ID: 0000003559 – 008
MS25012/00E 08-06 © MTU

4.1.21 Tightening sequence for oil pan GGG
Number of cylinders Screw joint Number of screws Item
12V A (long side) 28 1 to 14
12V to 20V B (driving end side) 8 -
12V to 20V C (free end side) 10 -
Bolt oil pan to crankcase and equipment carrier alternately and in several steps.
Tightening torque (→ Page 23).

TIM ID: 0000003560 – 002
MS25012/00E 08-06 © MTU

Threaded connections for oil pan GGG
A Screw
B Screw
C Screw
TIM ID: 0000003560 – 002
MS25012/00E 08-06 © MTU

4.1.22 Engine lifting equipment - Overview
Overview
1 Lifting eye 2 Cylinder head screw

TIM ID: 0000003190 – 001
MS25012/00E 08-06 © MTU

Engine lifting equipment
1 Lifting eye 2 Thrust washer 3 Cylinder head screw
TIM ID: 0000003190 – 001
MS25012/00E 08-06 © MTU

4.1.23 Engine lifting equipment – Removal
Preconditions
Engine lifting equipment – Removal
1. Remove cylinder head screws (2).
2. Remove cylinder head screws and thrust
washers (1).
3. Remove lifting eyebolt (3).
TIM ID: 0000003191 – 004
MS25012/00E 08-06 © MTU

4.1.24 Engine lifting equipment – Cleaning
Material

Compressed air.
Risk of injury!

Engine lifting equipment – Cleaning

2. Blow all parts clear with compressed air.
TIM ID: 0000003192 – 002
MS25012/00E 08-06 © MTU

4.1.25 Engine lifting equipment – Check
Material

Spare parts

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

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

damage.
Measure shaft length of the cylinder Value (→ Page 321) Replace

head screws with depth gauge. exceeded.
TIM ID: 0000003193 – 004
MS25012/00E 08-06 © MTU

4.1.26 Engine lifting equipment – Installation
Special tools

Torque wrench 60-320 Nm F30047446 1
Check engine lifting equipment (→ Page 131).
Engine lifting equipment – Installation

1. Place lifting eye (3) on cylinder head and align to
the bores for the cylinder head screws.
Note: If only cylinder head screws at lifting eye
were undone just tighten these two cylinder
head screws to specified tightening torque.
2. Screw in cylinder head screw (2) with thrust

washer (1) and use torque wrench to tighten to
specified tightening torque (→ Page 23).
TIM ID: 0000003194 – 004
MS25012/00E 08-06 © MTU

4.1.27 End housing driving end – Overview
End housing with externally mounted components
200 Flywheel housing 700 Screw 1250 Screw

250 Dead-center indicator 750 Screw 1300 Guard plate
300 Screw 800 Spring washer 1350 Screw
400 Plug screw 900 O-ring 1400 Screw
450 Sealing ring 1000 Guard plate 1450 Spacer bushing
550 Sealing ring 1050 Guard plate 1550 O-ring
600 Adapter 1100 Screw 1650 Screw
610 Blanking cone 1150 Washer
620 Nut 1200 Guard plate
TIM ID: 0000027987 – 001
MS25012/00E 08-06 © MTU

50 Flywheel housing 350 Spacer bushing 700 Thrust washer

100 Crankshaft bearing, driving end 450 Guard plate 800 Screw
200 Guard plate 500 Screw 850 Washer
250 Screw 550 Screw
300 Screw 600 Spacer bushing
TIM ID: 0000027987 – 001
MS25012/00E 08-06 © MTU

Configuration of guide bushing for removal and installation of end housing
1 Support 2 Crankshaft 3 Guide bushing

TIM ID: 0000027987 – 001
MS25012/00E 08-06 © MTU

4.1.28 End housing, driving end – Removal
Special tools

Support bracket T80091550 1
Lifting gear T80091551 1
Suspended load.
Danger to life!

Risk of injury!
TIM ID: 0000016568 – 002
MS25012/00E 08-06 © MTU

Assembly position
1. Oil pan faces down.
2. Oil pan faces up.
Removing end housing

1. Screw support bracket to end housing and, using a lightly tensioned rope, attach to crane.
2. Remove all screws for end housing on crankcase (→ Page 133).
3. Remove end housing horizontally from crankcase.
4. Remove O-rings.
TIM ID: 0000016568 – 002
MS25012/00E 08-06 © MTU

4.1.29 End housing, driving end disassembly
Special tools

Removal tool for crankshaft bearing, driving end F6557190 1
Lukas cylinder B80096717 1
Hand pump set B80146893 1
Material

Engine oil SAE 10 W
Equipment can drop off.

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

1. Remove thrust washer as shown in overview
drawing (→ Page 133).
2. Cut axial groove in crankshaft bearing, leaving wall
thickness of approx. 1 mm to relieve tension in
bearing.
3. Install removal tool (2) on end housing.
4. Attach Lukas cylinder (1) to crane and mount
on removal tool (2).
5. Connect HP line to Lukas cylinder (1) and hand
pump.
6. Fill hand pump with engine oil SAE 10 W.
7. Vent hand pump and pipework until bubble-free oil
emerges.
8. Press off bearing.
9. Relieve hand pump.
10. Remove removal tool (2) and Lukas cylinder (1).
11. Remove remaining parts as per overview drawing
(→ Page 133).
TIM ID: 0000026883 – 001
MS25012/00E 08-06 © MTU

4.1.30 End housing, driving end – Cleaning
Material

Compressed air.
Risk of injury!

End housing, driving end – Cleaning

2. Thoroughly blow end housing, driving end, and all threads clear with compressed air.
TIM ID: 0000003195 – 002
MS25012/00E 08-06 © MTU

4.1.31 End housing, driving end – Check
Special tools

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

Spare parts

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

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

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

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

driving end. Value (→ Page 141)
* Replace crankshaft bearings during "Extended component maintenance".

TIM ID: 0000026884 – 001
MS25012/00E 08-06 © MTU

4.1.32 End housing , driving end – Tolerances
No. Designation Stage Tol. size Toleranced size Clearance Interference Limit
Basic value
size
1 Ring gear bore 707.030 707.290 0.76 1.08
Flywheel outer Ø 708.05 708.11
2 Flywheel bore 299.968 300.0 0 0.064
Drive flange 300.0 300.032

outer Ø
3 Bearing surface 209.549 209.685

of drive flange,
outer Ø
4 Flywheel 240.000 240.072 0.278 0.590

housing bore
Radial-lip shaft 240.350 240.590

seal outer Ø
Radial-lip shaft seal pressed in flush

TIM ID: 0000026913 – 001
MS25012/00E 08-06 © MTU

4.1.33 End housing, driving end – Assembly
Special tools

Insertion tool F30378426 1
Locating device F6557153 1
Material

Liquid nitrogen

Suspended load.
Danger to life!

Risk of injury!
Installing crankshaft bearing

1. Place end housing on suitable surface to allow
installation of the crankshaft bearing in the correct
position.
2. Install stop (1) on rear side of end housing (2).
3. Secure stop (1) on front side of end housing
(2) using two nuts.
TIM ID: 0000016413 – 002
MS25012/00E 08-06 © MTU

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

5. Insert crankshaft bearing (3) and insertion tool (2),
ensuring they are correctly positioned with regard
to each other (position mark/notch mark) (4).
6. Press down pins (1) and crankshaft bearing
by turning.
7. Chill crankshaft bearing (3) with insertion tool
(2) in liquid nitrogen.
8. Place crankshaft bearing with insertion tool (2) at

end housing (1) in 12 o’clock position (arrowed).
9. Insert chilled crankshaft bearing with insertion tool
(2) up to stop in end housing (1).
10. After a brief dwell period, unlock and remove
insertion tool (2).
11. Remove stop from rear side of end housing.
12. Install thrust washer as per overview drawing
(→ Page 133).
13. Install support bracket on end housing.
14. Install remaining parts as per overview drawing
(→ Page 133).
TIM ID: 0000016413 – 002
MS25012/00E 08-06 © MTU

4.1.34 End housing, driving end – Installation
Special tools

Bracket T80091550 1
Bracket T80091102 1
Support F6781672 1
Flange 1
Socket-head screws 000912016030 6
Guide bushing F6782971 1
Material

Fast cleaner (Loctite 7061) 50518 1
Suspended load.
Danger to life!

Risk of injury!
End housing, driving end – Installation

1. Use fast cleaner to clean sealing face (arrows)
between end housing and crankcase.
2. Coat sealing face (arrows) evenly with surface
sealant and smooth.
3. Coat O-rings (1) with grease and insert in bores.
TIM ID: 0000016571 – 004
MS25012/00E 08-06 © MTU

Note: The illustration shows the engine rotated

through 180°, i.e. the oil pan mating face
faces upwards.
4. Use fast cleaner to clean sealing face (arrows) on

crankcase (1).
5. Screw flange on to crankshaft end.
6. Slide guide bushing (2) over flange and secure
with screws.
Note: Oil pan faces down.
7. Install bracket (1).

8. Install holder (2) on end housing. Make sure that
“TOP/OBEN” mark points upwards, irrespective of
the position of the crankcase.
9. Insert locating pin (4) into sensor holder of end
housing.
10. Attach end housing to crane via bracket.
11. Position end housing on guide bushing and push
towards crankcase as far as it will go.
Note: Oil pan faces up.
12. → 7. Follow the same procedure as described for

“oil pan facing down”.
TIM ID: 0000016571 – 004
MS25012/00E 08-06 © MTU

Note: Oil pan faces down.
13. Insert one screw with washer in upper inner

circle (1) and tighten to approx. 10 Nm.
14. Remove bracket.
15. Insert all screws with washers and tighten to
specified tightening torque (→ Page 23). Observe
the following tightening sequence:
15.1. Tighten screws in the upper inner circle (1) of
the end housing in any tightening sequence.
15.2. Tighten screws in the lower inner circle (2) of
the end housing in any tightening sequence.
15.3. Tighten screws in the outer area of the end
housing in any tightening sequence.
16. Tighten all screws with washers to specified
tightening torque (→ Page 23). Observe the
following tightening sequence:
16.1. Tighten screws in the upper inner circle (1)
of the end housing clockwise.
16.2. Tighten screws in the lower inner circle (2)
of the end housing clockwise.
16.3. Tighten screws in the outer area of the end
housing clockwise.
17. Release guide bushing from flange.
18. Remove holder from end housing.
19. Insert screws with washers in free holes and
tighten to specified tightening torque (→ Page 23).
20. Remove guide bushing from flange and remove
flange from crankshaft.
21. Remove excess sealant.
Note: Oil pan faces up.
22. → 13. Follow the same procedure as described for

“oil pan facing down”.
TIM ID: 0000016571 – 004
MS25012/00E 08-06 © MTU

4.1.35 Crankcase breather – Overview
Crankcase breather, version A
100 Vent housing 950 Plug screw 1950 Retainer

150 Bracket for oil separator 1000 Sealing ring 2050 Screw
200 Bracket for oil separator 1050 Plug screw 2100 Washer
380 Screw 1150 Plug-in pipe 2150 Pipe half-clamp
400 Washer 1200 O-ring 2200 Grommet
450 Gasket 1350 Nut 2210 Oil line
460 Cover 1400 Sealing cone 2220 Screw
465 O-ring 1500 Oil line 2300 Retainer
470 Screw 1600 Oil line 2350 Pipe half-clamp
500 Oil separator 1610 Retainer 2400 Grommet
550 Screw 1620 Pipe half-clamp 2450 Screw
600 Washer 1625 Grommet 2500 Screw
800 Screw 1630 Screw 2550 Screw
810 Screw 1700 Pipe half-clamp 2560 Washer
850 Screw 1750 Grommet 2650 Adapter
860 Washer 1800 Screw 2700 Sealing ring
TIM ID: 0000020789 – 002
MS25012/00E 08-06 © MTU

650 Manifold 3050 Retainer 3270 Screw

700 Clamp 3100 Screw 3350 Clamp
2800 Intake hose 3150 Clamp 3400 Screw
2810 Intake hose 3200 Screw 3450 Washer
2850 Intake hose 3250 Washer 3500 Nut
2860 Intake hose 3260 Clamp
2900 Clamp 3265 Spacer
TIM ID: 0000020789 – 002
MS25012/00E 08-06 © MTU

Oil separator
1 Diaphragm 2 Insert 3 Gasket

TIM ID: 0000020789 – 002
MS25012/00E 08-06 © MTU

Crankcase breather, version B
100 Vent housing 700 Gasket 1200 Hose

200 Screw 750 Screw 1300 Clamp
250 Screw 850 Cover 1400 Clamp
350 Plug screw 900 Retainer 1450 Retainer
400 Sealing ring 950 Air filter 1500 Screw
500 Plug-in pipe 1050 O-ring 1550 Nut
550 O-ring 1100 Clamp 1650 Plug screw
650 Cover plate 1110 Nut 1700 Sealing ring
TIM ID: 0000020789 – 002
MS25012/00E 08-06 © MTU

4.1.36 Crankcase ventilation – Removal
Preconditions
Crankcase ventilation – Removal
1. Remove lines and oil separator as per overview drawings (→ Page 147).
2. After removal, seal all connections with suitable plugs.
3. Protect oil separator from damage. Even minor damage may cause oil separator failure.
TIM ID: 0000003212 – 006
MS25012/00E 08-06 © MTU

4.1.37 Crankcase breather – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning crankcase breather (version A).

Note: Parts made of rubber or synthetic materials shall be protected from oil and fuel, wiped clean with a
dry cloth only, and never cleaned with organic cleaning agents.
Cleaning crankcase breather (version B).

1. Flush filter element with diesel fuel.
2. Blow out filter element with compressed air.
3. Clean all remaining parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
TIM ID: 0000027008 – 001
MS25012/00E 08-06 © MTU

4.1.38 Crankcase breather – Check
Material

Corrosion inhibitor
Spare parts

Line
Oil separator
Compressed air is pressurized.

Hot testing liquid.
WARNING Risk of injury and scalding!
• Pressure must not exceed 0.5 bar.
Checking crankcase breather
Item Findings Measure
Inspect oil separator visually for Damaged Replace

damage.
Check sealing faces and bolt-on Damaged • Rework: smooth with oilstone
faces for damage and wear. • Replace
Check thread for ease of movement. Damaged • Rework: recut thread

• Replace
Check oil return line with air and Leaking • Rework

corrosion inhibitor in water bath for • Replace
leaks.
• Air test pressure: 0.5 bar (do
not exceed test pressure)
• Water temperature min. 30 °C,
max. 40 °C
Visually inspect lines. • Mechanical damage Replace

• Scuffing
• Pressure marks
TIM ID: 0000027010 – 001
MS25012/00E 08-06 © MTU

4.1.39 Hengst oil separator – Disassembly
Special tools

Screwdriver (Torx 30) F30033099 1
Disassemble Hengst oil separator

1. Remove securing screws (2) for cover (1) with
screwdriver.
2. Remove cover (1) and O-ring.
3. Remove aerosol element (1) from oil separator

housing (2).
TIM ID: 0000027012 – 001
MS25012/00E 08-06 © MTU

4. Remove securing screws for cover (1).

5. Remove cover (1), spring (2) and O-ring.
6. Remove diaphragm (3) from oil separator housing.
TIM ID: 0000027012 – 001
MS25012/00E 08-06 © MTU

4.1.40 Hengst oil separator – Check
Spare parts

Diaphragms
Oil separator

Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
Hengst oil separator – Check
Item Findings Task
Visually inspect components for Damaged Replace

damage and wear.
Check sealing and bolt-on faces for Damaged • Corrective work: Smooth with
damage and condition. oilstone
• Replace
Check threads for ease of Damaged • Corrective work: Recut threads

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

with air in water bath.
• Air test pressure: 0.2 bar (do
not exceed test pressure)
Oil separator pressure control can only be checked when installed while engine is in operation. Vacuum or
overpressure is measured (e.g. with water pressure gauge) over entire engine speed range. Values should lie
between minus 10 mbar and plus 10 mbar (100 mm water column).
TIM ID: 0000027013 – 001
MS25012/00E 08-06 © MTU

4.1.41 Hengst oil separator – Assembly
Special tools

Screwdriver (Torx 30) F30033099 1
Material

Assemble Hengst oil separator

1. Coat O-ring (arrow) with grease and insert into
groove provided on oil separator housing (3).
2. Insert diaphragm (2) in oil separator housing
(3) ensuring it correctly positioned (curvature
facing up).
3. Fit spring (1) on diaphragm (2), ensuring spring (1)
is correctly seated at diaphragm (2).
4. Mount cover (1) on spring (2) in correct position.

5. Install screws using screwdriver and tighten
diagonally to specified tightening torque
(→ Page 23).
TIM ID: 0000027020 – 001
MS25012/00E 08-06 © MTU

6. Coat O-ring with grease and insert into groove

(arrow) provided on oil separator housing (2).
7. Insert aerosol element (1) in oil separator
housing (2), ensuring it is correctly positioned.
8. Mount cover (1) on oil separator housing and

insert screws (2) with screwdriver and tighten
diagonally and evenly to specified tightening
torque (→ Page 23).
9. Check oil separator for leaks (→ Page 156).
TIM ID: 0000027020 – 001
MS25012/00E 08-06 © MTU

4.1.42 Crankcase ventilation – Installation
Material

Spare parts

Gasket
O-ring
Rubber sleeve
Clamp
Crankcase ventilation – Installation

1. Remove all covers.
3. Install crankcase ventilation as per overview drawing (→ Page 147).
TIM ID: 0000005269 – 005
MS25012/00E 08-06 © MTU

4.2 Gear Train
4.2.1 Gearcase, free end – Overview
200 Equipment carrier 560 Screw 900 Washer

300 Plug screw 600 Cover 950 Nut
350 Sealing ring 650 Screw 1050 Screw
450 Gasket 750 O-ring 1100 Plug screw
500 Gasket 800 Stud 1150 Sealing ring
550 Cover 850 Screw 1250 Screw
TIM ID: 0000028639 – 001
MS25012/00E 08-06 © MTU

1350 Sealing ring 1450 Cable 1600 Grommet

1400 Banjo screw 1550 Pipe half-clamp 1650 Screw
TIM ID: 0000028639 – 001
MS25012/00E 08-06 © MTU

100 Equipment carrier 1000 Delivery valve 1700 Plug screw

400 Crankshaft bearing 1100 O-ring 1800 Plug screw
500 Idler gear 1200 O-ring 1900 Sealing ring
600 Axle 1300 Circlip 2000 Plug screw
700 O-ring 1400 Plug screw 2100 Pressure reduction valve
800 O-ring 1500 Sealing ring 2150 Plug screw
900 Screw 1600 Plug screw 2200 Sealing ring
TIM ID: 0000028639 – 001
MS25012/00E 08-06 © MTU

Arrangement of alignment tool for equipment carrier and equipment carrier cover
1 Equipment carrier 3 TOP/OBEN mark 5 Guide bushing

2 Alignment tool 4 Screw 6 Screw
TIM ID: 0000028639 – 001
MS25012/00E 08-06 © MTU

4.2.2 Gearcase, free end – Removal
Preconditions
Special tools

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

(arrows). Note that screws differ in length.
6. Remove all screws. TIM ID: 0000003049 – 008
MS25012/00E 08-06 © MTU

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

and remove with washers.
8. Carefully force gearcase (1) with rope slightly
pretensioned towards free end until it is released
from crankcase.
9. Remove O-rings.
10. Set gearcase down and protect from damage.
11. Seal openings with suitable covers.
TIM ID: 0000003049 – 008
MS25012/00E 08-06 © MTU

4.2.3 Gearcase, free end – Disassembly
Special tools

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

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

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

1. Place seal carrier on a suitable surface.
2. Use suitable extractor to pull out radial-lip shaft seal.
TIM ID: 0000003217 – 004
MS25012/00E 08-06 © MTU

4.2.4 Equipment carrier free end – Cleaning
Material


Compressed air.
Risk of injury!

Cleaning equipment carrier, free end

1. Clean elastomer parts with cleaner (Hakupur 312).
TIM ID: 0000003218 – 002
MS25012/00E 08-06 © MTU

4.2.5 Gearcase, free end – Check
Special tools

Bore gauge, 160-280 mm Y20091483 1
Material

Spare parts

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

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

scoring and indentation. • Indentations (→ Page 166)
Visible
Check threads in gearcase for ease Sluggish Recut threads

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

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

gearcase. Values (→ Page 169) (→ Page 166)
TIM ID: 0000003561 – 004
Measuring crankcase bearing bore Values exceeded. Replace gearcase.

in gearcase. Values (→ Page 169)
MS25012/00E 08-06 © MTU

4.2.6 Gearcase, free end – Tolerances
Crankshaft bearing, free end, 8/12/16V
No. Designation Stage Tol. size Deviation Clearance Interference Wear limit
Basic
lower upper min. max. min. max.
size
1 Gearcase bore 193.000 H6 0 +0,029 0,175 0,233 Interfer-

ence min.
Bearing outer Ø 193,204 0 +0,029 0.150
removed
2 Bearing bush 180,121 0 +0,069 0,321 0,430

bore
Bearing press-
fitted
Driver flange 179.800 -0,040 0

outer Ø h7
not press-fitted
TIM ID: 0000004665 – 002
MS25012/00E 08-06 © MTU

Crankshaft bearing, free end, 20V
Basic
size
1 Gearcase bore 193.000 H6 0 +0,029 0,175 0,233 Interfer-

ence min.
Bearing outer Ø 193,204 0 +0,029 0.150
removed
2 Bearing bush 180,121 0 +0,069 0,321 0,430 Clearance

bore max.
Bearing press- 0.450
fitted
Driver flange 179,740 h7 -0,040 0

outer Ø
not press-fitted
TIM ID: 0000004665 – 002
MS25012/00E 08-06 © MTU

4.2.7 Gearcase, free end – Assembly
Special tools

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

Denatured ethanol 40250 1
Loctite 7063 50594 1
Liquid nitrogen
Spare parts

Crankshaft bearing
Radial-lip shaft seal
Studs

Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
TIM ID: 0000003219 – 003
MS25012/00E 08-06 © MTU

Installing crankshaft bearing in equipment carrier

1. Insert eyebolts in equipment carrier.
2. Use rope to hook equipment carrier on to crane
with light initial load.
3. Lift equipment carrier and move to installation
position.
4. Place equipment carrier on a firm surface and
secure.
Note: Pay attention to “Oben/Top” (arrow) mark.
5. Install jig (1).
6. Clean crankshaft bearing with Loctite.

7. Insert crankshaft bearing (1) in locating device (2).
Note: Ensure that position marking on crankshaft
bearing (arrow) and notch mark on
insertion tool are aligned.
8. Insert insertion tool.
9. Lock crankshaft bearing (3) on insertion tool (2)

with tommy bars (1).
10. Chill insertion tool (2) with crankshaft bearing
(3) in liquid nitrogen. TIM ID: 0000003219 – 003
MS25012/00E 08-06 © MTU

Note: Location specified is by means of an

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

bearing (1) on inner side of equipment carrier
up to stop.
12. After 60 seconds, unlock and remove insertion
tool (2).
13. Check positions of oil bores on crankshaft bearing.
Installing radial-lip shaft seal in seal carrier (if

applicable)
1. Push radial-lip shaft seal with sealing lip facing
down on to installation mandrel.
2. Clean and degrease sealing face for radial-lip shaft
seal in seal carrier.
3. Coat sealing face of radial-lip oil seal with ethanol.
4. Press-fit radial-lip shaft seal with drift into seal
carrier.
TIM ID: 0000003219 – 003
MS25012/00E 08-06 © MTU

4.2.8 Gearcase, free end – Tightening sequence
Screw tightening sequence for assembly positions A, B: 1, 2, 3, 4, 5, 6
TIM ID: 0000015912 – 001
MS25012/00E 08-06 © MTU

4.2.9 Gearcase, free end – Installation
Special tools

Alignment device F6782344 1
Material

Express dry cleaner (Loctite 7063) 50594 1
Spare parts

O-ring
Suspended load.
Danger to life!

Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
TIM ID: 0000003239 – 007
MS25012/00E 08-06 © MTU

Installing gearcase
1. Install intermediate gears and axles (→ Page 187).
2. Install pressure valve (→ Page 567).
3. Install pressure-reducing valve (→ Page 540).
4. Clean alignment device (2).
5. Coat alignment device and guide bushing with
engine oil.
6. Install alignment device and guide bushing on
gearcase with screws (1). Ensure that the
“TOP/OBEN” mark points upwards, independent of
the position of the crankcase.
7. Remove guide bushing.
8. Clean crankshaft stub, driving end.

9. Screw flange and guide bushing (2) on to
crankshaft stub with screw (1).
10. Attach gearcase to crane using a rope.

11. Degrease contact surface with express dry cleaner
and dry clean.
12. Apply surface sealant with a spatula/roller to the
gearcase sealing face.
13. Coat O-rings (1) with grease and insert into
groove on gearcase.
TIM ID: 0000003239 – 007
MS25012/00E 08-06 © MTU

14. Using crane, move gearcase (3) over crankshaft

guide bushing (1). Always note:
14.1. The studs (2) must be in alignment.
14.2. Both idler gears and the crankshaft gear
must be in alignment with each other.
14.3. In each case, position one of the round
recesses on the idler gears so that screws
can be retightened. If the holes are not
visible, crank engine accordingly.
15. Screw in nuts and washers and tighten.
Note: Relieve load on crane ropes before

tightening nuts and screws. Screws
10.9 (1,4) may only be used once.
16. Tighten screws in order 5, 6, 3, 2, 4 and 1 using

torque wrench to specified tightening torque
(→ Page 23).
17. Install all securing screws (arrowed) and tighten

uniformly.
18. Remove securing screws of alignment device on
gearcase and on crankshaft.
TIM ID: 0000003239 – 007
MS25012/00E 08-06 © MTU

19. Screw in plug screws (1) and (2) with new

sealing rings.
20. Remove ropes and eyebolts.
21. Install oil line (→ Page 540).
TIM ID: 0000003239 – 007
MS25012/00E 08-06 © MTU

4.2.10 Gear train, free end – Overview
Item no. Designation Number of Circumferential backlash Axial clearance

teeth (mm) (mm)
1 Gear, coolant pump, 32 0.201 ±0.065 to gear 9 —

low-temperature circuit
2 Gear, coolant pump, 32 0.201 ±0.065 to gear 9 —

high-temperature circuit
TIM ID: 0000003220 – 002
3 Crankshaft gear 48 — —
4 Camshaft gear 96 0.286 ±0.081 to gear 3 0.1 to 0.18
5 Gear, H.P. fuel pump 32 0.201 ±0.065 to gear 6 —
6 Idler gear 89 0.285 ±0.080 to gear 3 0.2 to 0.6
MS25012/00E 08-06 © MTU

Item no. Designation Number of Circumferential backlash Axial clearance

teeth (mm) (mm)
7 Gear, battery-charging generator 19 0.222 ±0.128 to gear 6 —
8 Gear, oil pump 34 0.279 ±0.077 to gear 9 —
9 Idler gear 89 0.285 ±0.080 to gear 3 0.2 to 0.6
10 Gear, hydrostatic pump 34 0.201 ±0.065 to gear 9 —
1 Coolant pump drive gear 6 Gearcase, free end

2 Shaft 7 H.P. fuel pump drive gear
3 Idler gear 8 Main bearing, free end
4 Crankshaft 9 Drive flange, free end
5 Crankshaft gear 10 Drive gear
TIM ID: 0000003220 – 002
MS25012/00E 08-06 © MTU

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

1. Place equipment carrier on a clean and flat
surface.
2. Remove screws (1) and (2).
3. Insert jackscrews M8 with continuous thread in
thread (arrows) of axle (3).
4. Press off axle evenly.
Removing axles
1. Mark respective axle according to installation
position and remove from equipment carrier.
2. Remove idler gears from fit.
3. Remove bearing bushing of idler gear
(→ Page 190).
TIM ID: 0000003248 – 005
MS25012/00E 08-06 © MTU

4.2.12 Gear train, free end – Cleaning
Material

Compressed air.
Risk of injury!

Gear train, free end – Cleaning

1. Clean idler gears and oil bores of axles with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Thoroughly clean gear train, free end, by blowing clear with compressed air.
TIM ID: 0000003221 – 002
MS25012/00E 08-06 © MTU

4.2.13 Gear train, free end – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

Spare parts

Idler gears
Axle
TIM ID: 0000003222 – 006
MS25012/00E 08-06 © MTU

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

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

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

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

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

threads for ease of movement. • Sluggish
Measure bearing bushing bore in Values exceeded Replace bearing bushing bore
idler gear. Values (→ Page 185) (→ Page 190).
Use micrometer to measure outer Values exceeded Replace axle.

diameter of axles at running surface.
Values (→ Page 185)
Measure equipment carrier bore Values exceeded Replace equipment carrier.

of idler gear axles. Values
(→ Page 185)
TIM ID: 0000003222 – 006
MS25012/00E 08-06 © MTU

4.2.14 Gear train, free end – Tolerances
No. Designation Stage Tol. size Deviation Clearance Interference Wear

Basic limit
size
1 Equipment carrier 81.000 H7 0 +0.035 0 0.070 Clear-

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

bore ance
max.
TIM ID: 0000004681 – 001
Axle outer dia. 75.000 e7 –0.090 –0.060 0.080
MS25012/00E 08-06 © MTU

No. Designation Stage Tol. size Deviation Clearance Interference Wear

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

width ance
max.
Idler gear width 40.700 –0.100 0 0.900
Measure equipment carrier width unclamped.
6 Crankcase
TIM ID: 0000004681 – 001
MS25012/00E 08-06 © MTU

4.2.15 Gear train, free end – Installation
Special tools

Retainer 0015890321/00 1
Material

Engine oil
Spare parts

O-ring
Suspended load.
Danger to life!
Installing idler gear in gearcase

1. Coat bearing bushings in idler gear with engine oil.
2. Insert idler gear (2) through opening (arrowed) into
gearcase (1), ensuring it is correctly positioned.
TIM ID: 0000003249 – 004
MS25012/00E 08-06 © MTU

Installing axles
1. Ensure oil bores of axles (3) are perfectly clean.
2. Coat O-rings (1) and (2) with grease.
3. Insert O-ring (2) into groove of gearcase (4).
4. Fit O-ring (1) in groove in axle base.
5. Insert axles into gearcase. Pay attention to fit
of idler gear.
6. Press axle (3) into gearcase.

7. Install hex bolts (1) and tighten evenly.
8. Screw in hex bolt (2).
TIM ID: 0000003249 – 004
MS25012/00E 08-06 © MTU

Checking thrust distance and backlash

1. Install two eyebolts in gearcase.
2. Attach gearcase to crane with ropes and tension
ropes equally.
3. Position gearcase vertically.
4. Mount magnetic-base holder (3) with dial gauge
(2) on gearcase.
5. Measure thrust distance:
5.1. Place preloaded dial-gauge anvil on lateral
collar of idler gear (1).
5.2. Set dial gauge to zero.
5.3. Check thrust distance by moving idler gear
back and forth in axial direction. Thrust
distance limit values (→ Page 179).
6. Measure backlash:
6.1. Position preloaded dial-gauge anvil on tooth
flank of idler gear.
6.2. Set dial gauge to zero.
6.3. Move idler gear back and forth in radial
direction to check backlash.
6.4. Compare with specified values in table
(→ Page 179).
7. If limit values are exceeded, replace idler gears.
TIM ID: 0000003249 – 004
MS25012/00E 08-06 © MTU

4.2.16 Bearing bushing of idler gear – Removal and installation
Material

Liquid nitrogen
Spare parts

Bushing

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

1. Clean idler gear (→ Page 182)
2. Using a suitable sleeve and manual press, remove
bearing bushing (1) from idler gear (2).
TIM ID: 0000003223 – 005
MS25012/00E 08-06 © MTU

Bearing bushing – Installation

1. Measure main bore (3) in idler gear (2). Values
(→ Page 185)
2. Place idler gear on a suitable surface. Ensure that,
when inserting the bearing bushing (1), there is
no lateral projection.
3. Cool bearing bushing in liquid nitrogen and heat
idler gear to 80 °C.
4. Insert chilled bearing bushing in idler gear.
Observe distance (A) 0.35 mm ±0.15 mm.
TIM ID: 0000003223 – 005
MS25012/00E 08-06 © MTU

4.3 Crank Drive
4.3.1 Crank drive – Overview
Crank drive
1 Flywheel 4 Conrod 7 Vibration damper

2 Ring gear 5 Crankshaft 8 Crankshaft counterweight
3 Piston 6 Crankshaft gear, free end
TIM ID: 0000029532 – 001
MS25012/00E 08-06 © MTU

4.3.2 Crankshaft – Overview
Crankshaft
5 Crankshaft 15 Screw
10 Counterweight 20 Crankshaft gear
TIM ID: 0000029554 – 001
MS25012/00E 08-06 © MTU

Crankshaft with bearings
1 Crankshaft bearing, top 2 Crankshaft bearing, bottom
TIM ID: 0000029554 – 001
MS25012/00E 08-06 © MTU

4.3.3 Crankshaft – Removal
Preconditions
Special tools

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

Risk of injury!
Removing crankshaft bearing caps

1. Check marking (1) of the crankshaft bearing caps
in relation to the crankcase.
2. If there is no marking (1): starting at driving
end, emboss main bearing numbers making
sure they can be read from the same direction.
Height of numeral punch: 6 mm.
TIM ID: 0000003563 – 005
MS25012/00E 08-06 © MTU

3. Turn crankcase upside down in swivel frame with

oil pan mating horizontal and facing upwards.
4. Remove socket-head screws (arrows) and remove
strip (1) from crankcase (2).
5. Remove all lateral screws for crankshaft bearing
caps from crankcase.
6. Starting at 1st bearing cap (driving end), position

hydraulic pretensioner on bearing cap studs.
7. Insert hydraulic screw pretensioner by hand.
8. Connect high-pressure hoses (1) of hydraulic
pump to hydraulic pretensioner (2).
9. Position magnetic holder and dial gauges on
crankcase mating face.
10. Center both gauge tips on the measuring points.
11. Set preloaded dial gauges to zero.
12. Operate hydraulic pump and simultaneously

elongate studs by a max. 0.25 mm.
13. Use a pin to loosen crankshaft bearing cap nut.
14. Release studs.
15. Position magnetic holder, dial gauges and
hydraulic pretensioner on next bearing cap.
16. Loosen and remove all nuts in the same sequence.
TIM ID: 0000003563 – 005
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Removing crankshaft bearing caps

1. Use removal tool to remove crankshaft bearing caps.
2. Remove bearing shell from crankshaft bearing cap and mark.
3. Protect bearing shells from damage.
Crankshaft – Removal
1. To protect the crankshaft, fit sliding protection
sleeves over studs of first and last bearings.
2. Using rope (1) and crane, lift crankshaft (2) clear

of crankcase.
3. Ensure horizontal positioning of the crankshaft
when lifting.
4. Lower crankshaft on to firm supports.
TIM ID: 0000003563 – 005
MS25012/00E 08-06 © MTU

5. Use removal jig to remove bearing shells from

bearing pedestals.
6. Mark bearing shells that point towards the driving
end with the number of the corresponding main
bearing (arrow).
7. The marking (arrow) must be made by etching or
with a permanent marker.
TIM ID: 0000003563 – 005
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4.3.4 Crankshaft – Disassembly

Heavy object.
Risk of crushing!

Risk of injury!
Removing counterweights
1. Check that counterweights are numbered
consecutively.
2. If the numbering is not visible, punch in new
numbers.
3. Lower crankshaft on to firm assembly dolly.
4. Remove screws (2) and counterweight (1).
TIM ID: 0000029540 – 001
MS25012/00E 08-06 © MTU

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

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

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


Crankshaft - Cleaning
2. Clean crankshaft and all threads with compressed air.
TIM ID: 0000003228 – 004
MS25012/00E 08-06 © MTU

4.3.6 Crankshaft – Check
Special tools

DynaMIC hardness tester Y20506341 1
Retainer 0015890321/00 1
Bore gauge, 100-160 mm Y20091482 1
Material

Spare parts

Crankshaft
Counterweight
Screw
Compressed air.
Risk of injury!
Heavy object.
Risk of crushing!
TIM ID: 0000003229 – 008
MS25012/00E 08-06 © MTU

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

counterweights for wear.
Use micrometer to measure Values fallen short of. Corrective work: To be carried out
diameter and roundness of main only in workshops authorized by
bearing journals and crankpins. MTU.
Record measured values in data
sheet. Values (→ Page 205)
Check crankshaft counterweight Signs of cracks Replace crankshaft counterweight

with magnetic crack-testing method (→ Page 199).
for cracks.
Check crankshaft gear for stress Stress marks visible • Corrective work
marks. • Replace: To be carried out only
in workshops authorized by
MTU.
Using engineer’s blue, check that Unevenly fitted. Level mating face.
screw heads fit correctly.
Measure shaft length of screws with Dimension exceeded Replace screw.

depth gauge. Permissible shaft
length (→ Page 23)
Use magnetic crack-testing method Signs of cracks Replace screw.

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

condition. • Damaged
Checking crankshaft for cracks

1. Install crankshaft in longitudinal direction between
jaws of test device.
2. The specified magnetic field strength of 20 A/cm
to 60 A/cm must be applied at every part of
the component.
3. Use magnetic crack-testing method to check
crankshaft for longitudinal and transverse cracks.
Also check the oil and journal bores as well as the
mating faces on counterweights and threaded
bores.
Result: If there are signs of cracks, replace
crankshaft.
4. After crack-testing, demagnetize crankshaft. A
residual field strength of 2.5 A/cm to 4 A/cm
must not be exceeded.
TIM ID: 0000003229 – 008
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Checking crankshaft journal and taper

1. Check taper surfaces (arrows) for scoring and
damage.
2. Remove minor scoring and damage by polishing
with emery cloth.
3. Recondition taper: To be carried out only in
Checking hardness of journals

Note: Check hardness of all journals when
not installed.
1. Check hardness of all journals using the DynaMIC

tester or other suitable hardness tester. Required
hardness: 49 HRC to 53 HRC.
2. Check hardness of each journal at four points at
90° intervals around circumference.
Result: If values are fallen short of, contact
Service.
TIM ID: 0000003229 – 008
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Checking concentricity of crankshaft

1. Place crankshaft on rollers in main journals on main bearing.
• Main bearings 1 and 5 for 8 V
2. Use adjustable measuring holder and dial gauge to check bearing journals for concentricity.
3. If wear on circumference of journal is irregular, measure at transition from cylindrical section of journal to
radius. Values (→ Page 205).
Result: If measured values deviate: Recondition crankshaft only in workshops authorized by MTU.
TIM ID: 0000003229 – 008
MS25012/00E 08-06 © MTU

4.3.7 Crankshaft – Tolerances
Crankshaft bearing

anced value
size Lower Upper Min. Max. Min. Max.
Basic
size
1 Crankcase bore 0 171.000 H6 0 +0.025 171.035

for crankshaft Trans-
bearing verse
ovality
max. 0.050
1 171.500 H6 171.535
Trans-
verse
ovality
max. 0.050
2 172.000 H6
TIM ID: 0000029541 – 001
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anced value
Basic
size
2 Guide bearing 0-0 160.120 0 +0.054 0.120 0.199 Trans-

and crankshaft verse
bearing Ø 0-1 159.620 ovality
installed 0-2 159.120 max. 0.050
0-3 158.620
1-0 160.120
1-1 159.620
1-2 159.120
1-3 158.620
Main bearing Ø 0-0 160.000 h6 –0.025 0 159.970
0-1 159.500 h6 159.470
0-2 159.000 h6 158.970
0-3 158.500 h6 158.470
1-0 160.000 h6 159.970
1-1 159.500 h6 159.470
1-2 159.000 h6 158.970
1-3 158.500 h6 158.470
TIM ID: 0000029541 – 001
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Conrod bearings

anced value
Basic
size
1 Conrod bore 126.000 0 +0.025

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

bore,
conrod bearing 0-1 116.882
installed 0-2 116.682
0-3 116.482
Conrod bearing 0-0 117.000 h6 –0.022 0

journal Ø
0-1 116.800 h6
0-2 116.600 h6
0-3 116.400 h6
TIM ID: 0000029541 – 001
3 Crankpin length 97.500 −0.100 +0.100 0.200 0.600
Conrod width 48.600 −0.100 0
MS25012/00E 08-06 © MTU


anced value
Basic
size
4 Expansion 0-0 126.400 0 +1.000

dimension of
conrod bearing 0-1 126.400
shell, upper and 0-2 126.400
lower halves
0-3 126.400
TIM ID: 0000029541 – 001
MS25012/00E 08-06 © MTU

Crankshaft bearing – Expansion dimension

Basic value
1 Crankshaft bearing, upper half
2 Crankshaft bearing, lower half
3 Expansion 0-0 171.400 0 +1.000

dimension of
crankshaft 0-1 171.400
bearing, upper 0-2 171.400
and lower halves
0-3 171.400
1-0 171.900 0 +1.000
1-1 171.900
1-2 171.900
1-3 171.900
2-0 172.400 0 +1.000

TIM ID: 0000029541 – 001
2-1 172.400
2-2 172.400
2-3 172.400
MS25012/00E 08-06 © MTU

Crankshaft axial play

Basic value
1 Crankshaft axial 0.400 0.600 Play

play min.
0.400;
max. 0.600
2 Drive flange, 72.000 –0.010 +0.010

press-fitted
TIM ID: 0000029541 – 001
MS25012/00E 08-06 © MTU

Crankshaft bearing shells
Bearing shells installed and bearing caps tightened as per specification.

Measure crankshaft bearing bores:
• Determine diameters a, b1 and b2 in the measuring planes 1 and 2 and calculate the average for a, b1 and b2.
• Check roundness of crankshaft bearing bores.
• Possible deviations from roundness are a result of the average values for a, b1 and
b2 according to the formula: (b1+b2) /2 −a
Replace bearing shells if:
• roundness deviation >0.040
• b1 : b2 is above/below 0.040
• vertical ovality a > (b1+b2) /2
TIM ID: 0000029541 – 001
MS25012/00E 08-06 © MTU

Crankshaft gear, free end

Basic value
1 Gear, press- 145.500 −0.300 +0.300

fitted,
crankshaft end
to gear front face
2 Gear bore 131.000 0 +0.040

H7
Crankshaft outer 131.000t6 +0.122 +0.147 0.082 0.147

Ø
TIM ID: 0000029541 – 001
MS25012/00E 08-06 © MTU

Main bearing journal concentricity
Crankshaft (8V)
Max. permissible radial concentricity New Limit value
From main bearing journal 1 (driving end) to last main Concentricity : 0.120
bearing journal 5 (free end)
From main bearing journal to main bearing journal Concentricity : 0.050
Crankshaft (12V)
From main bearing journal 1 (driving end) to last Concentricity : 0.150

main bearing journal 7 (free end)
Crankshaft (16V)

Crankshaft (20V)
TIM ID: 0000029541 – 001

MS25012/00E 08-06 © MTU

4.3.8 Crankshaft – Assembly
Special tools

Adapter 0005892716/00 1
Tightening device F6787133 1
Clearance gauge Y4347843 1
Spare parts

Crankshaft gear
End cover
Heavy object.
Risk of crushing!

Risk of injury!
Installing counterweights
1. Measure shaft lengths of counterweight screws.
Max. shaft length (→ Page 23).
2. Smooth counterweight support with oilstone.
3. Mating faces on crankshaft and counterweight (2)
must be free of grease and dry.
4. Coat threads and screw head mating faces of
screws (1) with engine oil.
5. Position counterweights according to numbers on
crankshaft and hand-tighten screws.
TIM ID: 0000029542 – 001
MS25012/00E 08-06 © MTU

6. Insert clearance gauge (1) between

counterweights (2), use eccentric lever (3) to
clamp on crankshaft.
Note: For parallelism, the counterweights must

have contact with the clearance gauge.
7. Tighten screws to specified pretightenting torque

(→ Page 23).
8. Remove clearance gauge from crankshaft.

9. Fit tightening device (1), and turn screws on to
specified angle of further rotation (→ Page 23).
10. Balance crankshaft dynamically (→ Page 216).
11. Mark counterweights with numeral punches,
starting at driving end.
TIM ID: 0000029542 – 001
MS25012/00E 08-06 © MTU

4.3.9 Crankshaft – Balancing
Special tools

Master weights
Heavy object.
Risk of crushing!

Risk of injury!
Note: Illustration applies analogously to 12V and 20V
TIM ID: 0000028028 – 001
MS25012/00E 08-06 © MTU

Preparatory steps
1. Prior to balancing, seal all oil bores.
2. Support crankshaft at shaft stubs.
Note: There are various master weights that must be used for the respective construction stage (piston,
conrod and crankshaft).
3. Depending on stroke position (free residual moment), master weights for 8V and 16V must be used for dynamic
balancing to simulate the rotating and oscillating mass of piston rod and piston.
TIM ID: 0000028028 – 001
MS25012/00E 08-06 © MTU

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

stubs
Balancing assembly mass 434 kg 780 kg 836 kg
Balancing speed 150 rpm 150 rpm 150 rpm
Permissible residual 240 gcm 240 gcm 240 gcm

unbalance per balancing
plane for initial balancing
Permissible residual 720 gcm 720 gcm 720 gcm

unbalance per balancing
plane in other clamp
or balancing machine
(comparison)
Minimum wall thickness 5 mm 5 mm 5 mm

around bore
Bore values at counterweights

1. To balance crankshaft remove material from
counterweights by drilling with twist drill.
2. After balancing, recheck numbers on
counterweights and renumber if necessary.
A 5 ° (min.)
B 10 °
C 32 ° (min.)
D 20 mm (max. bore diameter)
E 40 mm (max. bore depth)
TIM ID: 0000028028 – 001
MS25012/00E 08-06 © MTU

4.3.10 Crankshaft bearing bore – Check
Special tools

Bore gauge, 100-160 mm Y20091482 1
Installation/removal device F6553647 1
Installation aid F6553649 1
Retainer 0015890321/00 1
Material

Engine oil
Spare parts

Crankshaft bearing shells
Compressed air.
Risk of injury!

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

TIM ID: 0000003231 – 005
MS25012/00E 08-06 © MTU

Measuring bearing shells

1. Turn crankcase in assembly dolly until oil pan
mating face is horizontal and facing upwards.
2. Wipe both sides of bores for crankshaft bearing in
crankcase and bearing shells with chamois leather.
3. Check codes for repair size and journal diameter
of new shells and bearing number of used
shells. These markings must be on sides facing
the driving end.
4. Compare crankcase data sheet and crankshaft
data sheet.
5. Manually press bearing shells on crankcase side
into crankcase bore to form a positive connection.
Ensure that oil bores (arrows) in bearing shells and
6. Insert bearing shells in crankshaft bearing caps

according to markings or bearing number.
7. Position bearing shell so that bearing numbers are
aligned and facing driving end.
8. Position installation tool (1) between bearing
cap stud and rear face of shell on side where
open joint is.
9. Press bearing shell on cap side (2) against guide
bearing shell on crankcase side. Make sure that
the shell joint is closed.
10. Align bearing shells axially.
11. Install crankshaft bearing cap (→ Page 222).
12. Adjust bore gauge with adjusting ring or

micrometer to reference size of bearing bore.
13. Coat running surfaces of crankshaft bearing
shells with engine oil.
14. Measure crankshaft bearing bore ID with bore
gauge.
15. Record measured values in data sheet.
16. Compare measured values with specifications
(→ Page 205).
17. If values are exceeded, recondition bearing shells
to next repair size or replace.
18. After measuring crankshaft bearing bores, if
TIM ID: 0000003231 – 005
necessary mark bearing shells according to

bearing point number.
MS25012/00E 08-06 © MTU

Checking crankshaft bearing bore without main bearing installed

1. Remove crankshaft bearing caps (→ Page 195).
2. Remove bearing shells. Protect against damage.
3. Install crankshaft bearing cap (→ Page 222).
4. Measure crankshaft bearing bore in same way as with installed bearing shells.
TIM ID: 0000003231 – 005
MS25012/00E 08-06 © MTU

4.3.11 Crankshaft – Installation
Special tools

Press-in tool F6555764 1
Alignment tool F6783003 1
Slide protection F6553645 2
Installation aid F6553649 1
Hydraulic set F6557936 1
High-pressure hose B80144827 1
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

Risk of injury!
TIM ID: 0000003232 – 006
MS25012/00E 08-06 © MTU

Installing bearing shells

1. Turn crankcase in assembly dolly until oil pan
mating face is horizontal and facing upwards.
2. Wipe both sides of bores for crankshaft bearing in
crankcase and bearing shells with chamois leather.
Note: Top and bottom bearing shells have
different part numbers. First crankshaft
bearing on driving end is designed as an
alignment bearing.
3. Use installation/removal tool to manually insert

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

bearing.
5. Lift crankshaft using rope slings (1) and crane.
6. Align crankshaft horizontally and vertically with
line of bores in crankcase and gradually lower
crankshaft.
TIM ID: 0000003232 – 006
MS25012/00E 08-06 © MTU

7. Remove protective sleeves and locating device.

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

cap with chamois leather, spray running surface
with engine oil and install.
9. Check alignment of upper and lower bearing
shells. Bearing numbers on shells must be aligned
and all numbers must face driving end.
10. Position installation tool (1) between bearing cap

stud and rear face of shell on side where joint is.
11. Compress bearing shell on cap side and press
against shell on crankcase side.
Result: The joint between the shells must be
closed.
12. Axially align bearing shells.
TIM ID: 0000003232 – 006
MS25012/00E 08-06 © MTU

Installing crankshaft bearing cap

1. Wipe bearing shell mating faces on crankshaft
bearing cap with chamois leather.
Note: Crankshaft bearing caps must not be

interchanged!
2. Assign bearing cap to respective bearing

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

respective bearing.
TIM ID: 0000003232 – 006
MS25012/00E 08-06 © MTU

4. Tap crankshaft bearing cap lightly to move to

final position.
5. Coat threads and mating faces of studs (1) with

engine oil.
6. Turn bearing cap nuts to mating face of bearing
caps.
7. Starting with 1st bearing cap (driving end or free

end), fit support sleeve (2) of hydraulic screw
pretensioner on studs (1) of respective crankshaft
bearing cap. TIM ID: 0000003232 – 006
MS25012/00E 08-06 © MTU

8. Turn hydraulic screw pretensioner (1) by hand

until it is in position.
9. Connect high-pressure hose of hydraulic hand

pump to hydraulic screw pretensioner.
10. Position magnetic holder with dial gauges on
crankcase mating face to measure stud elongation.
11. Position the two dial gauge tips centrally on the

respective measuring core (arrow) on the sleeve
measuring pin.
12. Set preloaded dial gauges to zero.
TIM ID: 0000003232 – 006
MS25012/00E 08-06 © MTU

13. Operate hydraulic hand pump and elongate studs

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

15. If residual elongation of studs is outside tolerance,
loosen nuts, and repeat nut tightening procedure; if
necessary, replace studs.
16. Mount dial gauges with magnetic holders and
hydraulic screw pretensioner on studs of adjacent
bearing cap and follow the same procedure to fit
all remaining nuts.
17. Coat screws (arrow) with engine oil.

18. Insert screws (arrow) and use torque wrench to
tighten to specified torque (→ Page 23).
19. Install strip (driving end) (→ Page 98).
20. In order to avoid damage to the

crankshaft bearings, install locating device (1)
before cranking the crankshaft.
TIM ID: 0000003232 – 006
MS25012/00E 08-06 © MTU

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

(free end).
22. Turn crankshaft with barring tool and check for
ease of movement.
Measuring axial play of crankshaft

Note: Measure axial play only with drive flange or
flywheel mounted.
1. Mount magnetic dial gauge holder with dial gauge

(1) on crankcase.
2. Position dial gauge tip on face of crankshaft.
3. Use pry bar to press crankshaft axially as far as
it will go.
4. Set preloaded dial gauge to zero.
5. Move crankshaft from stop to stop (arrows) and
enter measured value (axial play) on data sheet.
6. If the determined value is out of tolerance
(→ Page 205), remove crankshaft and determine
the cause.
TIM ID: 0000003232 – 006
MS25012/00E 08-06 © MTU

4.3.12 Flywheel on PTO flange, driving end – Overview
Crank drive
30 Radial-lip shaft seal 50 Flywheel
TIM ID: 0000028640 – 001
MS25012/00E 08-06 © MTU

10 Flywheel 50 Timing wheel 90 Dowel pin

20 Ring gear 60 Coiled spring pin 100 Screw
30 Drive flange 70 Washer 110 Washer
40 Stud 80 Screw
TIM ID: 0000028640 – 001
MS25012/00E 08-06 © MTU

Ass. installation/removal device
1 Spacer 5 Support A Reference dimension 238 mm

2 Pressure sleeve 6 Hex nut B Push-on dimension 17.6 mm
3 Tension spindle 7 Socket-head screw to 21 mm
4 Hydraulic nut 8 Flange
TIM ID: 0000028640 – 001
MS25012/00E 08-06 © MTU

4.3.13 Flywheel on PTO flange, driving end – Removal
Special tools

Installation/removal device for flywheel F0140168 1
Trestle T80091387 1
Guide sleeve (in addition to 20V) F6782322 1
Hand pump kit, 0-1000 bar B80146893 1
Hand pump kit, 0-3000 bar B80146887 1
Suspended load.
Danger to life!

Installing removal/installation device

1. Use screws to fasten spacer and flange to crankshaft.
2. Insert tension spindle in crankshaft.
3. Check reference dimension ”A” (→ Page 230).
4. Read off push-on dimension at flywheel.
5. Install installation/removal device as shown in overview drawing (→ Page 230).
Flywheel – Removal
1. Remove stud for expanding bore in flywheel.
2. Insert connecting piece (1) in connection (2).
3. Connect high-pressure line for expansion of
flywheel to connecting piece.
4. Insert adapter in connection of hydraulic nut (3).
5. Connect high-pressure line (4) to adapter.
6. Set hydraulic nut (3) to initial position (zero stroke).
7. Back off nut (5) (→ Page 230)past push-on
dimension.
TIM ID: 0000028641 – 001
MS25012/00E 08-06 © MTU

8. Fill hand pumps (1) and (2) with engine oil

SAE 10 W.
9. Vent hand pumps (1) and (2) and line system until
bubble-free oil emerges.
10. Fasten high-pressure line.
11. Operate hand pump (2) and attach hydraulic
nut with minimum pressure p2 (initial pressure
increase) to flywheel.
12. Read off maximum expansion pressure pmax at
flywheel.
13. Operate hand pump (1) for expanding the flywheel,
until half of the maximum expansion pressure
p1 is reached.
14. Maintain pressure p1 for approx. 5 minutes.
15. Increase the expansion pressure in steps of 0.1 x
pmax with holding times of approx. 2 minutes, until
the flywheel is released from the crankshaft. In
doing so, do not exceed the maximum expansion
pressure pmax.
16. Operate pump to maintain constant expansion
pressure.
17. Observe pressure p2 in hydraulic nut. The release
of the flywheel from the taper seat is indicated by
rising pressure p2.
18. Gradually drain oil in hydraulic nut, while at the
same time continuing to pump.
19. Relieve hand pumps (1) and (2).
20. Screw trestle into flywheel and attach flywheel to
crane with rope slightly pretensioned.
21. Remove installation/removal tool.
22. Install guide sleeve (arrow) with nut.
23. Lift flywheel over guide sleeve (arrow) and remove
from end housing.
24. Set flywheel down on a clean surface.
25. Install timing wheel.
26. Remove nut and assembly sleeve.
TIM ID: 0000028641 – 001
MS25012/00E 08-06 © MTU

4.3.14 Radial-lip shaft seal, driving end – Removal

Removing radial-lip shaft seal from end housing
1. Remove end housing, driving end (→ Page 136).
2. Use a suitable extractor to extract radial-lip shaft seal from end housing. Do not damage end housing and
crankshaft.
TIM ID: 0000003564 – 003
MS25012/00E 08-06 © MTU

4.3.15 Flywheel on PTO flange, driving end – Cleaning
Material

Compressed air.
Risk of injury!

Flywheel on PTO flange, driving end – Cleaning

2. Remove cleaner.
3. Thoroughly blow all threads clear with compressed air.
TIM ID: 0000003565 – 002
MS25012/00E 08-06 © MTU

4.3.16 Flywheel on PTO flange, driving end – Check
Material

Spare parts

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

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

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

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

• Replace
Measure outer diameter (hub) of Value fallen short of. Replace flywheel.
flywheel. Value (→ Page 141)
Check thread of expanding bore. Damaged Recut thread.

TIM ID: 0000003566 – 006
MS25012/00E 08-06 © MTU

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

Press-in tool F6554716 1
Material

Ethanol 40250 1
Spare parts

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

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

2. Fit radial-lip shaft seal, with sealing lip facing
outwards, on press-in tool.
3. Coat sealing face of radial-lip shaft seal with
ethanol.
4. Clean and degrease locating bore for radial-lip
shaft seal in end housing, driving end.
5. Position press-in tool and secure with hand screw.
6. Use press-in tool to install radial-lip shaft seal flush
in end housing, driving end.
7. Remove press-in tool with flange from crankshaft.
TIM ID: 0000003568 – 004
MS25012/00E 08-06 © MTU

4.3.18 Flywheel on PTO flange, driving end – Installation
Special tools

Installation/removal device for flywheel F0140168 1
Guide sleeve for flywheel F6782322 1
Trestle T80091387 1
Material

Engine oil
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

Installing timing wheel

1. Fasten timing wheel (2) on flywheel with
screws (1), do not tighten screws.
2. Drive spring pins (arrow) into flywheel.
3. Use torque wrench to tighten screws (1) to
TIM ID: 0000028642 – 001
MS25012/00E 08-06 © MTU

Installing removal/installation device

1. Use screws to fasten spacer and flange on crankshaft.
2. Insert tension spindle in crankshaft.
3. Check reference dimension ”A” (→ Page 230).
4. Read off push-on dimension at flywheel.
5. Install installation/removal device as shown in overview drawing (→ Page 230).
Press-fitting flywheel
1. Remove all covers prior to installation.
2. Degrease and dry taper faces on crankshaft and
flywheel using cleaner and lint-free cloth.
3. Coat lip of radial-lip oil seal with grease.
4. Insert tension spindle (1) and measure reference
dimension “A” (→ Page 230) of tension spindle.
5. Install spacer (3) and flange (2) together with
screws on crankshaft face.
6. Install assembly sleeve (arrow) with nut.

7. Use rope with light initial load to attach flywheel
to crane.
8. Use crane to insert flywheel over guide sleeve in
end housing,
9. Remove assembly sleeve (arrowed).
TIM ID: 0000028642 – 001
MS25012/00E 08-06 © MTU

10. To determine the push-on distance, use depth

gauge to measure the distance from spacer
face to flywheel face.
11. If measured value is smaller than push-on distance
“B”, check taper for dimensional accuracy.
12. Slide pressure sleeve and hydraulic nut (3) over

tension spindle and screw on nut (5) with support.
13. Insert connecting piece (1) in connection (2).
14. Connect high-pressure line for expansion of
flywheel on connecting piece.
15. Insert adapter in connection of hydraulic nut (3).
16. Connect high-pressure line (4) to adapter.
17. Set hydraulic nut (3) to initial position (zero stroke).
18. Fill hand pumps (1) and (2) with engine oil
SAE 10 W.
19. Vent hand pumps (1) and (2) and line system until
bubble-free oil emerges.
20. Fasten high-pressure line.
21. Moisten taper fits with expansion fluid before
press-fitting. To do this, operate hand pump (1)
until expansion fluid emerges at hub ends.
22. Operate hand pump (2) and bring hydraulic nut to
contact point on flywheel using minimum pressure.
23. Read off maximum expansion pressure pmax at
flywheel.
TIM ID: 0000028642 – 001
24. Pump in expansion fluid until expansion

pressure (p1) can no longer be increased (do
not exceed expansion pressure Pmax), then
increase press-on force by increasing press-on
pressure (p2).
25. Select press-on force so that final position
(pressure sleeve directly next to flywheel) is
established after approx. 5 steps.
MS25012/00E 08-06 © MTU

26. Open valve screw on hand pump (1) to release

expansion pressure.
27. Maintain maximum force-on pressure for 60
minutes, to ensure that the expansion fluid is
expelled from the joint and static friction can build
up between the fixed components.
28. Remove high-pressure lines.
29. Remove residual oil from expanding bore.
30. Insert stud.
31. Remove installation/removal device after specified
retention time has elapsed.
32. Do not subject press fitting to operating load
for at least 8 hours.
TIM ID: 0000028642 – 001
MS25012/00E 08-06 © MTU

4.3.19 Crankshaft PTO, free end – Overview
Vibration damper without auxiliary PTO
5 Vibration damper 60 O-ring

25 Protective cover for PTO, free end 75 Flange
30 Sealing ring 80 Conical spring washer
40 Plug screw 90 Screw
45 Screw 200 O-ring
TIM ID: 0000028643 – 001
MS25012/00E 08-06 © MTU

Vibration damper with auxiliary PTO
20 Flange 90 Vibration damper 180 Flange for PTO, free end

30 O-ring 110 Protective cover for PTO, free end 190 O-ring
40 Screw 120 O-ring 200 O-ring
60 Sealing ring 130 Conical spring washer 210 Screw
70 Plug screw 140 Screw 300 O-ring
TIM ID: 0000028643 – 001
MS25012/00E 08-06 © MTU

Vibration damper
20 Spring pack 70 Inner star 120 Belleville washer

30 Spacer 80 Shim 130 O-ring
40 Clamping ring 90 Injection timer 140 O-ring
50 Flange 100 Sealant
60 Side plate 110 Screw
TIM ID: 0000028643 – 001
MS25012/00E 08-06 © MTU

Arrangement of installation/removal tool for vibration damper
1 Spacer sleeve 9 Vibration damper

2 Flange A Reference dimension: 240 mm
3 Thrust sleeve B Dimension: 77 mm ± 0.05 mm
4 Hydraulic nut (distance between crankshaft front
5 Mount face and inner front face of vibration
6 Nut damper = length of spacer sleeve)
7 Puller spindle A Push-on dimension:
8 Screw 17.6 mm ± 2 mm
TIM ID: 0000028643 – 001
MS25012/00E 08-06 © MTU

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

Removal/installation tool F0140771 1
Carrying bracket T80091550 1
Lifting equipment T80091570 1
Guide sleeve F6780591 1
Flange F6553672 1
Screw 000912016016 1
Puller spindle F6782017 1
Hex nut B80098529 1
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!

TIM ID: 0000028644 – 001
MS25012/00E 08-06 © MTU

Removing vibration damper

1. Remove protective cover from vibration damper as
shown in overview drawing (→ Page 243).
2. Install spacer sleeve, receptacle and spacer
bushing as shown in overview drawing
(→ Page 243).
3. Insert puller spindle.
4. Check reference dimension "A" of puller spindle
(→ Page 243).
5. Connect high-pressure line (2).
6. Push thrust sleeve (6) on to puller spindle.
7. Read off push-on dimension ”a” at vibration
damper (1).
8. Push hydraulic nut (5) over puller spindle.
9. Screw on nut (4).
10. Connect high-pressure line (3) of hydraulic hand
pump to hydraulic press.
11. Set hydraulic nut (5) to initial zero stroke position.
12. Screw on nut (4) up to the stop and back off past
push-on dimension value.
Note: The hydraulic nut (press) is for cushioning
the vibration damper when it slides from
the taper seat and it is for safety.
13. Fill hydraulic hand pumps with engine oil SAE10.

14. Vent pumps and pipework until bubble-free oil
emerges.
15. Tighten high-pressure line.
16. Operate hydraulic hand pump (2) for hydraulic
nut and, using minimum pressure p2 (beginning
pressure increase), move hydraulic press up to
contact point on hub.
17. Read off maximum expansion pressure pmax
at vibration damper.
18. Operate hydraulic hand pump (1) for expanding
the vibration damper until expansion pressure is
half the permitted maximum p1.
19. Maintain pressure p1 for approx. 5 minutes.
20. Increase expansion pressure in steps of 0.1 x pmax
with hold times of approx. 2 minutes between
increases until the vibration damper is released
from crankshaft. Do not exceed max. expansion
pressure pmax.
21. Continue to pump to maintain constant expansion
pressure.
22. Monitor pressure p2 in hydraulic press. The
release of the vibration damper from the taper seat
is indicated by rising pressure p2.
TIM ID: 0000028644 – 001
23. Gradually release pressure in hydraulic press

while steadily operating pump for expansion fluid.
24. Relieve hydraulic hand pumps.
25. Disconnect high-pressure line.
26. Remove nut, hydraulic nut (press) and thrust
sleeve.
MS25012/00E 08-06 © MTU

27. Screw jig (3) on to vibration damper (2).

28. Remove vibration damper (2) with jig (3).
29. If required, remove flange (1) as per overview
TIM ID: 0000028644 – 001
MS25012/00E 08-06 © MTU

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

Disassembly of this component is not planned.
This component is an exchange component (Reman) and is available via the normal exchange procedure.
TIM ID: 0000003570 – 002
MS25012/00E 08-06 © MTU

4.3.22 Vibration damper on PTO, free end – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning vibration damper

2. Remove cleaner.
3. Blow out components with compressed air.
TIM ID: 0000003571 – 002
MS25012/00E 08-06 © MTU

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

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

Vibration damper
Heavy object.
Risk of crushing!

Risk of injury!
Checking vibration damper
Visually inspect vibration damper for • Damage Replace vibration damper.

damage and wear. • Visible wear
Measure sealing ring retainer Values overshot. Replace vibration damper.

borehole using inside fine-measuring
instrument. Values (→ Page 253)
Make visual check of running Visible wear. Replace flange

surface of flange for wear.
Measure outside diameter of flange Values undershot. Replace drive flange.

with outside micrometer. Values
(→ Page 253)
TIM ID: 0000028051 – 001
MS25012/00E 08-06 © MTU

4.3.24 Vibration damper on PTO, free end – Tolerances
Crankshaft seal, free end

Basic value
size
1 Seal carrier bore 230.000 H8 0 +0.072 0.278 0.590
Shaft seal outer 230.470 –0.120 +0.120

Ø
2 Running surface 200.000h11 -0.290 0

outer Ø
3 Radial-lip oil seal, press-fitted flush
Re 2: If running surface is worn: Spray-metallize running surface and perform infeed grinding.
TIM ID: 0000028645 – 001
MS25012/00E 08-06 © MTU

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

Installation/removal tool F0140771 1
Flange F6553672 1
Screw 000912016016 1
Puller spindle F6782017 1
Hex nut B80098529 1
Material

Engine oil
Spare parts

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

TIM ID: 0000028646 – 001
MS25012/00E 08-06 © MTU

Pressing on vibration damper

1. Install flange (if removed) with O-ring as per
overview drawing (→ Page 243) on equipment
carrier.
2. Clean and degrease tapers of crankshaft and
vibration damper.
3. Coat bearing surface of crankshaft bearing with oil.
4. Install spacer sleeve (2), spacer bushing (3) and
receptacle (4) as shown in overview drawing
(→ Page 243).
5. Screw in puller spindle (1).
6. Check reference dimension “A” of puller spindle,
see overview drawing (→ Page 243).
7. Screw fixture (2) onto vibration damper (1).

8. Use fixture (2) to push vibration damper (1) on
to crankshaft taper.
9. Measure distance between vibration damper inner

front face and spacer sleeve.
10. If measured value is less than push-on dimension
“a” (→ Page 243), check taper for dimensional
accuracy.
TIM ID: 0000028646 – 001
MS25012/00E 08-06 © MTU

11. Connect HP line (2).

12. Push thrust sleeve (6) on to puller spindle.
13. Set hydraulic press (5) to original zero stroke
position.
14. Mount and hand-tighten nut (4).
15. Connect HP line (3).
16. Fill hydraulic hand pumps with SAE 10 engine oil.

17. Vent pumps and pipework until bubble-free oil
emerges.
18. Tighten HP line.
19. Coat taper seating surfaces with expansion
fluid before pressing on vibration damper. For
this purpose, operate hydraulic hand pump (1)
until expansion fluid emerges at the vibration
damper end.
20. Operate hydraulic hand pump (2) for hydraulic
press and move press at minimum pressure
towards vibration damper until it will not go any
further.
21. Pump in expansion fluid until expansion pressure
p1 no longer rises. Then increase push-on force by
raising force-on pressure p2.
22. Repeat this procedure until the vibration damper
has reached its end position.
23. Select a push-on force so that the end position
is reached in approx. 5 steps.
24. Read off expansion pressure pmax at vibration
damper. Ensure that, during installation, the
required expansion pressure is less than the
maximum expansion pressure pmax.
Result: The push-on procedure is completed
when the thrust sleeve is in contact with the
crankshaft stop.
25. Relieve expansion pressure by releasing the valve
screw of the hydraulic hand pump.
26. Maintain maximum push-on pressure for 60
minutes, to ensure that the expansion fluid is
TIM ID: 0000028646 – 001
expelled from the joint and static friction can build

up between the fixed components.
27. Disconnect HP line.
MS25012/00E 08-06 © MTU

Note: Only for version without auxiliary PTO
28. Use torque wrench to tighten plug screw (1) to

specified tightening torque.
Name Size Type Lubricant Value/Standard

Plug screw M10 x 1 Tightening torque Engine oil 15 Nm +2 Nm
29. Allow specified holding time to pass and remove

nut, hydraulic press, thrust sleeve and puller
spindle.
30. Do not subject press fitting to operating load
for at least 8 hours.
31. Install protective cover with screws and O-ring as
shown in overview drawing (→ Page 243).
TIM ID: 0000028646 – 001
MS25012/00E 08-06 © MTU

4.3.26 Piston and conrod – Overview
1 Piston 3 Conrod bearing, top 5 Conrod cap

2 Conrod 4 Conrod bearing, bottom 6 Conrod screw
TIM ID: 0000029839 – 001
MS25012/00E 08-06 © MTU

1 Piston rod 3 Conrod screw

2 Conrod cap 4 Conrod bushing
TIM ID: 0000029839 – 001
MS25012/00E 08-06 © MTU

Variant A
50 Piston 150 Circlip 250 Taper-face compression ring

100 Piston pin 200 Keystone-type compression ring 300 Oil control ring
TIM ID: 0000029839 – 001
MS25012/00E 08-06 © MTU

Version B
1 Piston skirt 6 Circlip

2 Piston crown 7 Piston pin
3 Anti-fatigue sleeve 8 Rectangular-section ring
4 Piston nut 9 Taper-face compression ring
5 Coiled spring pin 10 Oil control ring
TIM ID: 0000029839 – 001
MS25012/00E 08-06 © MTU

4.3.27 Piston and conrod – Removal
Preconditions
• Preparatory steps have been carried out.
Special tools

Lifting gear with M6 thread T80092198 1
Lifting device with 2x M6 thread T80091025 1
Barring tool F6555791 1
Pointer for barring tool F6555792 1
Graduation plate, free end Y4341124 1
Socket insert, 22 A/F, conrod screws F30378352 1
Assembly dolly F6787914 1
Suspended load.
Danger to life!
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Remove piston and conrod in assembly dolly

1. Remove combustion residues from cylinder liner.
2. Remove carbon scraper ring (arrows)
(→ Page 108).
3. Install barring tool.
TIM ID: 0000029533 – 001
MS25012/00E 08-06 © MTU

Note: Bearing cap and piston rod are a single

unit and must not be interchanged.
4. Check marking (arrows) of conrod cap to piston

rod. If necessary, mark components.
Note: Bar crankshaft only with flywheel or axial

locating device mounted.
5. Pivot crankcase into assembly dolly.

6. Put conrod cap (1) on piston to be removed into
horizontal position.
7. Remove conrod screws and remove conrod
cap (1).
8. Remove bearing shell from conrod cap taking care
not to damage the meshing on the parting surface
of the conrod cap.
9. Protect conrod cap (1) against damage.
10. Turn crankcase in assembly dolly until the piston to

be removed with conrod is vertical.
11. Install lifting gear (1) on piston crown.
Note: Do not assert pressure to lifting gear.
12. Pull piston and conrod with crane from the

cylinder liner fit taking care not to damage the oil
spray nozzle.
13. Carefully place the piston and conrod onto a soft
surface and remove from the crane.
14. Remove lifting gear (1) from piston crown.
TIM ID: 0000029533 – 001
15. Seal openings with suitable plugs.
MS25012/00E 08-06 © MTU

4.3.28 Piston and conrod – Disassembly
Special tools

Piston-ring pliers F30450332 1
Heavy object.
Risk of crushing!

Risk of injury!
Removing conrod from piston

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

(2), holding conrod (1) firmly in position.
5. Remove conrod from piston.
TIM ID: 0000029555 – 001
MS25012/00E 08-06 © MTU

Removing piston rings

1. Stretch piston rings only until they can be removed
from the piston.
2. Remove piston rings with piston ring pliers in
sequence from top to bottom.
TIM ID: 0000029555 – 001
MS25012/00E 08-06 © MTU

4.3.29 Piston – Cleaning
Material

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

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

Risk of injury!

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

2. Clean area of piston ring grooves with rotating plastic brush.
3. After cleaning, blow out oil chamber and oil bores with compressed air.
TIM ID: 0000003576 – 005
MS25012/00E 08-06 © MTU

4.3.30 Piston – Check
Material

Spare parts

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

Risk of injury!
TIM ID: 0000004865 – 002
MS25012/00E 08-06 © MTU

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

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

(→ Page 270)
Check sliding surface of bronze • Stress marks Replace piston.

bush for stress marks and scoring. • Scores
visible
Check groove width with gauge Values exceeded. Replace piston.

blocks. If no gauge block is
available, alternatively a new piston
ring can be inserted in the groove
and the axial play checked with a
feeler gauge. Values (→ Page 270)
Check piston pin with magnetic Signs of cracks Replace piston pin.
crack-testing method for cracks.
Check condition of piston. • Traces of wear Replace piston pin.

• Scores
• Impact points
visible
Measure outer piston pin diameter Values exceeded. Replace piston pin.
with C-frame micrometer. Values
(→ Page 270)
Check piston rings. • Piston ring with burring, Replace

chipping or sharp edges
• If chrome layer has signs
of scoring, cracks or heat
discoloration.
TIM ID: 0000004865 – 002
MS25012/00E 08-06 © MTU

Piston rings – Check

1. Place piston ring (1) in ring gauge (3) to measure
piston ring end clearance. Ensure that piston ring
fits evenly in ring gauge.
2. Check ring end clearance with feeler gauge (2).
3. If values are exceeded (→ Page 270), replace
piston rings. Replace piston rings only in sets.
4. After installation of new piston rings, replace
cylinder liners (→ Page 108).
TIM ID: 0000004865 – 002
MS25012/00E 08-06 © MTU

4.3.31 Piston – Tolerances
Variant A
Piston bearing 12/16/20 V
Basic
1 Bushing ID 68.000 +0.070 +0.080 0.070 0.085 Clearance

max.
Piston pin outer 68.000 –0.005 0 0.090
dia.

max.
Piston pin outer 68.000 –0.008 0 0.030
dia.
Re 1: Bushing loose with 30000 N test load: Replace bushing.

TIM ID: 0000029556 – 001
MS25012/00E 08-06 © MTU

Piston rings 12/16/20 V
Basic
1 Groove width 4.828 0 +0.040 0.146 0.225
Keystone-type 4.672 –0.029 0.010

compression
ring
2 Groove width 4.000 0.060 0.080 0.060 0.115
Taper-face 4.000 –0.035 0

compression
ring
3 Groove width 5.000 +0.030 +0.050 0.030 0.085
Oil-control ring 5.000 –0.035 0

TIM ID: 0000029556 – 001
MS25012/00E 08-06 © MTU

Basic
4 Ring end clearance
Keystone-type 0.400 0.700

compression
ring
Taper-face 1.000 1.300

compression
ring
Oil-control ring 0.450 0.800
Measure ring end clearance in ring gauge 165.000 H6.
5 Measuring diameter, groove width or keystone-type compression ring height
TIM ID: 0000029556 – 001
MS25012/00E 08-06 © MTU

Piston clearance in cylinder liner 12/16/20 V
Basic
1 Liner dia. 170.000 0 +0.040 0.160 0.220

H7
Piston skirt dia. 169.830 –0.010 +0.010
2 Liner dia. 170.000 0 +0.040 0.199 0.261

H7
Piston skirt dia. 169.790 –0.011 +0.011
3 Liner dia. 170.000 0 +0.040 0.495 0.565

H7
Ring web dia. 169.490 –0.015 +0.015
4 Liner dia. 170.000 0 +0.040 0.685 0.755

H7
Presealing dia. 169.300 –0.015 +0.015
5 Scraper ring dia. 169.400 0 +0.063 0.885 0.978

TIM ID: 0000029556 – 001
H8
Top land dia. 168.500 –0.015 +0.015
6 Scraper ring dia. 169.400 0 +0.063 1.184 1.287

H8
Top land dia. 168.191 –0.015 +0.015
MS25012/00E 08-06 © MTU

Basic
Dimensions 1 to 5 measured vertically in relation to pin axis.
7 Piston skirt: spherical-oval
8 Ring webs: cylindrical-oval
9 Top land: conical-oval
TIM ID: 0000029556 – 001
MS25012/00E 08-06 © MTU

Version B
Piston bearing 12/16/20 V
Basic

max.
Piston pin outer 68.000 –0.005 0 0.090
dia.

max.
Piston pin outer 68.000 –0.005 0 0.032
dia.
3 MTU item number and stage stamped on
Re 1: Bushing loose with 30000 N test load: Replace bushing.

TIM ID: 0000029556 – 001
MS25012/00E 08-06 © MTU

Piston rings 12/16/20 V
Basic
1 Groove width 4.000 +0.170 +0.190 0.170 0.225 Clearance

max.
Rectangular- 4.000 –0.035 0 0.300
section ring
2 Groove width 4.000 + + 0.080 0.135 Clearance

0.080 0.100 max.
0.200
Taper-face 4.000 –0.035 0
compression
ring
3 Groove width 5.000 +0.080 +0.100 0.080 0.135 Clearance

max.
Oil-control ring 5.000 –0.035 0 0.200
4 Ring end clearance Clearance

max.
Rectangular- 0.400 0.700 0.900

section ring
TIM ID: 0000029556 – 001
Taper-face 1.000 1.300 1.500

compression
ring
Oil-control ring 0.450 0.800 1.000
Measure ring end clearance in ring gauge 165.000 H6.
MS25012/00E 08-06 © MTU

Piston clearance in cylinder liner 12/16/20 V
Basic
1 Liner dia. 170.000 0 +0.040 0.184 0.246

H7
Piston skirt dia. 169.805 –0.011 +0.011
2 Liner dia. 170.000 0 +0.040 0.285 0.345

H7
Piston skirt dia. 169.705 –0.010 +0.010
3 Liner dia. 170.000 0 +0.040 0.425 0.515

H7
Piston crown Ø 169.550 –0.025 +0.015
4 Liner dia. 170.000 0 +0.040 0.425 0.515

H7
Piston crown Ø 169.550 –0.025 +0.025
5 Scraper ring dia. 169.400 0 +0.063 0.575 0.688

TIM ID: 0000029556 – 001
H8
Piston crown Ø 168.800 –0.025 +0.025
Dimensions 1 to 5 measured vertically in relation to pin axis.
MS25012/00E 08-06 © MTU

Basic
6 Scraper ring dia. 169.400 0 +0.063 0.675 0.788

H8
Piston crown Ø 168.400 –0.025 +0.025
7 Piston skirt shape: spherical-oval

Skirt graphite-coated at each of 2 positions, free of graphite at 1 and 2 to measure the diameter.
TIM ID: 0000029556 – 001
MS25012/00E 08-06 © MTU

4.3.32 Conrod – Disassembly
Spare parts

Conrod
Conrod – Disassembly
1. Disassembly of conrod is not planned.
2. The conrod is an exchange component (Reman) and is available via the normal exchange procedure.
TIM ID: 0000004504 – 002
MS25012/00E 08-06 © MTU

4.3.33 Piston rod – Cleaning
Material

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


Cleaning the piston rod

1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then rinse with cleaning agent (Hakupur 312).
2. Use a brass brush to clean meshing on conrod and conrod bearing cap mating faces.
TIM ID: 0000004505 – 003
MS25012/00E 08-06 © MTU

4.3.34 Conrod – Check
Special tools

Testing device Y4341492 1
Test mandrel Y4341913 1
Test mandrel Y4341914 1
Bore gauge, 18-100 mm Y20091481 1
Bore gauge, 100-160 mm Y20091482 1
Material

Spare parts

Conrod
Conrod screw
Compressed air.
Risk of injury!
TIM ID: 0000004507 – 004
MS25012/00E 08-06 © MTU

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

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

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

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

(→ Page 288)
Check basic bore for stress marks • Stress marks • Corrective work
and scores. • Scores • Replace
visible
Inspect meshing for damage and Damaged Replace

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

1. Assemble conrod (→ Page 292).
2. Before measuring, rub down basic bore (2) with
emery cloth.
3. Adjust bore gauge (1) and measure main conrod
bore (→ Page 288).
4. If values are exceeded, replace conrod.
TIM ID: 0000004507 – 004
MS25012/00E 08-06 © MTU

Measuring conrod main bore with bearing shells

1. Coat sliding surfaces of bearing shells with
engine oil.
2. Measure conrod bearing bore. Values
(→ Page 288).
3. Enter measured values in data sheet.
4. Replace bearing shells if limit values are fallen
short of or exceeded.
5. Remove conrod screws, conrod cap and bearing
shells.
6. Protect bearing shells from damage.
Measuring conrod bush from piston pin end

1. Set bore gauge (1) to zero dimension of conrod
bushing bore and measure conrod bush bore (2).
Values (→ Page 288).
2. Values exceeded: Replace conrod bush only in
Checking conrod bush axial fit

1. Use test mandrel (1) and hydraulic press to
check conrod bush axial fit. Required test force F
(→ Page 288).
2. If test force is not reached, replace conrod.
TIM ID: 0000004507 – 004
MS25012/00E 08-06 © MTU

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

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

tighten conrod bearing screws.
2. Insert test mandrel (2) in large conrod bore so that
wide fit of test mandrel (arrow) faces conrod shaft
and narrow fit faces conrod bearing cap.
3. Clamp test mandrel (2) firmly with locking screw,
ensuring that test mandrel (2) does not tilt.
4. Insert test mandrel (1) in small conrod bore so that
wide fit of test mandrel (arrow) faces conrod shaft
and narrow fit faces oil bores of small conrod bore.
5. Clamp test mandrel (1) with locking screw.
TIM ID: 0000004507 – 004
MS25012/00E 08-06 © MTU

Checking axial parallelism

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

1. Set both dial gauges (1) for axial twist with setting
gauge (2) via dial gauge pointer to zero.
2. Remove setting gauge (2) from testing device (3).
3. Insert conrod with test mandrel (2) in V-blocks

(3) of testing device. Fixed support of adjustable
stop is set so that dial gauge pointer travel is
approx. 2 mm.
4. Press conrod at small conrod bore on fixed
support.
5. Read off and note values on dial gauges (1).
TIM ID: 0000004507 – 004
MS25012/00E 08-06 © MTU

Calculating axial parallelism

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

clearance (→ Page 288), calculate recorded value
on dial gauges as shown in the following example.
Description Value
Left dial gauge A = –0.05 mm
Right dial gauge B = +0.03 mm
Result = 0.08 mm
Result: Axial parallelism: 0.08 mm : 4 = 0.02 mm

2. Compare calculated value to (→ Page 288) .
3. If limit value is exceeded, replace conrod.
TIM ID: 0000004507 – 004
MS25012/00E 08-06 © MTU

Calculating axial twist

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

2. Compare calculated value to (→ Page 288) .
3. If limit value is exceeded, replace conrod.
TIM ID: 0000004507 – 004
MS25012/00E 08-06 © MTU

4.3.35 Conrod – Tolerances
Conrod bearings

anced value
Basic
size
1 Conrod bore 126.000 0 +0.025

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

bore
Conrod bearing 0-1 116.882
installed 0-2 116.682
0-3 116.482
Conrod 0-0 117.000 h6 –0.022 0

journal dia.
0-1 116.800 h6
0-2 116.600 h6
TIM ID: 0000029844 – 001
0-3 116.400 h6
3 Crankpin length 97.500 −0.100 +0.100 0.200 0.600
Conrod width 48.600 −0.100 0
MS25012/00E 08-06 © MTU


anced value
Basic
size
4 Expansion 0-0 126.400 0 +1.000

dimension
Conrod bearing 0-1 126.400
shell. upper and 0-2 126.400
lower halves
0-3 126.400
Conrod screw length

anced value
size
size
1 Screw length 103.000 −0.400 +0.200 104.500

removed
TIM ID: 0000029844 – 001
Notes:
Tighten conrod bearing - conrod - conrod cap according to torque specification.
Measure conrod bearing bore in a, b and c. Smallest dimension must be near a.
Re 1: Limit value exceeded: Replace screw.
MS25012/00E 08-06 © MTU

Conrod bore parallelism

Basic value
size
1 Conrod length 364.000 −0.100 +0.100
2 Axial parallelism 0.070 over a distance of 100 mm Inclination

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

Offset max. 0.350
Conrod weight 9.580 kg -0.060 +0.060

kg kg TIM ID: 0000029844 – 001
MS25012/00E 08-06 © MTU

Small conrod bore

Basic value
size
1 Conrod bore 0 75.000 H6 0 +0.019 0.101 +0.139
1 75.200 H6
2 75.400 H6
Conrod bushing 0 75.000 v6 +0.120 +0.139

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

ID
F Axial test force for conrod: 30000 N (tested conrod bushings are marked with an "X")
A Edges rounded
TIM ID: 0000029844 – 001
MS25012/00E 08-06 © MTU

4.3.36 Conrod – Assembly
Special tools

Socket, 22 A/F – Conrod screws F30378352 1
Material

Engine oil
Compressed air.
Risk of injury!
Incorrect installation of components and lines.

CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.
Preparing conrod
1. Blow out mating faces (arrows) on conrod and
conrod bearing cap with compressed air and clean.
2. Wipe bearing shell mating faces on conrod and
conrod bearing cap.
3. Before installing bearing shells, compare repair
stage data on conrod and on crankshaft data
sheet.
4. Mark bearing shells according to cylinder number
on end face.
TIM ID: 0000004508 – 005
MS25012/00E 08-06 © MTU

5. Insert lower conrod bearing shell (2) with securing

lug (arrow) in groove of conrod bearing cap (1).
6. Clamp conrod in assembly trolley or in bench

vise with aluminum jaws with mating face in
horizontal position.
7. Insert upper conrod bearing shell (2) with securing
lug (arrow) in groove of conrod (1).
8. Carefully press conrod bearing cap by hand
onto conrod.
9. Coat threads and screw head mating faces of
conrod screws with engine oil.
TIM ID: 0000004508 – 005
MS25012/00E 08-06 © MTU

Note: Thread must not be recut.
10. Carefully insert conrod bearing screw into conrod

bearing cap bore by hand to first contact with
thread flanks, then turn first three rotations
without a tool.
11. Install conrod bearing screws until screw heads
make contact and use socket wrench to tighten
firmly by hand. Ensure that conrod and conrod cap
serrations is closed at short and long conrod arms.
12. Use torque wrench (1) to tighten conrod screws to
specified tightening torque. Tightening sequence:
12.1.Short arm
12.2.Long arm

Conrod screw M20 x 1.5 Preload torque Engine oil 240 Nm +20 Nm
Conrod screw M20 x 1.5 Residual angle of rotation 90° +10°
Conrod screw M20 x 1.5 Control torque 450 Nm +20 Nm
TIM ID: 0000004508 – 005
MS25012/00E 08-06 © MTU

4.3.37 Piston and conrod – Assembly
Special tools

Piston ring pliers F30450332 1
Snap ring pliers F30002760 1
Material

Engine oil
Spare parts

Snap ring
Heavy object.
Risk of crushing!

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

Risk of injury!
WARNING • Only use specified tool and equipment.

TIM ID: 0000029557 – 001
MS25012/00E 08-06 © MTU

Installing piston rings

1. By turning coiled spring expander (2) in
bevelled-edge oil control ring (1) offset the
coiled spring expander gap (arrowed) to the
bevelled-edge oil control ring gap by 180°.
Note: When replacing piston rings the whole set

must be replaced at the same time.
2. Prepare piston rings as per installation instructions.

3. Following piston ring replacement replace the
cylinder liner (→ Page 108).
1 Rectangular-section ring
2 Taper-face compression ring
3 Bevelled-edge oil control ring
TIM ID: 0000029557 – 001
MS25012/00E 08-06 © MTU

4. Using piston ring pliers expand the piston rings

until they can be slid over the piston.
5. Install piston rings in ring grooves on piston,
starting from the bottom and working towards
the top.
5.1. Bevelled-edge oil control ring
5.2. Taper-face compression ring, TOP mark
facing towards piston crown
5.3. Bevelled-edge oil control ring, TOP mark
facing towards piston crown
6. Check piston rings for ease of movement.
Installing conrod in piston

1. Wipe down piston pin, conrod bushing and piston
pin bore with chamois leather and coat with
engine oil.
2. Insert conrod (1) into corresponding piston (2)
as per mark, ensuring that the shorter end (A) of
the diagonally split conrod faces piston cooling
bore (B).
3. Insert corresponding piston pin (2) in piston and

conrod (1) until it makes contact with the integrated
snap ring (arrowed).
TIM ID: 0000029557 – 001
MS25012/00E 08-06 © MTU

4. Insert second snap ring.

5. Check both snap rings for correct seating and
position (arrowed).
TIM ID: 0000029557 – 001
MS25012/00E 08-06 © MTU

4.3.38 Piston and conrod – Installation
Special tools

Lifting device with 2x M6 thread T80091025 1
Installation sleeves, piston/conrod for carbon scraper ring F6783605 1
Barring gear for graduation plate F6555791 1
Measuring device for TDC measurement in cylinder head Y4341919 1
Socket AF22 – conrod screws F30378352 1
Material

Engine oil
Suspended load.
Danger to life!
Suspended load.
Danger to life!
Heavy object.
Risk of crushing!
Compressed air.
Risk of injury!
TIM ID: 0000029534 – 001
MS25012/00E 08-06 © MTU

Preparing crankcase in assembly dolly

1. Rotate crankcase in assembly dolly until cylinder
liner (arrowed) is vertical.
2. Turn crankshaft until crankpin of piston/conrod to
be installed has reached installation position.
3. Wipe crankpin and running surface of cylinder liner
with chamois leather and spray with engine oil.
Preparing piston for installation

1. Spray piston and piston rings with engine oil.
2. Ensure that piston rings (arrowed) are evenly fitted
at 120° around piston circumference.
3. Center piston rings and oil-control ring in grooves.
Preparing conrod bearing for installation

1. Blow out mating faces (arrowed) on conrod and
conrod bearing cap with compressed air and check
that they are clean.
2. Wipe bearing shell contact surfaces on conrod and
conrod cap with chamois leather.
TIM ID: 0000029534 – 001
MS25012/00E 08-06 © MTU

3. Check whether the lower conrod bearing shell (2)

with lug (arrow) is still positioned correctly in the
groove of the conrod bearing cap (1).
4. Coat running surfaces of bearing shell with
engine oil.
Note: In order to guide the piston rod and avoid

damage to the oil spray nozzle, piston
installation must be carried out by two people.
Install piston with carbon scraper ring removed.
Installing piston and conrod in cylinder liner

1. Mount lifting gear (1) on piston (2).
2. Place piston installation sleeve (3) with chamfered
side up on cylinder liner (4).
3. Oil installation sleeve and cylinder liner inside.
4. Install piston in cylinder liner making sure that the
short arm of the piston rod points outwards to the
air intake side. Turn piston slightly so that the oil
spray nozzle is not damaged.
5. Carefully press the conrod bearing cap manually
onto the piston rod.
Installing conrod bearing caps

1. Coat thread and underside of screw head mating face with engine oil.
2. Manually insert conrod bearing screws (arrowed) into screw bore on conrod cap, then turn through three
revolutions without a tool.
3. Fit conrod bearing screws (arrowed) up to screw head and tighten firmly by hand using socket wrench,
ensuring that conrod serrations are closed.
4. Tighten conrod screws with torque wrench to specified tightening torque (→ Page 23).
TIM ID: 0000029534 – 001
5. Check conrod for axial movement.

6. Using a torque wrench, tighten conrod screws to specified tightening torque (→ Page 23).
7. Check thrust distance of conrod.
8. Remove lifting device and installation sleeve for piston with conrod.
9. Bar crankshaft and ensure that there is ease of movement between oil spray nozzle, piston and piston rod.
MS25012/00E 08-06 © MTU

Checking conrod thrust distance in assembly dolly

1. Use feeler gauge to check distance between
crankshaft web and conrod and between conrod
and conrod, pressed towards each other.
2. If thrust distance is below the minimum of 0.20 mm
or above the maximum of 0.60 mm, measured
pressed at three levels, readjust clearance.
3. Release conrod bearing screws and compensate
thrust distance.
4. Using a torque wrench, first pretighten conrod
cap screw on short conrod arm and then on
long conrod arm to specified tightening torque
(→ Page 23).
5. Re-check thrust distance.
6. Using a torque wrench, tighten conrod bearing
screws to specified tightening torque (→ Page 23).
Installing carbon scraper ring

1. Spray edge of cylinder liner and carbon scraper
ring with engine oil.
2. Insert carbon scraper ring.
Setting TDC indicator

1. Install pointer (1) on equipment carrier.
2. Install index plate (2) on crankshaft free end, set to
TDC marking of A1 and tighten.
3. Set piston A1 to firing TDC.
TIM ID: 0000029534 – 001
MS25012/00E 08-06 © MTU

4. Place bridge meter (1) with dial indicator (2)

onto crankcase.
5. Set dial gauge to zero.
6. Move piston several times up and down through
TDC until pointer of dial gauge registers its highest
reading.
7. Set dial gauge to zero and readjust index plate
accordingly.
8. Bar crankshaft in normal engine direction of
rotation to 5° before TDC, read dial gauge and
make a note of measured value.
9. Bar crankshaft past TDC to approx. 10° (to
take up bearing play).
10. Bar crankshaft against normal direction of engine
rotation to 5° after TDC, read dial gauge and make
a note of measured value.
11. Calculate mean value.
12. Bar crankshaft to approx. 10° after TDC, then bar
in direction opposite to normal direction of rotation
until dial gauge shows calculated mean value.
13. Set pointer of index plate to 5° after TDC and
tighten.
14. Rotate crankshaft to approx. 10° before TDC.
15. Repeat working steps 9 to 11 until measured
values at same degree figure are identical.
Result: Absolute TDC reached.
TIM ID: 0000029534 – 001
MS25012/00E 08-06 © MTU

4.4 Cylinder Head
4.4.1 Cylinder head and attachments – Overview
Cylinder head and attachments – Overview
1 Cylinder head 6 Spring retainer

2 Inlet valve 7 Valve collet
3 Exhaust valve 8 Valve rotator
4 Valve spring, inner 10 Plug screw
5 Valve spring, outer 11 Sealing ring
TIM ID: 0000003578 – 002
MS25012/00E 08-06 © MTU

2 Valve-seat insert, inlet * 6 Valve guide 11 Cylinder head

3 Valve-seat insert, exhaust * 7 Plug * Only on cylinder heads of
4 O-ring 8 Plug corresponding design
5 Sleeve 9 Plug
TIM ID: 0000003578 – 002
MS25012/00E 08-06 © MTU

1 Sealing ring 3 Cylinder head screw 5 Cylinder head screw

2 Gasket 4 Thrust washer
TIM ID: 0000003578 – 002
MS25012/00E 08-06 © MTU

4.4.2 Valve-seat turning machine for cylinder head
Working principle of valve-seat turning machine
The valve-seat turning machine is an inside turning device. While the cutter (3) rotates around the valve-seat
(5), a feed gear mechanism ensures a continuous outward feed motion (1). The feed motion under the proper
valve-seat angle (4) is defined by an inclined slideway in the exchangeable adapter head.
TIM ID: 0000004511 – 002
MS25012/00E 08-06 © MTU

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

To achieve maximum accuracy, the pilot must be supported by the supporting spider (7) below the valve seat. Slide
the supporting spider (7) over the pilot shaft to such position that the spring-loaded spider elements (1) rest just
below the valve seat level when the pilot is installed in the valve guide (4) and tighten the clamping screw (6).
Inserting the pilot into the valve guide
Remove clamping nut (3) from pilot and insert the threaded end of the pilot into the valve guide (4), until
the tapered portion (5) bears against the conical seating of the valve guide (4). The spring-loaded elements
TIM ID: 0000004511 – 002
(1) of the spider (7) will bear against the exhaust/inlet canal below the valve seat.
Locking the pilot
Screw clamping nut (3) onto the pilot and tighten with moderate force. Tighten the screws (6) on
top of the spider to lock the spring-loaded elements (1) of the spider (7). Apply standard machine
oil to the top and around the periphery of the pilot shaft.
MS25012/00E 08-06 © MTU

Setting up valve turning machine
Mounting the cutter

Fit the appropriate tool holder of the cutter (8) with an indexable insert and attach to the tool slide (7).
Placing the valve-turning machine on the pilot
Take care that the cutter (8) does not bump against the cylinder head.
Slide the valve-seat cutting machine over the pilot (10) until either the depth stop (3) rests upon
the pilot (10) or the cutter (8) contacts the cylinder head.
Aligning the cutting edge with the valve-seat center
Turn rapid tool adjuster (11) to position cutting edge of cutter over the valve-seat center (9). Hold
the machine with one hand. Loosen screw (4) of depth stop (3) and allow machine to slide down
until the cutting edge contacts the valve seat (9) lightly. Push depth stop (3) slightly downward
against the pilot (10) and then tighten depth stop locking screw (4).
Connecting the machine to power supply
Insert the round plug of the outlet cable (6) of the power supply unit (5) into the corresponding socket
(1) on the driving assembly (2) and allow the securing latch to engage.
TIM ID: 0000004511 – 002
MS25012/00E 08-06 © MTU

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

Slightly lift machine with one hand and then turn rapid tool adapter (11) with the other hand until the
cutting edge is just clear of the inner edge of the valve seat (10).
Setting cutting depth
To set the depth of cut, turn depth feed (3) counterclockwise. One notch of the depth-feed scale (4) corresponds
to a depth feed of 0.025 mm. As the valve seat (10) usually shows unequal wear, the depth of the first turning
cycle must be selected (max. 0.2 mm) to ensure that the entire valve-seat surface is undercut.
If the cutting edge is just scraping along the surface instead of undercutting the hard surface zone,
there is a risk of premature wear and chipping of the cutting edge.
Lubricating the valve seat
Apply a few drops of metalworking lubricant on hard valve-seat surfaces before turning.
Valve seat turning
Make sure that the pivoted lever (8) is engaged in the groove of the feed actuator (12). Select proper speed by
shifting the switch (6) at the power supply unit (5). Speed can be increased by changing over from 30 VDC to 42 VDC.
TIM ID: 0000004511 – 002
Hold driving unit (2) with both hands at the motors (1) and press pushbutton switch (7) to start the cutting pass.
Release the pushbutton switch (7) as soon as the cutter has been traversed beyond the top edge of the valve seat (10).
Repeating the cutting pass
Repeat steps with a cutting depth between 0.05 mm and 0.1 mm until the valve seat surface (10) is plane all around.
To ensure a smooth valve-seat surface (10) finish, proceed with a final pass at high speed with 0.025 mm cutting depth.
MS25012/00E 08-06 © MTU

Replacing the adapter head
Removing the adapter head

Unscrew the two screws (1) from the adapter head (2).
Turn adapter head (2) in the direction of the arrow until the back of the toothed rack (4) is no longer engaged with
the pinion (4) in the gear housing (6). Now the adapter head can be withdrawn off the gear housing (6).
Mounting the adapter head
Place adapter head (2) onto gear housing (6) so that the pinion (5) projecting from the gear housing (6)
is seated in the corresponding bore of the adapter head (2).
The adapter head (2) must be seated flush with the gear housing (6).
Screw the two screws (1) loosely into the gear housing so that the adapter head (2) can still be moved
to adjust proper clearance between toothed rack (4) and pinion.
Adjust the adapter head so that the gap between the toothed side of the rack (4) and the opposite side of
the recess (3) is approximately 0.3 mm to 0.5 mm. Tighten both screws (1).
Turn the rapid tool adjuster to move the tool slide back and forth. If tool slide does not
move freely, readjust the adapter head.
TIM ID: 0000004511 – 002
MS25012/00E 08-06 © MTU

4.4.3 Cylinder head – Removal
Preconditions
Special tools

Tightening equipment (power amplifier) F6553658 1
Plug B80144872 1
Installation/removal tool for plugs F30378956 1

Risk of injury!
Heavy object.
Risk of crushing!
TIM ID: 0000005025 – 009
MS25012/00E 08-06 © MTU

Removing cylinder head

1. Evenly release hex bolts (1) on the cylinder head
with power amplifier (2) and remove.
2. Screw plug (2) onto installation/removal tool and

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

oil supply line (arrowed) in crankcase and spread.
4. Ensure that the plug is firmly anchored.
5. Release insertion/removal tool (1) and remove.
TIM ID: 0000005025 – 009
MS25012/00E 08-06 © MTU

6. Attach cylinder head (2) to crane using support

bracket (1) and a lightly tensioned rope.
7. Lift off cylinder head (2) and set down on stable
surface.
8. Remove cylinder head gasket from mating face
of crankcase.
9. Remove plug from oil supply bore and close
with protective plug.
10. Use a screwdriver to remove sealing ring from

lower side of cylinder head.
TIM ID: 0000005025 – 009
MS25012/00E 08-06 © MTU

4.4.4 Cylinder head – Disassembly
Special tools

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

Risk of injury!

Risk of injury!
Removing valves
1. Place cylinder head on base plate (3).
2. Mount valve-spring compressor (2).
3. Screw in spindle (1) and compress valve springs
with valve-spring compressor (2) until the valve
collets (4) can be removed.
4. Remove valve collets (4) with a magnet.
5. Release valve springs and remove valve-spring
compressor (2).
TIM ID: 0000009347 – 005
MS25012/00E 08-06 © MTU

6. Remove valve spring retainer, valve springs

and valve rotators.
7. Lay cylinder head on its side.
8. Mark exhaust and inlet valves so that they can be
reinstalled in their original positions.
9. Place valves in storage rack (1).
Removing sleeve
1. Secure cylinder head.
2. Using socket, remove sleeve from cylinder head.
3. Remove O-ring from sleeve.
TIM ID: 0000009347 – 005
MS25012/00E 08-06 © MTU

4.4.5 Cylinder head – Cleaning
Material

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

Risk of injury!


Cleaning the cylinder head

TIM ID: 0000004510 – 005
MS25012/00E 08-06 © MTU

4.4.6 Cylinder head – Check
Special tools

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

Corrosion inhibitor
Spare parts

Cylinder head
Sealing ring
Gasket
Cylinder head screws
Thrust washer
Valve guides
Valves
Sleeve
Valve springs
Sliding pin
Valve rotator
Spring retainer
TIM ID: 0000004512 – 007
Valve collet
Compressed air.
Risk of injury!
MS25012/00E 08-06 © MTU

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

Risk of injury and scalding!
WARNING • Wear protective clothing, gloves, and goggles / safety mask.
Cylinder head - Check
Item Findings Task
Measure cylinder head height. Minimum height not reached Replace cylinder head.
Values (→ Page 321)
Check cylinder head mating face Damaged • Recondition

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

cylinder head for scores and wear. • Wear • Replace cylinder head.
visible.
Measure valve guides with limit plug Not dimensionally accurate Replace valve guides.
gauge. Values (→ Page 321)
Check valve springs for damage. • Damaged Replace valve springs

Check spring power and length of • Values below specification
valve springs. Values (→ Page 321)
Check thread for ease of movement. Sluggish • Recondition

• Replace cylinder head.
Check valve seats on cylinder head Pitting or wear • Recondition: (→ Page 307)
for pitting and wear. • Replace cylinder head.
Check cylinder head screw threads, Damaged Replace

screw head mating faces and thrust
washer for damage.
Measure shaft length of the cylinder Values exceeded (→ Page 321). Replace
head screws with depth gauge.
Check valves for damage. • Chrome layer damaged Replace

Check valves for concentricity and • Valve keyways damaged or
dimensional accuracy. Values burnt
(→ Page 321) • Out-of-round
Check spring retainer and valve • Scores Replace

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

TIM ID: 0000004512 – 007
Check sliding pin and valve bridge • Signs of wear Replace sliding pin.
bore for wear and damage. Values • Damage visible
(→ Page 321) • Not dimensionally accurate
MS25012/00E 08-06 © MTU

Checking cylinder head for leaks

Note: Install sleeve prior to leak test (→ Page 340).
1. Prepare water for water bath with corrosion inhibitor.

2. Install pressure testing device.
3. Place cylinder head in a water bath heated to 80 °C until cylinder head has warmed up.
4. Pressure-test cylinder head with 0.5 bar compressed air.
5. Pressure must be maintained with cylinder in water bath for at least 30 minutes. No air bubbles must emerge.
6. Remove hydraulic pressure testing device.
7. Replace leaking plugs (→ Page 338).
TIM ID: 0000004512 – 007
MS25012/00E 08-06 © MTU

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

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

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

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

installed
Valve stem Ø 10.935 −0.010 +0.010

TIM ID: 0000020751 – 001
2 Finished valve 11.000 H9 0 +0.043 0.055 0.118

guide bore
installed
Valve stem Ø 10.935 −0.010 +0.010
MS25012/00E 08-06 © MTU

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

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

or protrusion 1.100
inlet
TIM ID: 0000020751 – 001
MS25012/00E 08-06 © MTU

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

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

depth
3 Valve-seat insert 58.000 H6 0 +0.019

bore, inlet
Rework instructions:
• If a valve seat insert is replaced before the rework depth of 1.100 mm is reached, it must be machined until it
is flush with the contour depth to avoid that the valve seat insert protrudes into the combustion chamber.
• Max. rework of the valve-seat inserts by 0.300 mm into the depth, without machining the contour or the
valve cone.
TIM ID: 0000020751 – 001
MS25012/00E 08-06 © MTU

Inlet and exhaust valve-seat insert
Basic
size
1 Plug gauge 73.200 0 0

diameter
2 Plug gauge 87.130 0 0

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

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

depth
Combustion
chamber sealing
ring surface
TIM ID: 0000020751 – 001
MS25012/00E 08-06 © MTU

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

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

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

dimension 3.000
without ring
gauge
Valve seat height
TIM ID: 0000020751 – 001
MS25012/00E 08-06 © MTU

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

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

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

dimension 3.000
without ring
gauge
Valve seat height
TIM ID: 0000020751 – 001
MS25012/00E 08-06 © MTU

Valve springs, exterior
Basic
size
1 Spring length 83.900

released

compressed
Spring length 65.100

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

at compressed
spring length

compressed

when mod. valve
rotator is used
TIM ID: 0000020751 – 001
3.1 Spring force at 952.000 N -39 N +39 N Spring

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

Block dimension dimension
max. 47.700
MS25012/00E 08-06 © MTU

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

released

compressed

TIM ID: 0000020751 – 001
when mod. valve

rotator is used
2.1 Spring force 256.000 N

at compressed
spring length
MS25012/00E 08-06 © MTU

Basic
size

compressed

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

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

Block dimension dimension
max. 42.500
5 Winding dia. 23.000
6 Wire dia. 3.600
e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.300
e2 Spring seat, permissible parallelism deviation max. 0.400

TIM ID: 0000020751 – 001
MS25012/00E 08-06 © MTU

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

height
2 Protective sleeve 124.000 0 +0.200

mating surface
3 Protective sleeve 44.200 0 +0.100 0.100 0.300

bore
Protective sleeve 44.100 −0.100 0

external
diameter
4 Cylinder head M 24 x 1.5

and protective
sleeve thread
Rework instructions:
• Rework only until a satisfactory mating surface has been achieved.
• If the cylinder head height was reworked, the fire face contour of 13.800 +0.100 is to be re-established.
TIM ID: 0000020751 – 001
MS25012/00E 08-06 © MTU

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

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

screw
TIM ID: 0000020751 – 001
MS25012/00E 08-06 © MTU

4.4.8 Cylinder head – Repair
Special tools

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

Liquid nitrogen
Corrosion inhibitor
TIM ID: 0000004515 – 007
MS25012/00E 08-06 © MTU

Spare parts

Valve guide, inlet
Valve guide, exhaust

Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!

Removing the valve-seat insert

1. Clean valve guide using a hole brush.
2. Insert pilot into valve guide of cylinder head
(3) and secure.
3. Install head (2) and lathe tool on valve seat
lathe (1).
4. Position valve seat lathe (1) on pilot and install
steady rest.
5. Setup valve seat lathe (1) (→ Page 307).
6. Machine valve-seat insert so that the seat insert
extractor can be installed.
7. Remove steady rest, valve seat lathe (1) and pilot.
TIM ID: 0000004515 – 007
MS25012/00E 08-06 © MTU

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

insert to be removed (2).
9. Using seat insert extractor (1), remove valve-seat
insert (2).
10. Check bore of valve-seat insert (1) in cylinder
head. Values (→ Page 321).
Result: Replace cylinder head if the value
is exceeded.
Removing the valve guide

1. Place cylinder head on hydraulic press. Ensure
correct positioning of the cylinder head side.
2. Using the extractor and working from the
combustion side, press valve guide out of cylinder
head.
3. Check valve guide bore in cylinder head. Values
(→ Page 321).
Result: If the value is exceeded, recondition
bore to next stage.
4. Secure cylinder head on boring mill.
5. Ream valve guide bore in cylinder head.
Installing the valve guide

1. Prepare water for water bath with corrosion
inhibitor.
2. Place cylinder head (4) in water bath heated to
80°C until cylinder head (4) has warmed up.
3. Chill valve guide (2) in liquid nitrogen for approx.
20 to 30 mins.
4. Position heated cylinder head (4) on assembly
jig (3).
5. Using mandrel (1), position chilled valve guide
(2) in bore of cylinder head (4) until the stop of
assembly jig (3) is reached.
TIM ID: 0000004515 – 007
MS25012/00E 08-06 © MTU

Installing the valve-seat insert

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

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

seat lathe (1).
4. Position valve seat lathe (1) on pilot and install
steady rest.
5. Setup valve seat lathe (1) (→ Page 307).
Note: Note recondition dimension, required when
machining elliptical chamfer.
6. Only recondition valve seat surface until a

satisfactory surface has been established. Values
(→ Page 321).
7. Remove steady rest, valve seat lathe (1) and pilot.
TIM ID: 0000004515 – 007
MS25012/00E 08-06 © MTU

8. Recondtion valve seat surface (2) with associated

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

1. Insert pilot into valve guide.
2. Mount clamp ring (2) over inserted pilot and
secure.
3. Mount the tester (1) on clamp ring.
4. Set preloaded feeler of tester on valve seat
center (arrowed).
5. Check concentricity of valve seat in relation to
valve guide, values (→ Page 321).
Result: In event of deviation from test values,
recondition valve seat again.
6. Remove tester (1), clamp ring (2) and pilot.
Measuring valve seat depth

1. Adjust distance from plug gauge to ring gauge.
2. Set scale on dial gauge to zero.
3. Measure valve seat depth. Values (→ Page 321).
is exceeded.
TIM ID: 0000004515 – 007
MS25012/00E 08-06 © MTU

Regrinding valve seats

1. Mount valve (1) as directly as possible behind
valve head in valve grinder (2).
2. Set valve seat grinding angle on valve seat grinder.
3. Using low feed, grind valve seat only until a
satisfactory surface is achieved.
4. Measure height of outer valve seat edge as well as
valve seat width. Value (→ Page 321).
Result: If the value is not reached, replace valve.
Reconditioning elliptical chamfer (if required)

1. Insert pilot (3) for elliptical chamfer (2) into valve
guide.
2. Mount tester (1) over inserted pilot (3) and secure.
3. Set preloaded tester pointer (1) to elliptical
chamfer (2).
4. Align pilot (3) and elliptical chamfer (2) using
tester (1).
5. Secure pilot (3).
6. Remove tester (1).
7. Install suitable head and lathe tool to valve seat
lathe.
8. Position valve seat lathe on pilot and install
steady rest.
9. Set up valve seat lathe (→ Page 307).
Note: Use recondition dimension as for
machining valve seat surface.
10. Only recondition elliptical chamfer (2) until a

satisfactory surface has been achieved.
11. Check elliptical chamfer (2). Value (→ Page 321).
is exceeded.
Reconditioning the protective sleeve mating face.
1. Install countersink reamer tool in bore for protective sleeve.
2. Recondition seating surface for protective sleeve with countersink reamer tool. Value (→ Page 321).
TIM ID: 0000004515 – 007
MS25012/00E 08-06 © MTU

4.4.9 Cylinder head – Plug repair
Special tools

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

Cleaner (Loctite 7063) 50594 1
Screw locking compound (Loctite 270) 40083 1
Spare parts

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

Risk of injury!

TIM ID: 0000004867 – 004
MS25012/00E 08-06 © MTU

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

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

head bore until flush.
8. Check cylinder head for leaks (→ Page 318).
TIM ID: 0000004867 – 004
MS25012/00E 08-06 © MTU

4.4.10 Cylinder head – Assembly
Special tools

Valve spring compressor F6783833 1
Retainer 0015890321/00 1
Socket F30377634 1
Material

Engine oil
Spare parts

O-ring
Sealing ring

Risk of injury!
Heavy object.
Damage to equipment due to falling components!
WARNING • Ensure that all components are secured during removal and installation work.
TIM ID: 0000004513 – 007
MS25012/00E 08-06 © MTU

Installing sleeve
1. Clean sealing surface (arrow).
2. Coat O-ring (2) with grease and insert in groove
of sleeve (1).
3. Clamp cylinder head firmly.

4. Clean sealing surface of cylinder head.
5. Use torque wrench to tighten prepared sleeve to
Installing valves
1. Lay cylinder head on its side.
2. Wipe valves with chamois leather and coat valve
stems with engine oil.
3. Insert valves in valve guides. Observe correct
valve arrangement. Markings are on the end
of the valve stems.
IN Inlet
EX Exhaust
TIM ID: 0000004513 – 007
MS25012/00E 08-06 © MTU

4. The markings and installation positions of the

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

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

compressor on cylinder head.
7. Set cylinder head upright.
8. Slide valve rotator on to valve guide.
9. Fit outer and inner valve springs.
10. Fit valve spring retainers.
TIM ID: 0000004513 – 007
MS25012/00E 08-06 © MTU

11. Mount valve spring compressor (2).

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

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

1. Install dial gauge (2) on dial-gauge holder (1).
2. Set dial gauge (2) with preload on to plane face
of cylinder head (4).
3. Set dial gauge to 0.
4. Position dial-gauge stylus on valve head of
valves (3) and measure valve clearance to plane
surface.
5. If the reading is not within the tolerance
(→ Page 321), check valve seat at cylinder head
and valve head.
TIM ID: 0000004513 – 007
MS25012/00E 08-06 © MTU

4.4.11 Cylinder head – Installation
Special tools

Installation/removal tool for seal plug F30378956 1
Seal plug B80144872 1
Tightening tool (power amplifier) F6553658 1
Alignment tool for 8V and 12V cylinder heads F6558582 1
Alignment tool for 16V and 20V cylinder heads F6553648 1
Adjusting mandrel F30378324 2
Measuring tool for angle of rotation Y20044010 1
Material

Engine oil
Spare parts

Sealing ring
Gasket

Risk of injury!
Heavy object.
Risk of crushing!
TIM ID: 0000004514 – 007
Contamination in blind hole.

CAUTION • Inspect and clean blind hole.
MS25012/00E 08-06 © MTU

Cylinder head – Installation

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

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

is correct:
• A = Cylinder head side
• B = Piston side
TIM ID: 0000004514 – 007
MS25012/00E 08-06 © MTU

6. Remove seal plug.

7. Attach cylinder head (2) with carrying bracket (1)
and rope to crane, ensuring that the rope is
lightly pretensioned.
8. Place cylinder head (2) onto crankcase.
9. Coat thread, shaft and mating surfaces on heads

of cylinder head screws (1) with engine oil.
10. Observe assignment of cylinder head screws (1)
(engine lifting eye). Install cylinder head screws (1)
with thrust washers manually in crankcase.
11. Fit alignment tool (2) on inlet channels of cylinder
heads and tighten.
12. Align cylinder heads.
TIM ID: 0000004514 – 007
MS25012/00E 08-06 © MTU

13. Use power amplifier and torque wrench to tighten

cylinder head screws to specified tightening torque
in accordance with the tightening sequence.
A Exhaust side
B Inlet side

Cylinder head screw M22 x 2 Preload torque Engine oil 25 Nm
Cylinder head screw M22 x 2 Residual torque 180 Nm +10 Nm
Cylinder head screw M22 x 2 Residual angle of rotation 180 ° +10 °
Cylinder head screw M22 x 2 Control torque 400 Nm
14. Remove alignment tool.

TIM ID: 0000004514 – 007
MS25012/00E 08-06 © MTU

4.5 Valve Gear
4.5.1 Valve gear – Overview
Valve gear – Overview
1 Camshaft gear 5 Camshaft 9 Nut

2 Swing follower shaft 6 Pushrod 10 Adjusting screw
3 Swing follower, inlet 7 Shaft 11 Rocker arm, exhaust
4 Swing follower, exhaust 8 Rocker arm, inlet 12 Rocker-shaft support TIM ID: 0000028647 – 001
MS25012/00E 08-06 © MTU

4.5.2 Camshaft – Overview
Camshaft – Overview
50 Camshaft 550 Ring

100 Dowel pin 650 Screw
300 Camshaft gear 700 Washer
400 Timing wheel 850 Thrust bearing flange
500 Screw 950 Screw
TIM ID: 0000028648 – 001
MS25012/00E 08-06 © MTU

4.5.3 Camshaft – Removal
Preconditions
Special tools

Camshaft locating device F6553642 1
Camshaft installation/removal tool F30450435 1
Guide sleeve for camshaft 8V-16V F6782970 1
Guide sleeve for camshaft 20V F6781673 1
Guide sleeve for assembly on driving end F6781676 1
Guide sleeve for assembly on free end F6780579 1
Centering sleeve for assembly on free end F6780582 1
Heavy object.
Risk of crushing!
Camshaft drive – Removal

1. Remove camshaft gear as shown in overview drawing (→ Page 349).
2. To protect the crankcase from falling objects, cover equipment carrier from below.
Removing camshaft thrust bearing

1. Remove screws (1).
2. Remove thrust bearing flange (2).
3. Check thrust bearing flange (→ Page 376).
TIM ID: 0000003582 – 004
MS25012/00E 08-06 © MTU

Camshaft – Removal
1. Install inner guide sleeve (2) on face of camshaft,
free end.
2. Fasten guide flange (1) on crankcase.
3. Fasten outer guide sleeve (3) with screws (1) on

crankcase (2), driving end.
4. Screw inner guide sleeve (4), driving end, on to
camshaft.
5. Center guide sleeve to camshaft bearings.
6. Mount installation/removal tool on camshaft (2).

7. Attach camshaft with rope in middle (1) to crane.
8. Tension rope slightly and carefully withdraw
camshaft (2) horizontally from crankcase.
9. Remove guide sleeve.
TIM ID: 0000003582 – 004
MS25012/00E 08-06 © MTU

4.5.4 Camshaft – Cleaning
Material


Camshaft – Cleaning
1. Clean all parts with cleaning agent.
TIM ID: 0000003583 – 002
MS25012/00E 08-06 © MTU

4.5.5 Camshaft running surfaces and swing followers – Visual inspection
Special tools

Endoscope Y20045885 1
Spare parts

Camshaft
Roller tappet
Visually inspecting camshaft running surfaces

and swing followers
1. Remove valve drive (swing followers remain
installed) (→ Page 380).
2. Insert endoscope into crank drive through every
pushrod bore.
3. Visually check roller surface of cams, roller running
surfaces on the camshaft as well as swing
followers for damage and wear.
4. Replace swing follower if signs of corrosion are
visible, see illustrations (→ Page 380).
5. Replace camshaft if signs of corrosion are visible,
see illustrations (→ Page 368).
Install valve drive (→ Page 393).

TIM ID: 0000007957 – 005
MS25012/00E 08-06 © MTU

4.5.6 Camshaft – Check
Special tools

Hardness tester DynaMIC Y20506341 1
Measuring stand 0015890321/00 1
Material

Spare parts

Camshaft
Camshaft gear
Timing wheel
Hex screw
Spring washer
TIM ID: 0000003584 – 004
MS25012/00E 08-06 © MTU

Camshaft – Check
Using magnetic crack-test Crack indication Replace camshaft.

procedure, check camshaft for
cracks.
Check axial bearing flange with red Crack indication Replace camshaft.
dye penetrant for cracks.
Check mating face of camshaft gear. Stress marks visible • Recondition: Smooth with
oilstone or emery cloth.
• Replace
Check axial sliding surface, journal • Scores Replace camshaft.

faces and roller tracks of cams • Stress marks
for scores, stress marks and • Indentations
indentations. visible
Check tooth flank of camshaft gear Damaged Replace camshaft gear.

with magnifying glass.
Check screws for damage. Damaged Replace
Checking hardness of cam and journal

1. Use hardness tester to check cam hardness
(inlet/exhaust rocker arms) and journals. Required
hardness: 60 HRC ±2 HRC
2. Check hardness of each journal at four points at
90° intervals around circumference.
3. Replace camshaft if values are fallen short of.
TIM ID: 0000003584 – 004
MS25012/00E 08-06 © MTU

Checking concentricity and cam lift

1. Set camshaft at outer journals on to V-blocks
(2) or roller stands.
2. Place supporting mount (3) on center journal.
3. Measure radial run-out of cam base circle and
bearings with dial gauge (1). Values (→ Page 357).
TIM ID: 0000003584 – 004
MS25012/00E 08-06 © MTU

4.5.7 Camshaft – Tolerances
Concentricity of bearing points 8/12/16V
Max. permissible deviation from New Limit value

concentricity
During the concentricity check, provide supports for and align the following bearings.
• 8V: bearing 3 beginning at driving end
from bearing 1 to bearing 2 0.050
a from bearing to bearing 0.025
b all cams 0.010

0.010
TIM ID: 0000028649 – 001
MS25012/00E 08-06 © MTU

Concentricity of bearings 20V

Basic value
1 Reference 235.000 -0.150 +0.150

dimension
2 Camshaft bore 47.000 K6 -0.013 +0.003 0.067 0.094
Camshaft outer Ø 47.000u5 +0.070 +0.081
Re 1: Reference dimension: to be measured from bearing 3 to bearing 4
Max. permissible deviation from New Limit value

concentricity
During the concentricity check, provide supports for and align the following bearings.
TIM ID: 0000028649 – 001
from bearing 1 to bearing 2 0.050
a from bearing to bearing 0.025
b all cams 0.010

0.010
MS25012/00E 08-06 © MTU

Axial play

Basic value
1 Camshaft gear 32.000 H7 0 +0.025 0 0.050

bore
Camshaft outer Ø 32.000 h7 –0.025 0
2 Camshaft axial 0.100 0.166

play
3 Camshaft axial 0.100 0.235

play
4 Gear press-fitted flush with camshaft end
Re 4: max. permissible protrusion camshaft/camshaft gear: 0.020

TIM ID: 0000028649 – 001
MS25012/00E 08-06 © MTU

4.5.8 Camshaft – Installation
Special tools

Camshaft installation/removal tool F30450435 1
Guide sleeve for camshaft 8V-16V F6782970 1
Guide sleeve for camshaft 20V F6781673 1
Guide sleeve for assembly on free end F6780579 1
Centering sleeve for assembly on free end F6780582 1
Timing wheel, free end Y4341124 1
Feeler gauge Y20010128 1
Retainer 0015890321/00 1
Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!
TIM ID: 0000028650 – 001
MS25012/00E 08-06 © MTU

Camshaft – Installation
1. Attach outer guide sleeve (1) to driving end
of crankcase and carefully center to camshaft
bearings with inner guide sleeve (2).
2. Center guide flange (1) with guide sleeve (2) on

crankcase (free end) to camshaft bearings and
secure.
3. Position inner guide sleeve (2) on front of camshaft

(1) and tighten.
TIM ID: 0000028650 – 001
MS25012/00E 08-06 © MTU

4. Attach center of camshaft (arrow) with rope to

crane and wipe with chamois leather.
5. Spray camshaft, camshaft bearing and guide
sleeve with engine oil.
6. Install sliding block at outermost cam on camshaft.
7. Carefully insert camshaft up to second-last
bearing.
8. Position assembly extension (1) on camshaft (2)

and insert camshaft up to last bearing.
9. Secure camshaft axially and/or make sure that it
cannot fall out until thrust bearing is installed.
10. Remove inner/outer guide sleeve and assembly
extension.
Installing camshaft thrust bearing

1. Coat axial sliding surfaces with engine oil.
2. Cover bottom of equipment carrier so that no
screws can fall into housing.
3. Tighten thrust bearing flange (2) with screws(1).
TIM ID: 0000028650 – 001
MS25012/00E 08-06 © MTU

Installing locating device

1. Turn camshaft until locating bore (arrow), driving
end, is visible and at position shown.
2. Position locating device (1) on securing plane of

rocker shaft, driving end.
3. Insert dowel pin of guide tube (3) into camshaft
bore (2) and screw locating device into place
(arrows).
Installing timing wheel (camshaft gear)

1. Install pointer (2) on equipment carrier.
2. Install index plate (1) with barring tool on
crankshaft. Set to TDC mark of A1 and tighten.
3. Set piston A1 to firing TDC (→ Page 299).
TIM ID: 0000028650 – 001
MS25012/00E 08-06 © MTU

4. Cover bottom of equipment carrier so that no

objects can fall into housing.
5. Insert camshaft gear (1) in camshaft so that
dowel pins (4) engage in camshaft gear bore in
a vertical line.
6. Slide timing wheel (2) over dowel pins (4) and
install.
7. Insert screws (5) with spring washers and tighten
(→ Page 23). Note position of holes of dowel
pins to screw bores.
8. Use screws (3) to fasten timing wheel (2) on
camshaft gear (1).
Measuring backlash
1. Remove camshaft locating device.
2. Fit magnetic-base holder with dial gauge on
crankcase (free end).
3. Mount dial gauge tip with low preload on one tooth
flank of camshaft gear.
4. Set dial gauge to 0.
5. Check backlash by moving camshaft gear back
and forth. Circumferential backlash (→ Page 179).
Measuring camshaft axial play

1. Fit magnetic-base holder with dial gauge on
crankcase (free end).
2. Fit dial gauge pointer on timing wheel.
3. Press camshaft on camshaft gear in axial direction
up to stop.
4. Set preloaded dial gauge to zero.
5. Move camshaft from stop to stop and record
measured value (axial play). Axial play
(→ Page 357)
6. If axial play is out of tolerance, replace thrust
bearing (→ Page 374).
TIM ID: 0000028650 – 001
MS25012/00E 08-06 © MTU

Installing speed sensor

2. Turn speed sensor (2) slightly to install in housing
fit.
3. Insert screw (1) and tighten.
Checking speed sensor clearance

1. Pull camshaft on camshaft gear axially towards
free end (arrow) as far as it will go.
2. Measure clearance (X) with feeler gauge
(reference value 0.14 mm to 1.2 mm).
3. If clearance is less than 0.14 mm:
3.1. Fit appropriate number of adjusting shims of
0.3 mm thickness.
3.2. Measure clearance.
Checking camshaft control timing

1. Determine TDC position of piston in the following
way:
1.1. Install measuring device (2) with dial
gauge (1) at cylinder head A1.
1.2. Fit TDC mark (index plate) on crankshaft
journal, free end.
1.3. Install suitable TDC pointer on equipment
carrier or crankcase, driving end.
1.4. Using the barring tool, bar the engine until
the piston of cylinder A1 is in the firing TDC.
The piston is at firing TDC when both rocker
TIM ID: 0000028650 – 001
arms are unloaded, i.e. have clearance.

2. Move piston up and down several times and then
position so that pointer on dial gauge shows its
maximum reading.
3. Set dial gauge to zero.
4. Turn crankshaft in opposite direction of rotation by
approx. 10°.
MS25012/00E 08-06 © MTU

5. Set crankshaft in direction of rotation to 0.3 mm

(dial gauge indicator) before TDC.
6. Apply exact line marking on index plate, driving
end, or crankshaft journal, free end, opposite
TDC pointer tip.
7. Bar crankshaft in direction of rotation approx. 10°
past TDC (to compensate bearing clearance).
8. Bar crankshaft in opposite direction of rotation
to 0.3 mm after TDC and make a second mark.
To prevent measurement errors caused by
bearing clearance, the piston must always move
in direction of TDC.
9. Apply third mark at exact center between marks.
10. Align index plate so that mark for cylinder A1
corresponds to pointer.
11. Check TDC position.
12. Remove measuring device with dial gauge.
Measuring valve lift

1. Set cylinder A1 to firing TDC.
2. Release locknuts on adjusting screw.
3. Screw in adjusting screws until there is no longer
clearance.
4. Tighten locknuts slightly.
5. Mount magnetic-base indicator holder with dial
gauge on cylinder A1.
6. Place slightly preloaded dial gauge pointer on
valve bridge of inlet valve. Set scale to zero.
7. Slowly turn crankshaft further in direction of engine
rotation by 360°. Set to exact overlap TDC (line
marking on index plate).
8. Read valve stroke from dial gauge and enter
values in data sheet.
9. Mount dial gauge pointer on valve bridge of
exhaust valve and set scale to zero.
10. Further rotate crankshaft slowly in engine direction
of rotation until pointer of dial gauge no longer
moves.
11. Read valve stroke from dial gauge and enter
values in data sheet.
12. Check that specified values are attained.
Reference values, see (→ Page 39).
13. If reference value is not attained, contact Service.
14. Remove magnetic-base indicator holder with dial
gauge and TDC pointer.
15. Set valve clearance at cylinder A1 (→Operating
Instructions ).
TIM ID: 0000028650 – 001
MS25012/00E 08-06 © MTU

4.5.9 Camshaft drive – Overview
Camshaft drive – Overview
1 Screw 5 Thrust bearing flange

2 Ring 6 Screw
3 Timing wheel 7 Washer
4 Camshaft gear 8 Screw
TIM ID: 0000028651 – 001
MS25012/00E 08-06 © MTU

4.5.10 Camshaft drive – Removal
Special tools

Camshaft drive – Removal

1. Turn engine with barring tool in normal direction
of rotation until TDC mark and arrow on end
housing are aligned.
• If rocker arms on cylinder A1 are unloaded, the
piston is in firing TDC.
• If rocker arms on cylinder A1 are loaded, the
piston is in overlap TDC.
2. Remove valve drive (→ Page 380).
3. Disconnect electrical plug-in connection.

4. Remove screw (arrow).
5. Turn speed sensor (1) slightly to remove from
crankcase fit.
TIM ID: 0000028652 – 001
MS25012/00E 08-06 © MTU

Installing locating device

1. Turn camshaft until locating bore (arrow), driving
end, is visible and at position shown.
2. Position locating device (1) on securing plane of

swing-follower shaft (driving end).
3. Insert dowel pin of guide tube (3) into camshaft
bore (2) and screw locating device into place
(arrows).
Removing timing wheel (camshaft gear)

3. Remove timing wheel (2) and camshaft gear (1)
from camshaft and dowel pins (4).
4. To protect the crankcase from falling objects, cover
equipment carrier from below.
5. Do not remove locating device.
TIM ID: 0000028652 – 001
MS25012/00E 08-06 © MTU

4.5.11 Camshaft drive – Cleaning
Material

Compressed air.
Risk of injury!

Camshaft drive – Cleaning

1. Clean all components with cleaner.
3. Blow camshaft drive clear with compressed air.
TIM ID: 0000003589 – 002
MS25012/00E 08-06 © MTU

4.5.12 Camshaft drive – Check
Spare parts

Camshaft gear
Timing wheel
Screw
Spring washer
Camshaft drive – Check
Item Findings Task
Check surface condition of tooth • Scores • Corrective work

flanks with magnifying glass. • Stress marks • Replace
• Indentations
visible
Check timing wheel and camshaft Damaged • Corrective work

gear for damage. • Replace
Check threads of hex bolts for Damaged Replace

damage.
Check spring washer for damage. Damaged Replace

TIM ID: 0000003590 – 003
MS25012/00E 08-06 © MTU

4.5.13 Camshaft drive – Installation
Special tools

Graduated disc, free end Y4341124 1
Feeler gauge Y20010128 1
Holder 0015890321/00 1
Material

Petroleum jelly, white 40137 1
Spare parts

O-ring
Heavy object.
Risk of crushing!
For camshaft drive installation, see section “Installing timing wheel (camshaft gear)” (→ Page 360).
TIM ID: 0000003592 – 004
MS25012/00E 08-06 © MTU

4.5.14 Camshaft thrust bearing – Overview
Overview of camshaft thrust bearing
1 Thrust bearing flange 2 Hex screw

TIM ID: 0000003593 – 001
MS25012/00E 08-06 © MTU

4.5.15 Camshaft thrust bearing – Replacement
Material

Engine oil
Spare parts

Thrust bearing flange
Hex screw
Camshaft thrust bearing – Replacement

1. Remove camshaft drive (→ Page 368).
2. Replace camshaft thrust bearing as shown in overview drawing (→ Page 373).
TIM ID: 0000003594 – 001
MS25012/00E 08-06 © MTU

4.5.16 Camshaft thrust bearing – Cleaning
Material


Compressed air.
Risk of injury!

Camshaft thrust bearing – Cleaning

3. Blow thrust bearing clear with compressed air.
TIM ID: 0000003595 – 002
MS25012/00E 08-06 © MTU

4.5.17 Camshaft thrust bearing – Check
Material

Spare parts

Thrust bearing flange
Hex bolts
Camshaft thrust bearing – Check
Item Findings Task
Test trust bearing flange for cracks Signs of cracks Replace

using surface crack-test method.
Check mating faces, fits and sliding Damaged • Corrective work

surfaces for damage. • Replace
Check threads of hex bolts for ease Sluggish Replace

of movement.
TIM ID: 0000003596 – 002
MS25012/00E 08-06 © MTU

4.5.18 Valve drive – Overview
Rocker arms, swing followers
100 Rocker arm 250 Swing follower

150 Valve bridge 350 Hex screw
TIM ID: 0000028653 – 001
MS25012/00E 08-06 © MTU

Rocker shaft support
1 Snap ring 6 Nut 11 Shaft

2 Shim 7 Grooved pin 12 Rocker arm, exhaust valve
3 Bushing 8 Shaft support 13 Thrust pad
4 Adjusting screw 9 Oil spray nozzle
5 Rocker arm, inlet valve 10 Sealing plug
TIM ID: 0000028653 – 001
MS25012/00E 08-06 © MTU

Swing followers
1 Bushing 4 Swing follower, inlet valve 7 Stud

2 Ball seat 5 Roller
3 Swing follower, exhaust valve 6 Bushing
TIM ID: 0000028653 – 001
MS25012/00E 08-06 © MTU

4.5.19 Valve drive – Removal
Preconditions
Removing rocker arms
1. Bar crankshaft to bring piston of appropriate
cylinder to firing TDC. The piston is at firing TDC
when both rocker arms are unloaded.
Note: Ensure that no pushrod is removed by the
suction effect on the ball socket.
2. Remove screw (2) and remove rocker shaft

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

4. Pull out pushrods (1).
TIM ID: 0000003652 – 007
MS25012/00E 08-06 © MTU

Removing swing followers

2. Remove swing follower shaft with swing followers
(2) from crankcase.
TIM ID: 0000003652 – 007
MS25012/00E 08-06 © MTU

4.5.20 Valve drive – Disassembly

Risk of injury!
Disassembling rocker arms

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

1. Check whether the swing follower bushing must be
removed (→ Page 385).
2. If so, press out swing follower bushing (2) off swing
follower (1) using mandrel and hydraulic press.
TIM ID: 0000003598 – 004
MS25012/00E 08-06 © MTU

Removing bolt and roller

1. Check whether bolt and roller must be removed
(→ Page 385).
2. If removal is required:
2.1. Position swing follower between two prisms
ensuring sufficient support at both sides
of the bolt bore.
2.2. Using mandrel and hydraulic press, remove
bolt (1) from swing follower (2).
2.3. Remove roller (3) from installation position.
Removing bushing from exhaust rocker arm

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

2. If so, press out rocker arm bushing (1) off inlet
rocker arm (2) using mandrel and hydraulic press.
TIM ID: 0000003598 – 004
MS25012/00E 08-06 © MTU

4.5.21 Valve drive – Cleaning
Material

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


Cleaning the valve drive

2. Thoroughly blow out all parts with compressed air.
TIM ID: 0000004872 – 005
MS25012/00E 08-06 © MTU

4.5.22 Valve drive – Check
Special tools

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

Crack testing oil (Nr. 63) 40475 1
Crack testing paste (UV-Apelux Paste 1031) 40483 1
Spare parts

Snap ring
Lockwasher
Rocker shaft support
Bearing bushing
Swing follower
Swing follower shaft
Valve bridge
Roller
Pushrod
Hex screw
Adjusting screw
TIM ID: 0000004873 – 005
MS25012/00E 08-06 © MTU

Checking valve drive
Item Findings Task
Using the magnetic crack-testing Cracks visible Replace

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

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

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

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

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

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

1. Adjust bore gauge to basic size of bushing
bore and measure diameter of bore. Values
(→ Page 388).
2. If limits are exceeded, replace bearing bushing. TIM ID: 0000004873 – 005
MS25012/00E 08-06 © MTU

Measuring diameter of rocker shaft support axles

1. Using outside micrometer, measure outside
diameters of bearings. Values (→ Page 388).
2. If values are not attained, replace rocker shaft
support.
Measuring swing follower bushing bore

1. Adjust bore gauge to basic size of bushing bore
and measure diameter of bore.
2. If limits are exceeded, replace bearing bushing.
Values (→ Page 388).
3. Replace gaskets and sealing washers.
4. Make sure that oil bores are perfectly clean and
free of obstruction.
TIM ID: 0000004873 – 005
MS25012/00E 08-06 © MTU

4.5.23 Valve drive – Tolerances
Rocker shaft support, inlet and exhaust
size Basic
size
1 Rocker arm bore 50.000 H7 0 +0.025 0.018 0.059
Bush OD 50.000 s6 +0.043 +0.059
2 Bush bore
installed 45.000 0 +0.050 0.025 0.091 Clearance

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

support bore
Rocker shaft OD 45.000 f6 –0.041 –0.025

TIM ID: 0000004680 – 002
MS25012/00E 08-06 © MTU

Swing follower support, inlet and exhaust
size Basic
size
1 Swing follower 36.000 H7 0 +0.025 0.018 0.059

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

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

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

max.
Pin OD 14.000 h5 –0.008 0 0.065
TIM ID: 0000004680 – 002
5 Swing follower 14.000 P6 –0.026 –0.015 0.007 0.026

bore
Bush OD 14.000 h5 –0.008 0
MS25012/00E 08-06 © MTU

4.5.24 Valve drive – Assembly
Material

Liquid nitrogen
Engine oil

Compressed air.
Risk of injury!
Component is hot.
Risk of burning!

Risk of injury!
Assembling rocker arm assembly

1. Clamp rocker shaft support in vise with aluminum
jaws.
2. Insert adjusting screw (3) into rocker arm (1).
3. Attach nut (2) to adjusting screw, do not tighten.
4. Coat axles on rocker shaft support and bushings
of rocker arms with engine oil.
5. Fit rocker arm on axle.
6. Install second rocker arm similarly.
TIM ID: 0000003599 – 004
MS25012/00E 08-06 © MTU

7. Fit washer (1) and secure with snap ring (2).

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

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

TIM ID: 0000003599 – 004
MS25012/00E 08-06 © MTU

3. Heat swing follower to approx. 130 °C to 150 °C.

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

1. Chill bushing (1) in liquid nitrogen.
2. Heat exhaust rocker arm (2) to approx. 200° C.
3. Insert bushing, ensure flush seating. Projection is
not acceptable.
TIM ID: 0000003599 – 004
MS25012/00E 08-06 © MTU

4.5.25 Valve drive – Installation
Special tools

Timing disc, free end Y4341124 1
Box wrench, 19 mm F30038493 1
Box wrench, 24 mm F30501562 1
Ratchet F30027341 1
Material

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

1. Coat axle and bushes of swing followers with
engine oil.
2. Fit exhaust and inlet swing follower on
swing-follower shaft, ensuring they are correctly
positioned (arrows).
TIM ID: 0000003653 – 007
MS25012/00E 08-06 © MTU

3. Coat rollers and camshaft bushings with engine oil.

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

6. Ensure correct position of installation (arrow).
Installing pushrods
1. Coat ball seats and ball sockets of pushrods
(1) with engine oil.
2. Insert pushrods (1) through cylinder head into ball
seat of swing follower.
TIM ID: 0000003653 – 007
MS25012/00E 08-06 © MTU

Installing the rocker arm

1. Release nuts (6) of adjusting screws (1) on rocker
arm (4) and back off adjusting screw (1).
2. Place rocker shaft support (4) onto cylinder head.
Take care not to damage fit of grooved pins.
3. Check position of ball joints in pushrods (5).
4. After initial assembly and after extended
out-of-service period: Fill adjusting screws (1)
with engine oil (arrow).
5. Insert hex screw (2) with washer (3) into the
cylinder head and use torque wrench to tighten to
the specified torque (→ Page 23).
6. Adjust valve clearance (→Operating Instructions ).
TIM ID: 0000003653 – 007
MS25012/00E 08-06 © MTU

4.5.26 Cylinder head cover – Overview
Overview of cylinder head cover
1 Cylinder head cover

2 Cylinder head
3 Gasket
4 Washer
5 Hex screw
TIM ID: 0000003601 – 001
MS25012/00E 08-06 © MTU

4.5.27 Cylinder head cover – Removal

Cylinder head cover – Removal
1. Remove hex screws.
2. Remove cylinder head cover and gasket.
TIM ID: 0000003602 – 002
MS25012/00E 08-06 © MTU

4.5.28 Cylinder head cover – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning cylinder head cover

2. Dry all components using compressed air.
TIM ID: 0000003603 – 003
MS25012/00E 08-06 © MTU

4.5.29 Cylinder head cover – Check
Special tools

Oilstone 8205893261/00 1
Spare parts

Cylinder head cover
Screw
Checking the cylinder head cover
Check cylinder head cover for Damaged • Corrective work: Smoothen

damage. with emery cloth or oilstone.
• Replace
Check threads of screws for ease of Sluggish • Corrective work: Recut threads
TIM ID: 0000003604 – 004
MS25012/00E 08-06 © MTU

4.5.30 Cylinder head cover – Installation
Material

Engine oil
Spare parts

Gasket
Screw
Washer
Install cylinder head cover

1. Insert gasket into cylinder head cover.
2. Mount cylinder head cover on cylinder head.
3. Install screw and use torque wrench to tighten to
TIM ID: 0000003605 – 003
MS25012/00E 08-06 © MTU

4.6 High-Pressure Fuel System
4.6.1 HP fuel system – Overview
1 Distributor rail 5 Distributor rail 9 Pressure relief valve

2 Injector 6 HP line 10 Fuel distributor
3 Adapter 7 HP line 11 HP line
4 HP line 8 HP fuel pump
TIM ID: 0000028654 – 001
MS25012/00E 08-06 © MTU

4.6.2 High-pressure pump – Overview
1 High-pressure fuel pump 3 Spacer bushing 5 Screw

2 Screw 4 Retainer 6 Washer
TIM ID: 0000028661 – 001
MS25012/00E 08-06 © MTU

4.6.3 High-pressure pump – Removal
Special tools

Lifting device T80091497 1
Fuels are combustible.

Risk of fire and explosion!
WARNING • Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.
Heavy object.
Risk of crushing!
Component is hot.
Risk of burning!
Removing high-pressure pump

1. Hook high-pressure pump onto lifting device.
2. Remove securing screws as shown in overview drawing (→ Page 402).
3. Remove high-pressure pump.
TIM ID: 0000028673 – 001
MS25012/00E 08-06 © MTU

4.6.4 High-pressure pump – Disassembly

This assembly is a replacement part (Reman). It is available within the scope of the service-exchange scheme.
TIM ID: 0000003608 – 002
MS25012/00E 08-06 © MTU

4.6.5 High-pressure pump – Check
Spare parts

High-pressure pump
Screw
High-pressure pump – Check
Item Findings Task
Check connection thread on No ease of movement • Recondition

high-pressure pump for damage. • Replace
Check drive gear for damage. Damaged Replace high-pressure pump.
Check wiring for damage. Damaged Replace wiring.
Check sealing faces for damage. Damaged • Recondition

• Replace
TIM ID: 0000003609 – 003
MS25012/00E 08-06 © MTU

4.6.6 HP pump – Installation
Special tools

Material

Engine oil
Suspended load.
Danger to life!

HP pump – Installation
2. Attach lifting device for high-pressure pump.
3. Install HP pump as shown in overview drawing (→ Page 402).
4. Install screws and tighten to specified torque using a torque wrench.
Screw M12 x 50 Tightening torque Engine oil 100 Nm +10 Nm
TIM ID: 0000028674 – 002
MS25012/00E 08-06 © MTU

4.6.7 H.P. fuel pump – Control block replacement
Preconditions
Special tools
Material

Engine oil
Spare parts

Control block
O-ring

• Do not smoke.
Removing control block

1. Remove fuel lines on control block (1). Collect
emerging fuel.
2. Disconnect plug connection magnet to wiring
harness (W3), remove cable clamps and connector
holders.
3. Remove screws (3) and control block (1) from
H.P. pump.
TIM ID: 0000028679 – 001
Installing control block

1. Coat O-ring (2) with engine oil and insert in assigned groove.
2. Screw control block (1) with screws (3) on to H.P. pump and use torque wrench to tighten to specified
tightening torque (→ Page 23) .
3. Install holders for connectors and cables and connect plug connection.
4. Install fuel lines on control block (1).
5. Vent fuel lines.
MS25012/00E 08-06 © MTU

4.6.8 Injector – Overview
50 Injector 100 Hold-down clamp 150 Screw
TIM ID: 0000029343 – 001
MS25012/00E 08-06 © MTU

1 O-ring 2 CE-ring 3 O-ring

TIM ID: 0000029343 – 001
MS25012/00E 08-06 © MTU

4.6.9 Injector – Removal
Preconditions
Special tools

Puller F6784183 1

• Do not smoke.
Injector – Removal
1. Remove cable connectors from injector.
2. Remove screw (2) and remove hold-down

clamp (1).
3. Remove high-pressure line (4).
Note: While the adapter is removed, the injector
is drained.
4. Loosen adapter (3) up to the last one to two

thread turns.
5. Provide an appropriate container and drain the
fuel into it.
6. Remove the adapter (3) entirely.
TIM ID: 0000029010 – 001
MS25012/00E 08-06 © MTU

7. Apply extraction tool and remove injector.
8. Remove sealing ring (1) from injector or use a

self-made wire hook to pull it out of the cylinder
head.
9. Remove O-rings (2) from injector.
10. Cover all connections and bores, or seal with
suitable plugs.
TIM ID: 0000029010 – 001
MS25012/00E 08-06 © MTU

4.6.10 Fuel injector disassembly

This component is an exchange component (Reman) and is available through the usual exchange procedure.
TIM ID: 0000003616 – 001
MS25012/00E 08-06 © MTU

4.6.11 Injector – Cleaning
Material

Compressed air.
Risk of injury!

• Do not smoke.

Injector – Cleaning
TIM ID: 0000004869 – 002
MS25012/00E 08-06 © MTU

4.6.12 Injector – Check
Material

Crack testing oil (NR. 63) 40475 1
Crack testing paste (UV-Apelux Paste 1031) 40483 1
Spare parts

Fuel injector
Hold-down clamp
Screw
Check injector
Inspect fuel injector externally for Damaged Replace

damage.
Check screws and hold-down Indication of cracks Replace

clamp for cracks with magnetic
crack-testing method.
Check contact surfaces of hold-down Damaged • Rework: smooth with oilstone.

clamp. • Replace
Inspect sealing cone of fuel injector Damaged Replace injector.

for damage.
Check cable connections for Damaged Replace wiring harness.

damage.
Check thread on screw and injector Sluggish • Rework

valve for ease of movement. • Replace
TIM ID: 0000003617 – 002
MS25012/00E 08-06 © MTU

4.6.13 Injector – Installation
Special tools

Pressing tool F6784167 1
Combination insertion wrench; 17 mm F30025896 1
Combination insertion wrench, 19 mm F30025897 1
Combination insertion wrench, 27 mm F30029816 1
Material

Assembly paste (Optimoly Paste White T) 40477
Engine oil
Spare parts

O-rings
Sealing ring

• Do not smoke.
Install injector
1. Remove all blanking plugs before installing.
2. Pull new o-rings (delivered with injector) onto the
injector and coat with grease.
3. Fix new sealing ring with assembly paste onto the
injector, thereby observing the installation position
of the sealing ring.
4. Cost nozzle retaining nut (1) with assembly paste.
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5. Clean sealing face on cylinder head.

6. Insert injector into the cylinder head observing the
alignment of the adapter connection.
7. Lock press-in tool between the rocker arms in the
cylinder head openings (arrow).
8. Press injector into the cylinder head using the
press-in tool.
9. Coat screw head mating face and thread with

engine oil.
10. Place on the hold-down clamp (1) in correct
position and tighten screw (2) using torque wrench
to specified pretightening torque (→ Page 23).
11. Coat adapter (3) thread and sealing cone with
engine oil.
12. Install adapter (3) and use torque wrench to tighten
to specified tightening torque (→ Page 23).
13. Install screw (2) and adapter (3) and use torque
wrench to tighten to specified tightening torque
(→ Page 23).
14. Coat thread and sealing cone of HP line with
engine oil.
15. Install HP line (5) and union nuts (4,6) and use
torque wrench to tighten to specified tightening
16. Plug on the cable plug.
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4.6.14 HP fuel line – Overview
Single-walled HP line from fuel HP fuel pump to injector with

externally-mounted components
100 Single-walled fuel HP line 1000 Screw 1520 Grommet

200 Intermediate plate 1100 Grommet 1522 Nut
250 Screw 1150 Grommet 1524 Screw
300 Single-walled fuel distributor 1200 Pipe half-clamp 1526 Washer
400 Pressure relief valve for 16 V/20 V 1250 Pipe half-clamp 1528 Nut
420 Screw 1300 Retainer 1600 Retainer on injection pump
500 Single-walled fuel HP line 1350 Washer 1650 Grommet
600 Single-walled fuel HP line 1400 Screw 1700 Pipe half-clamp
700 Grommet 1450 Washer 1750 Screw
750 Pipe half-clamp 1500 Screw 1900 Washer
800 Grommet 1512 Retainer 2000 Single-walled HP accumulator, left
850 Pipe half-clamp 1514 Washer 2050 Single-walled HP accumulator, right
900 Spacer 1516 Screw 2200 Adapter
950 Washer 1518 Screw 2300 O-ring
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Jacketed HP line from HP fuel pump to injector with externally mounted components
100 Jacketed fuel line 1000 Screw 1522 Pipe half-clamp

200 Intermediate plate 1100 Grommet 1524 Screw
250 Screw 1150 Grommet 1526 Washer
300 Jacketed manifold 1200 Pipe half-clamp 1528 Nut
400 Breather valve for 16 V/20 V 1250 Pipe half-clamp 1600 Retainer on injection pump
420 O-ring 1300 Retainer 1650 Grommet
440 Screw 1350 Washer 1700 Pipe half-clamp
500 Fuel HP line 1400 Screw 1750 Screw
600 Jacketed fuel HP line 1450 Washer 1900 Washer
700 Grommet 1500 Screw 1950 Screw
750 Pipe half-clamp 1512 Retainer 2000 Jacketed HP accumulator, left
800 Grommet 1514 Washer 2050 Jacketed HP accumulator, right
850 Pipe half-clamp 1516 Screw 2150 Fuel HP line to injector
900 Spacer 1518 Nut 2200 Jacketed adapter
950 Washer 1520 Grommet 2300 O-ring
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HP accumulator, left engine side
1 Banjo union 6 Screw 11 Fillister head screw

2 HP accumulator 7 Hold-down clamp 12 Plug-in pipe
3 Ball 8 Plug 13 Flange
4 Union nut 9 Hold-down clamp
5 Screw 10 O-ring
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HP accumulator, right engine side
1 Screw 5 HP accumulator 9 Fillister head screw

2 Union nut 6 Flange 10 Plug-in pipe
3 Ball 7 O-ring 11 Flange
4 Banjo union 8 Hold-down clamp 12 Flange
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4.6.15 High-pressure line – Removal
Preconditions
• Engine is stopped and starting disabled

• Do not smoke.
Removing high-pressure line

1. Before removing the lines, take photos or mark add-on components and lines.
2. Remove lines as shown in overview drawing (→ Page 417).
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4.6.16 High-pressure fuel line – Cleaning
Material

Compressed air.
Risk of injury!


High-pressure fuel line – Cleaning

2. Thoroughly blow all parts clear with compressed air.
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4.6.17 High-pressure fuel line – Check
Material

Spare parts

High-pressure accumulator
High-pressure line
O-ring
High-pressure fuel line – Check
Item Findings Task
Check accumulator with dye Signs of cracks Replace pressure accumulator.

penetrant for cracks.
Check all threads for ease of Sluggish • Corrective work: Recut threads
Check sealing cones for damage. • Damage Replace

• Stress marks
visible
Check high-pressure line and fuel Damaged • Corrective work

return line for damage. • Replace
Check high-pressure line and Contaminated Clean (→ Page 422)

accumulator for contamination.
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4.6.18 HP line – Installation
Preconditions
Special tools

Material

Engine oil

• Do not smoke.
• Do not smoke.

Installing HP line
1. Install HP lines in the following order as per the
overview drawing, photos or attached marks
before removal (→ Page 417).
2. Tightening torques as per tightening specifications
(→ Page 23).
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3. Coat thread and screw heads with oil.

4. Install rails (2) on crankcase and use torque
wrench to tighten screws to specified tightening
5. Coat HP lines (1) on thread, sealing cone and
thrust ring with engine oil and install between rail
and adapter.
5.1. Tighten union nut of high-pressure line (1)
on rail to specified tightening torque using
torque wrench (→ Page 23).
5.2. Tighten union nut of high-pressure line (1) on
adapter to specified tightening torque using
6. In case of jacketed HP lines, rough-cut the thread
sealings on the fuel distributor.
6.1. Tighten union nuts of all 3 HP lines.
6.2. Once again release the union nuts.
6.3. Remove residual material.
7. Install distributor (7) on mount but do not tighten
screws.
8. Coat HP line (3) on thread, sealing cone and
thrust ring with engine oil and install between
distributor (7) and rail A-side, but do not tighten
union nut.
9. Coat HP line (6) on thread, sealing cone and
thrust ring with engine oil and install between
distributor (7) and rail B-side, but do not tighten
union nut.
10. Coat HP line (5) on thread, sealing cone and thrust
ring with engine oil and install between HP pump
and distributor (7), but do not tighten union nut.
11. Install retainer (4) for HP line but do not tighten
screw.
12. Tighten HP line union nuts alternately in stages
to pretightening torque (→ Page 23) in the
following order:
1. A (HP pump)
2. B (A-side of distributor)
3. C (B-side of distributor)
4. D (HP pump distributor)
5. E (rail, A-side)
6. F (rail, B-side)
13. Tighten screws, distributor (7) on mount.
14. Tighten union nuts on HP lines in the same
order as that used when pretightening (step →
12. ) using torque wrench to specified final
15. Align retainer (4) on HP lines and tighten screw.
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16. Screw in HP sensor (2) and temperature sensor

(1) and use torque wrench to tighten to specified
tightening torque (→ Page 23).
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4.6.19 Pressure relief valve on fuel distributor – Removal
Preconditions

• Do not smoke.
Removing high-pressure line

1. Remove pressure relief valve as shown in overview drawing (→ Page 417).
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4.6.20 Pressure relief valve on fuel distributor – Installation

• Do not smoke.

Installing pressure relief valve on fuel distributor

1. Install pressure relief valve on fuel distributor as per overview drawing (→ Page 417).
2. Tighten screws with torque wrench alternately in steps to specified pretightening torque (→ Page 23).
3. Tighten screws with torque wrench alternately in this order to the specified final tightening torque (→ Page 23).
TIM ID: 0000029385 – 001
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4.7 Low-Pressure Fuel System
4.7.1 Low-pressure fuel system – Overview
Fuel delivery pump
3 Fuel delivery pump 8 Washer 12 Screw

5 Coupling 10 Retainer
6 O-ring 11 Washer
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Fuel pipework between fuel delivery pump and fuel filter
1 Plug-in pipe 6 O-ring 11 Flange

2 O-ring 7 Hex bolt 12 Flange
3 Flange 8 Washer 13 O-ring
4 Non-return valve 9 Plug-in pipe 14 Hex bolt
5 O-ring 10 O-ring 15 Washer
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Fuel duplex filter
1 Valve (0.5 bar) 11 Fuel priming pump 21 Threaded nipple

2 Plug screw 12 Plug screw 22 Plug screw
3 Plug screw 13 Threaded union 23 Plug screw
4 Valve (2 bar) 14 Blanking cone 24 Filter head
5 Plug screw 15 Nut 25 Threaded union
6 Threaded union 16 O-ring 26 Blanking cone
7 Fuel line 17 Elbow 27 Nut
8 Plug screw 18 Screw 28 Threaded union
9 Screw 19 Threaded nipple 29 Threaded union
10 O-ring 20 Easy-change fuel filter 30 O-ring
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4.7.2 Fuel delivery pump – Overview
3 Fuel delivery pump 8 Washer 12 Screw

5 Coupling 10 Retainer
6 O-ring 11 Washer
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4.7.3 Fuel delivery pump – Removal
Preconditions

• Do not smoke.
Removing fuel delivery pump

1. Remove fuel delivery pump as per overview drawing (→ Page 432).
2. Remove coupling element from the drive shaft of the fuel delivery pump.
3. Remove O-ring.
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4.7.4 Fuel delivery pump – Disassembly

Remove fuel delivery pump (→ Page 433).
Disassembling fuel delivery pump

In the event of wear or a complaint, the fuel delivery pump must be replaced.
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4.7.5 Fuel delivery pump – Cleaning
Material

Compressed air.
Risk of injury!


Fuel delivery pump – Cleaning

2. Blow all parts clean thoroughly with compressed air.
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4.7.6 Fuel delivery pump – Check
Spare parts

Fuel delivery pump
Screw
Coupling

• Do not smoke.
Fuel delivery pump – Check
Item Findings Task
Perform external check of fuel Damaged Replace fuel delivery pump

delivery pump for perfect condition.
Check coupling for stress marks and Damaged Replace coupling

damage.
Check driver of pump shaft for wear. Damaged • Recondition: Smooth with
• Refer to manufacturer’s
documentation when replacing
the driver.
Check threads of securing screws. Damaged Replace
TIM ID: 0000003631 – 003
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4.7.7 Fuel delivery pump – Installation
Material

Grease (Kluthe Hakuform 30–10/Emulgier) X00029933 1
Engine oil
Spare parts

O-ring

• Do not smoke.
Fuel delivery pump – Installation

1. Coat O-ring (1) with grease and insert in groove.
2. Mount coupling element (2) on driver.
3. Align fuel delivery pump driver to coupling element.
4. Carefully insert fuel delivery pump in bore
and install as shown in overview drawing
(→ Page 432).
5. If the pump cannot be inserted up to the stop,
remove the pump again and check the position of
the driver to the coupling element.
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4.7.8 Fuel pipework from fuel delivery pump to fuel filter – Overview
1 Plug-in pipe 6 O-ring 11 Flange

2 O-ring 7 Screw 12 Flange
3 Flange 8 Washer 13 O-ring
4 Non-return valve 9 Plug-in pipe 14 Screw
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4.7.9 Fuel lines from fuel delivery pump to fuel filter – Removal
Preconditions

• Do not smoke.
Removing fuel lines from fuel delivery pump to fuel filter

1. Prior to removal of the lines take photos or mark add-on components and lines.
2. Disconnect fuel line and collect escaping fuel.
3. Remove fuel lines from fuel delivery pump to fuel filter as shown in overview drawing (→ Page 438).
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4.7.10 Fuel lines from fuel delivery pump to fuel filter – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning fuel lines

2. Thoroughly blow out plug-in pipes, flanges and non-return valve with compressed air.
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4.7.11 Fuel lines from fuel delivery pump to fuel filter – Check
Spare parts

Non-return valve
Flange
Plug-in pipe

Risk of injury!
Fuel lines from fuel delivery pump to fuel filter – Check
Item Findings Task
Visually check plug-in pipes, flanges and Damaged Replace

non-return valve for damage and wear.
Check plug-in pipes for leaks with air Leaking Replace

in water bath as necessary. A water
temperature of min = 30 °C or max = 40 °C
and a test pressure of 0.5 bar must be
maintained.
Check non-return valve for leaks and • Leaking Replace

check opening pressure. • Opening pressure
incorrect.
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4.7.12 Fuel lines from fuel delivery pump to fuel filter – Installation
Material

Spare parts

O-ring

• Do not smoke.
Fuel lines from fuel delivery pump to fuel filter – Installation

2. Install O-rings on plug-in pipes and coat with grease.
3. Install fuel lines as per overview drawing (→ Page 438).
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4.7.13 Fuel duplex filter – Overview
1 Valve (0.5 bar) 11 Fuel hand pump 21 Threaded nipple

2 Plug screw 12 Plug screw 22 Plug screw
3 Plug screw 13 Threaded union 23 Plug screw
4 Valve (1 bar) 14 Blanking cone 24 Filter head
5 Plug screw 15 Nut 25 Threaded union
6 Threaded union 16 O-ring 26 Blanking cone
7 Fuel line 17 Elbow 27 Nut
8 Plug screw 18 Screw 28 Threaded union
9 Screw 19 Threaded nipple 29 Threaded union
10 O-ring 20 Easy-change fuel filter 30 O-ring
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4.7.14 Fuel duplex filter – Removal
Preconditions
Special tools

Filter wrench F30379104 1

• Do not smoke.
Fuel duplex filter – Removal

1. Remove filter elements using filter wrench (1).
2. Collect emerging fuel.
3. Remove filter head as shown in overview drawing
(→ Page 443).
TIM ID: 0000003636 – 006
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4.7.15 Fuel duplex filter – Disassembly

• Do not smoke.
Fuel duplex filter – Disassembly

1. Remove and disassemble hand pump as shown in overview drawing (→ Page 443).
2. Disassemble filter head as shown in overview drawing.
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4.7.16 Fuel filter – Cleaning
Material

Compressed air.
Risk of injury!


Fuel filter – Cleaning

3. Thoroughly blow out all parts using compressed air.
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4.7.17 Fuel filter – Check

Risk of injury!
Checking fuel filter
Visually inspect filter head and hand Damaged Replace

pump for damage and condition
Check sealing and bolt-on faces for Damaged • Smooth with oilstone
damage • Replace
Check all threads and threaded Damaged • Rework: recut thread.

holes. • Replace
Leak-test filter head using air and Leaking • Replace plugs and sealing
water bath. Install filter elements rings
before carrying out leak test. Test • Replace filter head
temperature: min. 30 °C, max.
40 °C, if oil filter housing has to be
held in hands. Test pressure: 0.5
bar.
TIM ID: 0000003541 – 003
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4.7.18 Fuel duplex filter – Assembly
Material

Engine oil
Spare parts

Plug screw
O-ring

• Do not smoke.
Fuel duplex filter – Assembly

Note: Coat O-rings with grease.
1. Assemble filter head as shown in overview drawing (→ Page 443).

2. Assemble hand pump as shown in overview drawing and install on filter head (→ Page 443).
TIM ID: 0000003638 – 003
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4.7.19 Fuel duplex filter – Installation
Material


• Do not smoke.
Installing fuel duplex filter

1. Remove all plugs.
3. Install fuel duplex filter as shown in overview drawing (→ Page 443).
Installing easy-change fuel filter

1. Coat sealing rings (arrow) of filters with fuel.
2. Install filter and tighten by hand.
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4.7.20 Fuel pipework from fuel filter to HP pump – Overview
100 Fuel supply line 800 Nut 1250 Screw

300 Pipe half-clamp 1000 Fuel supply line 1300 Washer
350 Grommet 1020 Union 1450 Connecting piece
400 Screw 1030 Sealing ring 1500 O-ring
450 Washer 1060 Retainer 1550 Screw
500 Nut 1100 Pipe half-clamp 1600 Union
600 Screw 1110 Pipe half-clamp 1650 Sealing ring
650 O-ring 1150 Grommet
750 Sealing cone 1200 Screw
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4.7.21 Fuel pipework from fuel filter to HP pump – Removal
Preconditions

• Do not smoke.
Removing fuel pipework from fuel filter to HP pump

1. Release threaded union on fuel line and catch fuel as it escapes.
2. Remove fuel line with securing hardware as shown in overview drawing (→ Page 450).
3. After removal of the fuel lines, seal all connections with suitable plugs.
TIM ID: 0000003639 – 004
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4.7.22 Fuel pipework from fuel filter to high-pressure pump – Cleaning
Material

Compressed air.
Risk of injury!


Fuel pipework from fuel filter to high-pressure pump – Cleaning

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4.7.23 Fuel pipework from fuel filter to high-pressure pump – Check
Spare parts

Fuel line
Retainer

Risk of injury!
Fuel pipework from fuel filter to high-pressure pump – Check
Item Findings Task
Visually inspect fuel lines for Damaged • Corrective work

damage. • Replace
Pressure-test fuel line with air Leaking Replace

in water bath for leaks. A water
temperature of min. = 30 °C or
max. = 40 °C and a test pressure of
0.5 bar must be maintained.
damage. oilstone.
• Replace
Check threads of union nuts Sluggish • Corrective work: Recut threads

and threaded unions for ease of • Replace
movement.
Check securing elements on fuel Damaged Replace

lines for damage.
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4.7.24 Fuel pipework from fuel filter to HP pump – Installation
Material

Engine oil
Spare parts

Grommet

• Do not smoke.

Installing fuel pipework from fuel filter to HP pump

2. Install fuel pipework from fuel filter to HP pump as per overview drawing (→ Page 450).
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4.7.25 Leak off fuel pipework – Overview
100 Union 980 T piece 1400 Leak off fuel pipework

150 Sealing ring 1010 Spacer tube 1500 Union
400 Leak off fuel pipework 1020 Retainer 1550 Sealing ring
500 Leak off fuel pipework, right 1030 Pipe half-clamp 1700 Pipe half-clamp
600 Retainer 1040 Grommet 1750 Grommet
650 Screw 1050 Screw 1800 Pipe half-clamp
700 Pipe half-clamp 1060 Nut 1810 Pipe half-clamp
750 Grommet 1070 Screw 1850 Grommet
800 Screw 1110 Strap 1900 Screw
900 Leak off fuel pipework, left 1115 Screw 2000 Adapter
910 Spacer sleeve 1120 Screw 2050 Sealing ring
915 Retainer 1121 Washer 2100 Leak off fuel pipework
920 Screw 1125 Pipe half-clamp 2200 Pipe half-clamp
925 Pipe half-clamp 1130 Pipe half-clamp 2250 Grommet
930 Grommet 1135 Grommet 2300 Screw
935 Screw 1200 Leak off fuel pipework 2350 Nut
960 Leak off fuel pipework 1300 Leak off fuel pipework 2400 Washer
970 Leak off fuel pipework 1350 Check valve
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4.7.26 Leak-off fuel line – Removal
Preconditions

• Do not smoke.
Removing leak-off fuel line

1. Prior to removal of the lines take photos or mark add-on components and lines.
2. Release threaded union on fuel line and catch fuel as it escapes.
3. Remove fuel lines with securing hardware as per overview drawing (→ Page 455).
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4.7.27 Leak-off fuel pipework – Cleaning
Material

Compressed air.
Risk of injury!


Leak-off fuel pipework – Cleaning

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4.7.28 Leak-off fuel pipework – Check
Spare parts

Sealing rings

Risk of injury!
Leak-off fuel pipework – Check
Item Findings Task
Visually inspect all leak-off fuel lines Damaged • Corrective work

for damage. • Replace
Pressure-test leak-off fuel lines with Leaking Replace

air in water bath for leaks. A water
temperature of min = 30°C and
max = 40°C and a test pressure of
0.5 bar must be maintained.
Check banjo screws for damage and • Damaged • Corrective work: Recut threads
threads for ease of movement. • Threads sluggish. • Replace
damage oilstone.
• Replace
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4.7.29 Leak-off fuel line – Installation
Spare parts

Sealing ring
Grommet

• Do not smoke.

Installing leak-off fuel line

2. Install leak-off fuel line according to overview drawing (→ Page 455) or according to photos/markings.
TIM ID: 0000003647 – 007
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4.8 Exhaust Turbocharger
4.8.1 Exhaust turbocharger – Overview
100 Exhaust turbocharger 250 Screw

200 Screw 300 Gasket
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200 Y-pipe 500 Spacer sleeve 850 Screw

250 Sealing ring 550 Nut 900 Screw
350 Retainer 650 Sealing ring 950 Spacer bushing
400 Screw 700 Y-pipe 1000 Nut
450 Screw 800 Retainer
TIM ID: 0000020731 – 002
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4.8.2 Exhaust turbocharger – Removal
Preconditions
Exhaust turbocharger – Removal
1. Loosen nut (1) on threaded Y-pipe/flange
connection.
3. Remove exhaust turbocharger from Y-pipe in the
direction of the arrow.
4. Take off gasket.
5. Loosen nut (3) of the threaded Y-pipe/flange

connection and remove together with spacer
bushing.
6. Remove Y-pipe (2).
7. Remove screws (4) and exhaust turbocharger (1).
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4.8.3 Exhaust turbochargers – Clean
Material

Compressed air.
Risk of injury!


Clean exhaust turbochargers

1. Remove all deposits on functional areas and sealing faces.
2. Clean all functional areas and sealing faces with cleaner.
3. Rub all functional areas and sealing faces dry using a clean, lint-free rag.
4. Remove corrosion protector on new component with cleaner.
TIM ID: 0000029558 – 001
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4.8.4 Exhaust turbocharger – Check
Spare parts

Exhaust turbocharger
Retainer
Y-pipe
Exhaust turbocharger – Check
Item Findings Task
Check exhaust turbocharger Damaged Replace

externally for damage.
Check retainer externally for Damaged Replace

damage.
Check Y-pipe externally for damage. Damaged Replace
TIM ID: 0000029559 – 001
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4.8.5 Exhaust turbocharger – Installation
Special tools

Material

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

Gasket
Piston ring
Exhaust turbocharger – Installation

1. Coat thread and screw-head mating face of
screws (2) with assembly paste.
2. Position beaded gasket (3) on exhaust manifold.
3. Position exhaust turbocharger (1), arrange
retainer (4) and screw in screws (2) but do not
yet tighten.
4. Insert Y-pipe (5) in turbine outlet and install
retainer (4) as per overview drawing (→ Page 460).
5. Use torque wrench to tighten screws (2) crosswise
to the specified tightening torque (→ Page 23).
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6. Coat thread and screw-head mating face of

screws (5) with assembly paste.
7. Position beaded gasket (4) on exhaust manifold.
8. Position second turbocharger (1), inserting
Y-pipe (2) in turbine outlet at the same time.
9. Install screws (5) but do not yet tighten.
10. Install retainer (3) as per overview drawing
(→ Page 460).
11. Use torque wrench to tighten screws (5) crosswise
to the specified tightening torque (→ Page 23).
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4.9 Intercooler
4.9.1 Intercooler – Overview
50 Intercooler 350 Washer 700 Screw

150 Mounting bracket 450 Screw 800 Stud
200 Mounting bracket 500 Screw 850 Nut
300 Screw 600 Carrier
TIM ID: 0000020523 – 003
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Charge-air cooling
950 Elbow 1150 Plug screw 1350 Screw

1000 Plug screw 1200 Plug screw 1400 Washer
1100 Elbow 1300 O-ring
TIM ID: 0000020523 – 003
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4.9.2 Intercooler – Removal
Preconditions
Heavy object.
Risk of crushing!
Intercooler – Removal
1. Remove intercooler and elbow as per overview drawing (→ Page 467).
2. Attach intercooler to crane with rope and carefully raise from engine.
3. After removing the intercooler, seal all openings with suitable covers.
4. Protect intercooler from damage.
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4.9.3 Intercooler – Disassembly

Remove intercooler (→ Page 469).
Intercooler – Disassembly
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4.9.4 Intercooler – Cleaning

Work on the intercooler must always be carried out by qualified personnel.
The following contains instructions for the cleaning company.
Air-side cleaning
Grease and oil contamination of the intercooler’s air-side is to be removed in a closed cleaning unit.
The cleaning agent must circulate opposite to the cooling-air direction.
It is imperative to avoid damaging the cooler, especially the cooling fins.
To remove deposits, only use cleaning agents that do not attack metal surfaces (→Operating Instructions).
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits.
Water-side cleaning
It is recommended that the water-side be cleaned in a closed cleaning unit with forced flushing and filter.
The water-side can also be cleaned in an immersion- or ultrasonic bath.
To remove deposits, only use cleaning agents that do not attack metal surfaces (→Operating Instructions).
Dwell time depends on the condition and temperature of the solution and the nature and stubbornness of the deposits.
Intercooler flushing
After cleaning, flush the intercooler with water until pH values of clean water and rinsing water are
approximately the same (permissible difference pH value: 1 pH).
Intercooler drying and preservation
If the cooler is not to be put into operation immediately after cleaning, the cooler must be dried in
a drying oven for approx. 3 hours at a temperature of 110 to 120 °C.
After drying, the cooler must be preserved with a preservation agent.
TIM ID: 0000005011 – 002
MS25012/00E 08-06 © MTU

4.9.5 Intercooler – Check
Material

Emery cloth
Spare parts

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

Hot testing liquid.
Intercooler – Check
Item Findings Task
Visually inspect all components for Damaged • Recondition

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

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

1. Seal coolant chamber connections on intercooler with suitable sleeves and covers with gaskets and clamps.
TIM ID: 0000005013 – 002
2. Connect compressed air line at plug.

3. Preheat test bath to 80 °C.
4. Immerse intercooler in test bath.
5. Open compressed air supply and set pressure reducer to 0.5 bar.
6. Pressure-test intercoolers with air in water bath for leaks. Verify that no bubbles rise to the surface.
MS25012/00E 08-06 © MTU

7. Replace intercooler if leaks are found.

8. After checking, blow through cooling air ducts with compressed air in vertical direction.
TIM ID: 0000005013 – 002
MS25012/00E 08-06 © MTU

4.9.6 Intercooler – Installation
Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!
Installing intercooler
2. Use crane to place intercooler on engine.
3. Coat O-ring with grease.
4. Assemble in reverse order to disassembly (→ Page 469).
TIM ID: 0000028269 – 001
MS25012/00E 08-06 © MTU

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

2 Air supply from exhaust 4 Air supply to right-hand side
turbocharger to intercooler cylinders
TIM ID: 0000020377 – 002
MS25012/00E 08-06 © MTU

4.10.2 Air filter with retainers – Overview
05 Clamp 10 Air filter
TIM ID: 0000020382 – 001
MS25012/00E 08-06 © MTU

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

250 Rubber sleeve 550 Screw 800 Sealing ring
300 Clamp 600 Screw 900 Retainer
400 Retainer, right-hand side 650 Washer
450 Retainer 660 Washer
TIM ID: 0000020382 – 001
MS25012/00E 08-06 © MTU

4.10.3 Air filter with bracket – Removal
Preconditions
Air filter with bracket – Removal
1. Remove air filter and bracket as shown in overview drawing (→ Page 476).
TIM ID: 0000020387 – 002
MS25012/00E 08-06 © MTU

4.10.4 Air filters and retainers – Clean
Material


Compressed air.
Risk of injury!

Retainer parts
2. Thoroughly blow all parts clean with compressed air.
TIM ID: 0000028270 – 001
MS25012/00E 08-06 © MTU

4.10.5 Air filters and retainers – Check
Spare parts

Air filter
Elbow
Rubber sleeve
Clamp
Retainer
Check air filters and retainers
Air filter • Contaminated • Replace
Check elbow, holder and rubber • Traces of wear • Rework

sleeve for wear, cracks and damage. • Cracks • Replace
• Damage
Visible
Check clamps for ease of movement. • Sluggish • Rework

• Replace
TIM ID: 0000028271 – 001
MS25012/00E 08-06 © MTU

4.10.6 Air filter with retainers – Installation

Air filter with retainers – Installation
2. Install air filter and retainers as per overview drawing (→ Page 476).
TIM ID: 0000020392 – 001
MS25012/00E 08-06 © MTU

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

2 Charge air manifold 6 Washer
3 O-ring 7 Plug
4 Gasket 8 Sealing ring
TIM ID: 0000004255 – 001
MS25012/00E 08-06 © MTU

4.10.8 Air supply to cylinders, LHS – Removal
Preconditions
Removing the charge-air manifold
1. Remove charge-air manifold as per overview drawing starting from the free end (→ Page 482).
2. Remove gaskets and O-rings.
3. After removal, seal all openings with suitable plugs or covers.
TIM ID: 0000004256 – 004
MS25012/00E 08-06 © MTU

4.10.9 Air supply system to cylinders, left – Cleaning
Material

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


Cleaning charge-air manifold

1. Clean left charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow out charge-air manifold with compressed air.
TIM ID: 0000004257 – 002
MS25012/00E 08-06 © MTU

4.10.10 Air supply to cylinders, left side – Check
Material

Spare parts

Charge air manifold
Sealing ring
Screws
Plug screw
Compressed air.
Risk of injury!
Checking air supply to cylinders, LHS
Item Findings Task
Check charge air manifold for cracks Cracks visible Replace

with red dye penetrant.
Perform leak test on charge air Leaks • Replace blanking plug.

manifold with air in water bath at a • at blanking plugs • Replace charge air manifold.
maximum air pressure of 0.5 bar. • at charge air manifold
Check sealing and mating faces for • Uneven • Recondition: smooth with
evenness and damage. • Damaged oilstone.
• Replace
Check threads for ease of Sluggish • Recut threads.

movement. • Replace thread inserts.
Check screws and plugs for damage. Damaged Replace

TIM ID: 0000004258 – 003
MS25012/00E 08-06 © MTU

4.10.11 Air pipework to cylinders, left side – Installation
Material

Engine oil
Spare parts

O-ring
Gasket

Air pipework to cylinders, left side – Installation

2. Coat O-ring with grease and fit on charge air
manifold union (2).
3. Coat gaskets with grease and place on sealing
faces (arrows).
4. Install charge-air manifold (1) as shown in overview
drawing, (→ Page 482) beginning with driving end.
5. Insert screws with washer and retainer in charge
air manifold (1) and tighten.
TIM ID: 0000004259 – 004
MS25012/00E 08-06 © MTU

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

2 Charge air manifold 6 Washer 10 Sealing ring
3 O-ring 7 Plug 11 Plug
4 Gasket 8 Sealing ring 12 Sealing ring
TIM ID: 0000004260 – 001
MS25012/00E 08-06 © MTU

4.10.13 Air supply to cylinders, RHS – Removal
Preconditions
Removing the charge-air manifold
1. Remove charge-air manifold as per overview drawing starting from the free end (→ Page 487).
2. Remove gaskets and O-rings.
3. After removal, seal all openings with suitable plugs or covers.
TIM ID: 0000004261 – 004
MS25012/00E 08-06 © MTU

4.10.14 Air supply system to cylinders, right – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning the charge-air manifold

1. Clean right charge-air manifold with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow out charge-air manifold with compressed air.
TIM ID: 0000004262 – 002
MS25012/00E 08-06 © MTU

4.10.15 Air supply to cylinders, RHS – Check
Material

Spare parts

Charge air manifold
Sealing ring
Screws
Plug screw
Compressed air.
Risk of injury!
Checking air supply to cylinders, RHS
Item Findings Task
Check charge air manifold for cracks Cracks visible Replace

with red dye penetrant.
Perform leak test on charge air Leaks • Replace blanking plug.

manifold with air in water bath at a • at blanking plugs • Replace charge air manifold.
maximum air pressure of 0.5 bar. • at charge air manifold
Check sealing and mating faces for • Uneven • Recondition: smooth with
• Replace
Check threads for ease of Sluggish • Recut threads.

Check screws and plugs for damage. Damaged Replace

TIM ID: 0000004263 – 003
MS25012/00E 08-06 © MTU

4.10.16 Air pipework to cylinders, right side – Installation
Material

Engine oil
Spare parts

O-ring
Gasket

Charge air manifold – Installation

2. Coat O-ring with grease and fit on charge air
manifold union (2).
3. Coat gaskets with grease and place on sealing
faces (arrows).
4. Install charge-air manifolds (1) as shown in
overview drawing, (→ Page 487) beginning
with driving end.
5. Insert screws with washer and retainer in charge
air manifold (1) and tighten.
TIM ID: 0000004264 – 005
MS25012/00E 08-06 © MTU

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

350 O-ring 850 O-ring
400 Screw 900 Screw
450 Spacer tube 950 Spacer tube
600 Charge-air pipe, left-hand side 1100 Charge-air pipe, right hand side
650 Hoseline 1150 Hoseline
700 Clamp 1200 Clamp
TIM ID: 0000028272 – 001
MS25012/00E 08-06 © MTU

4.10.18 Air supply from turbocharger to intercooler – Removal
Preconditions
Air supply from turbocharger to intercooler – Removal
1. Before removing the air pipework, take photos or mark pipework accordingly.
2. Remove air supply pipework as per overview drawing (→ Page 492).
TIM ID: 0000028273 – 001
MS25012/00E 08-06 © MTU

4.10.19 Air supply from turbocharger to intercooler – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning air pipework

TIM ID: 0000020588 – 001
MS25012/00E 08-06 © MTU

4.10.20 Air supply from turbocharger to intercooler – Check
Material

Spare parts

Elbow
Charge-air manifold
Checking air supply from turbocharger to intercooler
Check elbow and charge-air manifold Sign of cracks Replace

with dye penetrant for cracks.
Check elbow and charge-air manifold Leaking: • Replace blanking plug.

with air in water bath and a maximum • at blanking plugs • Replace elbow.
air pressure of 0.5 bar for leaks. • at elbow
Check sealing and bolt-on faces for • Uneven • Rework: smooth with
• Replace
Check all threads for ease of Sluggish • recut thread.

TIM ID: 0000028280 – 001
MS25012/00E 08-06 © MTU

4.10.21 Air supply from turbocharger to intercooler – Installation
Material

Spare parts

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

3. Install air supply pipework as per overview drawing (→ Page 492) according to the photos taken or markings
made prior to removal.
TIM ID: 0000028281 – 001
MS25012/00E 08-06 © MTU

4.11 Exhaust Pipework
4.11.1 Exhaust pipework after cylinder head – Overview
200 Exhaust pipe 550 Screw 900 Lamellar ring

250 Exhaust pipe 600 Spacer sleeve 1000 Sealing ring
300 Exhaust pipe 700 Exhaust pipe 1050 Screw
400 Lamellar ring 750 Exhaust pipe 1100 Spacer sleeve
500 Gasket 800 Exhaust pipe
TIM ID: 0000020704 – 001
MS25012/00E 08-06 © MTU

4.11.2 Exhaust pipework after cylinder head – Removal
Preconditions

Risk of injury!
Exhaust pipework – Removal

1. Remove screws (2) with spacers (3).
2. Take off exhaust pipes (1) from cylinder heads.
3. Pull and twist exhaust pipes (1) to separate
them from one another.
4. Remove gaskets from the cylinder head exhaust
outlets.
TIM ID: 0000028282 – 001
MS25012/00E 08-06 © MTU

4.11.3 Exhaust pipework after cylinder head – Clean
Material

Compressed air.
Risk of injury!
Compressed air.
Risk of injury!


Cleaning exhaust pipework after exhaust turbocharger

1. Clean all parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Place components with deposits in a container with decarbonizer. Time for cleaning depends on the layer
thickness of the deposits.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
4. If deposits are stubborn, use synthetic shot-blasting pellets (nominal size 16 to 20) to help cleaning.
5. Remove cleaner.
TIM ID: 0000029406 – 001
MS25012/00E 08-06 © MTU

4.11.4 Exhaust pipework after cylinder head – Check
Material

Spare parts

Exhaust pipe
Screw
Checking exhaust pipework after cylinder head
Check exhaust pipe for Sign of cracks Replace

cracks with red penetrant
dye.
Check parts for stress marks, • Traces of wear Replace

wear and distortion. • Wear
• Deformation
Visible
Check sealing and contact • Uneven • Rework: smooth with oilstone

surfaces for evenness and • Damaged • Replace
damage.
TIM ID: 0000029123 – 001
MS25012/00E 08-06 © MTU

4.11.5 Exhaust pipework after cylinder head – Installation
Special tools

Material

Spare parts

Gasket
Lamellar ring

Risk of injury!
Installing exhaust pipework

2. Degrease and dry clean screw mating faces on
exhaust pipes and cylinder heads.
3. Coat lamellar rings (arrow) with assembly paste.
4. Insert screws (1) and spacers (2) into exhaust
pipe flanges.
5. Place gaskets (3) on the mating faces of the
exhaust inlet.
TIM ID: 0000028283 – 001
MS25012/00E 08-06 © MTU

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

overview drawing (→ Page 497).
7. Install screws (2) with spacers (3) and use torque
wrench to tighten diagonally to the specified
TIM ID: 0000028283 – 001
MS25012/00E 08-06 © MTU

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

20 Gasket 50 Screw
25 Screw 55 Washer
30 Washer 60 Nut
35 Nut 65 Washer
TIM ID: 0000020830 – 001
MS25012/00E 08-06 © MTU

50 Flange 200 Washer

150 Screw 250 Nut
TIM ID: 0000020830 – 001
MS25012/00E 08-06 © MTU

4.11.7 Exhaust pipe bellows after engine – Removal
Preconditions
Exhaust pipe bellows after engine – Removal
1. Remove exhaust pipe bellows as per overview drawing (→ Page 503).
TIM ID: 0000020827 – 001
MS25012/00E 08-06 © MTU

4.11.8 Exhaust pipe bellows after engine – Cleaning
Material

Compressed air.
Risk of injury!


Exhaust pipe bellows after engine – Cleaning

2. If deposits are stubborn, use synthetic shot-blasting pellets (nominal size 16 to 20) to facilitate cleaning.
3. Blow all parts dry with compressed air.
TIM ID: 0000028285 – 001
MS25012/00E 08-06 © MTU

4.11.9 Exhaust pipe bellows after engine – Check
Spare parts

Exhaust pipe bellows
Checking exhaust pipe bellows after engine
Check screws and nuts for damage. Damaged Replace
Check exhaust pipe bellows for • Traces of wear Replace

wear, damage and deformation. • Wear
• Deformation
Visible
Check sealing and contact surfaces • Uneven • Rework: smooth with oilstone
for evenness and damage. • Damaged • Replace
TIM ID: 0000028286 – 001
MS25012/00E 08-06 © MTU

4.11.10 Exhaust pipe bellows after engine – Installation
Material

Exhaust pipe bellows after engine – Installation

1. Before installation, remove all covers.
2. Coat screw threads with Ultra-Therm.
3. Install exhaust pipe bellows as per overview drawing (→ Page 503).
TIM ID: 0000020829 – 001
MS25012/00E 08-06 © MTU

4.12 Starting Equipment
4.12.1 Starter – Overview
Electric starter
50 Starter, right 150 Screw

TIM ID: 0000020779 – 001
MS25012/00E 08-06 © MTU

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

1. Mark all cables using suitable adhesive tape prior to removal.
2. Disconnect all cables from starter.
3. Protect all cables from damage.
4. Remove starter screws as per overview drawing (→ Page 509).
5. Remove starter.
6. Protect starter from damage.
TIM ID: 0000020784 – 001
MS25012/00E 08-06 © MTU

4.12.3 Starter – Disassembly
Starter – Disassembly
Entrust starter overhaul to an authorized and specialized company only.
TIM ID: 0000004236 – 002
MS25012/00E 08-06 © MTU

4.12.4 Starter – Cleaning

Compressed air.
Risk of injury!
Starter – Cleaning
1. Clean starter with compressed air; do not wet-clean.
2. Protect starter against humidity.
TIM ID: 0000004234 – 002
MS25012/00E 08-06 © MTU

4.12.5 Starter – Check
Spare parts

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

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

and check threads for ease of
movement.
Check mating face on end housing Wear traces are found. Recondition: smooth with oilstone
for wear. or emery cloth.
TIM ID: 0000004235 – 002
MS25012/00E 08-06 © MTU

4.12.6 Starter – Installation
Special tools

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

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

1. Coat starter pinion with Longtherm 2 Plus grease.
2. Install starter as per overview drawing (→ Page 509).
Connecting starter cables

1. Connect cables in accordance with the marking.
2. Install nuts and tighten with torque wrench to the specified tightening torques (→ Page 23).
3. Check starter operation.
TIM ID: 0000020780 – 001
MS25012/00E 08-06 © MTU

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

35 Screw 50 Adapter
TIM ID: 0000020744 – 001
MS25012/00E 08-06 © MTU

2 Screw 20 O-ring 38 Key disk

3 Washer 21 Screw 39 Grooved ball bearing
4 Rotor stage 2 22 Flange 40 Spring washer
5 Key disk 23 O-ring 41 Spacer
6 Sealing spacer 24 Adjusting screw 42 Plate
7 Sealing strip 25 Turbine housing 43 Lockwasher
8 Grooved ball bearing 26 Screw 44 Slotted nut
9 O-ring 27 Plug 45 Inertia-drive starter (pinion)
10 Spring washer 28 Ring gear 46 Gearcase
11 Nozzle ring 29 Spacer 48 Washer
12 O-ring 30 Washer 49 Nut
13 Rotor stage 1 31 Turbine shaft 50 Cover
14 Key disk 32 Clamp ring 51 Screw
15 Sealing strip 33 Planetary gear 52 Housing
16 Screw 34 Washer 53 Compression spring
17 Nozzle 35 Planet pinion 54 Screw
18 Nozzle 36 Needle bearing 55 Drive housing
19 Plug 37 Pin 57 Needle bearing
TIM ID: 0000020744 – 001
MS25012/00E 08-06 © MTU

4.12.8 Starter – Removal
Preconditions
Heavy object.
Risk of crushing!
Starter – Removal
1. Remove pressure hose.
2. Remove starter as per overview drawing (→ Page 515).
3. Protect starter from damage.
TIM ID: 0000005423 – 006
MS25012/00E 08-06 © MTU

4.12.9 Starter – Disassembly
Special tools

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


Risk of injury!
Disassembling the starter

1. Mark relative positions of nozzle ring (1), turbine
housing (2), gearcase (3) and drive housing (5).
2. Unscrew nuts (4) and remove screws.
3. Pull drive housing (5) off gearcase (3).
4. Check needle bearing (→ Page 523).
• If needle bearing is damaged: Force needle
bearing out with a hydraulic press.
TIM ID: 0000020762 – 001
MS25012/00E 08-06 © MTU

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

snap ring pliers.
6. Remove grub screw (1).
7. Pull inertia-drive starter (4) off shaft (5).
8. Remove compression spring (3).
9. Remove screws fastening gearcase to turbine
housing as per overview drawing (→ Page 515).
10. Remove gearcase.
11. Remove O-ring.
12. Place gearcase (2) on holding jig (3).

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

17. Press out shaft (8) with hydraulic press (1).
18. Press out shaft (8) with grooved ball bearing (5).
19. If grooved ball bearing (5) remains in gearcase (3),
press grooved ball bearing (5) out of gearcase (3).
20. Undo screws (2) and remove plate (7).
21. Press grooved ball bearing (5) out of gearcase (3).
22. Remove planet pinion as per overview drawing
(→ Page 515).
23. Remove clamp ring from groove in pin with snap
ring pliers.
TIM ID: 0000020762 – 001
24. Slide pin out through opening in planetary gear.

25. Remove planet pinion and disks.
26. Remove other planet pinions in the same way.
27. Check needle bearing (→ Page 523).
• If needle bearing is damaged: Force needle
bearing out with a hydraulic press.
MS25012/00E 08-06 © MTU

28. Remove disk from turbine housing as per overview

29. Remove housing from nozzle ring as per overview
30. Counter rotor stage 2 (2) and remove screw with
washer as per overview drawing (→ Page 515).
Note: Note rotor installation position, this is
required for assembly.
31. Screw puller (1) onto shaft (3) and rotor 2 (2).
32. Pull rotor 2 (2) off shaft (3).
33. Drive spring key (4) out of groove in shaft (3).
34. Place turbine housing (4) on support (6).

35. Press shaft (2) completely out of turbine housing
with shaft removal tool (1) and hydraulic press.
36. Drive spring key (7) out of groove in shaft (2).
37. Remove spacer (3) from shaft (2).
38. Press shaft (2) out of grooved ball bearing (5) with
shaft removal tool (1) and hydraulic press.
TIM ID: 0000020762 – 001
MS25012/00E 08-06 © MTU

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

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

43. Undo screws (7) and remove nozzle (6).
44. Remove seal spacer (8) and sealing strip (9).
45. Drive seal spacer (8) out through shaft bore in
nozzle ring (2).
46. Remove sealing strips (10).
47. Press grooved ball bearing (11) out of nozzle
ring (2) with hydraulic press.
48. Unscrew flange (5).
49. Remove all O-rings.
TIM ID: 0000020762 – 001
MS25012/00E 08-06 © MTU

4.12.10 Starter – Cleaning
Material

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


Cleaning the starter

1. Do not wash the inertia-drive starter (pinion) with solvent-based cleaning agents.
2. Clean the drive housing externally, do not wash needle bearings with solvent-based cleaning agents.
3. Clean corroded steel parts with rust remover.
4. Clean all metal parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
TIM ID: 0000020747 – 001
MS25012/00E 08-06 © MTU

4.12.11 Starter – Check
Special tools

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

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

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

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

wear, indentations and fissures. • indentations
• fissures
TIM ID: 0000020748 – 001
visible
Measure planet gear (→ Table Wear Size not exact Replace

limits on page 525).
Check planetary gear for cracking • Cracks Replace

and burring in bores for pins and at • burrs
keyways. visible
MS25012/00E 08-06 © MTU

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

(→ Table Wear limits on page 525).
Check pins and disks for scoring • Scoring Replace

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

on page 525) .
Measure disk thickness Size not exact Replace

Check turbine shaft for cracking and • Cracks Replace

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

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

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

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

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

Check spacers for scoring and • Scoring Replace

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

edges.
TIM ID: 0000020748 – 001
MS25012/00E 08-06 © MTU

Check rotor for corrosion, erosion • Corrosion Replace

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

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

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

inch.
• 7.5:1 Outer Ø min. 2.3067
• 9:1 Outer Ø min. 2.3699
• 11.4:1 Outer Ø min. 2.4359
Planetary gear shaft:
Grooved ball bearing Ø Min. 1.180
Pin bore Max. 0.875
Pin:
TIM ID: 0000020748 – 001
Needle bearing Ø Min. 0.873
Disk:
Thickness Min. 0.055
MS25012/00E 08-06 © MTU

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

B Dimension, detrition on worn tooth *
* Max. admissible detrition dimension B on both tooth flanks
must not exceed 10 % of dimension A
TIM ID: 0000020748 – 001
MS25012/00E 08-06 © MTU

4.12.12 Starter – Assembly
Special tools

Wrench TDI-52-20134 1
Carrier shaft holding jig TDI-52-20202 1
Bearing pressing tool TDI-52-20143 1
Tool for bearing/seal TDI-2-26943 1
Torque wrench 0.5-5 Nm 0015384230 1
Ratchet F30027340 1
Material

Screw locking compound (Loctite 270) 40083 1
Acetone 40590 1
Gear grease TDI-9-94121-001 1
Spare parts

Grooved ball bearing
Sealing strips
O-rings
Screws
Heavy object.
Risk of crushing!

TIM ID: 0000020749 – 002

Risk of injury!
MS25012/00E 08-06 © MTU

Assembling the starter

Note: Exert pressure on inner race of bearing.
1. Support shaft (4) and press on new grooved ball

bearing (3) over spacer (2) with hydraulic press
and tool for bearing/seal (1).
Note:
• Exert pressure on outer race of bearing.
• Do not press on the end of the shaft
as the load may damage the balls
in the bearing.
2. Place turbine housing (2) on support.

3. Press shaft (3) into turbine housing (2) with
hydraulic press and tool for bearing/seal (1).
4. Press sealing strip (3) with sealing lip facing up

into nozzle ring (2) with hydraulic press and tool
for bearing/seal (1).
TIM ID: 0000020749 – 002
MS25012/00E 08-06 © MTU

5. Screw disk (10) onto turbine housing (12) with

new screws (11).
6. Tighten screws (11) to specified tightening torque
using a torque wrench (→ Page 23).
7. Remove spacer (9) and seal spacer (6).
8. Coat new O-ring (8) with grease and insert in
groove in turbine housing (12).
9. Screw nozzle ring (15) onto turbine housing (12)
with screws (14), but do not tighten screws (15).
10. Insert key disk (17) into groove in shaft (13).
11. Press rotor stage 1 (16) onto shaft (13) by hand as
noted during disassembly, use tool for bearing/seal
(1) only if necessary.
12. Provisionally install nozzle ring (2) on turbine
housing (12).
13. Tighten screws (14) through the large bores in
rotor stage 1 (16) to the specified torque with a
14. Remove nozzle ring (2) again.
15. Press sealing strip (5) with sealing lip facing up
into nozzle ring (2) with hydraulic press and tool
Note: Do not coat O-ring (4) with grease.
16. Insert new O-ring (4) into bearing bore of nozzle

ring (2).
17. Coat new O-ring (7) with grease and insert in
groove in nozzle ring (2).
18. Install nozzle ring (2) on turbine housing (12),
• the three flat parts of the nozzle ring are aligned
opposite the air inlet of the turbine housing.
19. Fit seal spacer (6) on shaft (13).

20. Insert spring washer (18) into bearing bore of
nozzle ring (2).
21. Support shaft (13) and press on new grooved
ball bearing (3) with hydraulic press and tool
22. Fit seal spacer on shaft.
23. Press sealing strip with sealing lip facing up into
nozzle ring with hydraulic press and tool for
bearing/seal.
24. Insert key disk in groove in shaft.
25. Press rotor stage 2 onto shaft by hand as noted
during disassembly, use tool for bearing/seal only
if necessary.
26. Screw rotor stage 2 onto shaft with screw and
washer as per overview drawing (→ Page 515).
TIM ID: 0000020749 – 002
27. Tighten screw to specified tightening torque using

a torque wrench (→ Page 23).
28. Clean grease off screw threads securing housing
to nozzle ring with acetone and dry, then apply a
drop of screw locking compound.
29. Screw housing onto nozzle ring as per overview
MS25012/00E 08-06 © MTU

30. Tighten screws to specified tightening torque using

31. Coat new O-ring with grease and insert in groove
in flange.
32. Screw flange onto turbine housing.
34. Press needle bearing into planet pinion, if removed.
35. Fill needle bearing spaces with gear grease.
36. Insert planet pinion (5) with disks (3) on both sides
in the chases in the shaft (1) of the planetary gear.
37. Insert pin (2) through opening in planetary gear,
ensuring that anti-rotation tangs (6) engage in
retaining slots.
38. Insert clamp ring (4) into groove in pin with snap
ring pliers.
39. Install other planet pinions in the same way.
Note: Exert pressure on inner race of bearing.
40. Support planetary gear and press new grooved

ball bearing (3) onto shaft (2) with hydraulic press
and bearing pressing tool (1).
TIM ID: 0000020749 – 002
MS25012/00E 08-06 © MTU

Note: Exert pressure on outer race of bearing.
41. Press new grooved ball bearing (3) into gearcase

(4) with hydraulic press.
42. Screw plate (1) onto gearcase (4).
43. Fit spring washer (6) and spacer (5) on shaft (2)
and bring into contact with grooved ball bearing.
44. Insert shaft (2) in gearcase (4).
45. If shaft (2) does not slide into bearing bore, press
on gearcase (4) until grooved ball bearing is
seated in installation position.
46. Place gearcase (2) on holding jig (3).

47. Apply lockwasher (4).
48. Counter gearcase (2), screw on slotted nut (5) with
wrench (1) and tighten to specified torque with
49. Secure slotted nut (5) to preclude turning by
folding back a lug on the lockwasher (4).
50. Coat new O-ring with grease and fit on outer
diameter of gearcase (2).
51. Fill gears in middle of planetary gear thoroughly
with gear grease.
52. Install gearcase on turbine housing, turn planetary
gear a little in so doing.
53. Screw on gearcase as per overview drawing
(→ Page 515).
55. Insert key disks in grooves in shaft.
56. Slide inertia-drive starter (4) and compression
spring (3) onto shaft (5) until grub screw bore (1) is
aligned with bore for grub screw in shaft.
57. Screw in grub screw (1) and tighten.
58. Insert snap ring (2) in chase in grub screw (1).
59. Press needle bearing into drive housing until
flush, if removed.
60. Fill needle bearing spaces with gear grease.
61. Screw drive housing onto gearcase.
62. Tighten nuts of threaded connections to
specified tightening torque with a torque wrench
TIM ID: 0000020749 – 002
(→ Page 23).
MS25012/00E 08-06 © MTU

4.12.13 Starter – Installation
Material

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

1. Coat starter pinion with Longtherm 2 Plus grease.
2. Attach starter to crane.
3. Insert starter into opening on end housing.
4. Align securing holes on starter with holes on end housing flange.
5. Secure starter with screws to flange.
6. Detach starter from crane.
7. Connect pressure hose to starter.
TIM ID: 0000005424 – 003
MS25012/00E 08-06 © MTU

4.13 Lube-oil System, Lube-oil Circuit
4.13.1 Lube oil system – Overview
1 Oil cooler 3 Centrifugal oil filter

2 Oil pan 4 Oil filter
TIM ID: 0000029124 – 001
MS25012/00E 08-06 © MTU

4.13.2 Lube-oil pump with drive – Overview
1 Oil pump 6 Banjo screw 11 Grommet

2 Screw 7 Sealing ring 12 Screw
3 Washer 8 Oil line 13 Spacer sleeve
4 Screw 9 Retainer
5 Pressure reducing valve 10 Pipe half-clamp
TIM ID: 0000029407 – 001
MS25012/00E 08-06 © MTU

4.13.3 Lube-oil pump with drive – Removal
Special tools

Heavy object.
Risk of crushing!
Removing oil pump with safety valve

Note: The illustration does not show engine in
installation position.
1. Unscrew all screws (1) on the oil pump (2).

2. Attach support bracket to oil pump and with rope,
slightly tensioned, to crane.
3. Remove oil pump from equipment carrier and
place aside.
Removing oil line and pressure reducing valve

1. Remove oil line from equipment carrier as per overview drawing (→ Page 534).
2. Remove pressure reducing valve from equipment carrier.
3. Remove sealing rings.
4. Seal connections with suitable plug.
5. Protect oil line from damage.
TIM ID: 0000029430 – 001
MS25012/00E 08-06 © MTU

4.13.4 Lube-oil pump with drive – Disassembly

Lube-oil pump – Disassembly
1. Do not disassemble lube oil pump.
2. Contact Service.
TIM ID: 0000004243 – 002
MS25012/00E 08-06 © MTU

4.13.5 Lube oil pump with drive – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning oil line

TIM ID: 0000004244 – 003
MS25012/00E 08-06 © MTU

4.13.6 Lube-oil pump with drive – Check
Material

Spare parts

Oil pump
Pressure reduction valve
Oil line
Banjo screw
Screw
Pipe half-clamp
Test liquid is hot and pressurized.

WARNING • Wear protective clothing, gloves, and goggles / safety mask.
TIM ID: 0000004871 – 002
MS25012/00E 08-06 © MTU

Lube-oil pump with drive – Check
Item Findings Task
Visually inspect outside of lube-oil Damaged Have lube-oil pump operation

pump for damage and defects. checked and repaired at
manufacturer.
Visually inspect oil line for damage. Damaged • Corrective work

• Replace
Check sealing faces for irregularities. Uneven • Corrective work and check for
evenness with ink-check plate.
• Replace
Check banjo screws for damage and • Damaged Replace

threads for ease of movement. • Sluggish
Check drive gear with dye penetrant Signs of cracks Replace

for cracks.
Check tooth flanks of drive gear • Stress marks • Corrective work

for stress marks, indentations and • Indentations • Replace lube-oil pump
chipping. • Chipping
visible
Check breather valve for opening Opening pressure not reached or Replace
pressure of 15 bar. Test medium: exceeded.
Engine oil SAE 30 medium
temperature: from 90 °C to 100 °C.
Disassembly of the pressure Damaged Replace

reduction valve is not planned;
check for damage by visual
inspection only.
Check pressure reduction valve Opening pressure not reached, or Replace

opening pressure. Operation: The exceeded.
valve limits the oil flow so that a
constant pressure of 5.5 +1 bar is
maintained at the last crankshaft
bearing. Medium temperature: from
90 °C to 100 °C, design pressure at
n/min 1.5 bar at n/max 7 bar of oil
pump.
TIM ID: 0000004871 – 002
MS25012/00E 08-06 © MTU

4.13.7 Lube-oil pump with drive – Installation
Special tools

Material

Spare parts

Sealing ring
Grommet
O-ring
Heavy object.
Risk of crushing!
Compressed air.
Risk of injury!
Installing lube-oil pump on equipment carrier

1. Degrease sealing face on equipment carrier
and lube-oil pump.
2. Apply Loctite 573 to sealing face on equipment
carrier.
3. Attach oil pump with support bracket to crane.
4. Insert oil pump into equipment carrier, making
sure gears engage correctly.
5. Screw in screws (1) and (2) for oil pump and use
torque wrench to tighten diagonally to specified
TIM ID: 0000004245 – 006
MS25012/00E 08-06 © MTU

Installing pressure reducing valve

1. Coat O-ring with grease and insert in groove of
pressure reducing valve (arrow).
2. Insert pressure reducing valve (1) in equipment
carrier and tighten to specified torque using a
Installing oil line

1. Prior to installation, remove all blanking plugs.
2. Blow out oil line with compressed air.
3. Install oil line loosely using attaching parts as per overview drawing (→ Page 534).
4. Install banjo screws and use torque wrench to tighten to specified tightening torque (→ Page 23).
TIM ID: 0000004245 – 006
MS25012/00E 08-06 © MTU

4.13.8 Oil filter – Overview
50 Oil filter housing 400 Screw 450 Oil filter

150 O-ring 405 Screw 560 Oil collection tank
200 O-ring 410 Stud 570 Spacer sleeve
250 O-ring 415 Stud 800 Plug screw
300 Screw 420 Washer 810 Sealing ring
350 Screw 430 Nut
TIM ID: 0000029126 – 001
MS25012/00E 08-06 © MTU

50 Oil filter housing 200 O-ring 350 Washer

100 Oil filter housing 250 O-ring
150 O-ring 300 Screw
TIM ID: 0000029126 – 001
MS25012/00E 08-06 © MTU

4.13.9 Oil filter – Removal
Preconditions
• Engine is stopped and starting disabled
Special tools

Filter wrench F30379104 1
Remove oil filter

1. Remove oil filter with filter wrench.
2. Drain oil from oil filter into a suitable container.
Removing oil filter housing

1. Remove oil filter housing as shown in overview drawing (→ Page 542).
TIM ID: 0000029127 – 001
MS25012/00E 08-06 © MTU

4.13.10 Oil filter housing – Disassembly

Disassembling oil filter housing
Note: Remove double nipple and plugs screws only if necessary.
1. Unscrew screws and disassemble oil filter housing as per overview drawing (→ Page 542).
2. Remove O-rings.
TIM ID: 0000029128 – 001
MS25012/00E 08-06 © MTU

4.13.11 Oil filter housing – Clean
Material

Compressed air.
Risk of injury!


Cleaning oil filter housing

2. Blow out/off all parts with compressed air.
TIM ID: 0000004281 – 004
MS25012/00E 08-06 © MTU

4.13.12 Oil filter housing – Check
Special tools

Test bath

Hot testing liquid.
Checking oil filter housing
Check all sealing, mating and sliding • Traces of wear • Rework: smooth with oilstone
surfaces for wear, scoring and • Scores or emery cloth.
indentations. • Indentations • Replace
Visible
Check all threads and threaded Damaged • Rework: recut thread.

holes. • Replace
Pressure-test oil filter housing with Leaking • Replace blanking plug.

air in water bath for leaks. Install • Replace oil filter housing.
filter elements before carrying out
leak test. Test temperature: min.
30 °C, max. 40 °C, if oil filter
housing has to be held in hands.
Test pressure: 0.5 bar
TIM ID: 0000028378 – 001
MS25012/00E 08-06 © MTU

4.13.13 Oil filter housing – Assembly
Material

Spare parts

O-rings
Assembling oil filter housing

1. Coat o-rings with grease and insert into annular grooves as per overview drawing (→ Page 542).
2. Install oil filter housing as shown in overview drawing (→ Page 542).
TIM ID: 0000029129 – 001
MS25012/00E 08-06 © MTU

4.13.14 Oil filter – Installation
Material

Engine oil
Spare parts

O-ring
Installing oil filter housing

3. Insert o-rings into annular grooves of oil filter housing as per overview diagram (→ Page 542).
4. Install oil filter housing as shown in overview drawing (→ Page 542).
Install oil filter

1. Coat sealing ring of oil filter with oil.
2. Install oil filter and tighten by hand.
TIM ID: 0000029130 – 001
MS25012/00E 08-06 © MTU

4.13.15 Centrifugal oil filter – Overview
50 Carrier 300 O-ring 500 O-ring

150 Screw 350 O-ring 550 Stud
200 Screw 400 Centrifugal oil filter 600 Washer
250 Washer 450 Restrictor 650 Nut
TIM ID: 0000028381 – 001
MS25012/00E 08-06 © MTU

4.13.16 Centrifugal oil filter – Removal
Preconditions
Centrifugal oil filter – Removal
1. Remove centrifugal oil filter according to overview drawing (→ Page 550).
2. Seal all openings with suitable covers.
TIM ID: 0000004453 – 004
MS25012/00E 08-06 © MTU

4.13.17 Centrifugal oil filter – Disassembly

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

4. Drain remaining oil from centrifugal oil filter into
suitable container.
TIM ID: 0000028382 – 001
MS25012/00E 08-06 © MTU

5. Carefully remove rotor unit (1) from shaft/housing

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

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

10. Remove rotor cover (5) from rotor body (4).
11. Remove partition plate (2) from lower rotor part (1).
12. Remove O-rings from lower rotor part (1).
TIM ID: 0000028382 – 001
MS25012/00E 08-06 © MTU

4.13.18 Centrifugal oil filter – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning the rotor unit

TIM ID: 0000004455 – 004
MS25012/00E 08-06 © MTU

4.13.19 Centrifugal oil filter – Check
Material

Red penetrant dye for surface crack-testing procedure
Spare parts

Housing
Rotor
Nozzle
Pipe
Screw
Compression spring
Valve plunger
Plug
Centrifugal oil filter – Check
Item Findings Task
Check all sealing, mating and sliding • Wear • Recondition: smooth with
surfaces for wear, scoring and • Scores oilstone or emery cloth.
indentations. • Indentations • Replace
visible.
Using red penetrant dye, check the Cracks indicated Replace rotor unit.
housing and substructure for cracks.
Check all threads and threaded Damaged • Recondition: recut threads.

bores. • Replace
Check journals on rotor and bearing Wear visible • Recondition: smooth with
running surfaces on shaft for wear. oilstone or emery cloth.
• Replace
Check valve piston and spring Wear visible • Recondition

(→ Page 550) for wear traces. • Replace
TIM ID: 0000004456 – 002
MS25012/00E 08-06 © MTU

4.13.20 Centrifugal oil filter – Assembly
Material

Engine oil
Spare parts

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

1. Coat O-rings with grease and insert in grooves on
rotor cover and lower rotor section.
2. Place partition plate (2) on lower rotor section (1).
3. Place rotor body (4) on lower rotor section (1).
4. Insert new paper insert (3) in rotor body (4).
TIM ID: 0000028383 – 001
MS25012/00E 08-06 © MTU

5. Fit cover (2) on rotor body (3).

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

8. Carefully insert rotor unit (1) in housing (3).
9. Check rotor (1) for smooth running.
10. Coat O-ring (4) with grease and insert in groove
on housing (3).
11. Insert valve piston (2) with plug and compression
spring.
12. Fit cover (1) on housing (2).

TIM ID: 0000028383 – 001
MS25012/00E 08-06 © MTU

13. Tighten screw (1) to specified tightening torque

(→ Page 23).
14. Install V-band clamp (3) and use toggle (2) to
tighten to specified tightening torque (→ Page 23).
TIM ID: 0000028383 – 001
MS25012/00E 08-06 © MTU

4.13.21 Centrifugal oil filter – Installation
Material

Spare parts

O-ring

Centrifugal oil filter – Installation

2. Coat O-ring with grease and insert.
3. Install centrifugal oil filter as shown in overview drawing (→ Page 550).
TIM ID: 0000004458 – 004
MS25012/00E 08-06 © MTU

4.13.22 Oil cooler – Overview
1 Oil cooler 5 Oil cooler housing 9 Hex nut

2 O-ring 6 O-ring 10 Hex screw
3 Hex screw 7 Stud 11 O-ring
4 Washer 8 Washer 12 Plug screw
TIM ID: 0000028387 – 001
MS25012/00E 08-06 © MTU

1 Plug 2 Sealing ring 3 Plug screw

TIM ID: 0000028387 – 001
MS25012/00E 08-06 © MTU

4.13.23 Oil cooler – Removal
Special tools

Hot oil.
Oil can contain combustion residues which are harmful to health.
WARNING Risk of injury and poisoning!
• Avoid contact with skin.
• Do not inhale oil vapor.
Heavy object.
Risk of crushing!
Oil cooler – Removal

1. Secure oil cooler (3) with lifting gear (2) and crane.
3. Remove oil cooler with lifting gear (2).
4. Catch any oil remains that emerge.
5. Cover all openings in the oil cooler housing.
TIM ID: 0000028388 – 001
MS25012/00E 08-06 © MTU

4.13.24 Oil heat exchanger – Cleaning
Material

Porozink made by Parobe-Chemie
Porodox made by Henkel
Branorol 32/10 made by Brangs u. Heinrich
3 to 5% P3 FD solution made by Henkel.
High-pressure water jet.

Risk of injury!
WARNING • Do not direct water jet at persons, electric or electronic equipment.
Compressed air.
Risk of injury!

Cleaning water side

1. Inspect oil heat exchanger for contamination before cleaning water side.
2. Clean with a suitable cleaning agent, e.g. Porodox or Porozink if encrustations of hardness minerals, dirt and
oil deposits are visible on the water side (inlet area).
Note: Soaking time depends on the condition and temperature of the solution and the nature and
stubbornness of the deposits.
3. Fill cleaning agent into the oil heat exchanger.

4. Flush the oil heat exchanger with water after cleaning. pH value difference between fresh water and flushing
water max. 1 pH
5. Dry and preserve the oil heat exchanger if it is not put back into operation immediately.
5.1. Dry in a drying furnace.
• Temperature: 110 °C to 120 °C
• Drying time: 3 hours
5.2. Preserving oil heat exchanger
• Preservative: Branorol 32/10
• Dosage: 2 ml Branorol 32/10 per liter of cooling volume
6. Seal openings with suitable covers after preserving.
Cleaning oil side

1. Replace oil heat exchanger in case of swarf ingress in engine oil system, e.g. due to piston seizure or
bearing damage.
TIM ID: 0000028391 – 001
2. Connect oil side to a closed-circuit flushing facility.

• Filter system mesh size: 0.05 mm
Note: Flush with cleaning agent against the direction of oil flow during operation
3. Prepare cleaning agent in accordance with manufacturer’s instructions. Cleaning agent: 3 to 5% P3 FD solution
• Flushing pressure: 3 bar to 4 bar at 150 liters/minute to 300 liters/minute
• Cleaning results may be additionally improved by use of ultrasound.
MS25012/00E 08-06 © MTU

4. Flush the oil heat exchanger with water after cleaning. pH value difference between fresh water and flushing
water max. 1 pH
5. Dry and preserve the oil heat exchanger if it is not put back into operation immediately. (see Cleaning water
side)
TIM ID: 0000028391 – 001
MS25012/00E 08-06 © MTU

4.13.25 Oil heat exchanger – Check
Spare parts

Oil heat exchanger

Oil heat exchanger – Check
Item Findings Task
Visually inspect oil cooler for Damaged Replace

damage.
Check oil and coolant chambers of Leaking Replace

oil cooler for leaks.
• Test pressure: oil side: 25 bar
• Test pressure: coolant side: 8
bar
Check all sealing and mating faces • Damage • Recondition: smooth with
for stress marks and damage • Stress marks oilstone or emery cloth.
visible • Replace
TIM ID: 0000028392 – 001
MS25012/00E 08-06 © MTU

4.13.26 Oil cooler – Installation
Special tools

Guide pin F6555799 1
Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!
Oil cooler – Installation

1. Remove covers from oil cooler housing.
3. Insert O-rings in oil cooler housing.
4. Fit oil cooler (3) with lifting gear (2) and guide pin
in correct position (plug screws (1) in direction of
“driving end”).
5. Insert screws (4).
6. Remove lifting gear (2).
TIM ID: 0000028393 – 001
MS25012/00E 08-06 © MTU

4.13.27 Oil system in crankcase – Overview
Oil system
1 Delivery valve 10 Pipe 19 O-ring

2 O-ring 11 Pipe 20 O-ring
3 O-ring 12 Oil spray nozzle 21 Retainer
4 Circlip 13 Screw 22 Retainer
5 Washer 14 Circlip 23 Pipe
6 O-ring 15 Delivery valve 24 Pipe
7 O-ring 16 O-ring 25 Oil spray nozzle
8 Retainer 17 O-ring 26 Screw
9 Retainer 18 Washer
TIM ID: 0000029457 – 001
MS25012/00E 08-06 © MTU

1 Delivery valve 4 O-ring 7 Retainer

2 O-ring 5 Pipe 8 Retainer
3 Washer 6 Retainer 9 Oil spray nozzle
TIM ID: 0000029457 – 001
MS25012/00E 08-06 © MTU

4.13.28 Oil system in crankcase – Removal
Preconditions
Special tools


Risk of injury!
Removing bracket for oil spray nozzle

1. Install barring device at crankshaft (→ Page 222).
2. Turn crankshaft with barring device until oil spray
nozzle (1) to be removed is accessible.
3. Remove screws (arrows).
4. Remove oil spray nozzle (1) from retainer (2).
5. Mark oil spray nozzle (1) with a pen according to
cylinder side and cylinder number.
6. Protect oil spray nozzle (1) against damage.
Removing oil pipe connection

1. Remove screw (arrows).
2. Remove holder (2) from oil pipe fit (3).
3. Remove oil pipe (1) from retainer (2).
4. Remove all other oil spray nozzles in same
manner.
TIM ID: 0000004463 – 006
MS25012/00E 08-06 © MTU

Removing washer (sealing fit)

1. Remove washer (2) from crankcase (1).
2. Remove O-rings.
3. Protect washer (2) against damage.
Removing delivery valve

1. Remove pressure valve as per overview drawing
(→ Page 567).
2. Unscrew plug screws.
3. Remove snap ring (1) from housing.
4. Remove delivery valve (3) from housing.
5. Remove O-rings (2) and (4)
TIM ID: 0000004463 – 006
MS25012/00E 08-06 © MTU

4.13.29 Oil pipework in crankcase – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning oil spray nozzles and oil pipes

2. Remove cleaner.
3. Blow oil pipes, retainers and oil spray nozzle dry with compressed air.
Cleaning washer (sealing fit)

2. Remove cleaner.
3. Then blow washer dry (sealing fit) with compressed air.
TIM ID: 0000004464 – 002
MS25012/00E 08-06 © MTU

4.13.30 Oil pipework in crankcase – Check
Special tools

Testing device Y4341968 1
Material

Spare parts

Oil spray nozzle
Pipe
Retainer
Washer (sealing fit)
Delivery valve
Component to be tested is under pressure.

Risk of explosion!
DANGER • Observe test specification.

Risk of injury!
TIM ID: 0000004465 – 004
MS25012/00E 08-06 © MTU

Oil pipework in crankcase – Check
Item Findings Task
Check oil spray nozzles with dye Signs of cracks Replace

penetrant for cracks.
Check oil bore of oil spray nozzles Contamination visible. • Corrective work: Clean
for obstruction and ensure it is • Replace
particularly clean.
Check oil spray nozzle with testing Deformation of oil spray nozzle. Replace
device for deformation.
Test oil pipes for leaks with air in Leaking Replace

water bath as necessary. Maintain a
water temperature of min. = 30 °C
or max. = 40 °C and a test pressure
of 0.5 bar.
Check threads for ease of Sluggish • Corrective work: Recut threads

Check mating and sealing faces of • Damaged • Corrective work: Smooth with
oil spray nozzle. • Stress marks oilstone or emery cloth.
visible • Replace
Check washer (sealing fit) for wear, • Stress marks Replace

cracks and damage. • Cracks
• Damage
visible
Check bore in crankcase for wear. Visible signs of wear. Smooth with emery cloth.
Do not disassemble delivery valve! Damaged Replace

Visually inspect delivery valve for
damage.
Check delivery valve for read Fallen short of or exceeded Replace delivery valve.
opening pressure ± 0.25 bar.
Check sealing face of delivery valve Uneven • Corrective work: Smooth with
for evenness. oilstone.
• Replace
TIM ID: 0000004465 – 004
MS25012/00E 08-06 © MTU

4.13.31 Oil pipework in crankcase – Installation
Special tools

Material

Engine oil
Spare parts

O-rings
Circlip
Compressed air.
Risk of injury!
Installing oil spray nozzle bracket and oil pipes

1. Prior to installation, remove all plugs.
2. Install bracket (1) so that dimension "a" points
towards crankcase.
TIM ID: 0000004466 – 004
MS25012/00E 08-06 © MTU

3. Coat O-rings with grease and insert in grooves of

oil pipes (1) and (3).
4. Insert oil pipes (1) and (3) in retainer (2) and
secure with hex screws (arrow) on crankcase.
5. Screw oil spray nozzle (1) with hex bolts (2) on

to retainer and use torque wrench to tighten to
6. After installing, bar engine and ensure there is
clearance between oil spray nozzle and piston.
TIM ID: 0000004466 – 004
MS25012/00E 08-06 © MTU

Installing washer (sealing fit)

1. Coat O-rings with grease and insert in grooves
(arrows) of washer.
2. Align oil pipe so that inner O-ring is not damaged.

3. Press-fit washer (2) manually in crankcase (3).
TIM ID: 0000004466 – 004
MS25012/00E 08-06 © MTU

Installing delivery valve

1. Coat O-ring with grease and insert in groove
(arrow).
2. Coat O-ring (arrow) with grease and insert in

groove on delivery valve.
3. Insert delivery valve (3) in bore of housing up to

stop.
4. Secure delivery valve with circlip (1).
5. Use torque wrench to tighten plug screw with
new sealing ring to specified tightening torque
(→ Page 23).
TIM ID: 0000004466 – 004
MS25012/00E 08-06 © MTU

4.13.32 Turbocharger oil supply – Overview
150 Oil line 600 Gasket

200 Union 650 Screw
450 Oil return line, left-hand side 750 Gasket
500 Oil return line, left-hand side 800 Nut
TIM ID: 0000028691 – 001
MS25012/00E 08-06 © MTU

300 Oil line 1050 Screw

350 Union 1150 Gasket
900 Oil return line, right-hand side 1200 Nut
1000 Gasket 1300 Plug screw
TIM ID: 0000028691 – 001
MS25012/00E 08-06 © MTU

4.13.33 Turbocharger oil supply – Removal
Preconditions
Turbocharger oil supply – Removal
1. Remove oil lines as per overview drawing (→ Page 578).
3. Protect oil lines from damage.
TIM ID: 0000028692 – 001
MS25012/00E 08-06 © MTU

4.13.34 Turbocharger oil supply – Cleaning
Material

Compressed air.
Risk of injury!


Turbocharger oil supply – Cleaning

2. Remove cleaner.
3. Blow turbocharger oil supply pipework dry with compressed air.
TIM ID: 0000028693 – 001
MS25012/00E 08-06 © MTU

4.13.35 Turbocharger oil supply – Check
Spare parts

Pipe
Flange
Adapter
Strap
Compressed air.
Risk of injury!

Risk of injury!
Turbocharger oil supply – Check
Item Findings Task
Visually inspect oil return line for Damaged Replace

damage.
Pressure-test oil return line with air Leaking Replace

in water bath for leaks. Maintain a
water temperature of min. = 30 °C
or max. = 40 °C and a test pressure
of 0.5 bar.
Check connection parts and Damaged Replace

securing elements on oil return lines
for damage.
Check sealing and bolt-on faces. Damaged • Corrective work: Smooth with
• Replace
Check threads for ease of Sluggish • Corrective work: Recut threads

TIM ID: 0000028694 – 001
MS25012/00E 08-06 © MTU

4.13.36 Turbocharger oil supply – Installation
Material

Engine oil
Spare parts

Sealing ring
Compressed air.
Risk of injury!

Turbocharger oil supply – Installation

2. Install oil lines as shown in overview drawing (→ Page 578).
3. Check oil lines for leaks after next engine start.
TIM ID: 0000028699 – 001
MS25012/00E 08-06 © MTU

4.14 Coolant System
4.14.1 Coolant system – Overview
1 Vent lines 3 Engine coolant pump 5 Coolant distribution housing

2 Water system after cylinder 4 Thermostat housing
TIM ID: 0000029133 – 001
MS25012/00E 08-06 © MTU

4.14.2 Engine coolant pump – Overview
1 Engine coolant pump 4 Screw 7 Washer

2 O-ring 5 Screw
3 Screw 6 Nut
TIM ID: 0000004492 – 003
MS25012/00E 08-06 © MTU

1 Water pump shaft 11 Shaft seal

2 Impeller 12 Rotary seal
3 Bearing housing 13 O-ring
4 Seal carrier 14 Screw
5 Volute 15 Washer
6 Spacer sleeve 16 O-ring
7 Gear 17 Screw
8 Angular-contact ball bearing 18 Washer
9 Cylindrical roller bearing 19 Sealing ring
10 Snap ring 20 Plug screw
TIM ID: 0000004492 – 003
MS25012/00E 08-06 © MTU

4.14.3 Engine coolant pump – Removal
Preconditions
Special tools

Heavy object.
Risk of crushing!

Risk of injury!
Engine coolant pump – Removal

1. Attach engine coolant pump with lifting gear and support bracket to crane using a slightly tensioned rope.
2. Remove screws for engine coolant pump as per overview drawing (→ Page 585).
3. Use crowbar to separate engine coolant pump from front cover and remove.
4. Remove O-ring.
5. Seal all openings with suitable covers.
TIM ID: 0000004493 – 005
MS25012/00E 08-06 © MTU

4.14.4 Engine coolant pump – Disassembly
Special tools

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


Risk of injury!
Engine coolant pump – Disassembly

1. Mark installation position of bearing housing (1)
and volute (3) in relation to one another.
2. Remove all bolts (2).
3. Use crowbar to separate volute (3) from bearing
housing (1) and remove it.
TIM ID: 0000004494 – 007
MS25012/00E 08-06 © MTU

4. Place engine coolant pump in (2) retaining

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

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

with aluminum jaws.
11. Use hydraulic spindle (1) and puller tool (2) to
remove gear from water pump shaft.
TIM ID: 0000004494 – 007
MS25012/00E 08-06 © MTU

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

off seal carrier (1).
TIM ID: 0000004494 – 007
MS25012/00E 08-06 © MTU

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

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

press cylindrical roller bearing (3) out of bearing
housing (4).
TIM ID: 0000004494 – 007
MS25012/00E 08-06 © MTU

19. Press counterring (1) off bearing housing (3).

20. Use impact extractor to remove shaft seal (2) from
TIM ID: 0000004494 – 007
MS25012/00E 08-06 © MTU

4.14.5 Engine coolant pump – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning the engine coolant pump

2. Blow all parts clean thoroughly with compressed air.
TIM ID: 0000004495 – 005
MS25012/00E 08-06 © MTU

4.14.6 Engine coolant pump – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

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

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

Risk of injury!
TIM ID: 0000004496 – 006
MS25012/00E 08-06 © MTU

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

cavitation.
Check bearing housing, impeller Crack indication Replace

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

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

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

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

diameters on engine coolant pump,
impeller, seal carrier and bearing
housing and gear with inside and
outside micrometer. Values and
measuring points (→ Page 596)
TIM ID: 0000004496 – 006
MS25012/00E 08-06 © MTU

4.14.7 Engine coolant pump – Tolerances
size Basic
size
1 Seal carrier 90.000 K7 −0.025 +0.010 0.025 0.025
Angular-contact 90.000 −0.015 0

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

bore
Angular-contact 90.000 −0.015 0

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

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

bore
TIM ID: 0000004679 – 003
5 Bearing housing 80.000 K7 −0.021 +0.009 0.022 0.021

bore
Cylindrical roller 80.000 −0.013 0

bearing
MS25012/00E 08-06 © MTU

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

bearing bore
7 Gear bore 39.000 H7 0 +0.025 0.018 0.059
Shaft outer diam. 39.000 s6 +0.043 +0.059
size Basic
size
Shaft seal outer 72.000 +0.130 +0.230

diam.
2 Shaft outer diam. 48.000 −0.100 0
If running surface is worn: Recondition pump shaft by spray-metallizing and plunge-cut grinding.
TIM ID: 0000004679 – 003
3 Rotary seal 35.000 h8 −0.039 0 0.040 0.100

inner diam.
Rotary seal outer 78.200 −0.030 0

diam.
MS25012/00E 08-06 © MTU

size Basic
size
4 Impeller bore 35.000 H5 0 +0.009 0.032 0.050
Shaft outer diam. 35.000 t5 +0.048 +0.059
5 Rotary seal
Counterring
If wear traces are found: Replace components together
s1 : 0.7 to 1.1
s2 : 0.6 to 1.5
s3 : 0.5 to 0.65
s4 : 0.08 to 0.5
TIM ID: 0000004679 – 003
MS25012/00E 08-06 © MTU

4.14.8 Engine coolant pump – Assembly
Special tools

Press-fit tool for angular-contact ball bearings F30378152 1
Press-fit tool for roller bearings F30378153 1
Press-fit tool for shaft seal F30450990 1
Press-in tool for rotary seal F6784612 1
Fixture for bearing housing F6780563 1
Fixture for shaft with bearing F6781573 1
Retaining device F6780561 1
Pliers for snap ring F30002760 1
Material

Ethanol 40250 1
Engine oil
Spare parts

Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Shaft seal
Rotary seal
O-ring
Component is hot.
Risk of burning!
Heavy object.
Risk of crushing!
TIM ID: 0000004497 – 006

Risk of injury!
MS25012/00E 08-06 © MTU

Engine coolant pump – Assembly

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

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

housing (3), using snap ring pliers (1).
3. Check that snap ring (2) fits correctly.

angular-contact ball bearing (3) on to pump
shaft (4).
TIM ID: 0000004497 – 006
MS25012/00E 08-06 © MTU


spacer sleeve (3) on to pump shaft (4).

inner ring (2) of cylindrical roller bearing on to
pump shaft (3).
Note: Apply press-in pressure to bearing outer

ring (3).

pump shaft into bearing housing (4).
TIM ID: 0000004497 – 006
MS25012/00E 08-06 © MTU

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

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

shaft seal into seal carrier (3).
10. Coat O-ring with grease and insert in groove.

11. Place bearing housing (1) in fixture (4).
12. Use screws (2) to install seal carrier on bearing
housing (1) and tighten them evenly. TIM ID: 0000004497 – 006
MS25012/00E 08-06 © MTU

13. Heat gear (2) to 200 °C.

14. Place bearing housing (3) with seal carrier and
holding fixture (4) on to hydraulic press (1).
15. Use hydraulic press (1) to push heated gear (2) on
to shaft up to stop and hold until shrink connection
between shaft and gear is firm.
16. Coat O-ring on counterring (2) with grease and

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

23. Place two feeler plates (clearance
S1 = 0.7 mm to 1.1 mm) on seal carrier (3),
arranged at 180° towards one another.
24. Push heated impeller (2) with hydraulic press (1)
until it stops at feeler plates.
25. Measure clearance S1 between impeller (2) and
seal carrier (3) with feeler gauge.
26. If measured value is out of tolerance, determine
the cause and replace components, if necessary.
TIM ID: 0000004497 – 006
MS25012/00E 08-06 © MTU

27. Set volute (3) down on bearing housing (1)

according to the installation position marking
made before removal.
28. Tighten screws (2).
29. Turn pump shaft to check ease of movement.
30. Measure clearance S2 (0.6 mm to 1.5 mm)
between impeller and volute (3) with feeler gauge.
31. If gap clearance is out of tolerance, determine the
cause and replace components, if necessary.
TIM ID: 0000004497 – 006
MS25012/00E 08-06 © MTU

4.14.9 Engine coolant pump – Installation
Special tools

Material

Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!

Risk of injury!
Engine coolant pump – Installation

2. Coat O-ring (1) with grease.
3. Insert O-ring (1) in groove on bearing housing of
engine coolant pump.
TIM ID: 0000004498 – 006
MS25012/00E 08-06 © MTU

4. Attach engine coolant pump with lifting gear

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

carrier, ensuring it is correctly positioned.
6. Insert screws (2) and washers and tighten evenly.
7. Remove lifting gear and support bracket.
TIM ID: 0000004498 – 006
MS25012/00E 08-06 © MTU

4.14.10 Coolant supply for engine coolant pump, intake side – Overview
Elbow with attached components
1 Elbow 6 Washer 11 Connecting piece

2 Plug screw 7 Retainer 12 Banjo screw
3 Sealing ring 8 Screw 13 Sealing ring
4 O-ring 9 Washer
5 Screw 10 Drain valve
TIM ID: 0000028466 – 001
MS25012/00E 08-06 © MTU

Coolant pipework
1 Plug-in pipe 5 Screw 9 Flange

2 Plug-in pipe 6 O-ring 10 O-ring
3 O-ring 7 Pipe 11 Screw
4 Flange 8 O-ring
TIM ID: 0000028466 – 001
MS25012/00E 08-06 © MTU

4.14.11 Coolant pipework for engine coolant pump, intake side – Removal
Preconditions
Coolant pipework for engine coolant pump, intake side – Removal
1. Prior to removal of the lines take photos or mark attachments and lines.
2. Remove all monitoring units installed in coolant lines.
3. Remove coolant pipework for engine coolant pump on intake side as shown in overview drawing (→ Page 607).
TIM ID: 0000004544 – 004
MS25012/00E 08-06 © MTU

4.14.12 Coolant supply for engine coolant pump, intake side – Clean
Material

Compressed air.
Risk of injury!


Cleaning coolant lines

2. Remove cleaner.
3. Blow dry coolant lines with compressed air and preserve in oil bath.
TIM ID: 0000028468 – 001
MS25012/00E 08-06 © MTU

4.14.13 Coolant pipework to engine coolant pump, intake side – Check
Spare parts

Elbow
Flange
Plug-in pipe
Retainer
Connecting piece
Drain valve

Risk of injury!
Coolant pipework to engine coolant pump, intake side – Check
Item Findings Task
Visually inspect retainers, plug-in • Stress marks • Corrective work: Smooth with
connections and annular grooves on • Pitting oilstone or emery cloth.
elbows and connecting lines for stress • Cavitation • Replace
marks, pitting and cavitation. visible
Check sealing and mating faces for Damaged • Corrective work: Smooth with
wear and damage. oilstone or emery cloth.
• Replace
Pressure-test coolant lines with air Leaking Replace

in water bath for leaks as necessary.
Maintain a water temperature of min.
= 30 °C / max. = 40 °C and a test
pressure of 0.5 bar.
Check operation of drain valve. Damaged Replace

TIM ID: 0000004546 – 002
MS25012/00E 08-06 © MTU

4.14.14 Coolant pipework for engine coolant pump, intake side – Installation
Material

Engine oil
Spare parts

Sealing rings
O-rings

Coolant lines – Installation

2. Coat all O-rings with grease.
3. Install coolant pipework for engine coolant pump on intake side as shown in overview drawing (→ Page 607).
4. Install all monitoring units in coolant lines.
TIM ID: 0000004547 – 004
MS25012/00E 08-06 © MTU

4.14.15 Coolant pipework after cylinder – Overview
Coolant pipework after cylinder – Overview

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

250 Manifold 850 Screw 1450 O-ring
300 Manifold 950 Plug screw 1500 Screw
350 Connecting piece 1050 Manifold 1550 Screw
450 O-ring 1100 Manifold 1650 O-ring
500 Screw 1150 Manifold 1700 O-ring
550 Screw 1200 Connecting piece 1800 Screw
650 O-ring 1260 Plug screw 1850 Spacer bushing
TIM ID: 0000020355 – 001
MS25012/00E 08-06 © MTU

4.14.16 Coolant pipework after cylinder – Removal
Preconditions
Coolant pipework after cylinder – Removal
1. Remove manifolds as per overview drawing (→ Page 613).
TIM ID: 0000004548 – 004
MS25012/00E 08-06 © MTU

4.14.17 Coolant pipework after cylinder – Clean
Material

Compressed air.
Risk of injury!


Cleaning coolant pipework after cylinder

TIM ID: 0000004549 – 003
MS25012/00E 08-06 © MTU

4.14.18 Coolant pipework after cylinder – Check
Spare parts

Manifold
Connecting piece
Compressed air.
Risk of injury!

Hot testing liquid.
Checking coolant pipework after cylinder
Visually inspect plug connections and Damaged • Rework: smooth with oilstone
annular grooves on connecting piece and or emery cloth.
manifold for wear, pitting and cavitation. • Replace
Check manifold with air and corrosion Leaking Replace

inhibitor in water bath for leaks. Maintain
a coolant temperature of min. = 30 °C or
max. = 40 °C at a test pressure of 0.5 bar.
TIM ID: 0000004550 – 002
MS25012/00E 08-06 © MTU

4.14.19 Coolant pipework after cylinder – Installation
Material

Engine oil
Grease (Kluthe Hakuform 30–10/emulsifier) X00029933 1
Spare parts

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

2. Blow out manifolds with compressed air.
4. Install manifolds free of tension as shown in overview drawing (→ Page 613).
TIM ID: 0000004551 – 004
MS25012/00E 08-06 © MTU

4.14.20 Preheating unit – Overview
1 Pump 5 Thermostat
2 Gasket 6 Non-return flap
3 Screw-in heater 7 Plug
4 Gasket 8 Sealing ring
TIM ID: 0000004525 – 001
MS25012/00E 08-06 © MTU

4.14.21 Preheating unit – Removal

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

WARNING • Let the engine cool down.
Removing preheating unit

1. Switch off preheating unit and disconnect from power supply.
2. Close shutoff valves.
3. Remove screws from flanges.
4. Attach preheating unit to crane and take up all slack on cables.
5. Remove all screws on mounting frame.
6. Loosen flanges.
7. Remove gaskets from flanges.
8. Use crane to lift preheating unit off mounting frame and set it down.
9. Fit open flanges with covers to protect against dirt.
TIM ID: 0000004574 – 003
MS25012/00E 08-06 © MTU

4.14.22 Preheating unit, screw-in heating element – Replacement
Special tools

Hot-air blower 0005388520 1
Spare parts

Seal
Screw-in heating element
Electrical voltage.

Removing the screw-in heating element

1. Check that there is adequate space to remove the
screw-in heating element: Preheating housing
length plus 5 cm. Remove the preheating unit if
this is not the case (→ Page 619).
2. Providing that adequate space is available for
removal:
2.1. Switch off the preheating unit.
2.2. Close shut-off valves in the supply and
return lines.
2.3. Disconnect the preheating unit power
supply.
3. Unscrew nuts on cover.
4. Remove cover and seal.
5. Remove heat-shrinkable hose at cable duct.
6. Note down cable connections.
7. Disconnect cables and pull out of cable duct.
8. Remove housing and seal.
TIM ID: 0000019951 – 001
MS25012/00E 08-06 © MTU

9. Unscrew screw-in heating element (2) at flange (3)

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

1. Clean screw-in heating element holder on housing.
2. Fit new seal on screw-in heating element.
3. Insert screw-in heating element into housing and screw in.
4. Fit new heat-shrinkable hose over the cable and slide the cable through the cable duct.
5. Connect cable to screw-in heating element.
6. Push the heat-shrinkable hose over the cable duct and shrink fit with a hot-air blower.
7. Fit cover with seal and screw down with nuts.
8. When the preheating unit has been removed: Install preheating unit (→ Page 624).
9. When the preheating unit has not been removed:
9.1. Connect preheating unit to power supply.
9.2. Open shut-off valves in the supply and return lines.
9.3. Switch on preheating unit.
TIM ID: 0000019951 – 001
MS25012/00E 08-06 © MTU

4.14.23 Preheating unit, coolant pump – Replacement
Special tools

Spare parts

Seal
Pump assy. with motor
Electrical voltage.

Removing the pump

1. Switch off the preheating unit.
2. Close shut-off valves in the supply and return lines.
3. Disconnect preheating unit from power supply.
5. Remove cover on pump motor.
6. Note down cable connections.
7. Disconnect cables from motor control and pull out of cable duct.
8. Remove screws at flanges (→ Page 618).
9. Pull out pump together with pump motor.
10. Remove seals at flanges.
Installing the pump

1. Clean flanges.
2. Fit new seals on flanges (→ Page 618).
3. Position pump and pump motor between flanges and screw on.
4. Fit new heat-shrinkable hose over the cable and slide the cable through the cable duct.
5. Connect cables to motor control.
6. Push the heat-shrinkable hose over the grommet and shrink fit with a hot-air blower.
7. Connect preheating unit to power supply.
8. Open shut-off valves in the supply and return lines.
TIM ID: 0000019952 – 001
9. Switch on preheating unit
MS25012/00E 08-06 © MTU

4.14.24 Preheating unit, thermostat – Replacement
Special tools

Spare parts

Thermostat
Electrical voltage.

Removing the thermostat

1. Check that there is adequate space to remove the screw-in heating element: Preheating housing length plus
5 cm. Remove the preheating unit if this is not the case (→ Page 619).
2. Providing that adequate space is available for removal:
2.1. Switch off the preheating unit.
2.2. Close shut-off valves in the supply and return lines.
2.3. Disconnect the preheating unit power supply.
3. Remove screws on thermostat cover and take off the cover (→ Page 618).
5. Disconnect cables on thermostat and pull out of cable duct.
6. Pull thermostat out of holder tube.
Installing the thermostat
1. Insert thermostat in holder tube (→ Page 618).
2. Fit heat-shrinkable hose over the cable.
3. Insert cable through cable duct and connect to thermostat.
4. Install cover.
5. Push the heat-shrinkable hose over the cable duct and shrink fit with a hot-air blower.
6. When the preheating unit has been removed: Install preheating unit (→ Page 624).
7. When the preheating unit has not been removed:
7.1. Connect preheating unit to power supply.
7.2. Open shut-off valves in the supply and return lines.
7.3. Switch on preheating unit.
TIM ID: 0000019953 – 001
MS25012/00E 08-06 © MTU

4.14.25 Preheating unit – Installation
Spare parts

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

1. Remove covers from flanges.
Note: Pay attention to flow direction indicated by arrows on pump and non-return valve.
2. Position preheating unit with crane ensuring proper alignment with mounting frame and flanges.
3. Fit gaskets in the flanges.
4. Screw preheating unit into place with the screws on the mounting frame.
5. Detach preheating unit from crane.
6. Screw on flanges.
7. Connect preheating unit to power supply.
8. Open shut-off valves.
9. Vent cooling circuit.
10. Switch on preheating unit.
11. Check preheating unit for leaks during operation.
TIM ID: 0000004575 – 005
MS25012/00E 08-06 © MTU

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

250 Sealing ring 4600 Sealing ring 5560 Retainer
550 Vent line 4850 Retainer 5650 Pipe half-clamp
600 Vent line 4860 Spacer bushing 5700 Grommet
650 T piece 4900 Pipe half-clamp 5750 Screw
700 Vent line 4950 Grommet 5800 Nut
750 Vent line 5000 Screw 5850 Washer
800 T piece 5050 Nut 5950 Pipe half-clamp
850 Vent line 5150 Washer 6000 Pipe half-clamp
950 Vent line 5250 Washer 6050 Grommet
1950 Union 5300 Retainer 6100 Spacer bushing
4350 Vent line 5400 Pipe half-clamp
4400 Vent line 5450 Grommet
TIM ID: 0000020740 – 001
MS25012/00E 08-06 © MTU

200 Double union 3400 Screw 4110 Screw

250 Sealing ring 3500 Retainer 4120 Washer
350 Vent line 3550 Screw 4150 Pipe half-clamp
400 T piece 3600 Washer 4200 Grommet
450 Vent line 3650 Pipe half-clamp 4250 Screw
500 Vent line 3700 Grommet 4300 Vent line
3050 Adapter union 3750 Screw 5250 Washer
3100 Sealing ring 3850 Double union 5300 Retainer
3150 Vent line 3900 Sealing ring 5350 Screw
3250 Retainer 3950 Vent line 5400 Pipe half-clamp
3300 Pipe half-clamp 4000 T piece 5450 Grommet
3350 Grommet 4100 Retainer 5500 Screw
TIM ID: 0000020740 – 001
MS25012/00E 08-06 © MTU

1150 Distribution 1700 Sealing cone

1160 Plug screw 2400 Vent line
1170 Sealing ring 2410 Hoseline
1250 Retainer 2500 Banjo screw
1300 Screw 2550 Sealing ring
1400 Screw 2650 Union
1450 Nut 2700 Sealing ring
1550 Double union 2800 Pipe half-clamp
1600 Sealing ring 2850 Grommet
1650 Nut 2900 Screw
TIM ID: 0000020740 – 001
MS25012/00E 08-06 © MTU

1050 Union 2250 Grommet 5000 Screw

1100 Sealing ring 2300 Screw 5050 Nut
1800 Vent line 2310 Washer 5150 Washer
1850 Vent line 4700 Plug screw 5600 Pipe half-clamp
1950 Union 4750 Sealing ring 5700 Grommet
2000 Sealing ring 4860 Spacer bushing 5750 Screw
2100 Union 4910 Pipe half-clamp 5800 Nut
2200 Pipe half-clamp 4950 Grommet 5850 Washer
TIM ID: 0000020740 – 001
MS25012/00E 08-06 © MTU

4.14.27 Engine coolant and charge-air cooling vent – Removal
Preconditions
Engine coolant and charge-air cooling vent – Removal
1. Prior to removal of the lines take photos or mark attachments and lines.
2. Remove engine coolant and charge-air cooling vent (→ Page 625).
TIM ID: 0000004532 – 005
MS25012/00E 08-06 © MTU

4.14.28 Engine coolant and charge-air coolant ventilation – Cleaning
Material

Compressed air.
Risk of injury!


Engine coolant and charge-air coolant ventilation – Cleaning

2. Thoroughly blow out coolant and charge-air coolant ventilation with compressed air and preserve in oil bath.
TIM ID: 0000004552 – 003
MS25012/00E 08-06 © MTU

4.14.29 Engine coolant and charge-air coolant ventilation – Check
Spare parts

Pipe
Elbow
Vent line
Distributor
T-piece
Retainer
Elbow
Spacer sleeve

Risk of injury!
Compressed air.
Risk of injury!
Engine coolant and charge-air coolant ventilation – Check
Item Findings Task
Check lines, elbow, distributor, T-piece, retainer, Damaged Replace

elbow and spacer sleeve for damage.
Check coolant lines for leaks in water bath, using Leaking Replace
compressed air and corrosion inhibitor. Maintain a
water temperature of min. = 30 °C / max. = 40 °C and
a test pressure of 0.5 bar.
Check threads for damage and ease of movement. Damaged or sluggish • Corrective work: Recut
threads
• Replace
TIM ID: 0000004553 – 002
MS25012/00E 08-06 © MTU

4.14.30 Engine coolant and charge-air cooling vent – Installation
Material

Engine oil
Spare parts

Grommet
Pipe clamp half
Compressed air.
Risk of injury!

Engine coolant and charge-air cooling vent – Installation

2. Install engine coolant and charge-air cooling vent as shown in overview drawing (→ Page 625).
TIM ID: 0000004537 – 006
MS25012/00E 08-06 © MTU

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

2 O-ring 5 Nut
3 Screw 6 Washer
TIM ID: 0000004491 – 002
MS25012/00E 08-06 © MTU

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

2 Impeller 9 Cylindrical roller bearing 16 O-ring
3 Bearing housing 10 Snap ring 17 Screw
4 Seal carrier 11 Shaft seal 18 Washer
5 Volute 12 Rotary seal 19 Plug screw
6 Spacer sleeve 13 O-ring
7 Gear 14 Screw
TIM ID: 0000004491 – 002
MS25012/00E 08-06 © MTU

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

Risk of injury!
Charge-air coolant pump – Removal

1. Remove securing screws for charge-air coolant pump as shown in overview drawing (→ Page 633).
2. Use crowbar to release charge-air coolant pump from equipment carrier and remove.
3. Mask installation hole for charge-air coolant pump.
4. Remove O-ring from charge-air coolant pump.
TIM ID: 0000004486 – 006
MS25012/00E 08-06 © MTU

4.14.33 Charge-air coolant pump – Disassembly
Special tools

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


Risk of injury!
Charge-air coolant pump – Disassembly

1. Mark installation position of bearing housing (1)
and volute (3) in relation to one another.
2. Remove all bolts (2).
3. Use crowbar to separate volute (3) from bearing
housing (1) and remove it.
TIM ID: 0000004488 – 003
MS25012/00E 08-06 © MTU

4. Place engine coolant pump in (2) retaining

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

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

with aluminum jaws.
11. Use hydraulic spindle (1) and removal tool (2) to
remove gear from water pump shaft.
TIM ID: 0000004488 – 003
MS25012/00E 08-06 © MTU

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

off seal carrier (1).
TIM ID: 0000004488 – 003
MS25012/00E 08-06 © MTU

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

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

cylindrical roller bearing out of bearing housing (4).
TIM ID: 0000004488 – 003
MS25012/00E 08-06 © MTU

19. Press out counterring (1).

20. Use impact extractor to remove shaft seal (2) from
TIM ID: 0000004488 – 003
MS25012/00E 08-06 © MTU

4.14.34 Charge-air coolant pump – Cleaning
Material

Compressed air.
Risk of injury!


Charge-air coolant pump – Cleaning

2. Blow all components thoroughly with compressed air.
TIM ID: 0000004479 – 003
MS25012/00E 08-06 © MTU

4.14.35 Charge-air coolant pump – Check
Special tools

Bore gauge, 18-100 mm Y20091481 1
Material

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

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

Risk of injury!
TIM ID: 0000004480 – 004
MS25012/00E 08-06 © MTU

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

cavitation.
Check bearing housing, impeller Crack indication Replace

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

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

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

diameters on pump shaft, impeller,
seal carrier and bearing housing
and gear with inside and outside
micrometer. Values and measuring
points (→ Page 644)
TIM ID: 0000004480 – 004
MS25012/00E 08-06 © MTU

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

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

bore
Angular contact 90.000 –0.015 0

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

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

bore
TIM ID: 0000004864 – 003
Shaft outer Ø 40.000 k5 +0.002 +0.013
5 Bearing housing 80.000 K7 –0.021 +0.009 0.022 0.021

bore
Cylindrical roller 80.000 –0.013 0

bearing
MS25012/00E 08-06 © MTU

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

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

TIM ID: 0000004864 – 003
MS25012/00E 08-06 © MTU

size Basic
size
Shaft seal 72.000 +0.130 +0.230

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

inner Ø
4 Impeller bore 35.000 H5 0 +0.011 0.032 0.050
Shaft outer Ø 35.000 t5 +0.048 +0.059
5 Rotary seal
Counterring
If wear traces are found: Replace components together
s1 : 0.4 to 0.6
TIM ID: 0000004864 – 003
s2 : 0.6 to 1.52
s3 : 0.08 to 0.5
MS25012/00E 08-06 © MTU

4.14.37 Charge-air coolant pump – Assembly
Special tools

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

Ethanol 40250 1
Corrosion inhibitor oil
Spare parts

Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Shaft seal
Rotary seal
O-ring
Component is hot.
Risk of burning!
Heavy object.
Risk of crushing!
TIM ID: 0000004489 – 004

Risk of injury!
MS25012/00E 08-06 © MTU

Assembling charge-air coolant pump

Note: Apply pressure to bearing outer ring.

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

housing (3), using snap ring pliers (1).
3. Check that snap ring (2) is correctly seated.
TIM ID: 0000004489 – 004
MS25012/00E 08-06 © MTU

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

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

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

onto pump shaft (3) using hydraulic press and
mandrel (1).
TIM ID: 0000004489 – 004
MS25012/00E 08-06 © MTU

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

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

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

shaft seal into seal carrier (3).
TIM ID: 0000004489 – 004
MS25012/00E 08-06 © MTU

10. Position intermediate washer in sealing ring

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

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

18. Place bearing housing (3) with seal carrier and
holding fixture (4) onto hydraulic press (1).
19. Use hydraulic press (1) to push heated gear (2)
onto shaft to stop position and hold until shrink
connection between shaft and gear is fixed.
TIM ID: 0000004489 – 004
MS25012/00E 08-06 © MTU

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

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

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

to the installation position marking made before
removal.
29. Tighten screws (2).
30. Turn pump shaft to check ease of movement.
31. Use feeler gauge to check clearance S2 (0.6 mm to
1.5 mm) between impeller and volute (3).
32. If measured clearance is out of tolerance,
determine the cause and replace components,
if necessary.
TIM ID: 0000004489 – 004
MS25012/00E 08-06 © MTU

4.14.38 Charge-air coolant pump – Installation
Material

Grease (Kluthe Hakuform 30–10/emulsifier) X00029933 1
Engine oil
Spare parts

O-ring
Heavy object.
Risk of crushing!

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

1. Remove all plugs.
2. Coat O-ring (1) with grease.
3. Insert O-ring (1) in groove on bearing housing of
charge-air coolant pump.
TIM ID: 0000004490 – 004
MS25012/00E 08-06 © MTU

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

position in bore on equipment carrier.
5. Insert screws (2) with washers.
6. Tighten screws (2) evenly.
TIM ID: 0000004490 – 004
MS25012/00E 08-06 © MTU

4.14.39 Coolant system from/to intercooler – Overview
100 Coolant return line 700 Screw

150 Coolant return line 800 O-ring
200 Coolant inlet line 850 Screw
250 Coolant inlet line 950 Retainer
300 Pipe line 1000 Pipe half-clamp
350 O-ring 1010 Pipe half-clamp
500 Screw 1060 Nut
600 Twin elbow 1070 Washer
TIM ID: 0000028542 – 001
MS25012/00E 08-06 © MTU

4.14.40 Coolant pipework from/to intercooler – Removal
Preconditions
Removing coolant pipework
1. Before removing the lines, it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove lines as per overview drawing (→ Page 655).
3. Remove sealant.
4. After removal, seal all connections with suitable plugs.
TIM ID: 0000004528 – 005
MS25012/00E 08-06 © MTU

4.14.41 Coolant system from/to intercooler – Clean
Material

Compressed air.
Risk of injury!


Cleaning coolant system from/to intercooler

TIM ID: 0000004536 – 003
MS25012/00E 08-06 © MTU

4.14.42 Coolant system from/to intercooler – Check
Spare parts

Coolant pipe
Pipe

Risk of injury!
Compressed air.
Risk of injury!
Checking coolant system from/to intercooler
Check sealing surfaces for irregularities. Uneven • Rework: smooth with

• Replace
Check all parts for damage. Damaged Replace
Check thread for freedom of movement Sluggish or damaged • Rework: Recut thread
and damage. • Replace
If necessary, check coolant lines for leaks Leaking Replace

in water bath, using compressed air and
corrosion inhibitor. Maintain a coolant
temperature of min. = 30 °C or max.
= 40 °C at a test pressure of 0.5 bar.
TIM ID: 0000004538 – 002
MS25012/00E 08-06 © MTU

4.14.43 Coolant system from/to intercooler – Installation
Material

Engine oil
Compressed air.
Risk of injury!
Installing coolant system from/to intercooler

2. Blow out coolant system from/to intercooler with compressed air.
3. Install coolant system pressureless from/to intercooler as per overview drawing (→ Page 655).
TIM ID: 0000004530 – 004
MS25012/00E 08-06 © MTU

4.14.44 Coolant pipework – Overview
Coolant distribution housing
50 Coolant distribution housing 250 O-ring 450 O-ring

150 O-ring 300 Screw 500 Screw
200 O-ring 350 Screw 700 Plug screw
TIM ID: 0000028581 – 001
MS25012/00E 08-06 © MTU

Sealing components
1 Coolant distribution housing 8 Plug screw

2 End cover 9 Sealing ring
3 Plug screw 10 Plug screw
4 Sealing ring 11 Sealing ring
6 Sealing ring 13 Sealing ring
TIM ID: 0000028581 – 001
MS25012/00E 08-06 © MTU

4.14.45 Coolant distribution housing – Removal
Preconditions
Suspended load.
Danger to life!
Coolant distribution housing – Removal

1. Insert eyebolts in coolant distribution housing and attach the housing using crane and rope.
2. Remove screws and washers for coolant distribution housing as shown in overview drawing (→ Page 660).
3. Using crane and rope, remove coolant distribution housing from gearcase.
4. Remove O-rings.
5. After removal, seal all connections with plugs.
TIM ID: 0000028582 – 001
MS25012/00E 08-06 © MTU

4.14.46 Coolant distribution housing – Cleaning
Material

Compressed air.
Risk of injury!


Coolant pipework with thermostat – Cleaning

TIM ID: 0000028583 – 001
MS25012/00E 08-06 © MTU

4.14.47 Coolant distribution housing – Check
Material

Spare parts

Coolant distribution housing
Compressed air.
Risk of injury!
Component is hot.
Risk of burning!
Coolant distribution housing – Check
Item Findings Task
Check all parts for damage and Damaged Replace

wear.
Check coolant distribution housing Signs of cracks Replace

with dye penetrant for cracks.
Check all contact and sealing • Stress marks • Corrective work: Smooth with
surfaces for damage and stress • Damage oilstone or emery cloth.
marks. visible • Replace
Check locating bores of thermostat Damaged • Corrective work: Smooth with

elements for damage. emery cloth.
• Replace
Check threads in coolant distribution Sluggish Replace thread inserts.

housing for ease of movement.
Sealing rings and O-rings – Replace
Check coolant and oil chambers Leaking Replace

of coolant distribution housing for
leaks with air and corrosion inhibitor
TIM ID: 0000028584 – 001
in water bath. Maintain a coolant

temperature of min. = 30 °C or
max. = 40 °C and a test pressure of
0.5 bar.
MS25012/00E 08-06 © MTU

4.14.48 Coolant distribution housing – Installation
Special tools

Eyebolt 000580010000 2
Mandrel F30379297 1
Material

Engine oil
Spare parts

O-rings
Suspended load.
Danger to life!
Coolant distribution housing – Installation

1. Coat O-rings with grease and insert in grooves (1)
in equipment carrier.
2. Insert plug screw (2).
3. Coat mating face of coolant distribution housing on
equipment carrier (arrow) with Loctite 518.
TIM ID: 0000028585 – 001
MS25012/00E 08-06 © MTU

Note: When fitting coolant distribution housing

in position, make sure O-rings are not
damaged.
4. Carefully place coolant distribution housing on

equipment carrier with crane and rope and align.
5. Fasten coolant distribution housing as shown in
overview drawing (→ Page 660).
TIM ID: 0000028585 – 001
MS25012/00E 08-06 © MTU

4.14.49 Thermostat – Overview
Thermostat housing (HT)
1 Plug-in pipe 5 Screw 9 Flange

2 Plug-in pipe 6 O-ring 10 O-ring
3 O-ring 7 Line 11 Screw
4 Flange 8 O-ring
TIM ID: 0000028626 – 001
MS25012/00E 08-06 © MTU

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

100 Plug screw 145 Sealing ring 200 O-ring
110 Twin elbow 160 Screw 300 Plug screw
120 Plug screw 170 Screw 350 Plug screw
125 Sealing ring 175 Screw 400 Sealing ring
130 Plug screw 185 Plug-in pipe
135 Sealing ring 190 Flange
TIM ID: 0000028626 – 001
MS25012/00E 08-06 © MTU

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

200 Thermostat element 750 Spacer tube 1300 Gasket
300 Thermostat housing 850 Screw 1450 Line
400 Screw 900 Screw 1500 O-ring
450 Screw 950 Washer 1600 Flange
550 O-ring 1050 Plug screw 1650 O-ring
600 Screw 1150 Elbow 1700 Screw
TIM ID: 0000028626 – 001
MS25012/00E 08-06 © MTU

4.14.50 Thermostat – Removal
Preconditions
Removing the thermostat
1. Remove thermostat (high-temperature circuit) as per overview drawing (→ Page 667).
2. Remove thermostat (low-temperature circuit) as per overview drawing (→ Page 667).
TIM ID: 0000028627 – 001
MS25012/00E 08-06 © MTU

4.14.51 Thermostat – Disassembly

Thermostat – Disassembly
1. Remove end cover.
2. Remove thermostat element from thermostat housing (→Maintenance Manual).
TIM ID: 0000028629 – 001
MS25012/00E 08-06 © MTU

4.14.52 Thermostat – Cleaning
Material

Compressed air.
Risk of injury!


Thermostat – Cleaning
TIM ID: 0000028628 – 001
MS25012/00E 08-06 © MTU

4.14.53 Thermostat – Check
Spare parts

Thermostat housing
Thermostat – Check
Item Findings Task
Check all parts for damage and Damaged Replace

condition.
Check all contact and sealing • Stress marks • Corrective work: Smooth with
surfaces for damage and stress • Damage oilstone or emery cloth.
marks. visible • Replace
Check locating bores of thermostat Damaged • Corrective work: Smooth with

elements for damage. emery cloth.
• Replace
Gaskets, sealing rings and O-rings – Replace

TIM ID: 0000028630 – 001
MS25012/00E 08-06 © MTU

4.14.54 Thermostat – Installation

Installing the thermostat
2. Assemble in reverse order of disassembly (→ Page 670).
TIM ID: 0000028631 – 001
MS25012/00E 08-06 © MTU

4.15 Power Supply, Engine Side
4.15.1 Battery-charging generator – Overview
Generator with generator drive, right side
100 Drive 900 Washer 1550 Screw

200 O-ring 1000 Nut 1600 Spacer sleeve
250 Screw 1050 Screw 1650 Retainer
300 Screw 1100 Washer 1700 Retainer
350 Washer 1150 Nut 1750 Screw
400 Generator 1200 Poly-vee belt 1800 Screw
500 Belt pulley 1250 Belt tensioner 1850 Washer
600 Retainer 1300 Screw 1900 Washer
700 Screw 1350 Washer 1950 Nut
750 Washer 1400 Protective cover
850 Screw 1500 Retainer
TIM ID: 0000020817 – 002
MS25012/00E 08-06 © MTU

Generator with generator drive, left side
50 Drive 400 Screw 625 Washer

100 O-ring 410 Retainer 650 Protective cover
125 Screw 425 Washer 725 Screw
130 Screw 450 Nut 750 Spacer sleeve
140 Retainer 475 Screw 825 Screw
150 Washer 480 Retainer 850 Screw
175 Generator 500 Washer 875 Washer
225 Belt pulley 525 Nut 900 Washer
275 Retainer 550 Poly-vee belt 925 Nut
325 Screw 575 Belt tensioner
350 Washer 600 Screw
TIM ID: 0000020817 – 002
MS25012/00E 08-06 © MTU

4.15.2 Battery-charging generator – Removal
Preconditions
Heavy object.
Risk of crushing!
Disconnecting cables
1. Before disconnecting, affix adhesive tape on all cables at terminals so that they can be labeled.
2. Label the adhesive tape with the corresponding terminal marking.
3. Disconnect all cables on battery-charging generator.
4. Protect all cables from damage.
Removing battery-charging generator and generator

drive
1. Loosen screws (6, 7).
2. Push down belt tensioning pulley (5) with a suitable
tool until V-belt becomes loose.
3. Tighten screw (7).
4. Remove screw (6).
5. Remove belt tensioning pulley and V-belt (2).
6. Secure battery-charging generator (1) with rope
and crane.
8. Carefully remove battery-charging generator.
9. Protect battery-charging generator from damage.
10. Remove bracket (4) and generator drive as shown
in overview drawing (→ Page 675).
TIM ID: 0000020819 – 002
MS25012/00E 08-06 © MTU

4.15.3 Battery-charging generator – Disassembly
Disassembling battery-charging generator

Have battery-charging generator overhauled by an authorized workshop only.
TIM ID: 0000004822 – 002
MS25012/00E 08-06 © MTU

4.15.4 Battery-charging generator – Cleaning
Material

Compressed air.
Risk of injury!


Cleaning battery-charging generator

1. Clean generator with compressed air only; do not use any liquids in cleaning process.
2. Clean all metal parts using cleaner (Snow-White 11-0) and rinse with cleaner (Hakupur 312).
TIM ID: 0000004823 – 002
MS25012/00E 08-06 © MTU

4.15.5 Battery-charging generator – Check
Spare parts

Generator
Belt pulley
V-belt
Generator drive
Checking battery-charging generator
Check battery-charging generator Damaged Replace

externally for damage.
Check all contact surfaces and Damaged • Rework: smooth with oilstone
mating faces for damage. or emery cloth.
• Replace
Check thread for ease of movement. Sluggish • Rework: recut thread.

• Replace
Check battery-charging generator Abnormal running noises Disassemble battery-charging

for abnormal running noises. generator (→ Page 678).
TIM ID: 0000004830 – 002
MS25012/00E 08-06 © MTU

4.15.6 Battery-charging generator – Installation
Material


Risk of injury!
Heavy object.
Risk of crushing!

Installing generator drive

1. Coat O-ring with grease and correctly position
generator drive (4) in gearcase.
2. Install bracket (arrowed) for guard plate as shown
in overview drawing (→ Page 675).
3. Screw in screws (3) with washers and tighten
diagonally.
4. Install holder (2) with screws (1) and washers.
TIM ID: 0000028725 – 001
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Installing battery-charging generator

1. Install battery-charging generator (1) on to
holder (4) using screws (3).
2. Install belt tensioning pulley (5).
3. Insert securing screw (6) by hand only.
4. Place new drive belt (2) onto belt pulleys.
Note: When screw (7) is loosened, the belt
tensioning pulley immediately springs to
full tension. Observe safety instructions.
5. Loosen screw (7) slightly.

6. Use torque wrench to tighten screw (6) to specified
7. Use torque wrench to tighten screw (7) to specified
8. Install electrical cables on battery-charging
generator.
9. Install guard plate as shown in overview drawing
(→ Page 675).
TIM ID: 0000028725 – 001
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4.16 Mounting/Support
4.16.1 Engine mounting / support – Overview
Variant A
1 Engine mounting bracket 2 Engine mount

TIM ID: 0000004292 – 001
MS25012/00E 08-06 © MTU

Variant B
1 Engine mounting bracket 2 Engine mount
TIM ID: 0000004292 – 001
MS25012/00E 08-06 © MTU

4.16.2 Engine mounting – Overview
Version A
1 Washer 6 Screw
2 Screw 7 Washer
3 Nut 8 Engine mounting bracket
4 Washer 9 Dowel pin
5 Damper mount 10 O-ring
TIM ID: 0000029544 – 001
MS25012/00E 08-06 © MTU

Variant B
1 Screw 3 Engine mounting bracket 5 Screw

2 Washer 4 Damper mount 6 Washer
TIM ID: 0000029544 – 001
MS25012/00E 08-06 © MTU

Engine supports
1 Engine support 3 Engine support 5 Screw

2 Screw 4 Screw 6 Nut
TIM ID: 0000029544 – 001
MS25012/00E 08-06 © MTU

Engine supports, 20V
1 Engine support 3 Engine support

2 Screw 4 Screw
TIM ID: 0000029544 – 001
MS25012/00E 08-06 © MTU

4.16.3 Engine mount – Removal
Special tools

Box wrench F30379609 1
Engine can tilt over.

Danger to life!
Suspended load.
Danger to life!
Option A
1. Install engine supports on starter mounting flange,
if there are no engine supports on driving end.
2. Remove foundation screws (3) from resilient
mount to be removed.
3. Remove screws (1) and screws (2) from engine
mounting bracket.
4. Remove engine mount from crankcase.
Option B
1. Install engine supports on starter mounting flange,
if no engine supports are already installed
on driving end.
2. Remove screws (1) from engine mounting bracket.
3. Remove foundation screws (2) from resilient
mount to be removed.
4. Remove engine mount from crankcase.
TIM ID: 0000028726 – 001
MS25012/00E 08-06 © MTU

4.16.4 Engine mounts – Cleaning

Compressed air.
Risk of injury!
Cleaning engine mounts

Note: Do not allow resilient rubber mounts to come into contact with oil and fuel.
1. Wipe rubber surfaces with dry cloth only; do not clean with organic detergents.
2. Blow out all parts thoroughly with compressed air.
TIM ID: 0000004501 – 002
MS25012/00E 08-06 © MTU

4.16.5 Engine mounts – Check
Material

Spare parts

Engine mounting bracket
Damper mount
Dowel pin
Checking engine mounts
Check engine mounting bracket for cracks Sign of cracks Replace

with red penetrant dye.
Using the magnetic crack-testing method, Sign of cracks Replace

check central buffer for cracks.
Check central buffer for wear and damage. • Traces of wear Replace
• Damage
Visible
Check resilient rubber mounts for cracks and • Damage Replace

deformation (visual inspection). • Cracks
• Deformation
Visible
Check thread for ease of movement. Sluggish • Rework: recut thread.

• Replace
Check bolt-on faces for flatness. Uneven • Rework: smooth with oilstone.
• Replace
Check grooves for O-rings for damage. Damaged • Rework

• Replace
TIM ID: 0000004502 – 002
MS25012/00E 08-06 © MTU

4.16.6 Engine mounting – Installation

Engine can tilt over.
Danger to life!
Suspended load.
Danger to life!
Engine mounting – Installation

1. Install engine mounting bracket with resilient mount, screws and washers as shown in overview drawing
(→ Page 685).
2. Tighten screws with torque wrench to specified tightening torque (→ Page 23).
TIM ID: 0000028727 – 002
MS25012/00E 08-06 © MTU

4.17 Monitoring, Control and Regulation Equipment
4.17.1 Monitoring, control and regulation devices – Overview
Engine Control Unit (ECU)

TIM ID: 0000004209 – 001
MS25012/00E 08-06 © MTU

4.17.2 Engine wiring harnesses and brackets – Overview
Designation Pin assignment
Engine wiring harness X2 ECU

W2
B1 Camshaft speed
B5 Oil pressure
B5.3 Oil pressure
B6 Engine coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Engine speed
B16 Engine coolant pressure
B26 Charge-air coolant temperature
B33 Fuel temperature
B34 Fuel pressure after filter
B43 Charge-air coolant pressure
B48 Fuel HP pressure after HP pump
B50 Crankcase pressure
M8 HP fuel pump actuator
X21.2 POM-CAN
XF33 Coolant level
XF46 Leak-off fuel
XF57 Charge-air coolant level
XM2 Oil priming pump
XXY44 W4 ventilation control
XY44 Ventilation control

W4
Y39.1 to Y39.8 Injectors, engine side A
Y39.11 to Y39.18 Injectors, engine side B

TIM ID: 0000029134 – 001

W12
B4.1 to B4.8 Temperature sensors for single exhaust gas, engine side
A
B4.10 to B4.18 Temperature sensors for single exhaust gas, engine side
B
MS25012/00E 08-06 © MTU

Engine wiring harness W2 (standard version)
1 Wiring harness W2 4 Pressure sensor 7 Pressure sensor

2 Speed sensor 5 Pressure sensor 8 Bush
3 Temperature sensor 6 Pressure sensor 9 O-ring
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

Engine wiring harness W2 (for classification or optional)
1 Wiring harness W2 4 Pressure sensor 7 Pressure sensor

2 Speed sensor 5 Pressure sensor 8 Bush
3 Temperature sensor 6 Pressure sensor 9 O-ring
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

Engine wiring harness W4
55 Wiring harness W4 Y39.6 Injector A6 Y39.14 Injector B4

Y39.1 Injector A1 Y39.7 Injector A7 Y39.15 Injector B5
Y39.2 Injector A2 Y39.8 Injector A8 Y39.16 Injector B6
Y39.3 Injector A3 Y39.11 Injector B1 Y39.17 Injector B7
Y39.4 Injector A4 Y39.12 Injector B2 Y39.18 Injector B8
Y39.5 Injector A5 Y39.13 Injector B3
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

Engine wiring harness W12 (for classification or optional)
1 Wiring harness W12 B4.6 Temperature sensor A6 B4.14 Temperature sensor B4

B4.1 Temperature sensor A1 B4.7 Temperature sensor A7 B4.15 Temperature sensor B5
B4.2 Temperature sensor A2 B4.8 Temperature sensor A8 B4.16 Temperature sensor B6
B4.3 Temperature sensor A3 B4.11 Temperature sensor B1 B4.17 Temperature sensor B7
B4.4 Temperature sensor A4 B4.12 Temperature sensor B2 B4.18 Temperature sensor B8
B4.5 Temperature sensor A5 B4.13 Temperature sensor B3
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

Retainer for engine governor
200 Retainer 900 Screw

250 Spacer bushing 1000 Retainer
300 Screw 1050 Spacer sleeve
400 Retainer 1100 Screw
500 Screw 1150 Nut
550 Nut 1200 Damper
600 Damper 1250 Washer
650 Nut 1350 Ground strap
700 Washer 1400 Screw
800 Retainer 1450 Nut
850 Spacer bushing 1500 Washer
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

3600 Retainer 3900 Cable clamp 4400 Clamp

3675 Cable clamp 4000 Retainer 4450 Spacer bushing
3750 Cable clamp 4050 Screw 4500 Screw
3800 Cable clamp 4100 Washer 4550 Screw
3825 Retainer 4150 Nut 4650 Washer
3875 Spacer 4200 Cable clamp 5700 Retainer
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

1350 Ground strap 2350 Clamp 3360 Retainer

1450 Nut 2450 Washer 3380 Washer
1500 Washer 2550 Retainer 3390 Cable clamp
2150 Clamp 2600 Screw 3450 Cable clamp
2200 Screw 2650 Washer 3500 Cable clamp
2250 Washer 2700 Nut 5700 Retainer
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

2800 Retainer 3150 Cable clamp 3320 Clamp

2850 Screw 3200 Cable clamp 3330 Screw
2900 Washer 3250 Retainer 3340 Washer
2950 Nut 3275 Screw 3600 Retainer
3000 Cable clamp 3300 Retainer 3675 Cable clamp
3050 Cable clamp 3310 Screw 5350 Cable clamp
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

4300 Cable clamp 4650 Washer 5000 Washer

4400 Clamp 4900 Retainer 5600 Retainer
TIM ID: 0000029134 – 001
MS25012/00E 08-06 © MTU

4.17.3 Engine wiring harnesses – Removal
Preconditions
Hot oil.
Hot oil.

Removing engine wiring harnesses

1. Observe safety regulations.
2. Remove engine wiring harnesses as per overview drawing (→ Page 694).
TIM ID: 0000029518 – 002
MS25012/00E 08-06 © MTU

4.17.4 Engine wiring harness – Clean
Material

Cleaner (Hakupur 312 at 2% concentration)


Cleaning engine wiring harness

1. Clean engine wiring harness with cleaning agent.
2. Remove cleaner.
TIM ID: 0000029520 – 001
MS25012/00E 08-06 © MTU

4.17.5 Engine wiring harness – Check
Material

Cable tie
Insulating tape
Heat-shrinkable hose
Spare parts

Engine wiring harness
Checking engine wiring harness

1. The engine governor continuously monitors all engine wiring harnesses.
2. The engine governor detects and reports the following errors to the connected monitoring system:
• Defective electrical assemblies
• Cabling damage
• Short circuits
• Sensor values outside of the plausibility range.
3. Carry out following checks and maintenance:
Check engine wiring harness for • Cracks • Rework: repair using insulating
cracks, kinks and chafing • Kinks tape or heat-shrinkable hose.
• Chafing • Replace engine wiring harness.
visible
Check shrink-formed components Damaged Replace shrink-formed components.

for damage.
Check plug connections for Damaged • Rework: Straighten plug

damages. connections.
• Replace plug connector.
Check engine wiring harness for Loose engine wiring harness Re-fix engine wiring harness with
tight seating. cable tie.
TIM ID: 0000029521 – 001
MS25012/00E 08-06 © MTU

4.17.6 Engine wiring harnesses – Installation
Spare parts

Retainer
Elastomeric spring
Guard plate


Installing engine wiring harnesses

1. Observe safety regulations.
2. Install engine wiring harnesses as per overview drawing (→ Page 694).
TIM ID: 0000029522 – 002
MS25012/00E 08-06 © MTU

4.17.7 Sensors, actuators and injectors – Overview

Illustration applies analogously to 12 V 4000 Gx3
1 Temperature sensors for single

exhaust gas B4.1 to B4.8
(engine side A)
2 B34 (P fuel after filter)
3 M8 (HP fuel pump actuator)
The injectors (Y39.1 to Y39.8, engine side A) are underneath the cylinder head covers of the cylinder.
Replacement of injectors and activities required for this (→Operating instructions ).
TIM ID: 0000029524 – 001
MS25012/00E 08-06 © MTU

1 B50 (P crankcase) 6 B01 (N camshaft)

2 B05.3 (P lube oil before filter) 7 B48 (P fuel, rail)
3 B05 (P lube oil after filter) 8 B43 (P charge-air coolant)
4 B33 (T fuel, rail) 9 B26 (T charge-air coolant)
5 B07 (T lube oil) 10 B06 (T-coolant)
TIM ID: 0000029524 – 001
MS25012/00E 08-06 © MTU

1 Temperature sensors for single 2 B16 (P coolant)

exhaust gas B4.11 to B4.18 3 B10 (P charge-air)
(engine side B) 4 B09 (T charge-air)
The injectors (Y39.11 to Y39.18, engine side B) are underneath the cylinder head covers of the cylinder.
Replacement of injectors and activities required for this (→Operating instructions )
TIM ID: 0000029524 – 001
MS25012/00E 08-06 © MTU

1 B13 (N crankshaft)
TIM ID: 0000029524 – 001
MS25012/00E 08-06 © MTU

4.17.8 Sensors, actuators and injectors – Removal

• Do not smoke.
• Do not smoke.
Hot oil.

Remove temperature sensors (B6, B7, B9, B26, B33)

1. Observe the following general information:
• The structure and electrical features of the
sensors and identical. They are removed
identically.
• Arrangement and position of the sensors
(→ Page 708).
2. Observe the following before removing:
B7 (oil temperature) A little engine oil may escape during removal. Capture
engine oil in a vessel.
B33 (fuel temperature) A little fuel may escape during removal. Capture fuel in
a vessel.
3. Release bayonet lock (1) and pull out the plug (2).
4. Place wrench on nut (3) and unscrew the sensor.
TIM ID: 0000029529 – 001
MS25012/00E 08-06 © MTU

Remove temperature sensors for single exhaust gas

(A-side B4.1, B4.2....) and (B-side B4.11, B4.12....).
sensors and identical. They are removed
identically.
(→ Page 708).
2. Unscrew union nut (1) from temperature sensor.
3. Pull temperature sensor out of the threaded
connectors (2).
Remove pressure sensors (B5, B5.3, B10, B16, B43)

1. Generell beachten:
• Die Sensoren sind konstruktiv und elektrisch
baugleich. Der Ausbau erfolgt identisch.
• Anordnung und Lage der Sensoren
(→ Page 708).
• Beim Ausbau des Sensors B5 (Öldruck)
können geringe Mengen Motorenöl austreten.
Motorenöl in bereitgestelltem Gefäß auffangen.
2. Bajonettverschluss (1) lösen und Stecker (2)
abziehen.
3. Schlüssel an Mutter (3) ansetzen und den Sensor
ausschrauben.
Drucksensor (B34) ausbauen

• Anordnung und Lage des Sensors
(→ Page 708).
• Beim Ausbau des Sensors B34 (Kraftstoffdruck
nach Filter) können geringe Mengen Kraftstoff
austreten. Kraftstoff in bereitgestelltem Gefäß
auffangen.
abziehen.
ausschrauben.
TIM ID: 0000029529 – 001
MS25012/00E 08-06 © MTU


(→ Page 708).
• Beim Ausbau des Sensors B48
(Kraftstoffhochdruck) können geringe
Mengen Kraftstoff austreten. Kraftstoff in
bereitgestelltem Gefäß auffangen.
abziehen.
ausschrauben.

(→ Page 708).
• Beim Ausbau des
Sensors B50 (Kurbelgehäusedruck) können
geringe Mengen Motorenöldämpfe austreten.
abziehen.
ausschrauben.
Drehzahlsensoren (B1, B13) ausbauen

(→ Page 708).
2. Bajonettverschluss (1) des Drehzahlsensors (2)
lösen und vom Stecker (3) der Motorverkabelung
abziehen.
3. Schraube (4) ausschrauben.
4. Drehzahlsensor (2) herausziehen.
TIM ID: 0000029529 – 001
MS25012/00E 08-06 © MTU

4.17.9 Sensors, actuators and injectors – Check
Material

Isopropyl alcohol
Spare parts

Pressure sensor
Pressure monitor
Speed sensor
Temperature sensor
Level monitor
Sensors, actuators and injectors – Check

1. Always note:
• The governor is able to detect defective electric assemblies, wire breaks, short circuits and deviating
sensor values.
2. Carry out the following checks:
Item Findings Task
Check sensors and actuators for Loose sensors or actuators. Retighten securing screws.
secure seating.
Check security of plug connections. Loose plug connections. Connect plug connections properly
and tighten.
Check sensors, actuators and Damaged Replace

plug connections for mechanical
damage.
Check sensors, actuators and plug Contamination visible. Clean relevant assembly with
connections for contamination (e.g. isopropyl alcohol.
oil sludge).
TIM ID: 0000029531 – 001
MS25012/00E 08-06 © MTU

4.17.10 Sensors, actuators and injectors – Installation
Material

Spare parts

O-ring
Sealing ring
Adjusting washer
Install temperature sensors (B6, B7, B9, B26, B33)

sensors and identical. They are installed
identically.
(→ Page 708).
2. Coat sensor O-ring with grease.
3. Manually screw sensor into the borehole.
4. Use torque wrench to tighten nut (3) to specified
5. Plug on the plug (2) and tighten the bayonet
lock (1).
Install temperature sensors for single exhaust gas

(A-side B4.1, B4.2....) and (B-side B4.11, B4.12....).
sensors and identical. They are installed
identically.
(→ Page 708).
2. Insert temperature sensor into the threaded
connectors (2).
3. Using a torque wrench, tighten nut to specified
4. Tighten union nut (1) on temperature sensor to
TIM ID: 0000029530 – 001
MS25012/00E 08-06 © MTU

Install pressure sensors (B5, B5.3, B10, B16, B43)

baugleich. Der Anbau erfolgt identisch.
(→ Page 708).
2. O-Ring des Sensors mit Fett bestreichen.
3. Sensor in Bohrung von Hand einschrauben.
4. Mutter (3) mit Drehmomentschlüssel auf
vorgeschriebenes Anziehdrehmoment
(→ Page 23) anziehen.
5. Stecker (2) aufstecken und Bajonettverschluss (1)
anziehen.
Drucksensor (B34) anbauen

(→ Page 708).
anziehen.

(→ Page 708).
anziehen.
TIM ID: 0000029530 – 001
MS25012/00E 08-06 © MTU


(→ Page 708).
anziehen.
Drehzahlsensoren ( B13) anbauen

(→ Page 708).
3. Abstandsmaß “A” siehe Tabelle unten
ermitteln. Falls erforderlich mit Passcheibe an
Befestigungsbohrung unterlegen
Abstandsmass “A” (Zwischen Sensor und Messrad)
MDEC 1 mm bis 1,3 mm
DDEC 0,5 mm bis 1 mm
4. Sensor in die Bohrung einstecken und eindrücken.

5. Sensor (2) mit Schraube (4) anziehen.
6. Stecker des Sensors (2) in die Buchse (3) der
Motorverkabelung stecken. Bajonettverschluss (1)
anziehen.
7. Wenn nötig, Sensorkabel auf die richtige Länge
TIM ID: 0000029530 – 001
aufrollen und mit Kabelbindern fixieren.
MS25012/00E 08-06 © MTU

Drehzahlsensoren (B1) anbauen

(→ Page 708).
3. Sensor in die Bohrung einstecken und eindrücken.
4. Sensor (2) mit Schraube (4) anziehen.
5. Stecker des Sensors (2) in die Buchse (3) der
Motorverkabelung stecken. Bajonettverschluss (1)
anziehen.
6. Wenn nötig, Sensorkabel auf die richtige Länge
aufrollen und mit Kabelbindern fixieren.
Füllstandsonde extern(F33, F57) anbauen

1. O-Ring mit Fett bestreichen.
3. Mutter von Sensor (3) mit Drehmomentschlüssel
auf vorgeschriebenes Anziehdrehmoment
4. Stecker (1) aufstecken und Bajonettverschluss
(2) anziehen.
TIM ID: 0000029530 – 001
MS25012/00E 08-06 © MTU

TIM ID: 0000029530 – 001
MS25012/00E 08-06 © MTU

Special Tools 721
5 Special Tools
5.1 Standard tools – Overview
Order no. Designation Quan-

Use tity
8205891159/00 General tool kit 1

TIM ID: 0000009214 – 003
MS25012/00E 08-06 © MTU

722 Special Tools
5.2 Special tools – Overview
Part No. Designation / Use Qty.
Y20097353 Endoscope 1
Y20010175 Bore gauge, 275-300 mm 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 723
Y20002705 C-frame micrometer, 275-300 1

mm
Y20091483 Bore gauge, 160-280 mm 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

724 Special Tools

mm

mm
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 725
Y20091481 Bore gauge, 18-100 mm 1

mm
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

726 Special Tools
Y20011268 Dial gauge 1
Y20002779 Depth gauge, 500 mm 1
F0099994 Swivel frame 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 727
F6557935 Hydraulic kit 1
F6557936 Hydraulic kit 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

728 Special Tools
F6783824 Camshaft bearing removal 1

device
B80146893 Hand pump kit 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 729
F6786993 Swivel frame 1
F6557186 Hydraulic screw pretensioner 2

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

730 Special Tools
F6553646 Installation/removal tool for 1

main bearing stud
F6555771 Stop device for plug (main oil 1

gallery)
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 731
F6555738 Assembly jig for camshaft 1

bearing
F30378754 Assembly mandrel for end 1

cover
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

732 Special Tools
F30450446 Camshaft bearing shrink-on 1

tool
F6555763 Guide bushing for camshaft 1

bearing shrink-on tool
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 733
F30026582 Torque wrench, 20-100 Nm 1
F30027340 Ratchet adapter 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

734 Special Tools
F6785078 Removal tool for carbon 1

scraper ring
F6557114 Removal tool for cylinder liner 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 735
F6787880 Press-in tool for cylinder liner 1
Y20000326 Micrometer, 150-175 mm 1
40002 Penetrant remover (standard 1

check)
40004 Aqueous developer (standard 1

check)
TIM ID: 0000009600 – 001
40488 Dye penetrant (standard 1

check)
MS25012/00E 08-06 © MTU

736 Special Tools
T80092075 Eyebolt 4
T80092075 Eyebolt 4
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 737
F30047446 Torque wrench 60-320 Nm 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

738 Special Tools

mm
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 739
0015890321/00 Retainer 1
T80091550 Support bracket 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

740 Special Tools
T80091551 Lifting gear 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 741
F6557190 Removal tool for crankshaft 1

bearing, driving end
B80096717 Lukas cylinder 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

742 Special Tools
B80146893 Hand pump set 1
F30378426 Insertion tool 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 743
F6557153 Locating device 1
T80091550 Bracket 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

744 Special Tools
T80091102 Bracket 1
F6781672 Support 1
Flange 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 745
000912016030 Socket-head screws 6
F6782971 Guide bushing 1
F30033099 Screwdriver (Torx 30) 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

746 Special Tools
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 747
B80146411 Adapter 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

748 Special Tools
B80096717 Lucas cylinder 1
F6557191 Press-out tool 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 749
F30378425 Insertion tool 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

750 Special Tools
F30377680 Installation mandrel for 1

radial-lip shaft seal
F6782344 Alignment device 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 751

mm

mm
Master weights
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

752 Special Tools

mm
Y20506341 DynaMIC hardness tester 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 753
Y20091482 Bore gauge, 100-160 mm 1
F6553644 Crankshaft locating device 2

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

754 Special Tools
F6783568 Removal tool for crankshaft 1

bearing caps
F6557936 Hydraulic set 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 755
B80144827 High-pressure hose 1
B80144838 Distributor 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

756 Special Tools
Y4341947 Measuring device 1
F6553645 Slide protection 2
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 757
0005892716/00 Adapter 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

758 Special Tools
F6787133 Tightening device 1
Y4347843 Clearance gauge 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 759
F6555764 Press-in tool 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

760 Special Tools
F6783003 Alignment tool 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 761
F6553649 Installation aid 1
B80146524 Distributor 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

762 Special Tools
F6553647 Installation/removal device 1
F0140168 Installation/removal device for 1

flywheel
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 763
T80091387 Trestle 1
F6782322 Guide sleeve (in addition to 1

20V)
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

764 Special Tools
B80146893 Hand pump kit, 0-1000 bar 1
B80146887 Hand pump kit, 0-3000 bar 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 765
F6554716 Press-in tool 1
B80146887 Hand pump kit 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

766 Special Tools
F6782322 Guide sleeve for flywheel 1
F0140771 Removal/installation tool 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 767
T80091550 Carrying bracket 1
T80091570 Lifting equipment 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

768 Special Tools
F6780591 Guide sleeve 1
F6781745 Guide sleeve 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 769
F6553672 Flange 1
000912016016 Screw 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

770 Special Tools
F6782017 Puller spindle 1
B80098529 Hex nut 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 771
F0140771 Installation/removal tool 1
T80092198 Lifting gear with M6 thread 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

772 Special Tools
T80091496 Lifting gear with M8 thread 1
T80091025 Lifting device with 2x M6 1

thread
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 773
F6555791 Barring tool 1
F6555792 Pointer for barring tool 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

774 Special Tools
Y4341124 Graduation plate, free end 1
F30378352 Socket insert, 22 A/F, conrod 1

screws
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 775
F6787914 Assembly dolly 1
F30450332 Piston-ring pliers 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

776 Special Tools
F30450332 Piston ring pliers 1
F30002760 Snap ring pliers 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 777
F6783605 Installation sleeves, 1

piston/conrod for carbon
scraper ring
F6555791 Barring gear for graduation 1

plate
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

778 Special Tools
Y4341919 Measuring device for TDC 1

measurement in cylinder head
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 779
F30378352 Socket AF22 – conrod screws 1
Y4341492 Testing device 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

780 Special Tools
Y4341913 Test mandrel 1
Y4341914 Test mandrel 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 781
F30378352 Socket, 22 A/F – Conrod 1

screws
Y20090113 Limit plug gauge for valve 1

guide (as-new dimension), 11
mmH7
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

782 Special Tools
Y20097473 Limit plug gauge for repaired 1

ready-to-use valve guide,
11mm H9

guide bore in cylinder head,
19.00mm H7
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 783

19.10mm H7

19.30mm H7
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

784 Special Tools
Y4340442 Check gauge for inlet valve 1

seat
Y4340443 Check gauge for exhaust 1

valve seat
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 785
Y4343688 Pressure testing device 1
Y20000083 C-frame micrometer, 0-25 mm 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

786 Special Tools
F6553658 Tightening equipment (power 1

amplifier)
B80144872 Plug 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 787

plugs

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

788 Special Tools
F6783833 Valve spring compressor 1
F30377634 Socket 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 789
F6783749 Tool kit without elliptical 1

chamfer reconditioning
F6783751 Tool kit (accessory) 1

for elliptical chamfer
reconditioning
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

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

removal
F30450433 Indexable insert 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 791
F6554300 Mounting plate for valve guide 1

installation
F30450348 Valve guide extractor 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

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

0 cylinder head bore
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 793

I cylinder head bore

II cylinder head bore
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

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

guide
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 795
Y20091080 Plug gauge for stage 0 1

cylinder head bore
Y20097512 Plug gauge for stage I cylinder 1

head bore
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

796 Special Tools
Y20097513 Plug gauge for stage II 1

cylinder head bore
F30450631 Valve seat contour restoring 1

tool for exhaust valve with
valve-seatinsert
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 797
F30450632 Valve seat contour restoring 1

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

contour restoring tool
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

798 Special Tools
Y4340443 Exhaust valve gauge 1
Y4340442 Inlet valve gauge 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 799
Y4341935 Valve seat test device 1
F30451554 Countersink reamer tool 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

800 Special Tools
F30450751 Inserting mandrel for 1

valve-seat insert, inlet
F30450750 Inserting mandrel for 1

valve-seat insert, exhaust
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 801
T80090944 Carrying bracket 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

802 Special Tools

seal plug
B80144872 Seal plug 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 803
F6553658 Tightening tool (power 1

amplifier)
F6558582 Alignment tool for 8V and 12V 1

cylinder heads
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

804 Special Tools
F6553648 Alignment tool for 16V and 1

20V cylinder heads
F30378324 Adjusting mandrel 2
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 805
Y20044010 Measuring tool for angle of 1

rotation

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

806 Special Tools
F30378617 Mandrel, Ø 20 mm 1
F30377862 Guide sleeve for mandrel 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 807
F30271842 Mandrel, Ø 24 mm 1
F30377635 Mandrel, Ø 30 mm 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

808 Special Tools
Y20506341 Hardness tester DynaMIC 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 809
0015890321/00 Measuring stand 1
F6553642 Camshaft locating device 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

810 Special Tools
F30450435 Camshaft installation/removal 1

tool
F6782970 Guide sleeve for camshaft 1

8V-16V
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 811
F6781673 Guide sleeve for camshaft 1

20V
F6781676 Guide sleeve for assembly on 1

driving end
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

812 Special Tools

driving end

free end
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 813
F6780582 Centering sleeve for assembly 1

on free end
F6555791 Barring tool 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

814 Special Tools
Y4341124 Timing wheel, free end 1
Y4341919 Measuring device 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 815
Y20010128 Feeler gauge 1
Y4341124 Graduated disc, free end 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

816 Special Tools
0015890321/00 Holder 1
Y4341124 Timing disc, free end 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 817
F30038493 Box wrench, 19 mm 1
F30501562 Box wrench, 24 mm 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

818 Special Tools
F30027341 Ratchet 1
8205893261/00 Oilstone 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 819
T80091497 Lifting device 1
T80091497 Lifting equipment 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

820 Special Tools
F6784183 Puller 1
F6784167 Pressing tool 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 821
F30025896 Combination insertion 1

wrench; 17 mm
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

822 Special Tools

wrench, 19 mm

wrench, 27 mm
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 823
F30379104 Filter wrench 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

824 Special Tools
0015384230 Torque wrench 1
F30043446 Torque wrench 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 825
F30027340 Ratchet 1
Pin Ø 0.084 inch 2
Pin Ø 0.096 inch 2
Pin Ø 0.0864 inch 2
TDI-52-20134 Wrench 1
TDI-2-26945 Shaft removal tool 1
TDI-52-20076 Puller, rotor stage 2 1
TDI-52-20202 Carrier shaft holding jig 1
TDI-52-20143 Bearing pressing tool 1
TDI-2-26943 Tool for bearing/seal 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

826 Special Tools
0015384230 Torque wrench 0.5-5 Nm 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 827
Test bath

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

828 Special Tools
F6555799 Guide pin 1
Y4341968 Testing device 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 829

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

830 Special Tools
F6781539 Hydraulic spindle 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 831
F6780562 Puller tool for impeller 1
F6780561 Puller tool for gear 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

832 Special Tools
F6781573 Holding fixture 1
F30275611 Carrier for several mandrels 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 833
F30450991 Impact extractor for shaft seal 1
F30378152 Press-fit tool for 1

angular-contact ball bearings
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

834 Special Tools
F30378153 Press-fit tool for roller 1

bearings
F30450990 Press-fit tool for shaft seal 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 835
F6784612 Press-in tool for rotary seal 1
F6780563 Fixture for bearing housing 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

836 Special Tools
F6781573 Fixture for shaft with bearing 1
F6780561 Retaining device 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 837
F30002760 Pliers for snap ring 1
0005388520 Hot-air blower 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

838 Special Tools
F30378152 Installation tool for 1

angular-contact ball bearing
F30378153 Installation tool for roller 1

bearing
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 839
F30450990 Installation tool for shaft seal 1
F6784612 Installation tool for rotary seal 1

TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

840 Special Tools
F6780563 Bearing housing support 1
F6781573 Support for shaft with bearing 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 841
F30275611 Support for various mandrels 1
000580010000 Eyebolt 2
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

842 Special Tools
F30379297 Mandrel 1
F30379609 Box wrench 1
TIM ID: 0000009600 – 001
MS25012/00E 08-06 © MTU

Special Tools 843
5.3 General workshop equipment – Overview

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

wrench
TIM ID: 0000009216 – 002
MS25012/00E 08-06 © MTU

844 Special Tools

Use tity
F30025896 Open end wrench 1

bit

bit
TIM ID: 0000009216 – 002
MS25012/00E 08-06 © MTU

Special Tools 845

Use tity

bit

bit
TIM ID: 0000009216 – 002
MS25012/00E 08-06 © MTU

846 Special Tools

Use tity
F30047446 Torque wrench 1
F30450902 Ratchet bit 1
TIM ID: 0000009216 – 002
MS25012/00E 08-06 © MTU

Special Tools 847

Use tity
F30501631 Starter wrench 1
TIM ID: 0000009216 – 002
MS25012/00E 08-06 © MTU

848 Special Tools

Use tity
5505890921/00 Compression 1
pressure recorder
5505890921/06 Diagram sheets 1
TIM ID: 0000009216 – 002
MS25012/00E 08-06 © MTU

Special Tools 849
5.4 Measuring tools – General overview

Use tity
Y20000088 Outside micrometer 1
Y20000085 Outside micrometer 1

TIM ID: 0000009215 – 002
MS25012/00E 08-06 © MTU

850 Special Tools

Use tity
Y20000665 Adjusting ring 1

(9 mm)
Y20000918 Depth gauge 1
TIM ID: 0000009215 – 002
MS25012/00E 08-06 © MTU

Special Tools 851

Use tity
Y20001743 Caliper gauge 1
Y20016482 Bore gauge 1

TIM ID: 0000009215 – 002
MS25012/00E 08-06 © MTU

852 Special Tools

Use tity
TIM ID: 0000009215 – 002
MS25012/00E 08-06 © MTU

Special Tools 853

Use tity

TIM ID: 0000009215 – 002
MS25012/00E 08-06 © MTU

854 Special Tools
TIM ID: 0000009215 – 002
MS25012/00E 08-06 © MTU

Appendix 855
6 Appendix
6.1 Manufacturer’s documentation

See manufacturer’s documentation.
TIM ID: 0000007620 – 001
MS25012/00E 08-06 © MTU

856 Appendix
6.2 MTU contact/service partner

You will find the MTU-contact person/service partner for your region at www.mtu-online.com.
TIM ID: 0000007624 – 002
MS25012/00E 08-06 © MTU

Appendix 857
6.3 Index
A Air supply from turbocharger to intercooler –
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . 50 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
Air filter with bracket – Removal . . . . . . . . . . . 478 Air supply from turbocharger to intercooler –
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
Air filter with retainers – Installation . . . . . . . . 481
Air supply from turbocharger to intercooler –
Air filter with retainers – Overview . . . . . . . . . . 476
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Air filters and retainers – Check . . . . . . . . . . . 480
Air supply system to cylinders, left –
Air filters and retainers – Clean . . . . . . . . . . . . 479 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
Air Intake / Air Supply . . . . . . . . . . . . . . . . . . . 475 Air supply system to cylinders, right –
Air filter with bracket – Removal . . . . . . 478 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Air filter with retainers – Installation . . . 481
Air supply system to cylinders, right –
Air filter with retainers – Overview . . . . 476
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
Air filters and retainers – Check . . . . . . 480
Air filters and retainers – Clean . . . . . . . 479 Air supply to cylinders, left side – Check . . . . . 485
Air intake / air supply – Overview . . . . . 475 Air supply to cylinders, LHS – Removal . . . . . 483
Air pipework to cylinders, left side – Air supply to cylinders, RHS – Check . . . . . . . 490
Installation . . . . . . . . . . . . . . . . . . . . . . 486
Air supply to cylinders, RHS – Removal . . . . . 488
Air pipework to cylinders, right side –
Installation . . . . . . . . . . . . . . . . . . . . . . 491 Auxiliary materials, fire prevention and
Air supply from turbocharger to intercooler environmental protection . . . . . . . . . . . . . . . . . 18
– Check . . . . . . . . . . . . . . . . . . . . . . . . 495
Air supply from turbocharger to intercooler B
– Cleaning . . . . . . . . . . . . . . . . . . . . . . 494
Air supply from turbocharger to intercooler Battery-charging generator – Check . . . . . . . . 680
– Installation . . . . . . . . . . . . . . . . . . . . . 496 Battery-charging generator – Cleaning . . . . . . 679
Air supply from turbocharger to intercooler Battery-charging generator – Disassembly . . . 678
– Overview . . . . . . . . . . . . . . . . . . . . . . 492 Battery-charging generator – Installation . . . . 681
Air supply from turbocharger to intercooler
– Removal . . . . . . . . . . . . . . . . . . . . . . 493 Battery-charging generator – Overview . . . . . 675
Air supply system to cylinders, left – Battery-charging generator – Removal . . . . . . 677
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 484 Bearing bushing of idler gear – Removal and
Air supply system to cylinders, right – installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 489
Air supply system to cylinders, right –
Overview . . . . . . . . . . . . . . . . . . . . . . . . 487 C
Air supply to cylinders, left side – Camshaft – Check . . . . . . . . . . . . . . . . . . . . . 354
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 485 Camshaft – Cleaning . . . . . . . . . . . . . . . . . . . 352
Air supply to cylinders, LHS –
Camshaft – Installation . . . . . . . . . . . . . . . . . . 360
Removal . . . . . . . . . . . . . . . . . . . . . . . . 483
Air supply to cylinders, RHS – Camshaft – Overview . . . . . . . . . . . . . . . . . . . 349
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 490 Camshaft – Removal . . . . . . . . . . . . . . . . . . . 350
Air supply to cylinders, RHS – Camshaft – Tolerances . . . . . . . . . . . . . . . . . . 357
Removal . . . . . . . . . . . . . . . . . . . . . . . . 488
Camshaft drive – Check . . . . . . . . . . . . . . . . . 371
Intake air system to cylinders, left –
Overview . . . . . . . . . . . . . . . . . . . . . . . . 482 Camshaft drive – Cleaning . . . . . . . . . . . . . . . 370
Air intake / air supply – Overview . . . . . . . . . . 475 Camshaft drive – Installation . . . . . . . . . . . . . . 372
Air pipework to cylinders, left side – Camshaft drive – Overview . . . . . . . . . . . . . . . 367
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 486 Camshaft drive – Removal . . . . . . . . . . . . . . . 368
TIM ID: 0000007624 – 002
Air pipework to cylinders, right side – Camshaft running surfaces and swing followers
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 491 – Visual inspection . . . . . . . . . . . . . . . . . . . . . 353
Air supply from turbocharger to intercooler – Camshaft thrust bearing – Check . . . . . . . . . . 376
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495 Camshaft thrust bearing – Cleaning . . . . . . . . 375
Air supply from turbocharger to intercooler – Camshaft thrust bearing – Overview . . . . . . . . 373
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
Camshaft thrust bearing – Replacement . . . . . 374
Centrifugal oil filter – Assembly . . . . . . . . . . . . 556
MS25012/00E 08-06 © MTU

858 Appendix
Centrifugal oil filter – Check . . . . . . . . . . . . . . 555 Charge-air coolant pump –

Centrifugal oil filter – Cleaning . . . . . . . . . . . . 554 Installation . . . . . . . . . . . . . . . . . . . . . . 653
Charge-air coolant pump –
Centrifugal oil filter – Disassembly . . . . . . . . . 552
Overview . . . . . . . . . . . . . . . . . . . . . . . . 633
Centrifugal oil filter – Installation . . . . . . . . . . . 559 Charge-air coolant pump –
Centrifugal oil filter – Overview . . . . . . . . . . . . 550 Removal . . . . . . . . . . . . . . . . . . . . . . . . 635
Centrifugal oil filter – Removal . . . . . . . . . . . . 551 Charge-air coolant pump –
Tolerances . . . . . . . . . . . . . . . . . . . . . . 644
Charge-air coolant pump – Assembly . . . . . . . 647
Coolant distribution housing –
Charge-air coolant pump – Check . . . . . . . . . 642 Check . . . . . . . . . . . . . . . . . . . . . . . . . . 664
Charge-air coolant pump – Cleaning . . . . . . . 641 Coolant distribution housing –
Charge-air coolant pump – Disassembly . . . . 636 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 663
Coolant distribution housing –
Charge-air coolant pump – Installation . . . . . . 653
Installation . . . . . . . . . . . . . . . . . . . . . . 665
Charge-air coolant pump – Overview . . . . . . . 633 Coolant distribution housing –
Charge-air coolant pump – Removal . . . . . . . 635 Removal . . . . . . . . . . . . . . . . . . . . . . . . 662
Charge-air coolant pump – Tolerances . . . . . . 644 Coolant pipework – Overview . . . . . . . . 660
Coolant pipework after cylinder –
Conrod – Assembly . . . . . . . . . . . . . . . . . . . . 292
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Conrod – Check . . . . . . . . . . . . . . . . . . . . . . . 281 Coolant pipework after cylinder –
Conrod – Disassembly . . . . . . . . . . . . . . . . . . 279 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . 615
Conrod – Tolerances . . . . . . . . . . . . . . . . . . . . 288 Coolant pipework after cylinder –
Installation . . . . . . . . . . . . . . . . . . . . . . 617
Conversion tables . . . . . . . . . . . . . . . . . . . . . . 41
Coolant distribution housing – Check . . . . . . . 664 Overview . . . . . . . . . . . . . . . . . . . . . . . . 613
Coolant distribution housing – Cleaning . . . . . 663 Coolant pipework after cylinder –
Coolant distribution housing – Installation . . . . 665 Removal . . . . . . . . . . . . . . . . . . . . . . . . 614
Coolant pipework for engine coolant
Coolant distribution housing – Removal . . . . . 662
pump, intake side – Installation . . . . . . . 612
Coolant pipework – Overview . . . . . . . . . . . . . 660 Coolant pipework for engine coolant
Coolant pipework after cylinder – Check . . . . . 616 pump, intake side – Removal . . . . . . . . 609
Coolant pipework after cylinder – Clean . . . . . 615 Coolant pipework from/to intercooler –
Removal . . . . . . . . . . . . . . . . . . . . . . . . 656
Coolant pipework to engine coolant pump,
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
intake side – Check . . . . . . . . . . . . . . . 611
Coolant pipework after cylinder – Coolant supply for engine coolant pump,
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613 intake side – Clean . . . . . . . . . . . . . . . . 610
Coolant pipework after cylinder – Removal . . . 614 Coolant supply for engine coolant pump,
Coolant pipework for engine coolant pump, intake side – Overview . . . . . . . . . . . . . 607
intake side – Installation . . . . . . . . . . . . . . . . . 612 Coolant system – Overview . . . . . . . . . 584
Coolant system from/to intercooler –
Coolant pipework for engine coolant pump,
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 658
intake side – Removal . . . . . . . . . . . . . . . . . . . 609
Coolant pipework from/to intercooler – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . 657
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656 Coolant system from/to intercooler –
Coolant pipework to engine coolant pump, Installation . . . . . . . . . . . . . . . . . . . . . . 659
intake side – Check . . . . . . . . . . . . . . . . . . . . 611 Coolant system from/to intercooler –
Coolant supply for engine coolant pump, intake Overview . . . . . . . . . . . . . . . . . . . . . . . . 655
side – Clean . . . . . . . . . . . . . . . . . . . . . . . . . . 610 Engine coolant and charge-air coolant
Coolant supply for engine coolant pump, intake ventilation – Check . . . . . . . . . . . . . . . . 631
side – Overview . . . . . . . . . . . . . . . . . . . . . . . 607 Engine coolant and charge-air coolant
ventilation – Cleaning . . . . . . . . . . . . . . 630
TIM ID: 0000007624 – 002
Coolant System . . . . . . . . . . . . . . . . . . . . . . . 584 Engine coolant and charge-air coolant

Charge-air coolant pump – ventilation – Overview . . . . . . . . . . . . . . 625
Assembly . . . . . . . . . . . . . . . . . . . . . . . 647 Engine coolant and charge-air cooling
Charge-air coolant pump – Check . . . . 642 vent – Installation . . . . . . . . . . . . . . . . . 632
Charge-air coolant pump – Engine coolant and charge-air cooling
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 641 vent – Removal . . . . . . . . . . . . . . . . . . . 629
Charge-air coolant pump – Engine coolant pump – Assembly . . . . . 599
Disassembly . . . . . . . . . . . . . . . . . . . . . 636 Engine coolant pump – Check . . . . . . . 594
MS25012/00E 08-06 © MTU

Appendix 859
Engine coolant pump – Cleaning . . . . . 593 Piston – Check . . . . . . . . . . . . . . . . . . . 267

Engine coolant pump – Disassem- Piston – Cleaning . . . . . . . . . . . . . . . . . 266
bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588 Piston – Tolerances . . . . . . . . . . . . . . . 270
Engine coolant pump – Installation . . . . 605 Piston and conrod – Assembly . . . . . . . 295
Engine coolant pump – Overview . . . . . 585 Piston and conrod – Disassembly . . . . . 264
Engine coolant pump – Removal . . . . . 587 Piston and conrod – Installation . . . . . . 299
Engine coolant pump – Tolerances . . . . 596 Piston and conrod – Overview . . . . . . . 258
Preheating unit – Installation . . . . . . . . . 624 Piston and conrod – Removal . . . . . . . . 262
Preheating unit – Overview . . . . . . . . . . 618 Piston rod – Cleaning . . . . . . . . . . . . . . 280
Preheating unit – Removal . . . . . . . . . . 619 Radial-lip shaft seal, driving end –
Preheating unit, coolant pump – Installation . . . . . . . . . . . . . . . . . . . . . . 238
Replacement . . . . . . . . . . . . . . . . . . . . 622 Radial-lip shaft seal, driving end –
Preheating unit, screw-in heating element Removal . . . . . . . . . . . . . . . . . . . . . . . . 235
– Replacement . . . . . . . . . . . . . . . . . . . 620 Vibration damper on PTO, free end –
Preheating unit, thermostat – Check . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Replacement . . . . . . . . . . . . . . . . . . . . 623 Vibration damper on PTO, free end –
Thermostat – Check . . . . . . . . . . . . . . . 673 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 251
Thermostat – Cleaning . . . . . . . . . . . . . 672 Vibration damper on PTO, free end –
Thermostat – Disassembly . . . . . . . . . . 671 Disassembly . . . . . . . . . . . . . . . . . . . . . 250
Thermostat – Installation . . . . . . . . . . . 674 Vibration damper on PTO, free end –
Thermostat – Overview . . . . . . . . . . . . . 667 Installation . . . . . . . . . . . . . . . . . . . . . . 254
Thermostat – Removal . . . . . . . . . . . . . 670 Vibration damper on PTO, free end –
Coolant system – Overview . . . . . . . . . . . . . . 584 Removal . . . . . . . . . . . . . . . . . . . . . . . . 247
Vibration damper on PTO, free end –
Tolerances . . . . . . . . . . . . . . . . . . . . . . 253
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
Crank drive – Overview . . . . . . . . . . . . . . . . . . 192
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657 Crankcase – Assembly . . . . . . . . . . . . . . . . . . 98
Coolant system from/to intercooler – Crankcase – Check . . . . . . . . . . . . . . . . . . . . 83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 659 Crankcase – Checking upper and lower cylinder
Coolant system from/to intercooler – liner fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655 Crankcase – Cleaning . . . . . . . . . . . . . . . . . . . 78
Crank Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Crankcase – Disassembly . . . . . . . . . . . . . . . 75
Conrod – Assembly . . . . . . . . . . . . . . . 292 Crankcase – Overview . . . . . . . . . . . . . . . . . . 72
Conrod – Check . . . . . . . . . . . . . . . . . . 281
Crankcase – Tolerances . . . . . . . . . . . . . . . . . 89
Conrod – Disassembly . . . . . . . . . . . . . 279
Conrod – Tolerances . . . . . . . . . . . . . . . 288 Crankcase and attachments – Overview . . . . 71
Crank drive – Overview . . . . . . . . . . . . 192 Crankcase breather – Check . . . . . . . . . . . . . 153
Crankshaft – Assembly . . . . . . . . . . . . . 214 Crankcase breather – Cleaning . . . . . . . . . . . 152
Crankshaft – Balancing . . . . . . . . . . . . . 216
Crankcase breather – Overview . . . . . . . . . . . 147
Crankshaft – Check . . . . . . . . . . . . . . . 201
Crankshaft – Disassembly . . . . . . . . . . 199 Crankcase ventilation – Installation . . . . . . . . . 159
Crankshaft – Installation . . . . . . . . . . . . 222 Crankcase ventilation – Removal . . . . . . . . . . 151
Crankshaft – Overview . . . . . . . . . . . . . 193 Crankshaft – Assembly . . . . . . . . . . . . . . . . . . 214
Crankshaft – Removal . . . . . . . . . . . . . 195
Crankshaft – Balancing . . . . . . . . . . . . . . . . . . 216
Crankshaft – Tolerances . . . . . . . . . . . . 205
Crankshaft - Cleaning . . . . . . . . . . . . . . 200 Crankshaft – Check . . . . . . . . . . . . . . . . . . . . 201
Crankshaft bearing bore – Check . . . . . 219 Crankshaft – Disassembly . . . . . . . . . . . . . . . 199
Crankshaft PTO, free end – Crankshaft – Installation . . . . . . . . . . . . . . . . . 222
Overview . . . . . . . . . . . . . . . . . . . . . . . . 243
Crankshaft – Overview . . . . . . . . . . . . . . . . . . 193
Flywheel on PTO flange, driving end –
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Crankshaft – Removal . . . . . . . . . . . . . . . . . . 195
TIM ID: 0000007624 – 002
Flywheel on PTO flange, driving end – Crankshaft – Tolerances . . . . . . . . . . . . . . . . . 205

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 236 Crankshaft - Cleaning . . . . . . . . . . . . . . . . . . . 200
Crankshaft bearing bore – Check . . . . . . . . . . 219
Installation . . . . . . . . . . . . . . . . . . . . . . 239
Flywheel on PTO flange, driving end – Crankshaft PTO, free end – Overview . . . . . . 243
Overview . . . . . . . . . . . . . . . . . . . . . . . . 230
Removal . . . . . . . . . . . . . . . . . . . . . . . . 233
MS25012/00E 08-06 © MTU

860 Appendix
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . 304 Engine – Removal . . . . . . . . . . . . . . . . . . . . . 60

Cylinder head – Assembly . . . . . . . . . . 340 Engine – Running-in procedure . . . . . . . . . . . 66
Cylinder head – Check . . . . . . . . . . . . . 318
Engine Casing and Add-on Components . . . . 69
Cylinder head – Cleaning . . . . . . . . . . . 317
Crankcase – Assembly . . . . . . . . . . . . . 98
Cylinder head – Disassembly . . . . . . . . 315
Crankcase – Check . . . . . . . . . . . . . . . 83
Cylinder head – Installation . . . . . . . . . . 344
Crankcase – Checking upper and lower
Cylinder head – Plug repair . . . . . . . . . 338
cylinder liner fit . . . . . . . . . . . . . . . . . . . 80
Cylinder head – Removal . . . . . . . . . . . 312
Crankcase – Cleaning . . . . . . . . . . . . . 78
Cylinder head – Repair . . . . . . . . . . . . . 332
Crankcase – Disassembly . . . . . . . . . . 75
Cylinder head – Tolerances . . . . . . . . . 321
Crankcase – Overview . . . . . . . . . . . . . 72
Cylinder head and attachments –
Crankcase – Tolerances . . . . . . . . . . . . 89
Overview . . . . . . . . . . . . . . . . . . . . . . . . 304
Crankcase and attachments –
Valve-seat turning machine for cylinder
Overview . . . . . . . . . . . . . . . . . . . . . . . . 71
head . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Crankcase breather – Check . . . . . . . . 153
Cylinder head – Assembly . . . . . . . . . . . . . . . 340 Crankcase breather – Cleaning . . . . . . 152
Cylinder head – Check . . . . . . . . . . . . . . . . . . 318 Crankcase breather – Overview . . . . . . 147
Cylinder head – Cleaning . . . . . . . . . . . . . . . . 317 Crankcase ventilation – Installation . . . 159
Crankcase ventilation – Removal . . . . . 151
Cylinder head – Disassembly . . . . . . . . . . . . . 315
Cylinder liner – Check . . . . . . . . . . . . . . 111
Cylinder head – Installation . . . . . . . . . . . . . . . 344 Cylinder liner – Cleaning . . . . . . . . . . . . 110
Cylinder head – Plug repair . . . . . . . . . . . . . . 338 Cylinder liner – Installation . . . . . . . . . . 115
Cylinder head – Removal . . . . . . . . . . . . . . . . 312 Cylinder liner – Overview . . . . . . . . . . . 106
Cylinder liner – Removal . . . . . . . . . . . . 108
Cylinder head – Repair . . . . . . . . . . . . . . . . . . 332
Cylinder liner – Tolerances . . . . . . . . . . 113
Cylinder head – Tolerances . . . . . . . . . . . . . . 321 End housing , driving end –
Cylinder head and attachments – Tolerances . . . . . . . . . . . . . . . . . . . . . . 141
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 End housing driving end – Overview . . . 133
Cylinder head cover – Check . . . . . . . . . . . . . 399 End housing, driving end –
Assembly . . . . . . . . . . . . . . . . . . . . . . . 142
Cylinder head cover – Cleaning . . . . . . . . . . . 398
End housing, driving end – Check . . . . 140
Cylinder head cover – Installation . . . . . . . . . . 400 End housing, driving end – Cleaning . . . 139
Cylinder head cover – Overview . . . . . . . . . . . 396 End housing, driving end –
Cylinder head cover – Removal . . . . . . . . . . . 397 Installation . . . . . . . . . . . . . . . . . . . . . . 144
End housing, driving end – Removal . . . 136
Cylinder liner – Check . . . . . . . . . . . . . . . . . . . 111
End housing, driving end
Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . 110 disassembly . . . . . . . . . . . . . . . . . . . . . 138
Cylinder liner – Installation . . . . . . . . . . . . . . . 115 Engine layout . . . . . . . . . . . . . . . . . . . . 69
Cylinder liner – Overview . . . . . . . . . . . . . . . . 106 Engine lifting equipment – Check . . . . . 131
Engine lifting equipment – Cleaning . . . 130
Cylinder liner – Removal . . . . . . . . . . . . . . . . . 108
Engine lifting equipment –
Cylinder liner – Tolerances . . . . . . . . . . . . . . . 113 Installation . . . . . . . . . . . . . . . . . . . . . . 132
Engine lifting equipment – Removal . . . 129
E Engine lifting equipment - Overview . . . 127
Hengst oil separator – Assembly . . . . . 157
End housing , driving end – Tolerances . . . . . 141 Hengst oil separator – Check . . . . . . . . 156
End housing driving end – Overview . . . . . . . . 133 Hengst oil separator – Disassembly . . . 154
End housing, driving end – Assembly . . . . . . . 142 Oil pan – Check . . . . . . . . . . . . . . . . . . 121
End housing, driving end – Check . . . . . . . . . 140 Oil pan – Cleaning . . . . . . . . . . . . . . . . 120
Oil pan – Installation . . . . . . . . . . . . . . . 122
End housing, driving end – Cleaning . . . . . . . 139
Oil pan – Overview . . . . . . . . . . . . . . . . 118
End housing, driving end – Installation . . . . . . 144 Oil pan – Removal . . . . . . . . . . . . . . . . 119
End housing, driving end – Removal . . . . . . . 136 Tightening sequence for oil pan
TIM ID: 0000007624 – 002
End housing, driving end disassembly . . . . . . 138 GGG . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Engine – Assembly . . . . . . . . . . . . . . . . . . . . . 63 Engine coolant and charge-air coolant ventilation
– Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
Engine – Checking condition before a major
overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Engine coolant and charge-air coolant ventilation
– Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
Engine – Disassembly . . . . . . . . . . . . . . . . . . 61
Engine coolant and charge-air coolant ventilation
Engine – Installation . . . . . . . . . . . . . . . . . . . . 65
– Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
MS25012/00E 08-06 © MTU

Appendix 861
Engine coolant and charge-air cooling vent – Exhaust pipework after cylinder head –
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 632 Check . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Engine coolant and charge-air cooling vent – Exhaust pipework after cylinder head –
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Exhaust pipework after cylinder head –
Engine coolant pump – Assembly . . . . . . . . . . 599
Installation . . . . . . . . . . . . . . . . . . . . . . 501
Engine coolant pump – Check . . . . . . . . . . . . 594 Exhaust pipework after cylinder head –
Engine coolant pump – Cleaning . . . . . . . . . . 593 Overview . . . . . . . . . . . . . . . . . . . . . . . . 497
Engine coolant pump – Disassembly . . . . . . . 588 Exhaust pipework after cylinder head –
Removal . . . . . . . . . . . . . . . . . . . . . . . . 498
Engine coolant pump – Installation . . . . . . . . . 605
Engine coolant pump – Overview . . . . . . . . . . 585
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Engine coolant pump – Removal . . . . . . . . . . 587
Engine coolant pump – Tolerances . . . . . . . . . 596 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . 69 Exhaust pipework after cylinder head –
Engine lifting equipment – Check . . . . . . . . . . 131 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Engine lifting equipment – Cleaning . . . . . . . . 130 Exhaust pipework after cylinder head –
Engine lifting equipment – Installation . . . . . . . 132 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
Engine lifting equipment – Removal . . . . . . . . 129 Exhaust pipework after cylinder head –
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
Engine lifting equipment - Overview . . . . . . . . 127
Exhaust Turbocharger . . . . . . . . . . . . . . . . . . 460
Engine mount – Removal . . . . . . . . . . . . . . . . 689
Exhaust turbocharger – Check . . . . . . . 464
Engine mounting – Installation . . . . . . . . . . . . 692 Exhaust turbocharger – Installation . . . 465
Engine mounting – Overview . . . . . . . . . . . . . 685 Exhaust turbocharger – Overview . . . . . 460
Engine mounting / support – Overview . . . . . . 683 Exhaust turbocharger – Removal . . . . . 462
Exhaust turbochargers – Clean . . . . . . 463
Engine mounts – Check . . . . . . . . . . . . . . . . . 691
Exhaust turbocharger – Check . . . . . . . . . . . . 464
Engine mounts – Cleaning . . . . . . . . . . . . . . . 690
Exhaust turbocharger – Installation . . . . . . . . . 465
Engine side and cylinder designations . . . . . . 22
Exhaust turbocharger – Overview . . . . . . . . . . 460
Engine wiring harness – Check . . . . . . . . . . . . 706
Exhaust turbocharger – Removal . . . . . . . . . . 462
Engine wiring harness – Clean . . . . . . . . . . . . 705
Exhaust turbochargers – Clean . . . . . . . . . . . . 463
Engine wiring harnesses – Installation . . . . . . 707
Engine wiring harnesses – Removal . . . . . . . . 704
Engine wiring harnesses and brackets – F
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694 Flywheel on PTO flange, driving end –
Equipment carrier free end – Cleaning . . . . . . 167 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Exhaust pipe bellows after engine – Check . . . 507 Flywheel on PTO flange, driving end –
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Exhaust pipe bellows after engine –
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 Flywheel on PTO flange, driving end –
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 508 Flywheel on PTO flange, driving end –
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 Flywheel on PTO flange, driving end –
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505 Fuel delivery pump – Check . . . . . . . . . . . . . . 436
Exhaust Pipework . . . . . . . . . . . . . . . . . . . . . . 497 Fuel delivery pump – Cleaning . . . . . . . . . . . . 435
Exhaust pipe bellows after engine – Fuel delivery pump – Disassembly . . . . . . . . . 434
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 507
TIM ID: 0000007624 – 002
Fuel delivery pump – Installation . . . . . . . . . . . 437

Exhaust pipe bellows after engine – Fuel delivery pump – Overview . . . . . . . . . . . . 432
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 506
Exhaust pipe bellows after engine – Fuel delivery pump – Removal . . . . . . . . . . . . 433
Installation . . . . . . . . . . . . . . . . . . . . . . 508 Fuel duplex filter – Assembly . . . . . . . . . . . . . 448
Exhaust pipe bellows after engine – Fuel duplex filter – Disassembly . . . . . . . . . . . 445
Overview . . . . . . . . . . . . . . . . . . . . . . . . 503 Fuel duplex filter – Installation . . . . . . . . . . . . 449
Removal . . . . . . . . . . . . . . . . . . . . . . . . 505 Fuel duplex filter – Overview . . . . . . . . . . . . . . 443
MS25012/00E 08-06 © MTU

862 Appendix
Fuel duplex filter – Removal . . . . . . . . . . . . . . 444 Gear train, free end – Overview . . . . . . . . . . . 179
Fuel filter – Check . . . . . . . . . . . . . . . . . . . . . . 447 Gear train, free end – Removal . . . . . . . . . . . . 181
Fuel filter – Cleaning . . . . . . . . . . . . . . . . . . . . 446 Gear train, free end – Tolerances . . . . . . . . . . 185
Fuel injector disassembly . . . . . . . . . . . . . . . . 412 Gearcase, free end – Assembly . . . . . . . . . . . 171
Fuel lines from fuel delivery pump to fuel filter – Gearcase, free end – Check . . . . . . . . . . . . . . 168
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 Gearcase, free end – Disassembly . . . . . . . . . 166
Fuel lines from fuel delivery pump to fuel filter – Gearcase, free end – Installation . . . . . . . . . . 175
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Gearcase, free end – Overview . . . . . . . . . . . 160
Fuel lines from fuel delivery pump to fuel filter –
Gearcase, free end – Removal . . . . . . . . . . . . 164
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
Gearcase, free end – Tightening sequence . . . 174
Fuel lines from fuel delivery pump to fuel filter –
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 Gearcase, free end – Tolerances . . . . . . . . . . 169
Fuel pipework from fuel delivery pump to fuel General Conditions . . . . . . . . . . . . . . . . . . . . . 13
filter – Overview . . . . . . . . . . . . . . . . . . . . . . . 438 Abbreviations . . . . . . . . . . . . . . . . . . . . 50
Auxiliary materials, fire prevention and
Fuel pipework from fuel filter to high-pressure
environmental protection . . . . . . . . . . . 18
pump – Check . . . . . . . . . . . . . . . . . . . . . . . . . 453
Conversion tables . . . . . . . . . . . . . . . . . 41
Fuel pipework from fuel filter to high-pressure Engine side and cylinder
pump – Cleaning . . . . . . . . . . . . . . . . . . . . . . . 452 designations . . . . . . . . . . . . . . . . . . . . . 22
Fuel pipework from fuel filter to HP pump – General information regarding the
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 Tolerances and Wear Limits List . . . . . . 21
Fuel pipework from fuel filter to HP pump – General Instructions . . . . . . . . . . . . . . . 13
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 Personnel and organizational
requirements . . . . . . . . . . . . . . . . . . . . . 14
Fuel pipework from fuel filter to HP pump –
Repairing threaded bores with threaded
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
inserts (Heli-Coil) . . . . . . . . . . . . . . . . . 47
Safety precautions when working on the
G engine . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Settings . . . . . . . . . . . . . . . . . . . . . . . . . 39
Bearing bushing of idler gear – Removal Standards for warning notices in the
and installation . . . . . . . . . . . . . . . . . . . 190 publication . . . . . . . . . . . . . . . . . . . . . . 20
Equipment carrier free end – Torque specifications for screws, nuts and
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 167 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gear train, free end – Check . . . . . . . . . 183 Transport . . . . . . . . . . . . . . . . . . . . . . . 49
Gear train, free end – Cleaning . . . . . . . 182 General information regarding the Tolerances
Gear train, free end – Installation . . . . . 187 and Wear Limits List . . . . . . . . . . . . . . . . . . . . 21
Gear train, free end – Overview . . . . . . 179 General Instructions . . . . . . . . . . . . . . . . . . . . 13
Gear train, free end – Removal . . . . . . . 181 General workshop equipment – Overview . . . 843
Gear train, free end – Tolerances . . . . . 185
Gearcase, free end – Assembly . . . . . . 171
Gearcase, free end – Check . . . . . . . . . 168 H
Gearcase, free end – Disassembly . . . . 166 H.P. fuel pump – Control block replace-
Gearcase, free end – Installation . . . . . 175 ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Gearcase, free end – Overview . . . . . . 160
Hengst oil separator – Assembly . . . . . . . . . . 157
Gearcase, free end – Removal . . . . . . . 164
Gearcase, free end – Tightening Hengst oil separator – Check . . . . . . . . . . . . . 156
sequence . . . . . . . . . . . . . . . . . . . . . . . 174 Hengst oil separator – Disassembly . . . . . . . . 154
Gearcase, free end – Tolerances . . . . . 169 High-pressure fuel line – Check . . . . . . . . . . . 423
Gear train, free end – Check . . . . . . . . . . . . . . 183 High-pressure fuel line – Cleaning . . . . . . . . . 422
TIM ID: 0000007624 – 002
Gear train, free end – Cleaning . . . . . . . . . . . . 182

Gear train, free end – Installation . . . . . . . . . . 187
MS25012/00E 08-06 © MTU

Appendix 863
High-Pressure Fuel System . . . . . . . . . . . . . . 401 Intercooler – Check . . . . . . . . . . . . . . . . . . . . . 472

Fuel injector disassembly . . . . . . . . . . . 412 Intercooler – Cleaning . . . . . . . . . . . . . . . . . . . 471
H.P. fuel pump – Control block
Intercooler – Disassembly . . . . . . . . . . . . . . . . 470
replacement . . . . . . . . . . . . . . . . . . . . . 407
High-pressure fuel line – Check . . . . . . 423 Intercooler – Installation . . . . . . . . . . . . . . . . . 474
High-pressure fuel line – Cleaning . . . . 422 Intercooler – Overview . . . . . . . . . . . . . . . . . . 467
High-pressure line – Removal . . . . . . . . 421 Intercooler – Removal . . . . . . . . . . . . . . . . . . . 469
High-pressure pump – Check . . . . . . . . 405
High-pressure pump – Disassembly . . . 404
High-pressure pump – Overview . . . . . 402 L
High-pressure pump – Removal . . . . . . 403 Leak off fuel pipework – Overview . . . . . . . . . 455
HP fuel line – Overview . . . . . . . . . . . . 417 Leak-off fuel line – Installation . . . . . . . . . . . . . 459
HP fuel system – Overview . . . . . . . . . . 401
HP line – Installation . . . . . . . . . . . . . . . 424 Leak-off fuel line – Removal . . . . . . . . . . . . . . 456
HP pump – Installation . . . . . . . . . . . . . 406 Leak-off fuel pipework – Check . . . . . . . . . . . . 458
Injector – Check . . . . . . . . . . . . . . . . . . 414 Leak-off fuel pipework – Cleaning . . . . . . . . . . 457
Injector – Cleaning . . . . . . . . . . . . . . . . 413 Low-Pressure Fuel System . . . . . . . . . . . . . . . 429
Injector – Installation . . . . . . . . . . . . . . . 415 Fuel delivery pump – Check . . . . . . . . . 436
Injector – Overview . . . . . . . . . . . . . . . . 408 Fuel delivery pump – Cleaning . . . . . . . 435
Injector – Removal . . . . . . . . . . . . . . . . 410 Fuel delivery pump – Disassembly . . . . 434
Pressure relief valve on fuel distributor – Fuel delivery pump – Installation . . . . . 437
Installation . . . . . . . . . . . . . . . . . . . . . . 428 Fuel delivery pump – Overview . . . . . . . 432
Pressure relief valve on fuel distributor – Fuel delivery pump – Removal . . . . . . . 433
Removal . . . . . . . . . . . . . . . . . . . . . . . . 427 Fuel duplex filter – Assembly . . . . . . . . 448
High-pressure line – Removal . . . . . . . . . . . . . 421 Fuel duplex filter – Disassembly . . . . . . 445
High-pressure pump – Check . . . . . . . . . . . . . 405 Fuel duplex filter – Installation . . . . . . . 449
High-pressure pump – Disassembly . . . . . . . . 404 Fuel duplex filter – Overview . . . . . . . . . 443
Fuel duplex filter – Removal . . . . . . . . . 444
High-pressure pump – Overview . . . . . . . . . . . 402 Fuel filter – Check . . . . . . . . . . . . . . . . . 447
High-pressure pump – Removal . . . . . . . . . . . 403 Fuel filter – Cleaning . . . . . . . . . . . . . . . 446
HP fuel line – Overview . . . . . . . . . . . . . . . . . . 417 Fuel lines from fuel delivery pump to fuel
HP fuel system – Overview . . . . . . . . . . . . . . . 401 filter – Check . . . . . . . . . . . . . . . . . . . . . 441
Fuel lines from fuel delivery pump to fuel
HP line – Installation . . . . . . . . . . . . . . . . . . . . 424 filter – Cleaning . . . . . . . . . . . . . . . . . . . 440
HP pump – Installation . . . . . . . . . . . . . . . . . . 406 Fuel lines from fuel delivery pump to fuel
filter – Installation . . . . . . . . . . . . . . . . . 442
Fuel lines from fuel delivery pump to fuel
I filter – Removal . . . . . . . . . . . . . . . . . . . 439
Important Information . . . . . . . . . . . . . . . . . . . 11 Fuel pipework from fuel delivery pump to
Prerequisites for maintenance tasks and fuel filter – Overview . . . . . . . . . . . . . . . 438
general assembly instructions . . . . . . . . 11 Fuel pipework from fuel filter to
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 866 high-pressure pump – Check . . . . . . . . 453
Initial engine operation . . . . . . . . . . . . . . . . . . 68 Fuel pipework from fuel filter to
high-pressure pump – Cleaning . . . . . . 452
Injector – Check . . . . . . . . . . . . . . . . . . . . . . . 414
Fuel pipework from fuel filter to HP pump
Injector – Cleaning . . . . . . . . . . . . . . . . . . . . . 413 – Installation . . . . . . . . . . . . . . . . . . . . . 454
Injector – Installation . . . . . . . . . . . . . . . . . . . . 415 Fuel pipework from fuel filter to HP pump
Injector – Overview . . . . . . . . . . . . . . . . . . . . . 408 – Overview . . . . . . . . . . . . . . . . . . . . . . 450
Fuel pipework from fuel filter to HP pump
Injector – Removal . . . . . . . . . . . . . . . . . . . . . 410
– Removal . . . . . . . . . . . . . . . . . . . . . . 451
Intake air system to cylinders, left – Leak off fuel pipework – Overview . . . . 455
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482 Leak-off fuel line – Installation . . . . . . . 459
TIM ID: 0000007624 – 002
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467 Leak-off fuel line – Removal . . . . . . . . . 456

Intercooler – Check . . . . . . . . . . . . . . . . 472 Leak-off fuel pipework – Check . . . . . . . 458
Intercooler – Cleaning . . . . . . . . . . . . . . 471 Leak-off fuel pipework – Cleaning . . . . . 457
Intercooler – Disassembly . . . . . . . . . . 470 Low-pressure fuel system –
Intercooler – Installation . . . . . . . . . . . . 474 Overview . . . . . . . . . . . . . . . . . . . . . . . . 429
Intercooler – Overview . . . . . . . . . . . . . 467 Low-pressure fuel system – Overview . . . . . . 429
Intercooler – Removal . . . . . . . . . . . . . . 469
Lube oil pump with drive – Cleaning . . . . . . . . 537
MS25012/00E 08-06 © MTU

864 Appendix
Lube oil system – Overview . . . . . . . . . . . . . . 533 Monitoring, Control and Regulation

Lube-oil pump with drive – Check . . . . . . . . . . 538 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
Engine wiring harness – Check . . . . . . 706
Lube-oil pump with drive – Disassembly . . . . . 536
Engine wiring harness – Clean . . . . . . . 705
Lube-oil pump with drive – Installation . . . . . . 540 Engine wiring harnesses –
Lube-oil pump with drive – Overview . . . . . . . 534 Installation . . . . . . . . . . . . . . . . . . . . . . 707
Lube-oil pump with drive – Removal . . . . . . . . 535 Engine wiring harnesses – Removal . . . 704
Engine wiring harnesses and brackets –
Lube-oil System, Lube-oil Circuit . . . . . . . . . . 533
Overview . . . . . . . . . . . . . . . . . . . . . . . . 694
Centrifugal oil filter – Assembly . . . . . . . 556
Monitoring, control and regulation devices
Centrifugal oil filter – Check . . . . . . . . . 555
– Overview . . . . . . . . . . . . . . . . . . . . . . 693
Centrifugal oil filter – Cleaning . . . . . . . 554
Sensors, actuators and injectors –
Centrifugal oil filter – Disassembly . . . . 552
Check . . . . . . . . . . . . . . . . . . . . . . . . . . 715
Centrifugal oil filter – Installation . . . . . . 559
Centrifugal oil filter – Overview . . . . . . . 550
Installation . . . . . . . . . . . . . . . . . . . . . . 716
Centrifugal oil filter – Removal . . . . . . . 551
Lube oil pump with drive – Cleaning . . . 537
Overview . . . . . . . . . . . . . . . . . . . . . . . . 708
Lube oil system – Overview . . . . . . . . . 533
Lube-oil pump with drive – Check . . . . . 538
Removal . . . . . . . . . . . . . . . . . . . . . . . . 712
Lube-oil pump with drive –
Disassembly . . . . . . . . . . . . . . . . . . . . . 536 Mounting/Support . . . . . . . . . . . . . . . . . . . . . . 683
Lube-oil pump with drive – Engine mount – Removal . . . . . . . . . . . 689
Installation . . . . . . . . . . . . . . . . . . . . . . 540 Engine mounting – Installation . . . . . . . 692
Lube-oil pump with drive – Overview . . . 534 Engine mounting – Overview . . . . . . . . 685
Lube-oil pump with drive – Removal . . . 535 Engine mounting / support –
Oil cooler – Installation . . . . . . . . . . . . . 566 Overview . . . . . . . . . . . . . . . . . . . . . . . . 683
Oil cooler – Overview . . . . . . . . . . . . . . 560 Engine mounts – Check . . . . . . . . . . . . 691
Oil cooler – Removal . . . . . . . . . . . . . . 562 Engine mounts – Cleaning . . . . . . . . . . 690
Oil filter – Installation . . . . . . . . . . . . . . 549 MTU contact/service partner . . . . . . . . . . . . . . 856
Oil filter – Overview . . . . . . . . . . . . . . . . 542
Oil filter – Removal . . . . . . . . . . . . . . . . 544
Oil filter housing – Assembly . . . . . . . . . 548 O
Oil filter housing – Check . . . . . . . . . . . 547 Oil cooler – Installation . . . . . . . . . . . . . . . . . . 566
Oil filter housing – Clean . . . . . . . . . . . . 546 Oil cooler – Overview . . . . . . . . . . . . . . . . . . . 560
Oil filter housing – Disassembly . . . . . . 545 Oil cooler – Removal . . . . . . . . . . . . . . . . . . . . 562
Oil heat exchanger – Check . . . . . . . . . 565
Oil heat exchanger – Cleaning . . . . . . . 563 Oil filter – Installation . . . . . . . . . . . . . . . . . . . 549
Oil pipework in crankcase – Check . . . . 572 Oil filter – Overview . . . . . . . . . . . . . . . . . . . . . 542
Oil pipework in crankcase – Oil filter – Removal . . . . . . . . . . . . . . . . . . . . . 544
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 571 Oil filter housing – Assembly . . . . . . . . . . . . . . 548
Oil pipework in crankcase –
Installation . . . . . . . . . . . . . . . . . . . . . . 574 Oil filter housing – Check . . . . . . . . . . . . . . . . 547
Oil system in crankcase – Overview . . . 567 Oil filter housing – Clean . . . . . . . . . . . . . . . . . 546
Oil system in crankcase – Removal . . . 569 Oil filter housing – Disassembly . . . . . . . . . . . 545
Turbocharger oil supply – Check . . . . . 582 Oil heat exchanger – Check . . . . . . . . . . . . . . 565
Turbocharger oil supply – Cleaning . . . 581
Turbocharger oil supply – Oil heat exchanger – Cleaning . . . . . . . . . . . . 563
Installation . . . . . . . . . . . . . . . . . . . . . . 583 Oil pan – Check . . . . . . . . . . . . . . . . . . . . . . . 121
Turbocharger oil supply – Overview . . . 578 Oil pan – Cleaning . . . . . . . . . . . . . . . . . . . . . 120
Turbocharger oil supply – Removal . . . 580 Oil pan – Installation . . . . . . . . . . . . . . . . . . . . 122
Oil pan – Overview . . . . . . . . . . . . . . . . . . . . . 118
M Oil pan – Removal . . . . . . . . . . . . . . . . . . . . . 119
TIM ID: 0000007624 – 002
Maintenance schedule matrix . . . . . . . . . . . . . 54 Oil pipework in crankcase – Check . . . . . . . . . 572

Maintenance tasks . . . . . . . . . . . . . . . . . . . . . 56 Oil pipework in crankcase – Cleaning . . . . . . . 571
Manufacturer’s documentation . . . . . . . . . . . . 855 Oil pipework in crankcase – Installation . . . . . 574
Measuring tools – General overview . . . . . . . . 849 Oil system in crankcase – Overview . . . . . . . . 567
Monitoring, control and regulation devices – Oil system in crankcase – Removal . . . . . . . . 569
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
MS25012/00E 08-06 © MTU

Appendix 865
P Sensors, actuators and injectors – Check . . . . 715

Personnel and organizational require- Sensors, actuators and injectors –
ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
Piston – Check . . . . . . . . . . . . . . . . . . . . . . . . 267 Sensors, actuators and injectors –
Piston – Cleaning . . . . . . . . . . . . . . . . . . . . . . 266 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
Piston – Tolerances . . . . . . . . . . . . . . . . . . . . 270 Sensors, actuators and injectors –
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Piston and conrod – Assembly . . . . . . . . . . . . 295
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Piston and conrod – Disassembly . . . . . . . . . . 264
Special tools – Overview . . . . . . . . . . . . . . . . . 722
Piston and conrod – Installation . . . . . . . . . . . 299
Standard tools – Overview . . . . . . . . . . . . . . . 721
Piston and conrod – Overview . . . . . . . . . . . . 258
Standards for warning notices in the
Piston and conrod – Removal . . . . . . . . . . . . . 262
publication . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Piston rod – Cleaning . . . . . . . . . . . . . . . . . . . 280
Starter – Assembly . . . . . . . . . . . . . . . . . . . . . 527
Power Supply, Engine Side . . . . . . . . . . . . . . . 675
Starter – Check . . . . . . . . . . . . . . . . . . . . . . . . 513,
Battery-charging generator – Check . . . 680
523
Battery-charging generator –
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 679 Starter – Cleaning . . . . . . . . . . . . . . . . . . . . . . 512,
Battery-charging generator – 522
Disassembly . . . . . . . . . . . . . . . . . . . . . 678 Starter – Disassembly . . . . . . . . . . . . . . . . . . . 511,
Installation . . . . . . . . . . . . . . . . . . . . . . 681 Starter – Installation .................... 514,
Overview . . . . . . . . . . . . . . . . . . . . . . . . 675
Starter – Overview ..................... 509,
Battery-charging generator –
515
Removal . . . . . . . . . . . . . . . . . . . . . . . . 677
Starter – Removal . . . . . . . . . . . . . . . . . . . . . . 510,
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
517
Preheating unit – Installation . . . . . . . . . . . . . . 624
Starting Equipment . . . . . . . . . . . . . . . . . . . . . 509
Preheating unit – Overview . . . . . . . . . . . . . . . 618 Starter – Assembly . . . . . . . . . . . . . . . . 527
Preheating unit – Removal . . . . . . . . . . . . . . . 619 Starter – Check . . . . . . . . . . . . . . . . . . . 513,
Preheating unit, coolant pump – 523
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 622 Starter – Cleaning . . . . . . . . . . . . . . . . . 512,
522
Preheating unit, screw-in heating element –
Starter – Disassembly . . . . . . . . . . . . . . 511,
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 620
518
Preheating unit, thermostat – Replace- Starter – Installation ............... 514,
ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623 532
Prerequisites for maintenance tasks and general Starter – Overview ................ 509,
assembly instructions . . . . . . . . . . . . . . . . . . . 11 515
Pressure relief valve on fuel distributor – Starter – Removal . . . . . . . . . . . . . . . . . 510,
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 517
Pressure relief valve on fuel distributor –
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 T
Thermostat – Check . . . . . . . . . . . . . . . . . . . . 673
R Thermostat – Cleaning . . . . . . . . . . . . . . . . . . 672
Radial-lip shaft seal, driving end – Thermostat – Disassembly . . . . . . . . . . . . . . . 671
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Thermostat – Installation . . . . . . . . . . . . . . . . . 674
Radial-lip shaft seal, driving end – Thermostat – Overview . . . . . . . . . . . . . . . . . . 667
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
TIM ID: 0000007624 – 002
Thermostat – Removal . . . . . . . . . . . . . . . . . . 670

Repairing threaded bores with threaded inserts
Tightening sequence for oil pan GGG . . . . . . . 125
(Heli-Coil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Torque specifications for screws, nuts and
bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
S Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Safety precautions when working on the Turbocharger oil supply – Check . . . . . . . . . . 582
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Turbocharger oil supply – Cleaning . . . . . . . . . 581
MS25012/00E 08-06 © MTU

866 Appendix
Turbocharger oil supply – Installation . . . . . . . 583 Camshaft thrust bearing –

Turbocharger oil supply – Overview . . . . . . . . 578 Replacement . . . . . . . . . . . . . . . . . . . . 374
Cylinder head cover – Check . . . . . . . . 399
Turbocharger oil supply – Removal . . . . . . . . . 580
Cylinder head cover – Cleaning . . . . . . 398
Cylinder head cover – Installation . . . . . 400
V Cylinder head cover – Overview . . . . . . 396
Valve drive – Assembly . . . . . . . . . . . . . . . . . . 390 Cylinder head cover – Removal . . . . . . 397
Valve drive – Assembly . . . . . . . . . . . . . 390
Valve drive – Check . . . . . . . . . . . . . . . . . . . . 385 Valve drive – Check . . . . . . . . . . . . . . . 385
Valve drive – Cleaning . . . . . . . . . . . . . . . . . . 384 Valve drive – Cleaning . . . . . . . . . . . . . 384
Valve drive – Disassembly . . . . . . . . . . . . . . . 382 Valve drive – Disassembly . . . . . . . . . . 382
Valve drive – Installation . . . . . . . . . . . . . . . . . 393 Valve drive – Installation . . . . . . . . . . . . 393
Valve drive – Overview . . . . . . . . . . . . . 377
Valve drive – Overview . . . . . . . . . . . . . . . . . . 377 Valve drive – Removal . . . . . . . . . . . . . 380
Valve drive – Removal . . . . . . . . . . . . . . . . . . 380 Valve drive – Tolerances . . . . . . . . . . . . 388
Valve drive – Tolerances . . . . . . . . . . . . . . . . . 388 Valve gear – Overview . . . . . . . . . . . . . 348
Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 Valve gear – Overview . . . . . . . . . . . . . . . . . . 348
Camshaft – Check . . . . . . . . . . . . . . . . 354 Valve-seat turning machine for cylinder
Camshaft – Cleaning . . . . . . . . . . . . . . 352 head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Camshaft – Installation . . . . . . . . . . . . . 360 Vibration damper on PTO, free end –
Camshaft – Overview . . . . . . . . . . . . . . 349 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Camshaft – Removal . . . . . . . . . . . . . . 350
Camshaft – Tolerances . . . . . . . . . . . . . 357 Vibration damper on PTO, free end –
Camshaft drive – Check . . . . . . . . . . . . 371 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Camshaft drive – Cleaning . . . . . . . . . . 370 Vibration damper on PTO, free end –
Camshaft drive – Installation . . . . . . . . . 372 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Camshaft drive – Overview . . . . . . . . . . 367 Vibration damper on PTO, free end –
Camshaft drive – Removal . . . . . . . . . . 368 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Camshaft running surfaces and swing Vibration damper on PTO, free end –
followers – Visual inspection . . . . . . . . . 353 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Camshaft thrust bearing – Check . . . . . 376
Camshaft thrust bearing – Cleaning . . . 375 Vibration damper on PTO, free end –
Camshaft thrust bearing – Overview . . . 373 Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
TIM ID: 0000007624 – 002
MS25012/00E 08-06 © MTU

Manual de Manutenção 16V, 12V 4000

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Manual de Manutenção 16V, 12V 4000

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MTU_ValueService

Instructions for Major Overhaul

1 General Information ............................................................ 11

MS25012/00E 08-06 © MTU

4.1.12 Cylinder liner – Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

MS25012/00E 08-06 © MTU

4.3.1 Crank drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

MS25012/00E 08-06 © MTU

4.4.11 Cylinder head – Installation ......................................... 344

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4.6.17 High-pressure fuel line – Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

MS25012/00E 08-06 © MTU

4.10.1 Air intake / air supply – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

MS25012/00E 08-06 © MTU

4.13.2 Lube-oil pump with drive – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

MS25012/00E 08-06 © MTU

MS25012/00E 08-06 © MTU

4.16.1 Engine mounting / support – Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683

MS25012/00E 08-06 © MTU

MS25012/00E 08-06 © MTU

1.1 Important Information

1.1.1 Prerequisites for maintenance tasks and general

Prerequisites for maintenance tasks

General assembly instructions

MS25012/00E 08-06 © MTU

MS25012/00E 08-06 © MTU

1.2 General Conditions

1.2.1 General Instructions

MS25012/00E 08-06 © MTU

1.2.2 Personnel and organizational requirements

TIM ID: 0000000509 – 001

MS25012/00E 08-06 © MTU

1.2.3 Safety precautions when working on the engine

Safety precautions when putting the equipment into operation

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

MS25012/00E 08-06 © MTU

into shaft end until correct sealing is achieved.

MS25012/00E 08-06 © MTU

Working on electrical/electronic assemblies

MS25012/00E 08-06 © MTU

1.2.4 Auxiliary materials, fire prevention and environmental protection

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MS25012/00E 08-06 © MTU

1.2.5 Standards for warning notices in the publication

TIM ID: 0000002862 – 001

MS25012/00E 08-06 © MTU

Explanation of terms for dimensions of new components

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

Basic size Designed size without fit symbol or permissible

Deviation Permissible tolerance of toleranced/basic size.

Clearance Difference between bore and shaft diameter when bore

Interference Difference between bore and shaft diameter when bore

Explanation of terms for reconditioning of components

Reworking instructions If wear limits are exceeded or values are below

MS25012/00E 08-06 © MTU

1.2.7 Engine side and cylinder designations

1 KGS = Free end 3 KS = Driving end

TIM ID: 0000000415 – 002

MS25012/00E 08-06 © MTU

1.2.8 Torque specifications for screws, nuts and bolts

Studs for crankshaft bearing cap in crankcase 80 Nm

Studs (Nominal length: 347.5 mm to 348.5 mm):

Stud elongation for crankshaft bearing cap ΔI = 1.15 mm +0.05 mm