MTU 12 V 4000M Main Engine Workshop Manual

Service Publication
Diesel Engine
8V 396 TE.4
12V 396 TE.4
16V 396 TE.4
Maintenance Manual
M020046/20E
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This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Other than for this purpose, the handbook shall not be reproduced, used or disclosed to others without our prior consent.
Subject to alterations and amendments.
Le manuel devra être observé en vue d'éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
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Amendment Service!
Any changes in contents will be sent to you in the form of an amendment,
provided you complete the reverse of this receipt card and return it to us.
M020046/20E
Maintenance Manual
Postcard
MTU Friedrichshafen GmbH

8V 396 TE.4 Department SCT
12/16V 396 TE.4
88040 Friedrichshafen
GERMANY
No. Date Name
Please mark all filed amendments here.
1.
2.
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4.
5.
6.
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16.
Please use block capitals!
Receipt Amendment No. 1.

2.
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Publication number:
4.
M020046/20E
5.
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Department
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Postal box number
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(Postal code) City 15.
Country 16.
General Section 1
Page 1
1 General
Contents
1.1 Important Information
1.2 Designation of engine sides and cylinders
1.3 Tightening specifications for bolts and nuts
1.4 Settings
1.5 Dangers at working area
1.6 Data sheets
1.7 Index
1.8 Publication summary
20038/10 E –12.96–
General Section 1.1
Page 1
1.1 Important Information

This manual is intended for use by technical personnel responsible for the maintenance and servicing of the MTU
V 396 TB4 diesel engine.
This manual describes
– scheduled service operations from maintenance echelons W5 and W6 as well as
– non-scheduled service operations on the individual assemblies.
Index sheets divide this handbook into 3 main sections.
Assembly classifications
The third main section is further subdivided in assembly sections 01 to 88. The information on these assemblies is the
same in all MTU Product Support documentation.
Every assembly section is further divided into subassembly sections (where required).
Example:
3. 1. 2
Subassembly group
Assembly section
Main section
Because the information on assemblies and subassemblies is produced according to a single building-block system
for all engine types, the numbers are not necessarily in numerical sequence.
Alternative subassemblies are either without an index, or are provided with indices ”a, b, c” etc.
Example: 3.1.2a
There can be only one subassembly group 3.1.2 for any individual engine, thus:
3.1.2 without index
or
3.1.2a
or
3.1.2b etc.
The section on each subassembly group is divided into seven operations; the final digit is always identical for all of
these:
.1 Before-removal operations
.2 Removal
.3 Disassembly
.4 Inspection and repair
.5 Assembly
.6 Installation
.7 After-installation operations
All seven procedures will not be required for every subassembly. In these cases, the corresponding sections will not
appear in either the text or the table of contents, but the remaining sections will retain their respective end digits.
Alternative operations are identified in the index with ”a, b, c” etc., while the basic operation is not provided with an index.
Example:
3.1.2.1 Before-removal operations
3.1.2.2 Removal (8V)
3.1.2.2a Removal (16V)
3.1.2.4 Inspection and repair
3.1.2.6 Assembly (8V)
3.1.2.6a Assembly (16V)
3.1.2.7 After-installation operations
20038/10 E –12.96–
General Section 1.1
Page 2
When several operations are combined in a single section (e.g. where no supplementary illustrations are required),
a corresponding note will appear in the table of contents.
Example:
3.1.9.1 Before-removal operations (see 3.1.9)
3.1.9.2 Removal (see 3.1.9)
3.1.9.4 Inspection and repair (see 3.1.9)
3.1.9.6 Assembly (see 3.1.9)
Quickly finding the sought-after information

The manual provides the following aids for assistance in finding the desired section:
– The contents listings on the main cover sheets provide references to the tables of contents for the individual
sections.
– An alphabetical subject index in the first main section provides direct access to the individual sections.
– The individual assemblies are listed in the group summary on the cover sheet to the 3rd main section.
Basic requirements for maintenance and service work

Customers performing their own maintenance must ensure that the following conditions and basic requirements are
satisfied:
– All safety regulations are observed
– Comprehensive assortment of general-purpose tools is provided
– Cleaning and testing equipment is provided
– Work is performed by trained personnel
– Special tools are provided
– Service area is adequately equipped
For further supplements to this handbook, see 1.8
20038/10 E –12.96–
General Section 1.1
Page 3
General assembly instructions

D Component cleanness:
Clean the removed parts with cold cleaner or a similar substance and immerse in engine oil SAE 30 to protect
against corrosion.
To clean components with combustion residues, immerse in decarboniser.
Areas of all components that come into contact with oil, fuel, coolant, water and combustion air must be clean.
D Components requiring ”special cleanness” (e.g. oil and fuel-carrying components) must be cleaned with suitable
cleaning procedures before assembly, checked for particular cleanness and treated accordingly.
D Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners.
Parts dirtied with oil and fuel must be cleaned immediately.
The parts should be wiped with a dry cloth.
Elastomer parts, e.g. engine mounts, damping elements, couplings and V-belts, must not be painted, but must
be covered before all painting work.
Note: Component packaging must only be removed immediately before installation.
D Radial-lip shaft seals treated by the manufacturer with oil show as a result definite signs of swelling when deliv-
ered. They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation.
D The surfaces of parts that slide against each other must be lubricated with SAE30 engine oil when installed,
unless otherwise specified.
D Before installing shaft seals:
On the shaft, the sealing lip of the shaft seal must be coated with white petroleum jelly and the shaft running
surface with thin-film lubricant or SAE30 engine oil.
In the support bore, the outer surface of metal outer jackets - unless otherwise specified in the drawing – must
be coated with surface sealant. For elastomer outer jackets or combined metal/elastomer outer jackets, the
outer surface must be coated with denaturated ethanol.
This symbol applies to radial-lip shaft seals and its significance depends on its position.
The arrow indicates the position of the sealing lip.
D O-rings and surfaces moving against them during installation (bores and shafts) must be coated with white pe-
troleum jelly, unless otherwise specified.
When installing O-rings with counterrings in coolant pumps, always follow the installation instructions.
D After installing O-rings in shaft grooves, in order to remedy twists caused by installation, pass a rounded mark-
ing tool under the sealing ring in the direction of the circumference if the O-ring diameter is sufficiently large.
Make sure that the O-ring is not damaged.
D Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on
the flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be
fitted to the component and then (no more than 20 minutes later) the seal components screwed together.
Oil, multi-purpose grease or other materials must not be used to fix the position.
D Before installing antifriction bearings, lightly lubricate the bearing seats.
Only remove the bearings from their original packaging immediately before installation so they do not get dirty.
Do not remove the corrosion inhibitor from the bearings in original packaging.
Use petroleum spirit or acid-free kerosene to clean the antifriction bearings.
After cleaning, relubricate the bearings with engine oil.
20038/10 E –05.97–
General Section 1.1
Page 4
During assembly, do not apply (axial) forces to antifriction elements and do not hit the bearing rings with a
hammer (use assembly aids).
Do not use an open flame to heat bearing inner races.
The temperature should be between 80°C und 100 °C and must not exceed 120 °C.
Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
D Dry bearings must not be oiled.
D When installing gears, the teeth must be lubricated with SAE30 engine oil.
D 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 warping and damage. Corrosion inhibitors (e.g. oil, grease) must be removed from support and
mating surfaces.
D After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate must be re-
moved and the parts coated with SAE30 engine oil.
D Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
D Cable connections with cutting ring threaded connections must be installed in a vice and tightened, the thread
first being coated with thin-film lubricant.
D If components are to be marked by etching, after the etching is completed the solution must be removed by
means of neutralization agent. The affected parts must then be preserved with SAE30 engine oil.
D Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes, O-rings) must be coated at the sup-
port and mating surfaces with assembly paste, unless otherwise specified in the drawing.
D The assembly surfaces of screws, nuts, washers and of parts to be tensioned must be clean and polished or
provided with the specified surface protection and free from warping and damage. Corrosion inhibitors (e.g. oil,
grease) must be removed. Threads and screw heads must be coated with lubricant before assembly as per
tightening specifications.
Unless otherwise specified, the following lubricants should be used:
– SAE30 engine oil for general application
– Assembly paste in hot part areas.
Information on installing the Flexmaster pipe connection

To improve adhesion between the sealing ring and pipe, as well as prevent loosening of the sealing ring, both
pipe ends are to be thoroughly degreased to at least the insertion depth. Remove paint from the area near the
sealing ring. Otherwise, paint particles loosened during installation or operation result in leakage.
Deburr sharp edges on the pipe resulting from cutting.
Push seal carriers and sealing rings onto both ends of of the pipe.
To ease installation, the sealing rings can be dipped in water first.
Note: No oil, grease, graphite or other lubricants must be used for sealing rings.
20038/10 E –05.97–
General Section 1.1
Page 5
1 Sleeve
2 Sealing ring
3 Seal carrier
4 Clamps
5 Screw
6 Self-locking nut
In event of alignment offset (v) of pipes to be con-

nected, pipe ends of the sleeve must not touch.
Permitted size of flush offset is determined by depth
of insertion of pipe ends (g) and by permitted angle
of 2°.
The depth of insertion (g) is to be marked before-
hand for a well centred fit.
Clamp halves are fitted over seal carrier and sleeve,

tightened with screw and self-locking nuts until di-
mension ”a” is achieved.
Note: Replace deformed clamps.
Clamps must not be tightened on block.
Replace self-locking nuts after loosening
and retightening several times.
Dimension ”a” for pipe outer diameters:
from 12 mm to 26.9 mm min. 2 mm max. 5 mm
from 28 mm to 60.3 mm min. 4 mm max. 8 mm
from 63.5 mm to 127 mm min. 8mm max. 12 mm
20038/10 E –05.97–
General Section 1.1
Page 6
Threaded connections without tightening specifications

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

– Torque tightening
Manually tighten screw connections with 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. Pro-
ceed in the same manner for torsionally-protected unions. These instructions apply also to testing torque.
Note: If no tolerance for tightening torque is stated, the tightening tolerance is +10% of specified
torque.
– Torque angle tightening
The additional angles of rotation specified in the tightening specifications must be achieved and may be ex-
ceeded within the specified tolerance.
If no tightening tolerance is specified, the following tolerances must be observed:
+ 5° for angle of further rotation less than/equal to 90°
+ 10° for angle of further rotation greater than 90°
Before angle-of-rotation tightening, each screw head must be colour-marked so that after tightening it is poss-
ible to check that the angle of rotation is correct (exception: colour-marking is not necessary in the case of a
self-monitoring NC screwdriver).
Note: The checking toque serves to check whether the angle-of-rotation tightening has been carried
out.
The torque is less than the angle of rotation tightening and must therefore not be used to replace
the angle of rotation tightening.
– Tightening to elongation
Tightening must be carried out in accordance with tightening specifications taking the tightening tolerance into
consideration.
20038/10 E –05.97–
General Section 1.1
Page 7
Threaded bores for threaded inserts (heli-coil)
Thread Blind hole dia. (max./min.) Twist drill dia.

M 6 6.31 6.1–6.2–6.25
6.04
M 8 8.35 8.1–8.2–8.25–8.3
8.04
M 8x1 8.32 8.1–8.2–8.25–8.3
8.04
M 10 10.40 10.25
10.05
M 12 12.50 12.25–12.5
12.05
M 12 x 1.5 12.43 12.25
12.05
M 14 14.53 14.25–14.5
14.06
M 14 x 1.5 14.43 14.25
14.05
M 15 x 2 15.30 15.25
15.20
M 16 16.53 16.25–16.5
16.06
M 16 x 1.5 16.43 16.25
16.05
M 24 x 1.5 24.43 24.25
24.05
M 26 x 1.5 26.43 26.25
26.05
M 30 x 1.5 30.43 30.25
30.05
Removing and installing threaded inserts (heli-

coil)
If necessary, remove thread insert from bore (left
side) with suitable removal tool.
Bore core hole with suitable twist drill – see table.
Cut thread with special tapped bore.
Note: Do not countersink bore
Mount spindle (2) and mouthpiece (1) corresponding
to thread.
Groove on mouthpiece must be aligned with mark-
ings on installation tool (arrows).
L92_23443
20038/10 E –05.97–
General Section 1.1
Page 8
Insert thread insert (2) into spindle (1) in installation

tool.
Driver journal of thread insert must be in groove
(arrow).
2
L92_23443
Use spindle to turn thread insert through mouth

piece until it is flush at front (arrow).
L92_23443
Mount installation tool on threaded hole and install

insert without applying pressure to spindle.
Note: Turn thread insert 1/2 to 1 1/2 thread
turns deeper than thread bore surface.
Use bolt shearer to remove driver journal to M14.
In event of threaded inserts over M14, move driver
journal up and down with pointed pliers and remove.
L92_23443
20038/10 E –05.97–
General Section 1.2
Page 1
1.2 Designation of Engine Sides and Cylinders
Engine sides are always designated as viewed from the driving end (KS).
For the purpose of cylinder designation (in accordance with DIN ISO 1204), the cylinders of left engine side are desig-
nated ”A” and those on the right engine side are designated ”B”.
Each cylinder bank is numbered consecutively from No. 1, starting at the driving end of the engine.
Other components and assemblies are also numbered consecutively starting at No. 1 at the driving end.
Applicable designations and abbreviations

Drive end = KS
Free end = KGS
Left side
Right side
Top side
Bottom side
20046/20 E –02.96–
General Section 1.3
Page 1
1.3 Tightening Specifications for Bolts and Nuts
Designation Torque specifications Lubricant See
Crankcase
Stress bolt with identification number on front,
for crankshaft bearing cap
New size, overall length:
– long stud 279 mm
– short stud 239 mm
in crankcase
– long stud projection 169.0 mm ± 0.5 mm Thread-locking 3.1.2.4
– short stud projection 169.0 mm ± 0.5 mm agent – Loctite 270
Stress bolt, without identification number on front,
with journal on screw end, for crankshaft bearing cap
– long stud 296.2 mm ± 0.2 mm
– short stud 256.2 mm ± 0.2 mm
in crankcase
– long stud projection 169.3 mm ± 0.7 mm Engine oil 3.1.2.4
– short stud projection 169.3 mm ± 0.7 mm
– max. projection 173.0 mm
– Stress bolt in crankcase 70 Nm + 7 Nm Engine oil 3.1.2.4
– inner stud elongation 1.3 mm + 0.05 mm Molykote G-n plus 3.1.2.6
– outer stud elongation 1.1 mm + 0.05 mm
optional tightening with stress bolt with identification
number
– inner collar nut, initial tightening torque 200 Nm
– outer collar nut, initial tightening torque 100 Nm
– inner collar nut, additional angle of rotation °
270 +20 °
– outer collar nut, additional angle of rotation °
270 +20 °
M18 bolt for crankshaft alignment bearing cover 300 Nm + 30 Nm Molykote G-n plus 3.1.2.6
Stress bolt for intermediate frame
– long stud 426.7 mm ± 0.2 mm
– short stud 386.7 mm ± 0.2 mm
– max. bolt length prior to assembly 3.1.2b.6
inner stress bolt 431 mm
outer stress bolt 391 mm
Stress bolts in crankcase 70 Nm + 7 Nm Engine oil 3.1.2b.6
Collar nuts for crankcase intermediate frame with
torque
– inner collar nuts 240 Nm + 20 Nm Molykote G-n plus 3.1.2b.6
– outer collar nuts 170 Nm + 20 Nm
M12 bolts for intermediate frame 100 Nm + 10 Nm Engine oil 3.1.2b.6
– Release collar nuts
– Stress bolts to elongation in 2 stages
1st Stage: inner stud 0.50 +0.05 mm
1st Stage: outer stud 0.50 +0.05 mm
2nd Stage: inner stud 1.15 +0.05 mm
Overall length, inner stress bolt 1.65 mm
2nd Stage: outer stud 0.90 +0.05 mm
Molykote G-n plus 3.1.2b.6
Overall length, outer stress bolt 1.40 mm
M18 bolts for intermediate frame (thrust bearing) 300 Nm + 30 Nm
Plug for main oil gallery 300 Nm Engine oil 3.1.1.4
M8 bolt for oil spray nozzle 21 Nm + 2 Nm Engine oil 3.1.4.6
M12 bolt for flywheel housing 100 Nm + 10 Nm Engine oil 3.1.8.6
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General Section 1.3
Page 2
Gear train
M10 stress bolt on idler gear for engine coolant pump 45 Nm + 4 Nm Engine oil 3.2.1.6
drive assembly, right side
M12 stress bolt on idler gear for generator drive as- 90 Nm Engine oil 3.2.1.6
sembly, left side
Nut for end cover, right side
Idler gear for coolant pump drive assembly 21 Nm Engine oil 3.2.1.6
Nut for end cover, left side 42 Nm Engine oil 3.2.1.6
Idler gear for generator drive
Stress bolt for idler gear of engine oil pump drive 0.19 mm to 0.21 mm Engine oil 3.2.2.6a
8V/12V, elongation 3.15.1.6a
– test torque in tightening direction 180 Nm
Stress bolt for engine oil pump drive idler gear on oil 200 Nm + 20 Nm Engine oil 3.2.2.6a
pan, 16V 3.15.2.6a
Stress bolt for engine oil pump drive idler gear on 45 Nm + 4 Nm Engine oil 3.2.2.6a
intermediate frame
Running gear
Stress bolt for crankshaft couterweights
– bolt length max. 143 mm
– initial tightening torque 100 Nm + 10 Nm Molykote G-n plus 3.3.1.5
– additional angle of rotation 180° +20°
– test torque in tightening direction 300 Nm +10 Nm
Plug on crankshaft M 22x1.5 120 Nm Engine oil 3.3.1.5
M 36x1.5 360 Nm + 20 Nm Engine oil 3.3.3.6
M 10x1.5 20 Nm +2 Nm Engine oil 3.3.3.6
3.3.3a.6
Conrod cap bolt

Max. bolt length prior to assembly 85.0 mm
– initial pretightening torque 10 Nm + 10 Nm Engine oil 3.3.2.4
– subsequent pretightening torque 160 Nm + 16 Nm 3.3.2.6
– additional angle of rotation 90° +10° 3.3.2.6a
– test torque in tightening direction 380 Nm + 20 Nm
Piston crown bolts M10 x 1
– initial tightening torque 30 Nm + 3 Nm Molykote G-n plus 3.3.2.5
– release 0
– initial tightening torque 30 Nm + 3 Nm
– recheck initial torque 30 Nm + 3 Nm
Hex nut M16 x 1.5 in piston skirt
– Note: left-hand thread 30 Nm + 3 Nm Molykote G-n plus 3.3.2.5
Bolt for clamp ring, driving end
– tighten diagonally 3.3.4.6
– initial torque 10 Nm + 1 Nm Engine oil 3.3.4.6a
– tightening torque 46 Nm + 5 Nm
– final torque 46 Nm + 5 Nm
Bolt for oil seal carrier, driving end 20 Nm Engine oil 3.3.5.6
Bolt for bearing retaining plate, free end 100 Nm + 10 Nm Engine oil 3.3.6.6
20046/20 E –11.96–
General Section 1.3
Page 3
M12 bolt for vibration damper 70 Nm + 7 Nm Engine oil 3.3.8.5

side plate 3.3.8a.5
Stress bolt for vibration damper
– bolt length max. 68.0 mm
– initial tightening torque 200 Nm + 20 Nm Engine oil 3.3.8.6
– test torque in tightening direction 350 Nm
Sealing washer for socket-head screw on drive
member, vibration damper
1st stage diagonally 150 Nm + 15 Nm Engine oil 3.3.8a.6
2nd stage diagonally 350 Nm + 35 Nm
Plug in intermediate flange 365 Nm + 37 Nm Engine oil 3.3.9.6
3.3.9.6a
Bolts for intermediate flange, auxiliary PTO

– initial torque diagonally 245 Nm + 20 Nm Engine oil 3.3.9.6
– additional angle of rotation 90° +10° 3.3.9.6a
Cylinder head
Protective sleeve in cylinder head 60 Nm Engine oil 3.5.1.5
Securing bolts in cylinder heads
– 1st initial tightening torque 20 Nm + 10 Nm Engine oil 3.5.1.6
M18 securing bolt in cylinder head
– 2nd initial tightening torque 90 Nm + 10 Nm Engine oil 3.5.1.6
M20 securing bolt in cylinder head (clamp bolt)
– 2nd initial tightening torque 180 Nm + 10 Nm
– additional angle of rotation 90° +10° Engine oil 3.5.1.6
End plate bolts, drive and free ends 47 Nm + 10 Nm Engine oil 3.5.1.6
Valve gear
Bolts for camshaft alignment bearings 25 Nm Engine oil 3.6.1.6
Stress bolts for camshaft drive gear 60 Nm + 6 Nm Engine oil 3.6.1.6
Stress bolt (long) for rocker shaft
Max. bolt length prior to assembly 81 mm
– initial tightening torque 50 Nm Engine oil 3.6.3.6
– additional angle of rotation 90°
Stress bolt (short) for rocker shaft
– additional angle of rotation 45°
Bolt for valve gear housing 21 Nm Engine oil 3.6.4.6
Collar screw for cylinder head cover 4 Nm + 1 Nm Engine oil 3.6.4.6
Air intake system/exhaust system

M10 chamber bolts and frame bolts on intercooler in 15 Nm-30 Nm-45 Nm Engine oil 3.10.1a.5
three stages
20046/20 E –11.96–
General Section 1.3
Page 4
M12 chamber bolts and frame bolts on intercooler in 25 Nm-50 Nm-75 Nm Engine oil 3.10.1a.5
three stages
M12 cover bolt on intercooler 75 Nm Engine oil 3.10.1a.5
Bolt for charge air manifold 42 Nm + 4 Nm Engine oil 3.10.2.6
3.10.2.6a
M8 bolt with nut for corner joint between constant- 16 Nm + 2 Nm Ultra-Therm MTU 3.10.3.5
pressure manifold halves
M8 bolt for exhaust housing cover 20 Nm +2 Nm Ultra-Therm MTU 3.10.3.6
M12 bolt for exhaust pipe housing on cylinder heads 90 Nm + 10 Nm Ultra-Therm MTU 3.10.3.6
M12 bolt for end cover at end of constant-pressure 40 Nm + 4 Nm Ultra-Therm MTU 3.10.3.6
manifold halves on exhaust housing
M8 bolt for constant-pressure manifold half in ex-
haust pipe housing
– initial tightening torque 20 Nm +2 Nm Ultra-Therm MTU 3.10.3.6
– release 0
– final torque 20 Nm +2 Nm
Nut for cam roller on lever 8 Nm + 1 Nm Engine oil 3.10.4.5
Emergency air shut-off flaps
M12 bolts for connection housing on carrier housing 40 Nm + 4 Nm Ultra-Therm MTU 3.10.6a.5
3.10.6a
5.a
Exhaust turbocharger
Clamp for exhaust elbow 9 Nm + 1 Nm Ultra-Therm MTU 3.10.6a.6
M10 bolt for securing turbocharger 40 Nm + 4 Nm Ultra-Therm MTU 3.10.6a.6
M8 nut on link of accumulator link 10 Nm + 1 Nm Engine oil 3.10.8a.5
M10 bolt for exhaust elbow on diverter housing 40 Nm + 4 Nm Ultra-Therm MTU 3.10.11a.5
Fuel injection equipment
Nut for bearing flange on injection pump drive 47 Nm Engine oil 3.11.1.6
Bolt for end cover on injection pump drive 25 Nm Engine oil 3.11.1.6
M12 stress bolt for idler gear on drive shaft
Max. bolt length prior to assembly 38 mm 3.11.2.5
– initial tightening torque 50 Nm + 5 Nm Engine oil 3.11.2a.5
– additional angle of rotation 45° +5° 3.11.2b.5
M14 stress bolt for injection timer cams
– initial tightening torque 60 Nm + 6 Nm Engine oil 3.11.2a.5
– additional angle of rotation 45° + 5° 3.11.2b.5
M24 nut for coupling (two-part) on fuel injection pump 400 Nm + 30 Nm Engine oil 3.11.3.6
I (IIB)
M24 nut for coupling (single-part) on fuel injection 440 Nm + 30 Nm Engine oil 3.11.3a.6
pump I (IID)
Nut for flanges, pumps I and II 400 Nm + 30 Nm Engine oil 3.11.4.6
3.11.4a.6
M12 bolt for disc assembly 100 Nm + 10 Nm Engine oil 3.11.4.6

3.11.4a.6
3.11.5a.6
20046/20 E –11.96–
General Section 1.3
Page 5
Self-locking nut for disc assembly 29 Nm + 2 Nm - 3.11.4.6

3.11.4a.6
3.11.5a.6
Securing bolts for fuel injection pump

– Initial torque 10 Nm Engine oil 3.11.5.6
– Pretightening torque in sequence 1 to 4/6/8 25 Nm 3.11.5a.6
– Final tightening in sequence 1 to 4/6/8 47 Nm + 4 Nm
Constant-pressure delivery valve for injection pump
– release 0 3.11.5a.7
– tighten 200 Nm
Stress bolt for injection pump drive
Max. bolt length prior to assembly 165 mm 3.11.5.7
– initial tightening torque 180 Nm + 18 Nm Molykote G-n plus 3.11.5a.7
– additional angle of rotation 180° 3.11.5a
– test torque in tightening direction 300 +30 Nm 7.a
Thrust screw for nozzle holder (cylinder head) 100 Nm – 5 Nm Engine oil 3.11.6.6
Union nut for nozzle body 80 Nm + 10 Nm Engine oil -
Fuel system
Union nut on injection pump 40 Nm + 5 Nm Engine oil 3.12.1.6
Union nut on injection nozzle 35 Nm + 5 Nm Engine oil 3.12.1.6
Bolt on fuel filter cover 22.5 Nm ± 2.5 Nm Engine oil 3.12.3.5
M6 hexagon socket head screw for fuel delivery 7.5 Nm Engine oil 3.12.4.5
pump drive sleeve
Coolant pumps
Stress bolt for engine coolant pump impeller
– tightening torque 75 Nm + 8 Nm
– settle bolt by tapping head lightly with 1000g Engine oil 3.13.1.5
hammer
– Final torque 75 Nm + 8 Nm
Slotted nut for angular-contact ball bearing on pump 200 Nm + 20 Nm Engine oil 3.13.1.5
shaft
Cap nut for raw water pump impeller 200 Nm + 20 Nm Engine oil 3.13.2.5
Stress bolt for bilge pump impeller 90 Nm + 10 Nm Molykote G-n plus 3.13.3.5
Test torque for seating bilge pump impeller on taper 350 Nm - 3.13.3.5
Securing screws for cooler housing and 100 Nm + 10 Nm Engine oil 3.14.6.6
carrier
Threaded sleeve for engine coolant cooler 180 Nm + 18 Nm Engine oil 3.14.6.6
Oil pump
Bolt for cover and connecting housing on oil pump 40 Nm + 4 Nm Engine oil 3.15.1.5
housing 3.15.1b.5
3.15.2.5
3.15.2a.5
Stress bolt for drive gear on drive shaft 100 Nm + 10 Nm Engine oil 3.15.1.5
3.15.1b.5
3.15.2.5
3.15.2a.5
20046/20 E –11.96–
General Section 1.3
Page 6
Bolt for engine oil pump on oil pan 74 Nm + 7 Nm Engine oil 3.15.1.6
3.15.1.6a
3.15.2.6
3.15.2.6a
Bolt for engine oil pump in intermediate frame, 74 Nm + 7 Nm Engine oil 3.15.1b.6
12V/16V 3.15.2a.6
Bolt for oil delivery and suction lines in oil pan, 42 Nm + 4 Nm Engine oil 3.15.1.6
8V/12V 3.15.1.6a
Bolt for pressurised oil line and intake line in oil pan 42 Nm + 4 Nm Engine oil 3.15.2.6
16V 3.15.2.6a
Bolt for pressurised oil and intake line on crankcase 74 Nm + 7 Nm Engine oil 3.15.3a.6
intermediate frame 3.15.3b.6
Bolt for oil-metering pump 3 Nm + 0.3 Nm Engine oil 3.15.4.5
Oil system
Pretightening: M12 bolt, disc-type oil cooler 40 Nm to 50 Nm Engine oil 3.16.2a.5
on housing lower section 3.16.2b.5
3.16.3a.5
Bolt for oil cooler in oil pan 74 Nm + 7 Nm Engine oil 3.16.2a.5

3.16.2b.5
3.16.3a.5
Centre bolt for filter bowl 25 Nm Engine oil 3.16.4a.6

Nut for rotor of centrifugal oil filter 40 Nm + 10 Nm Engine oil 3.16.6.5
Starting system
Nut for starting air distributor disc 30 Nm + 5 Nm Engine oil 3.18.1.7
3.18.1.7a
3.18.1.7b
Union for starting valve 20 Nm + 5 Nm Engine oil 3.18.2.6
Engine mount, driving end (lockable)
M24 nut for tapered mount 600 Nm + 60 Nm Engine oil 3.19.1.5
M10 nut for tapered mount and flange 42 Nm + 4 Nm Engine oil 3.19.1.5
M16 bolt for securing engine mount upper section on 250 Nm + 25 Nm Engine oil 3.19.1.6
driving end to crankcase
M20 foundation bolt 500 Nm + 50 Nm Engine oil -
M20 foundation bolt with casting resin, bolt secured 175 Nm Engine oil -
with spring washer
Engine mount, free end (lockable)
M24 bolt for tapered mount 600 Nm + 60 Nm Engine oil 3.19.1.5
M16 bolt for engine carrier on upper-part of crank- 250 Nm + 25 Nm Engine oil 3.19.1.6
case
M10 bolt for tapered mount with bracket 42 Nm + 4 Nm Engine oil 3.19.1.5
M20 foundation bolt with alignment plates 500 Nm + 50 Nm Engine oil -
M20 foundation bolt with casting resin, 95 Nm Engine oil
bolt secured with spring washer -
20046/20 E –11.96–
General Section 1.3
Page 7
Engine mount, free end (with flange-mounted

gearbox)
M16 bolts for cover on carrier and resilient bush 180 Nm + 18 Nm Engine oil 3.19.1.5
M20 bolts for engine carrier on crankcase 350 Nm + 35 Nm Engine oil 3.19.1.6
Hydraulic fan drive
M8 bolt for disc on intermediate housing and cover 21 Nm + 2 Nm Engine oil 3.20.1a.5
M20 bolts for drive torus 430 Nm Engine oil 3.20.1a.6
3.20.1b.6
M12 bolt for drive torus on flange 65 Nm + 5 Nm Engine oil 3.20.1a.6
3.20.1b.6
M8 bolt for driver disc on drive torus 16 Nm + 2 Nm Engine oil 3.20.1a.6
3.20.1b.6
Securing bolt for intermediate housing on housing, 74 Nm + 8 Nm Engine oil 3.20.1a.6
tighten diagonally 3.20.1b.6
Stress bolt for drive and driven torus on ring 65 Nm + 5 Nm Engine oil 3.20.1a.6
3.20.1b.6
Securing bolt for intermediate housing cover, tighten 74 Nm + 8 Nm Engine oil 3.20.1a.6
diagonally 3.20.1b.6
Monitoring
M8 bolt for level switch to cooler housing 35 Nm + 4 Nm Engine oil 3.84.1.6
Speed transmitter in crankcase 50 Nm Engine oil 3.84.4.6
3.84.4a.6
Accessories (electrical/pneumatic)
M12 nut for resilient generator coupling 63 Nm Engine oil 3.86.1.6
Nut for coupling member on generator 300 Nm Engine oil 3.86.2.6
Bolts for centring elements on generator carrier 74 Nm + 7 Nm Engine oil 3.86.3a.6
3.86.3a.7
Generator carrier securing bolts on crankcase 74 Nm + 7 Nm Engine oil 3.86.3a.6
3.86.3a.7
Bolts for belt pulley on flange 43 Nm + 4 Nm Engine oil 3.86.3a.6
Nut for belt pulley on generator 120 Nm + 30 Nm Engine oil 3.86.3a.6
M12 nuts securing generator to carrier 74 Nm + 7 Nm Engine oil 3.86.3a.6
3.86.3a.7
Nut for coupling member to air compressor 180 Nm + 18 Nm Engine oil 3.86.4.6
3.86.4a.6
Nut in piston rod 7 Nm - 3.86.9.5
Stop on piston rod 95 Nm Thread-locking 3.86.9b.5
agent – Loctite 270
Threaded bush on end cover 30 Nm Thread-locking 3.86.9b.6
agent – Loctite 270
20046/20 E –11.96–
General Section 1.3
Page 8
Tightening torques for stress bolts as per standard MTN 5007

This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of strength
class 10.9 and the associated nuts.
Shaft and transition dimensions as to MMN 209 standard and material and machining to MMN 389 standard (bright
surface or with phosphate coating).
The values in the table are based on a friction coefficient tot = 0.125. Precondition: Thread and mating faces of screws
and nuts must be coated with engine oil prior to assembly.
An assembly tolerance of + 10% of the table values is permitted for unavoidable deviations of the tightening torque
from the table value during the tightening process – e.g. resulting from inaccurate readings and overtightening during
assembly
The specifications in the tables apply for hand tightening with a torque wrench.
Tightening torques = MA
Thread Not torsion-protected Torsion-protected*

MA (Nm) MA (Nm)
M 6 9 12
M 8 21 28
M 8x1 24 30
M 10 42 55
M 10 x 1.25 46 60
M 12 75 93
M 12 x 1.5 78 99
M 14 120 150
M 14 x 1.5 135 160
M 16 180 225
M 16 x 1.5 200 245
M 18 250 315
M 18 x 1.5 300 360
M 20 350 450
M 20 x 1.5 430 495
M 22 500 620
M 22 x 1.5 560 675
M 24 640 790
M 24 x 2 700 850
M 27 900 1170
M 27 x 2 1000 1230
M 30 1250 1575
*Protect shank against torsion when tightening.
20046/20 E –07.96–
General Section 1.3
Page 9
Tightening specification for setscrew and stud connections as per works standard MTN 5008
This works standard applies to setscrews not subjected to 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.
They do not apply to heat-proof screws in the hot component area.
Tightening torques MA are for screws of strength class 8.8 (bright surface, phosphate coating or galvanised) and 10.9
(bright surface or with phosphate coating).
The values in the table are based on a friction coefficient tot = 0.125.
Precondition: Thread and mating faces of screws and nuts must be coated in engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of + 10% of the table values is permitted
for unavoidable deviations of the tightening torque from the table value during the tightening process – e.g. resulting
from inaccurate readings and overtightening during assembly .
When tightening mechanically, the permitted assembly tolerance is + 15 %
Thread Hand-tightened Machine-tightened

8.8 10.9 8.8 10.9
MA (Nm) MA (Nm) MA (Nm) MA (Nm)
M 6 9 12 8 11
M 8 21 31 20 28
M 8x1 23 32 21 30
M 10 42 60 40 57
M 10 x 1.25 45 63 42 60
M 12 74 100 70 92
M 12 x 1.25 80 110 75 105
M 12 x 1.5 76 105 72 100
M 14 115 160 110 150
M 14x1.5 125 180 120 170
M 16 180 250 170 235
M 16 x 1.5 190 270 180 255
M 18 250 350 240 330
M 18 x 1.5 280 400 270 380
M 20 350 500 330 475
M 20 x 1.5 390 550 350 520
M 22 480 680 450 650
M 22 x 1.5 520 730 490 700
M 24 600 850 570 810
M 24 x 1.5 680 950 640 900
M 24 x 2 660 900 620 850
M 27 900 1250 850 1175
M 27 x 2 960 1350 900 1275
M 30 1200 1700 1100 1600
M 30 x 2 1350 1900 1250 1800
20046/20 E –07.96–
General Section 1.3
Page 10
Tightening torques for plugs as per standard MTN 5183–1
This standard applies to plugs as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN 3852, model A
(sealed by sealing ring DIN 7603–Cu).
DIN 908 DIN 910 DIN 7604A/C
Tightening torques MA are given for plugs made of steel (St) with surface protected by a phospate coating and
oiled or galvanised.
Thread and mating faces beneath heads must be coated with engine oil prior to assembly.
from the table value during the tightening process – e.g. resulting from inaccurate readings and overtightening dur-
ing assembly.
Tightening torques for plugs DIN 908, DIN 910 and DIN 7604A (with short screwed plug)
Thread inserted in
steel/gray cast iron Al-alloy
MA (Nm) MA (Nm)
M 10 x 1 15 15
M 12 x 1.5 35 25
M 14 x 1.5 35 25
M 16 x 1.5 40 30
M 18 x 1.5 50 35
M 20 x 1.5 55 45
M 22 x 1.5 60 50
M 24 x 1.5 70 60
M 26 x 1.5 80 70
M 27 x 2 80 70
M 30 x 1.5 100 90
M 30 x 2 95 85
M 33 x 2 120 110
M 36 x 1.5 130 115
M 38 x 1.5 140 120
M 42 x 1.5 150 130
M 45 x 1.5 160 140
M 48 x 1.5 170 145
M 52 x 1.5 180 150
M 56 x 2 190 160
M 64 x 2 205 175
20046/20 E –07.97–
General Section 1.3
Page 11
Tightening torques for plugs as per DIN 7604C (with long screwed plug)
Thread inserted in
steel/gray cast iron Al-alloy
MA (Nm) MA (Nm)
M8x1 10 10
M 22 x 1.5 80 65
M 26 x 1.5 105 90
M 30 x 1.5 130 130
M 38 x 1.5 140 120
M 45 x 1.5 160 140
20046/20 E –07.97–
General Section 1.3
Page 12
Tightening torques for banjo screws as per standard MTN 5183–2
This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603–Cu
MMN 223 (4 flow holes) N 15011 (3 flow holes)
Tightening torques MA are given for banjo screws made of steel (St) with surface protected by a phosphate coating
and oiled or galvanised.
ing assembly.
Thread inserted in
steel/gray cast iron/Al-alloy
MA (Nm)
M8x1 10
M 10 x 1 15
M 12 x 1.5 20
M 14 x 1.5 25
M 16 x 1.5 25
M 18 x 1.5 30
M 22 x 1.5 60
M 26 x 1.5 90
M 30 x 1.5 130
M 38 x 1.5 140
M 45 x 1.5 160
20046/20 E –07.97–
General Section 1.3
Page 13
Tightening torques for male connectors as per standard MTN 5183–3
This standard applies to male connectors DIN 2353, series L with screwed plug DIN 3852, model A (sealed by
sealing ring DIN 7603-Cu)
DIN 2353, model C
Tightening torques MA are given for male connectors made of steel (St) with surface protected by a phosphate
coating and oiled or galvanised.
ing assembly.
Thread inserted in
steel/gray cast iron
MA (Nm)
M 10 x1 10
M 12 x 1.5 20
M 14 x 1.5 40
M 16 x 1.5 50
M 18 x 1.5 60
M 22 x 1.5 70
M 26 x 1.5 100
M 32 x 2 160
M 42 x 2 260
M 48 x 2 320
20046/20 E –07.97–
General Section 1.4
Page 1
1.4 Settings
(Counterclockwise-rotating engine)
Firing order
Firing order for 8 V 396, long firing order A1 – B4 – A4-A2 – B3 – A3 – B2-B1

Firing order for 12 V 396, long firing A1 – B2 – A5 – B4 – A3 – B1 – A6 – B5 – A2 – B3 – A4 – B6
order
Firing order for 16 V 396, long firing A1 – B5 – A3-A5 – B2-B8 – A2-A8 – B3 – A7 – B4-B6 – A4-A6 – B1-B7
order
Direction of rotation, viewed towards driving end

Crankshaft counterclockwise
Camshafts clockwise
Fuel injection pump counterclockwise
Engine oil pump in oil pan, 6 - 12 V clockwise
Engine oil pump in oil pan, 16 V counterclockwise
Engine coolant pump counterclockwise
Raw water pump counterclockwise
Opening pressure of fuel injector nozzles, model 5550102051
Setting pressure with new spring 250 bar to 258 bar

Specified pressure with run-in spring 235 bar to 245 bar
Minimum pressure with run-in spring 220 bar
Opening pressure of fuel injection nozzles, version 555100751 / 2151 / 2551

Opening pressure of fuel injector nozzles, model 5550102651

Note
Pay attention to rolled-in opening pressure.
20046/20 E –02.96–
General Section 1.4
Page 2
Valve clearance with cold engine (approx. 20°C)
Inlet 0.30 mm
Exhaust 0.45 mm
Valve timing with valve clearance adjusted
after TDC before (°crankshaft degrees)

1 Inlet valve opens 36° before
TDC
2 Inlet valve closes 68° after
BDC
3 Exhaust valve opens 75° before
BDC
4 Exhaust valve closes 28° after
TDC
5 Overlap 64°
6 Start of injection pump delivery see Engine
Acceptance Test Record
7 Adjustment range of injection timer see De-
scription
before BDC after
Valve overlap measured at valve head, no valve clearance at TDC
Inlet cam, specified overlap + 0.4 + mm

1.72 mm – 0.5 mm
Exhaust cam, specified overlap + 0.3 + mm
1.47 mm – 0.25 mm
20046/20 E –02.96–
General Section 1.5
Page 1
1.5 Dangers at Working Area

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
These Safety Instructions must be read and followed by any persons operating or carrying
out maintenance on the machinery plant.
General safety and accident prevention regulations
D In addition to the instructions given in this publication, general safety and accident prevention regulations and
laws must be taken into consideration; these may vary from country to country.
D This MTU engine is a state-of-the-art product and conforms with all the applicable specifications and regula-
tions. Nevertheless, persons and property may be at risk in the event of:
– Incorrect use
– Servicing, maintenance and repair carried out by untrained members of staff
– Modifications or conversions
– Noncompliance with the Safety Instructions
Correct use
D The engine is to be used solely for the purpose stated in the contract. Any other use is considered improper
use. The manufacturer will accept no liability for any resultant damage. The responsibility is borne by the user
alone.
D Correct use also includes observation of the Operating Instructions and Maintenance Manual and compliance
with maintenance and repair instructions.
D Engine plants, assemblies or individual components which have been magnetically treated at MTU must remain
in this condition – see general guidelines on marine magnetics.
Personnel requirements
D Work on the engine must be carried out only by reliable personnel. The specified legal minimum age must be
respected.
D Only fully trained or qualified personnel must be employed. Responsibilities of the operating, maintenance and
repair personnel must be specified.
Modifications or conversions
D Modifications made by the customer to the engine may affect safety. No modifications or conversions must be
carried out without prior consent from MTU.
D No liability will be accepted for damage resulting from unauthorised modifications.
Organisational measures
D This Operation Manual must be made available to maintenance and servicing personnel.
D The personnel must be instructed on engine operation and repair by means of the Operation Manual, and in
particular the safety instructions must be explained. This is especially important for personnel who work on the
engine only on an occasional basis.
Spare parts
D Spare parts must at least satisfy the requirements specified by the manufacturer. This is guaranteed when origi-
nal components are used.
Working clothes and protective equipment
D Always wear protective shoes when working on plant.
D Select appropriate protective goggles for the work to be carried out. Always wear protective goggles when work-
ing with mallets, cutting tools, drift punches and similar tools.
D Work clothing must be tight-fitting so that it does not catch on rotating or projecting components. Do not wear
jewellery (e.g. rings, chains, etc.).
20038/10 97–07
General Section 1.5
Page 2
Welding work
D Never use the engine as earth connection! – (This prevents the welding current passing through the engine and
causing scorching or burning at bearings, sliding surfaces and tooth flanks, which can lead to pitting or other
material damage).
D Welding on the engine or mounted ancillaries is forbidden.
D Never place the welding cable across or near wiring harnesses of MTU plants. – (Welding current could be in-
duced in the wiring harnesses, which may result in damage to the electrical system).
D The earth connection of the welding unit must not be situated more than 60 cm from the weld location.
D If welding has to be carried out on components (e.g. exhaust manifold), these components must first be re-
moved from the engine.
D For the MTU electronics system (ECS) it is not necessary to remove the connectors to carry out welding work if
the power supply master switch is moved from ”ON” to ”OFF” and the cable is disconnected from the battery
negative and positive terminals.
D When carrying out welding work, always wear welding gloves, head protection, goggles, apron and other suit-
able protective clothing.
Transportation
D Lift the engine only with the lifting eyes provided.
D Use only the transportation and lifting equipment approved by MTU.
D The engine must only be transported in installation position.
Engine operation
D When the engine is running, ear protectors must always be worn in the engine room.
D The engine room must be well ventilated.
D To avoid injuries caused by falling, leaked or spilt engine oil and coolant must be cleaned up immediately or ab-
sorbed with appropriate bonding agents.
D Exhaust gases from combustion engines are poisonous and injurious to health if inhaled. The exhaust pipework
must be leak-free and discharge exhaust gases to atmosphere.
D During engine operation, do not touch battery terminals, generator terminals or cables. Inadequate protection of
electrical components can lead to electric shocks and serious injuries.
D Never disconnect coolant, oil, fuel, compressed air or hydraulic lines while the engine is running.
Maintenance and repair

D Compliance with maintenance specifications is an important safety factor.
D Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. The
engine must be secured against inadvertent starting and the battery disconnected. Attach sign ”Do not operate”
in operating area or to control equipment. Persons not involved must keep clear.
D Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance work must only be carried out by authorised, qualified personnel.
D Use only tools in perfect condition.
D Do not work on engines or components which are only held by lifting equipment or crane. Always support these
components on suitable frames or stands before beginning any maintenance or repair work.
D Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
20038/10 97–07
General Section 1.5
Page 3
D Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal
connections with caps or covers if a line is removed or opened.
D During maintenance or repair work, do not hit fuel lines with wrenches or other tools. To tighten connections
when installing lines, use the correct tightening torque and ensure that all retainers and dampers are installed
correctly.
D Ensure that all fuel injection lines and pressurised oil lines have sufficient play to avoid contact with other com-
ponents. Do not place fuel or oil lines near hot components.
D The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
D Do not bend lines under pressure or use force.
D In order to avoid burning, take special care when placing hot components on products when working with hot
liquids in pipelines, pipes and chambers.
D Until the engine has cooled, the breather cap must not be opened. Release the breather cap and allow pressure
to escape, before cap removal.
D Take special care when removing ventilation plugs or screws from engine. In order to avoid being sprayed with
highly-pressurised liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has re-
cently been shut down, as the liquids can still be hot.
D Take special care when draining hot fluids – risk of injury. Drain the fluids into a suitable container and wipe up
any spillages.
D When changing engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
D When working high on the engine, always use suitable ladders and work platforms. Make sure components are
placed on stable surfaces.
D To avoid damaging your back when lifting components weighing 25 kg (50 lb.) or more, use lifting gear or re-
quest aid from other workers. Ensure that all chains, hooks, slings, etc. are in good condition, are sufficiently
strong and that hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
D When electrical equipment is in operation, certain components of these appliances are electrically live.
D Non-observance of the warnings may result in serious, life-threatening injuries or damage to property or equip-
ment.
D Work on electrical equipment may only be carried out by qualified personnel. Switch off all live appliances be-
fore carrying out any work on electrical equipment.
D Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to
come into contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before con-
necting the cable to the battery, check battery polarity. Battery pole reversal may lead to injury through the
sudden discharge of acid or bursting of the battery body.
D Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against another component or by a hot surface. Never
connect wiring to a line which carries liquid.
D Before barring the engine, ensure that nobody is within the danger area. After working on the engine, check that
all guards have been reinstalled and that all tools and loose components have been removed from the engine.
Fire prevention
D Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires – there-
fore always keep the engine in a clean condition. Do not leave oil-soaked cloths on the engine. Do not store
combustible fluids near the engine. Do not allow dirt or foreign matter to accumulate near the engine, as this
constitutes a fire hazard.
D Welding work must not be carried out on pipes and components containing oil. Before welding, clean with a
noncombustible fluid.
20038/10 97–07
General Section 1.5
Page 4
D Never mix petrol/gasoline with diesel fuel. If petrol/gasoline is added to diesel fuel, there is increased risk of fire.
D When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoid
sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of
the engine or to the ground terminal of the starter.
D Always keep a fire extinguisher at hand and learn how to operate it.
Noise
D All work areas with a sound pressure level in excess of 85 dB (A) may cause hearing damage.
D Wear earplugs or earmuffs!

Environmental protection
D Dispose of used fluids and lubricants and filters in accordance with local regulations.
D Manipulation of the injection or control system can influence the engine performance and exhaust emissions. As
a result, compliance with environmental regulations may no longer be guaranteed.
Skin infections
D The preventive ointments issued are not intended to treat skin infections once they have occurred. If rashes of
any type appear (even minor ones), consult a doctor.
Warning signs
D Before putting the engine into service and before working on the engine, read and follow all warning signs. Do
not paint on warning signs. Replace illegible signs.
Auxiliary materials
D Use only fluids and lubricants that have been tested and approved by MTU.
D Fluids and lubricants must be kept in properly designated containers. When using fluids, lubricants and other
chemical substances, follow the safety instructions applicable to the product. Take special care when using hot
and caustic materials. When using inflammable materials, avoid all sparks and do not smoke.
Lead
D When working with lead or pastes containing lead, ensure that no lead is absorbed by the body (white powder
of lead, lead smoke, dirtied hands).
– Prevent the build-up of white powder of lead!
– Switch on fume extraction system!
– Wash hands before eating any food!
Chlorinated hydrocarbons
D When working with chlorinated hydrocarbons (e.g. perchlorethylene, trichlorethane) or other cold cleaners which
contain declared hazardous substances, health-endangering substances may be inhaled.
– Switch on ventilation and extraction systems!
– Observe fire prevention regulations!
– No smoking and no consumption of alcoholic beverages!
– Do not allow chlorinated hydrocarbons to come into contact with sewage water!
Acids and alkaline solutions
D When working with acids and alkaline solutions, always wear protective goggles/face guard, gloves and protec-
tive clothing.
– If such solutions are spilled onto clothing, remove the affected clothing immediately!
– Rinse injured parts of the body thoroughly with water!
– Rinse eyes immediately with eyedrops or clean mains water!
20038/10 97–07
General Section 1.5
Page 5
Painting
D When carrying out painting work outside the spray stands provided with fume extraction systems, ensure that
the area is well ventilated. Make sure that neighbouring work areas are not impaired.
– Always wear a mask providing protection against paint and solvent vapours!
– Observe fire prevention regulations!
– No smoking!
– No naked flames!
Liquid oxygen
D Liquid oxygen is highly inflammable.
D Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals). Do not
bring liquid oxygen into contact with the body (hands) as this causes frostbite and numbing.
– No smoking, no naked flames (risk of explosion). Oxygen enrichment in the air causes flash combustion!
– Do not store any inflammable substances (e.g. oils and greases) within 5 m of the area of work!
– Under no circumstances should clothing be oily or greasy!
– Make sure that fumes do not accumulate in clothing. Oxygen enrichment in fabric can cause working clothes to ignite
suddenly!
– On completion of work, do not smoke until clothing is completely free of fumes!
– Avoid knocks or impacts during this work!
Liquid nitrogen
D Liquid nitrogen should only be stored in small quantities and in regulation containers (without fixed seals).
D Do not bring liquid nitrogen into contact with the body (eyes, hands) as this causes frostbite and numbing.
– Wear protective clothing (including gloves and closed shoes) and protective goggles!
– Ensure the room is well ventilated (88% contamination of breathing air with nitrogen will result in suffocation)!
– Do not subject containers, fittings and tools to impact or shock!
Compressed air
D Compressed air is air which has been compressed at excess pressure and is stored in tanks from which it can
then be extracted.
D The pressure at which the air is kept can be read off at pressure gauges which must be connected to the com-
pressed air tanks and the compressed air lines.
D Pressure, especially when it acts suddenly, represents a hazard to the human body.
– 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 assembled for this pressure, or, if the permitted pressure for the
connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to per-
mitted pressure) must form an intermediate connection. Hose coupling and connections must be securely attached!
– Wear protective goggles when cleaning workpieces with compressed air or when using compressed air to remove
swarf!
– 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!
– Unauthorised use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of vessels, re-
sults in a risk of explosion!
– Forcing compressed air into thin-walled containers (e.g. containers made of metal, plastic or glass) for drying pur-
poses or to check for leaks results in a risk of explosion!
20038/10 97–07
General Section 1.5
Page 6
– Removing dirt from soiled clothes while still worn can result in a risk of injury.
Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back, the air can enter the
anal cavity and fatally rupture the intestines!
Used oils
D Used oils may contain combustion residues which are harmful to health.
– Rub barrier cream into hands!

– Clean hands thoroughly after contact with used oil!
Asbestos
Caution! Gaskets and seals used in this engine may contain asbestos.
Please pay attention to appropriately marked spare parts ”a” during repair work.
Health risk if asbestos dust is inhaled. Follow safety regulations!
Instructions for handling asbestos products:
1. Introductory remarks
Asbestos dust is created when asbestos and products containing asbestos are transported, sorted, machined or
processed.
Visible asbestos dust contains a proportion of breathable dust which is not visible, hangs for long periods in air and
is thrown up again by air currents when it settles.
Asbestos dust can cause malignant connective-tissue tumours even in low concentrations and after brief periods of
exposure.
The effects of disease caused by asbestos generally only become evident after decades.
When renovating asbestos-insulated facilities, assume that the asbestos concentration is very high if the asbestos
is not disposed of correctly.
Take special protective measures with breathing equipment (see Point 3).
2. Correct procedure
Do not remove asbestos from enclosed areas (e.g. ships, installations, vehicles) without taking safety precautions.
The asbestos from components which have been removed must be extracted outside enclosed spaces.
When disassembling components containing asbestos (e.g. asbestos-insulated exhaust pipework), ensure that no
asbestos dust is released into the air. This is achieved by following the steps below:
– Wrap the components in plastic sheeting and secure with adhesive tape.
– Moisten and wrap the components in damp cloths (exhaust elbows with fractures on the outer jackets are par-
ticularly dangerous due to the build-up of dust).
– Asbestos from removed components may only be released into sealed containers/receptacles (e.g. handling
sacks).
– Ensuring that no dust is created, carefully remove the components from the container. Leave the extracted as-
bestos in the container, seal the container tightly and forward for waste disposal (see Point 4).
Wear a P2 dust mask during this procedure (damage to the container is possible).
– Remove remaining asbestos thoroughly from the components using a vacuum cleaner authorised for asbestos.
– Remove the remnants of flat gaskets with a scraper only.
(The use of electromechanical devices is not permitted).
3. Personal protective equipment

When carrying out the tasks described in Part 2 and until the enclosed areas (ships, vehicles, containers etc.) have
been left, it is imperative to wear a dust mask of at least protection class P2. Once this work has been completed ,
these masks must be disposed of with the asbestos waste.
When exhaust pipework is being refitted in enclosed areas (ships, vehicles, containers etc.), only enter these areas
if wearing a dust mask with filter element of protection class P3.
20038/10 97–07
General Section 1.5
Page 7
The filter element must be renewed if breathing becomes laboured. The filter element is to be disposed of in the
same way as a P2 mask.
The above-mentioned dust masks do not provide protection against harmful gases and the lack of oxygen, e.g. in
the event of fire or in silos etc.
If it is not possible to extract all asbestos traces from work clothing, the disposable protective suits issued must be
worn.
Caution! Torn handling sacks must be sealed with adhesive tape.
Any released asbestos dust must be bound (moistened) and disposed of (see Point 4).
4. Correct disposal
Deposit waste in marked waste bags.
These bags must then be sealed tightly.
The personal protective equipment which has been used must also be disposed of with the waste.
Empty the vacuum cleaner in accordance with the operating instructions provided with the appliance.
Follow the waste disposal regulations of the relevant country.
In the Federal Republic of Germany, asbestos waste may be disposed of only after consultation with the disposal-
site operator.
Warning notices
D Section 3 of this publication contains especially emphasised safety instructions which begin with one of the fol-
lowing signal words according to the degree of danger:
– Take extreme care in these situations!
– Read and become acquainted with all warning notices and symbols before operating or repairing this product.
– Inform operating and maintenance personnel on all Safety Instructions.
20038/10 97–07
General Section 1.6
Page 1
1.6 Data Sheets

In order to prevent defective components from being reinstalled, or sound parts from being scrapped, it is essential
that testing and examination be performed exclusively by trained personnel using the appropriate test equipment.
All test and measurement equipment is exposed to a certain normal degree of wear during use.
It is thus essential that the test and measuring equipment be be inspected annually at a test station of appropriate
technical standard in order to ensure early detection of any deviations from specification.
An alternative is to have the equipment inspected by our Product Support service and MTU Friedrichshafen or by an
outside customer-service organisation.
Regardless of testing arrangment, it is essential that the equipment remain within the tolerances and dimension limits
specified in M070025.
The following data sheets should be used to record the individual examination results:
– Measuring crankcase bores
– Cylinder liner (installed)
– Axial play and backlash
– Crankshaft data sheet
– Crankshaft bearings
– Conrods
– Conrod bearing (shells installed)
– Timing and injection timing
– Piston gap setting
– Valve guide bushes
20038/10 E –11.92–
Engine Model
Data Sheet V 396
Crankcase Bores
Crankshaft bearing bores Specified Value: Serial No.
Bearing or cylinder 1 2 3 4 5 6 7 8
No. Crankcase No.
Measuring direction a Data Sheet No.

Measuring direction b
Checked by
Measuring direction c
Camshaft bearing bores Specified Value: Date
Measuring direction a A–bank
Measuring direction a B–bank
Cylinder liner bores – Upper fit Specified Value:
Cylinder liner bores – Lower fit Specified Value:
Roller tappet bores Specified Value:
Specified Value For specified values refer to Tolerances and wear Limits List.
Specified Value
E1213
Engine Model
Data Sheet V 396
Cylinder Liner (Installed) Serial No.
Crankcase No. ––––––––––––––––––––––––––––––
Cylinder liner, Part No. ––––––––––––––––––––––––––––––
Specified bore dimension ––––––––––––––––––––––––––––––
Measure In longitudinal (a) and transverse (b) direction

In measuring planes 1, 2, 3, 4.
Cylinder Direction Basic Actual Dimensions Cylinder Direc– Basic Actual Dimensions
No
No. dim
dim. No
No. tion dim
dim.
Measuring Planes Measuring Planes
1 2 3 4 1 2 3 4
A1 a B1 a
b b
A2 a B2 a
b b
A3 a B3 a
b b
A4 a B4 a
b b
A5 a B5 a
b b
A6 a B6 a
b b
A7 a B7 a
b b
A8 a B8 a
b b
A9 a B9 a
b b
A10 a B10 a
b b
Remarks:
Date: Checked by:
E2444
Engine Model
Data Sheet V 396
Axial Clearances and Tooth Backlash Engine No.
1. Generator and coolant pump idler gears
Axial clearance Axial runout Radial runout Tooth backlash

Specif. Actual Permiss. Actual Permiss. Actual Specif. Actual
Generator idler
gear
Coolant pump id-
ler gear
2. Oil pump idler gear
Tooth backlash Specified ––––––––––––––– Actual –––––––––––––––
3. Camshaft
Camshaft No. A–bank ––––––––––––––– B–bank –––––––––––––––
Camshaft axial clearance Specified –––––––––––––––
Actual A–bank ––––––––––––––– B–bank –––––––––––––––
4. Crankshaft
Crankshaft axial clearance Specified –––––––––––––– Actual –––––––––––––––
Crankshaft No. –––––––––––––––––––––– Charge ––––––––––––––
Remarks:
Date: Checked by:
E2442
KURBELWELLEN–KENNBLATT Typ
CRANKSHAFT DATA SHEET Model
Sach–Nr. Wellen–Nr.
Item No. Shaft No.
Zeichnungs–Nr. Abnahme
Drawing No. Classification
Meßstelle / Measuring Point 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Hublager–Ø
Crankpin Dia.
Grundlager–Ø
Main Journal Dia.
Anlaufbund Ölbohrungen einwandfrei gereinigt und verrundet.

Thrust collar Oil ducts thoroughly cleaned and edges smoothed.
Rundlauf Sämtliche Hohlkehlen und Ansenkungen nach Zeichnung.
Concentricity All fillets and countersinks as per drawing.
Härte Hublager Gegengewichtsauflageflächen Rt und Ebenheit nach Zeichnung.
Crankpin hardness Roughness height and flatness of counterweight seating surface as per drawing.
Härte Grundlager Winkligkeit der Gegengewichtbefestigungsgewinde nach Zeichnung.
Journal hardness Angularity of counterweigth securing thread as per drawing.
Rißprüfung Prüfmoment der Gegengewichtbefestigung nach Zeichnung.
Crack test Test torque of counterweight boltet joint as per drawing.
Bemerkungen / Remarks:
, den Prüfer / Checked by: Freigabe / Approved by:
D/E2437
Engine Model
Data Sheet V 396
Main Bearings Engine No.
Crankcase No. ––––––––––––––––––––
Crankshaft No. ––––––––––––––––––––
Specified dimensions
Main bearing ID ––––––––––––––––––––
Main journal OD ––––––––––––––––––––
Radial clearance ––––––––––––––––––––
Crankshaft axial clearance:–––––––––––––––––––––– Actual dimensions:–––––––––––––––
Measure and record Smallest diameter a, b and c in measuring planes 1 and 2

Bearing clearance definition = smallest diameter a
Bearing No. Actual dimensions
Basic dimension 1 2 3 4 5 6
Bearing ID b
Bearing ID c
Bearing ID a
Main journal OD
(actual)
Bearing clearance
(radial)
Bearing No. Actual dimensions

Basic dimension 7 8 9 10 11 12
Bearing ID b
Bearing ID c
Bearing ID a
Main journal OD
(actual)
Bearing clearance
(radial)
Remarks:
Date: Checked by:
E2443
Engine Model
Data Sheet V 396
Connecting Rods Engine No.
Connecting rod A1 A2 A3 A4 A5 A6 A7 A8
Conrod No.
Weight class
Charge
Connecting rod B1 B2 B3 B4 B5 B6 B7 B8
Conrod No.
Weight class
Charge
Remarks:
Date: Checked by:
E2350
Engine Model
Data Sheet V 396
Connecting Rod Random Checks
(Bearing Shells Installed) Engine No.
Order No. –––––––––––––––––––– Specified dimensions
Crankcase No. –––––––––––––––––––– Conrod bearing bore ––––––––––––––––––––
Radial clearance ––––––––––––––––––––
Measure: Diameters a, b1 and b2

Bearing clearance definition = smallest a, b1 or b2 value
A–bank
Actual dimensions
Cylinder Conrod Basic a b1 b2 Crank- Radial
No. No. pin clear–
ance
1
2
3
4
5
6
7
8
9
10
B–bank
Actual dimensions
Cylinder Conrod Basic a b1 b2 Crank- Radial
No. No. pin clear–
ance
1
2
3
4
5
6
7
8
9
10
Remarks:
Date: Checked by:
E2446
Engine Model
Data Sheet V 396
Valve and Injection Timing Engine No.
1. Timing Diagram
Speci- Actual
fied
Cylinder No.
Exhaust valve opens before BDC
Inlet valve opens before TDC
Exhaust valve closes after TDC
Inlet valve closes after BDC
Timing adjustment as per timing diagram
2. Cam Lift
Speci- Actual
fied
Cylinder No.
Inlet
Exhaust
3. Injection Timing
For commencement of delivery, see Engine History Card
Remarks:
Date: Checked by:
E2440
Engine Model
Installation Data Sheet V 396
Piston Crown Clearance Adjustment Engine No.
(Drawing No. 555 000 87 99)
1 Piston crown face A Cylinder head gasket thickness 2.0 mm D Cylinder liner projection
2 Cylinder liner B Crankcase top deck–to–piston crown face E Gap “S” before tightening cylinder head
3 Cylinder head gasket C Piston crown clearance bolts
4 Support plate F Support plate thickness
Using a dial gauge. move piston to TDC and measure piston projection projection B above cranckcase top deck.
Verify: Piston clearance ”C” must, in all cases, be at least 1.40 mm.
Measured projection ”B” Gasket thickness required ”A” Piston clearance ”C”
Thickness 0,08 mm
from 8.35 mm to 8.54 mm 2.0 mm from 1.42 mm to 1.79 mm
* In the case of 8.96 mm to 8.98 mm, use a gasket which is at least 2.34 mm thick.
Left bank A1 A2 A3 A4 A5 A6 A7 A8
Projection ”B” / actual dimension
Gasket thickness / actual dimension
Right bank B1 B2 B3 B4 B5 B6 B7 B8
Projection ”B” / actual dimension
Gasket thickness / actual dimension
Support plate selection
Measured liner projection ”D” 8.04 mm to 8.06 mm
Required support plate thickness ”F” 7.95 mm to 7.97 mm
Gap ”S” min. 0.090 mm to max. 0.130 mm
Left bank A1 A2 A3 A4 A5 A6 A7 A8
Liner projection ”D”
Support plate thickness ”F”
Right bank B1 B2 B3 B4 B5 B6 B7 B8
Liner projection ”D”
Support plate thickness ”F”
Remarks:
Date: Checked by:
D2441
Engine Model
Installation Data Sheet V 396
Piston Crown Clearance Adjustment Engine No.
1 Piston crown face A Cylinder head gasket thickness 2.0 mm D Cylinder liner projection
2 Cylinder liner B Crankcase top deck–to–piston crown face E Gap ”S” before tightening cylinder head
3 Cylinder head gasket C Piston crown clearance bolts
4 Support plate F Support plate thickness
Using a dial gauge, move piston to TDC and measure piston projection B above crankcase top deck
Verify: Piston crown clearance must, in all cases, be at least 1.40 mm
Measured Projection B Gasket Required Piston Crown Clearance C
from 8.16 mm to 8.52 mm 2.0 mm thick from 1.4 mm to 1.9 mm
Left bank cylinder A1 A2 A3 A4 A5 A6 A7 A8

Projection B, actual
Gasket thickness, actual
Right bank cylinder B1 B2 B3 B4 B5 B6 B7 B8
Projection B, actual
Gasket thickness, actual
Support Plate Selection
Liner projection D, measured 8.04 mm to 8.06 mm
Support plate thickness F, required 7.95 mm to 7.97 mm
Gap S min. 0.090 mm to max. 0.130 mm
Left bank cylinder A1 A2 A3 A4 A5 A6 A7 A8

Liner projection D
Support plate thickness F
Right bank cylinder B1 B2 B3 B4 B5 B6 B7 B8
Liner projection D
Support plate thickness F
Remarks:
Date: Checked by:
E2439/1
Engine Model
Data Sheet V 396
V l G
Valve id
Guides Engine No.
Remarks: –––––––––––––––––––––––––––––––––––––
––––––––––––––––––––––––––––––––––––––––––––––––––––
––––––––––––––––––––––––––––––––––––––––––––––––––––
Specified dia. ––––––––––––––––––––––––
1st Measure- 2nd Measure-

Cylinder Meas. ment: Cylinder Meas. ment:
Head No.
No Points Inlet Ex- Head No.
No Points Inlet Ex-
left Inlet Ex- haust left Inlet Exhaust haust
right haust right right left right
left
A1 A1
B1 B1
A2 A2
B2 B2
A3 A3
B3 B3
A1 A1
B1 B1
A2 A2
B2 B2
A3 A3
B3 B3
A1 A1
B1 B1
A2 A2
B2 B2
A3 A3
B3 B3
A1 A1
B1 B1
A2 A2
B2 B2
A3 A3
B3 B3
A1 A1
B1 B1
A2 A2
B2 B2
A3 A3
B3 B3
A1 A1
B1 B1
A2 A2
B2 B2
A3 A3
B3 B3
A = Parallel to engine longitudinal axis
Date: Name: B = Transverse to engine longitudinal axis
E2445
Index Section 1.7
Page 1
1.7 Index
4/2-way solenoid valve (air and exhaust Checking engine condition prior
flow control flap control) . . . . . . . . . . . . . . . 3.86.10a to W5 maintenance work and
4/2-way directional control valve to major overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
(cylinder cutout) . . . . . . . . . . . . . . . . . . . . . . . 3.86.6a Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.4
Checking oilways . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.4
A Checking operation of injection timer . . . . . . . 3.11.2a.7
Accessories (electric, pneumatic), Group . . . . . . 3.86
Checking pump timing . . . . . . . . . . . . . . . . . . . . 3.11.5.7
Accessories (mechanical), Group . . . . . . . . . . . . . 3.88
Checking start of delivery
Actuating cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 3.86.9 (injection pump removed) . . . . . . . . . . . . . . . 3.11.3.7
Actuating cylinder . . . . . . . . . . . . . . . . . . . . . . . . 3.86.9b Checking valve lift . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1.7
Actuation for turbocharger control . . . . . . . . . . 3.10.8a Clamp ring with grooved ball bearing,
Air and exhaust flow control flap control, driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.4
4/2-way solenoid valve . . . . . . . . . . . . . . . . 3.86.10a Cold starting system . . . . . . . . . . . . . . . . . . . . . . . 3.12.6
Air compressor drive . . . . . . . . . . . . . . . . . . . . . . 3.86.4 Compressed air distributor . . . . . . . . . . . . . . . . . 3.18.1
Air compressor drive . . . . . . . . . . . . . . . . . . . . . . 3.86.4a Connecting housing, fuel injection pump I, 16V 3.11.9
Air intake system . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Connecting rod and piston . . . . . . . . . . . . . . . . . . . 3.3.2
Air starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.4 Control unit for hydraulic fan drive
Air starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.4a with supplementary piston . . . . . . . . . . . . . . 3.20.3a
Air/exhaust system, Group . . . . . . . . . . . . . . . . . . . 3.10 Control unit for hydraulic fan drive . . . . . . . . . . . 3.20.3
Assembly, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
Auxiliary PTO, free end . . . . . . . . . . . . . . . . . . . . . 3.3.9 Cooalnt chamber, replacing end cover . . . . . . . 3.1.1.4
Auxiliary PTO, free end . . . . . . . . . . . . . . . . . . . . 3.3.9a Coolant expansion tank . . . . . . . . . . . . . . . . . . . 3.14.5c
Auxiliary PTO, free end . . . . . . . . . . . . . . . . . . . . 3.86.3 Coolant level monitoring, level switch . . . . . . . 3.84.1a
Coolant pump and generator drive,
B intermediate gears . . . . . . . . . . . . . . . . . . . . . . . 3.2.1
Bilge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13.3 Coolant pump, Group . . . . . . . . . . . . . . . . . . . . . . . . 3.13
Bolts, tightening specifications . . . . . . . . . . . . . . . . . 1.3 Coolant system (see Cooling system)
Coolant system, Group . . . . . . . . . . . . . . . . . . . . . . 3.14
C
Coolant thermostat
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1
(annular slide thermostat) . . . . . . . . . . . . . . 3.14.7b
Camshaft bearing bush . . . . . . . . . . . . . . . . . . . . . 3.1.5
Cover at free end, Group . . . . . . . . . . . . . . . . . . . . . 3.4
Carrier housing with exhaust turbocharger
Crank angle before TDC, determining . . . . . . . 3.11.5.7
and exhaust elbow . . . . . . . . . . . . . . . . . . . . 3.10.6a
Crank angle before TDC, determining . . . . . . 3.11.5a.7
Centrifugal oil filter . . . . . . . . . . . . . . . . . . . . . . . . 3.16.6
Crank gear (see Running gear)
Checking and adjusting valve clearance . . . . . . 3.6.3.7
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1
Checking and replacing dowel pins and studs 3.1.1.4
Crankcase breather (version B) . . . . . . . . . . . . . 3.1.7b
Checking and replacing studs . . . . . . . . . . . . . . . 3.1.1.4
Crankcase intermediate frame and stress
Checking camshaft timing/valve lift . . . . . . . . . . 3.6.1.7
bolts with damper . . . . . . . . . . . . . . . . . . . . . . 3.1.2b
Crankcase breather (version C) . . . . . . . . . . . . . 3.1.7c
20046/20 E –02.96–
Index Section 1.7
Page 2
Crankcase breather version A . . . . . . . . . . . . . . . . 3.1.7 Engine disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

Crankcase, Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Engine flange and driver, driving end . . . . . . . . . 3.3.3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1 Engine governor, Group . . . . . . . . . . . . . . . . . . . . . . . 3.7
Crankshaft bearing caps and bearing cap studs 3.1.2 Engine installation and initial operation . . . . . . . . . . 2.7
Cross-sections, engine . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Engine mount, crankcase . . . . . . . . . . . . . . . . . . 3.19.1
Cutaway drawings, engine . . . . . . . . . . . . . . . . . . . . . 2.8 Engine mounts, Group . . . . . . . . . . . . . . . . . . . . . . 3.19
Cylinder cutout, 4/2-way directional Engine oil filter suspended
control valve . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86.6a with intermediate housing . . . . . . . . . . . . . . 3.16.4b
Cylinder cutout, fuel injection pump 8V/12V . . 3.11.8 Engine oil filter with filter guide . . . . . . . . . . . . 3.16.4a
Cylinder cutout, fuel injection pump 8V/12V Engine oil heat exchanger
with 4/2-way solenoid valve . . . . . . . . . . . . . 3.11.8b with edge-type filter 12V . . . . . . . . . . . . . . . 3.16.2a
Cylinder cutout, fuel injection pump II, 16V . 3.11.8a Engine oil heat exchanger
Cylinder cutout, fuel injection pump II, 16V . . 3.11.8c with edge-type filter 16V . . . . . . . . . . . . . . . 3.16.3a
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 Engine oil heat exchanger

with edge-type filter 8V . . . . . . . . . . . . . . . . . 3.16.2b
Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . 3.6.4
Engine oil intake line and delivery line
Cylinder head, Group . . . . . . . . . . . . . . . . . . . . . . . . 3.5 with suction basket on crankcase
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 intermediate frame 12V . . . . . . . . . . . . . . . . 3.15.3b
Cylinders, designation . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Engine oil intake line and delivery line
with suction housing on crankcase
D intermediate frame 16V . . . . . . . . . . . . . . . . 3.15.3a
Danger in work place . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Engine oil lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16.1
Data sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Engine oil pump drive on crankcase pan,
idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2
Designation of engine sides and cylinders . . . . . . . 1.2
Engine oil pump drive on intermediate frame,
Determining crank angle before TDC . . . . . . . 3.11.5.7
idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2a
Determining crank angle before TDC . . . . . . 3.11.5a.7
Engine oil pump in oil pan 16V . . . . . . . . . . . . . 3.15.2
Determining TDC mark . . . . . . . . . . . . . . . . . . . . 3.5.1.4
Engine oil pump in oil pan 8V/12V . . . . . . . . . . 3.15.1
Drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.2
Engine oil pump on crankcase intermediate
Driver and engine flange, driving end . . . . . . . . . 3.3.3 frame 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15.1b
Engine oil pump on crankcase intermediate
E frame 16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15.2a
Electric starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.5
Engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Emergency air shut-off flaps . . . . . . . . . . . . . . . 3.10.4a
Engine running-in (V396.4) . . . . . . . . . . . . . . . . . . . . 2.6
End cover with elbow, free end . . . . . . . . . . . . . . 3.4.1
Engine sides and cylinder, designation . . . . . . . . . . 1.2
End housing with blocking . . . . . . . . . . . . . . . . . . 3.11.7
Engine speed sensor . . . . . . . . . . . . . . . . . . . . . . 3.84.4
End shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.6
Engine speed sensor . . . . . . . . . . . . . . . . . . . . . 3.84.4a
Engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Engine, removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Engine coolant chambers, pressure-testing . . . 3.14.9
Engine-gearbox actuation, Group . . . . . . . . . . . . . 3.87
Engine coolant cooler . . . . . . . . . . . . . . . . . . . . . 3.14.6
Exhaust connecting line . . . . . . . . . . . . . . . . . . 3.10.11a
Engine coolant pump . . . . . . . . . . . . . . . . . . . . . . 3.13.1
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.10.3
Engine coolant pump . . . . . . . . . . . . . . . . . . . . . . 3.14.1
Exhaust turbocharger, carrier housing . . . . . . . 3.10.6a
Engine cutaway drawings . . . . . . . . . . . . . . . . . . . . . 2.8
Exhaust turbocharger, exhaust elbow . . . . . . . 3.10.6a
Engine disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Exhaust turbocharger, Group . . . . . . . . . . . . . . . . . . 3.9
20046/20 E –02.96–
Index Section 1.7
Page 3
Hydraulic fan drive – Centre distance

F 218 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20.1a
Fan drive, Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Fan wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20.4 I
Flange, free end . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.7 Idler gear for engine oil pump drive
Flywheel damper with track ring, driving end . 3.3.3a on intermediate frame . . . . . . . . . . . . . . . . . . 3.2.2a
Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.8 Idler gear for engine oil pump drive on oil pan . 3.2.2
Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.8a Idler gears for coolant pump and

and generator drives . . . . . . . . . . . . . . . . . . . . 3.2.1
Flywheel with track ring, driving end . . . . . . . . . 3.3.3a
Important information . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Fuel collecting housing with hand pump . . . . . . 3.12.5
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Fuel delivery pump . . . . . . . . . . . . . . . . . . . . . . . . 3.12.4
Initial operation, engine . . . . . . . . . . . . . . . . . . . . . . . 2.7
Fuel duplex filter . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.3
Injection equipment (see Fuel injection equipment)
Fuel injection equipment, Group . . . . . . . . . . . . . . 3.11
Injection lines (see Delivery lines)
Fuel injection nozzle with nozzle holder . . . . . . 3.11.6
Injection timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.2a
Fuel injection pump 16V . . . . . . . . . . . . . . . . . . 3.11.5a
Injection timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.2b
Fuel injection pump coupling – (two parts),
free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.3 Inspection port cover on crankcase
intermediate frame . . . . . . . . . . . . . . . . . . . . . 3.1.10
Fuel injection pump coupling EP I,
driving end and EP II . . . . . . . . . . . . . . . . . . 3.11.4 Installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Fuel injection pump coupling EP I, Installing lowered oil pan . . . . . . . . . . . . . . . . . 3.1.6.6b

driving end and EP II . . . . . . . . . . . . . . . . . . . 3.11.4a Intake funnel and intake housing
Fuel injection pump drive . . . . . . . . . . . . . . . . . . . 3.11.1 with turbocharger control . . . . . . . . . . . . . . . 3.10.7
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . 3.11.5 Intake funnel and intake housing

without turbocharger control . . . . . . . . . . . . 3.10.7a
Fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.2
Intake housing with turbocharger control . . . . . 3.10.7
Fuel pressure lines . . . . . . . . . . . . . . . . . . . . . . . . 3.12.1
Intake housing without turbocharger control . . 3.10.7a
Fuel system, Group . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1a
G L
Gear case, cylinder head cover . . . . . . . . . . . . . . 3.6.4
Leak-off fuel, solenoid float switch . . . . . . . . . . 3.84.5
Gear train, Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Level switch (coolant level monitoring) . . . . . . 3.84.1a
General, Main section . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Longitudinal sections, engine . . . . . . . . . . . . . . . . . . 2.8
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86.1
Lowering oil pan . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.6.2b
Generator coupling . . . . . . . . . . . . . . . . . . . . . . . . 3.86.2
Lube oil (see Engine oil)
Generator drive, idler gears . . . . . . . . . . . . . . . . . . 3.2.1
Governor linkage, Group . . . . . . . . . . . . . . . . . . . . . . 3.8 M
Grooved ball bearing with clamp ring, Main oil gallery, replacing oil pipe . . . . . . . . . . . . 3.1.1.4
driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.4 Maintenance Operations W5 . . . . . . . . . . . . . . . . . . . 2.2
Group summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Measure and adjust piston top clearance
for piston with epsilon = 15.5 . . . . . . . . . . . . . 3.5.1.4
H Measuring and setting piston gap . . . . . . . . . . . 3.5.1.4
Hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.5
Measuring crankcase bores . . . . . . . . . . . . . . . . 3.1.1.4
Hydraulic fan drive – Centre distance
400 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20.1b Measuring crankshaft main bearing bore . . . . . 3.1.2.7
Miltac-microswitch (limit switch) . . . . . . . . . . . . . 3.84.6
20046/20 E –02.96–
Index Section 1.7
Page 4
Monitoring system, Group . . . . . . . . . . . . . . . . . . . . 3.84 Sea water (see Raw water)

Seal carrier, driving end . . . . . . . . . . . . . . . . . . . . 3.3.5
N Sequential turbocharging system . . . . . . . . . . . 3.27.1a
Nuts, tightening specifications . . . . . . . . . . . . . . . . . . 1.3
Sequential turbocharging system . . . . . . . . . . . 3.27.1b
O Setting start of delivery in accordance
with blocking method Injection pump I . 3.11.5a.7a
Oil (see Engine oil)
Setting start of delivery Injection pump II . . . 3.11.5a.7
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.6
Setting start of delivery with dial gauge
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.6a
Injection pump I . . . . . . . . . . . . . . . . . . . . . . 3.11.5a.7
Oil pump, Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Oil spray nozzle for piston cooling . . . . . . . . . . . . 3.1.4
Solenoid float switch (leak-off fuel) . . . . . . . . . . . 3.84.5
Oil system, Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86.10
Operation schedules, main section . . . . . . . . . . . . . . . 2
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86.7
P Speed transmitter (camshaft drive) . . . . . . . . . . 3.84.2
Pins, dowel pins and studs, check Speed transmitter (left engine side) . . . . . . . . . . 3.84.3
and replace . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.4 Speed transmitter drive (left engine side) . . . . 3.17.3
Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 Speed transmitter drive on camshaft
Pressure limiting valves, pressure relief drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17.1
valves and bypass valves . . . . . . . . . . . . . 3.16.5a Speed transmitter drive, Group . . . . . . . . . . . . . . . 3.17
Pressure relief valve (15 bar) . . . . . . . . . . . . . . . 3.15.5 Starting air lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.3
Pressure testing engine coolant chambers . . . . 3.14.9 Starting equipment (see Starting system)
Proximity switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84.6a Starting system, Group . . . . . . . . . . . . . . . . . . . . . 3.18
Publication summary . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.2
Push rods and rocker arms . . . . . . . . . . . . . . . . . . 3.6.3 Stress bolts and crankshaft bearings . . . . . . . . . 3.1.2
Supplementary control units, Group . . . . . . . . . . . 3.27
R Support ring, free end . . . . . . . . . . . . . . . . . . . . . 3.3.7a
Rack travel indicator . . . . . . . . . . . . . . . . . . . . . 3.11.10
Raw water lines . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14.3 T
Raw water pump . . . . . . . . . . . . . . . . . . . . . . . . . 3.13.2 Task description, main section . . . . . . . . . . . . . . . . . . . 3
Replacing bearing bushes for fuel injection TC (see Exhaust turbocharger)
pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.4 Three-phase alternator with V-belt drive . . . . . 3.86.3a
Replacing cover on coolant pump drive . . . . . . 3.1.1.4 Torque specifications for bolts and nuts . . . . . . . . . 1.3
Replacing fuel pump drive, bearing bushes . . . 3.1.1.4 Turbocharger control, actuation . . . . . . . . . . . . 3.10.8a
Replacing oil pipe in main oil gallery . . . . . . . . . 3.1.1.4
Replacing roller tappet guide bush . . . . . . . . . . 3.1.1.4 U
Replacing roller tappet, guide bush . . . . . . . . . . 3.1.1.4 Upper cover, auxiliary PTO end . . . . . . . . . . . . . . 3.1.9
Rockers and pushrods . . . . . . . . . . . . . . . . . . . . . . 3.6.3
V
Roller tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.2
Valve gear, Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Running gear, Group . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Valve seat lubrication . . . . . . . . . . . . . . . . . . . . . . 3.15.4
Running-in V396.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Vent and drain lines . . . . . . . . . . . . . . . . . . . . . . . 3.14.2
S Vibration damper, free end, with drive member 3.3.8a
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Vibration damper, free end, with flange . . . . . . . . 3.3.8
20046/20 E –02.96–
Task Description Section 1.8
Page 1
1.8 Publication Summary

Supplementary documentation for this manual includes:
– Description and Operating Instructions order-specific
– Fluids and Lubricants Specification A001061
– Marine Magnetics (General Guidelines) E530305
– Tools List M004021
– Tolerances and Wear Limits List M070026
– Test Procedures and Auxiliary Materials M070007
– Assembly Group Documentation for
– Fuel Injection Pump IIb M040073
– Fuel Injection Pump IId M040095
– Governor – R074 M040074
– Governor – Barber Colmann M040079
– Governor – R082-LS4 E530390
– Electro-magnetic governor actuator R082 M040082
– Exhaust Turbocharger ZR 110 M040085
– Starter M040076
– Generator M040075
– Coupling – E48/E56 N060385
– Coupling – F56 N060446
Specialised information on subjects such as
– Governor Setting
– Injection Timing
can be found in the Acceptance Test Record for the engine in question.
20046/20 E –12.96–
Operation Schedules Section 2
Page 1
2 Operation Schedules
Contents
2.1 Engine condition check prior to W5 maintenance or major overhaul
2.2 Maintenance operations W5
2.3 Engine removal
2.4 Engine disassembly
2.5 Engine assembly
2.6 Engine run-in V 396 TE.4
2.7 Engine installation and initial operation
2.8 Engine cutaway drawings
20038/10 E –11.92–
Operation Schedules Section 2.1
Page 1
2.1 Engine Condition Check prior to W5 Maintenance or

Major Overhaul
Before the engine is removed, a brief test should be conducted to assist in evaluating its condition and running behav-
iour. Deviations from the Engine Acceptance Test Record Data found during the test run provide valuable information
for subsequent overhaul services.
For instructions on operations to be performed, refer to:
– B = Engine Description and Operation Manual
– P = MTU Test Kit
Operations to be performed See
Perform preparatory tasks prior to engine start B

Start engine B
Run engine until normal operating temperature is reached B
Run engine at maximum possible power
Check engine speed, temperatures and pressures, when temperature gauge installed
Check running noises. No abnormal noises should be audible B
Check engine and external pipework for leaks during test run (visual inspection) B
Check intercooler drain line for water discharge and obstructions B
Check function of hydraulic fan drive
Check exhaust gas colour B
Run engine at adjustable no-load speed
Inspect fuel line connections for leaks
Remove cylinder head covers B
Check lubrication of valve gear B
Extract engine oil sample B
Analyse engine oil sample (spot test, water content, fuel dilution) P
Extract coolant sample B
Analyse coolant sample P
Check monitoring system and ECS for correct operation B
Shut down engine/check rundown of exhaust turbocharger B
Reduce coolant level in expansion tank and check trip setting of level switch B
(coolant level monitoring)
Drain coolant B
Fill cleaning system with cleaning solution
Start engine B
Flush cooling system
Shut down engine B
Disconnect H.P. fuel lines
Remove fuel injection nozzles with nozzle holders B
Check compression pressure B
Work listed here which is not relevant to the respective engine version can be disregarded.
20058/0 E –02.96–
Page 1
2.2 Maintenance Operations W5

– A = Turbocharger Manual
– B = Operation Manual
– E = Spare Parts Catalogue
– H = Manufacturer’s Instructions

Shut off fuel supply line B
Shut off compressed air supply line B
Shut off raw water supply line B
Switch off monitoring system
Switch off battery master switch
Drain coolant – take sample and analyze (MTU-test kit) B
Wash engine; do not use any chemical solvents
Check air intake shafts for leaks and damage B
Clean air filter, empty dust collection box B
Operate ratchet lever on engine oil edge-type filter several times B
Drain oil sludge from engine oil filters and check for metallic residue, B
inspect bearings if necessary
Change engine oil, take sample and analyze B
Replace engine oil filter elements and sealing rings B
B
Check layer thickness of oil residues in centrifugal oil filter B
Clean and check centrifugal oil filter; replace bearing if necessary B
Replace insertion sleeve of centrifugal oil filter
Remove carrier housing with exhaust turbocharger and exhaust elbow 3.10.6a.2
Disassemble and clean exhaust turbocharger A
Carry out visual inspection of components A
Check turbine housing, turbine wheel and compressor wheel for cracks A
Measure bearing clearance and compressor wheel A
Check ease of movement of turbine rotor and axial clearances B
Remove actuating cylinder and solenoid valve of TC control 3.10.8a.2
Disassemble and clean actuating cylinder 3.86.9.2
Visually inspect components for wear; replace gaskets 3.86.9.4
3.86.9b.2
3.86.9b.4
Remove and clean exhaust flow control flap, drive shaft and exhaust flow control flap 3.10.6a.3
and check for wear
Check ease of movement of exhaust flow control flap
Clean exhaust housing, exhaust pipes and hot components for cracks 3.10.3.4
Replace air flap stop, air flap gasket and sealing ring 3.10.8a.4
Check mounting of operating lever for wear 3.10.6a.5
Check ease of movement of air flow control flap 3.10.6a.4
Remove and clean intercooler; replace gaskets 3.10.1a.2
Check intercooler for leaks 3.10.1a.4
Clean intercooler drain line B
Check emergency air shut-off flaps for correct operation B
Remove and clean air supply pipework; replace gaskets 3.10.2.2
3.10.2.2a
20046/20 E –02.96–
Page 2

Remove fuel injection nozzles 3.11.6.2
Check injection pressure, working spray and check for leaks; replace nozzle body and needle if B
necessary
Replace sealing rings
Drain fuel duplex filter, replace filter elements B

Clean fuel prefilter (not delivered by MTU)
Check start of delivery of fuel injection pumps 3.11.3.7
Check multiple disc clutch (only on 16V engines) and coupling of fuel injection pumps 3.11.4.4
(visual inspection)
Remove rockers 3.6.3.2
Check rocker arms and adjusting screws 3.6.3.4
Remove cylinder heads 3.5.1.2
Recondition valve seats and valves 3.5.1.4
Check exhaust valve guides for wear, replace if necessary 3.5.1.4
Check cylinder head gaskets, replace sealing rings for coolant and oil discharge 3.5.1.6
Replace O-rings of protective sleeves in cylinder head 3.5.1.3
Replace valve stem seals 3.5.1.3
3.6.2.4
Check roller tappets for wear
Endoscopically inspect combustion chambers B
Check wear pattern in cylinder liners 3.1.3.4
Visually inspect piston crowns on combustion chamber side 3.3.2.4
Check vibration damper (visual inspection) 3.3.8
3.3.8a
Check and adjust valve clearance 3.6.3.7

Check cylinder head cover gasket, replace if necessary 3.6.4.4
Check security of adapters, locking and wiring of electronic governor and check damage B
Check control linkage between shutdown housing, governor and fuel injection pumps for ease of 3.10.7.6
movement and lubricate 3.11.8.6
Disassemble engine coolant pump, visually inspect components, replace sealing material 3.13.1.3
Check engine coolant pump relief bore for obstructions B
Disassemble raw water pump, visually inspect components, replace sealing material 3.13.2.3
Check raw water pump relief bore for obstructions B
Disassemble bilge pump, visually inspect components, replace sealing material 3.13.3.3
Check bilge pump relief bore for obstructions B
Clean strainer in coolant return lines B
Clean raw water filter (not delivered by MTU) H
Disassemble coolant cooler, clean and check for leaks 3.14.6.4
Visually inspect sealing element and slide valve of coolant thermostat 3.14.7b.5
Check function of fluid level monitor B
Check operation of monitoring system B
Check crankcase ventilation for obstructions –
20046/20 E –02.96–
Page 3

Check operation of air starter B
Check electric starter; replace carbon brushes as necessary B
Check generator; replace carbon brushes as necessary B
Check generator coupling B
Remove compressed air distributor, check and readjust 3.18.1.2
Remove and check starting and compression valves 3.18.2.2
Drain compressed air system; replenish lubricator oil supply B
Clean filter of compressed air system; replace filter if necessary B
Check exhaust system and check drainage system for obstructions B
Check fuel preheating unit B
Check function of hydraulic fan drive; replace thermal element of control unit if necessary 3.20.1a.7
3.20.3a.7
Check condition of resilient coupling B
Check hydraulic pump drive for coupling condition B
Check condition of V-belts on generator drive and check for tension 3.86.3a.7
Compressor unit: Carry out tasks in accordance with Manufacturer’s Documentation H
Check engine alignment B
Visually inspect condition of resilient engine mounting, gearbox mounting and base skid mounting B
Check security of securing screws of engine mounting, gearbox mounting and base skid mounting B
Grease lubrication points B
Fill engine oil system B
Fill coolant system B
Perform preparatory tasks prior to engine start B
Start engine B
Run engine until normal operating temperature is reached B
Check battery charge state, electrolyte specific gravity and electrolyte level H
Check condition and security of wiring B
Check alternator in accordance with Manufacturer’s Specifications H
Work listed here which is not relevant to the respective engine version can be disregarded. B
(see order-specific maintenance schedules).
20046/20 E –02.96–
Page 1
2.3 Engine Removal

Close fuel supply line B

Shut off compressed air supply line B
Shut off raw water supply line B
Drain oil with engine warm when possible B

Drain oil sludge from engine oil filter B
Examine oil sludge for metallic residues B
Drain coolant from engine; coolant temperature must be below 60 °C B
Drain raw water B
Wash machinery plant; do not use chemical solvents –
Release all connections
Seal open connections with lint-free plugs and covers
Remove engine securing bolts
Remove engine and support it on support pedestals
Install transportation locking device when engine is to be transported by road or rail (see Special
Publication)
Always use lifting brackets as shown in illustration drawings to suspend engine, align engine ac-
cording to centre of gravity; observe all transportation regulations.
Engine weight
For engine weight, see engine nameplate
20042/10 E –12.94–
Page 1
2.4 Engine Disassembly

Before beginning complete engine disassembly, it is advisable to take photographs of the engine from all sides or to
record all components installed on the engine in writing.
The sequence of the required operations in the following list corresponds to the order in which actual disassembly is
to be carried out.
Depending on workshop equiment, engine equipment and assembly personnel, it may be advisable to deviate from
the specified sequence.
Precise information on the individual operations is to be found in the section indicated.
Mark and disconnect electric cables –

Remove engine terminal box and wiring –
Remove measuring block and monitoring instruments –
Remove control unit for hydraulic fan drive 3.20.3.2
3.20.3a.2
Remove fan wheel 3.20.4.2
Remove hydraulic fan drive 3.20.1a
3.20.1b.2
Disconnect crankcase vent line 8V, 12V 3.1.7.2
3.1.7c.2
Disconnect crankcase vent line 12V, 16V 3.1.7b.2
Disconnect vent and drain lines 3.14.2.2
Disconnect engine coolant lines 3.14.1.2
Disconnect oil supply and return lines to centrifugal oil filter 3.16.1.2
Remove centrifugal oil filter 3.16.6.2
Disconnect raw water lines 3.14.3.2
Remove coolant expansion tank 3.14.5b.2
Remove engine coolant cooler 3.14.6.2
Remove coolant thermostat 3.14.7b.2
Remove cylinder head covers 3.6.4.2
Disconnect fuel supply and return lines 3.12.2.2
Disconnect H.P. fuel lines 3.12.1.2
Disconnect starting air lines 3.18.3.2
Disconnect engine oil lines 3.16.1.2
Remove magnetic float switch (leak-off fuel) 3.84.5.2
Remove actuating cylinder 3.10.8a.2
Remove actuator for turbocharger control 3.10.8a.2
Remove intake funnel, intake housing and air flow control flap for charge air control 3.10.7.2
3.10.7a.2
Remove end cover and/or exhaust connecting line 3.10.11a.2
Remove exhaust turbocharger with carrier housing and exhaust elbow 3.10.6a.2
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Remove exhaust system 3.10.3.2

Remove intercooler 3.10.1a.2
Remove emergency air shut-off flaps at intercooler 3.10.4a.2
Remove Miltac miniature switch/limit switch 3.10.4a.2
Remove oil pump for valve seat lubrication 3.15.4.2
Remove level switch (coolant level monitoring) 3.84.1a.2
Remove coolant expansion tank 3.14.5c.2
Remove engine coolant cooler 3.14.6.2
Remove coolant thermostat 3.14.7b.2
Remove upper aux. PTO end cover 3.1.9.2
Remove cold-start system 3.12.6.2
Remove fuel injection pump 8V, 12V 3.11.5.2
Remove fuel injection pump 16V 3.11.5a.2
Remove end housing with blocking 3.11.7.2
Remove cylinder cutout 8V, 12V 3.11.8.2
Remove cylinder cutout 16V 3.11.8a.2
Remove rack travel indicator 3.11.10.2
Remove fuel injection pump coupling 3.11.3.2
3.11.4.2
3.11.4a.2
Remove fuel injection pump drive 3.11.1.2
Remove injection timer 3.11.2a.2
3.11.2b.2
Remove fuel duplex filter 3.12.3.2
Remove air intake system 3.10.2.2
3.10.2a.2
Remove crankcase breather 8V, 12V 3.1.7.2
3.1.7c.2
Remove crankcase breather 16V 3.1.7b.2
Disconnect leak-off fuel lines 3.12.2.2
Remove fuel injector nozzles 3.11.6.2
Remove starting and decompression valves 3.18.2.2
Remove valve gear housing 3.6.4.2
Remove rockers and pushrods 3.6.3.2
Disconnect engine oil return lines from cylinder head 3.5.1.2
Remove cylinder heads 3.5.1.2
Remove roller tappets 3.6.2.2
Remove generator 3.86.1.2
Remove generator coupling 3.86.2.2
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Remove generator drive 3.86.3.2

Remove engine coolant pump 3.13.1.2
Remove air compressor drive (equipment-specific) 3.86.4.2
3.86.4a.2
Remove raw water pump 3.13.2.2
Remove bilge pump 3.13.3.2
Remove fuel collecting chamber with hand pump 3.12.5.2
Remove fuel delivery pump 3.12.4.2
Remove compressed air distributor 3.18.1.2
Remove speed transmitter 3.84.2.2
3.84.3.2
Remove speed transmitter drive 3.17
Remove engine speed sensor 3.84.4
Remove compressed air starter 3.18.4.2
3.18.4a.2
Remove electric starter 3.18.5.2
Remove engine oil filter 3.16.4a.2
Remove suspended oil filter 3.16.4b.2
Remove engine oil heat exchanger with edge-type filter element 3.16.2a.2
3.16.2b.2
3.16.3a.2
Remove pressure limiting, pressure relief and bypass valves 3.16.5a.2
Remove engine mounts 3.19.1.2
Remove aux. PTO at free end 3.3.9.2
Remove end cover at free end 3.4.1.2
Remove vibration damper with flange at free end 3.3.8.2
Remove vibration damper with driver at free end 3.3.8a.2
Remove flange at free end 3.3.7.2
Remove support ring at free end 3.3.7a.2
Remove bearing retaining plate at free end 3.3.6.2
Remove engine flange with drive member 3.3.3.2
Remove flywheel with track ring (order-specific) 3.3.3a.2
Remove oil seal carrier at driving end 3.3.5.2
Remove clamp ring and grooved ball bearing 3.3.4.2
Remove electric starter 3.18.5.2
Remove compressed air starter 3.18.4.2
Remove flywheel housing 3.1.8.2
3.1.8a.2
Install engine in roll-over assembly dolly 3.1.1.2
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Remove oil pan 3.1.6.2

Remove oil pan 3.1.6a.2
Remove pressure relief valve from oil pan 3.15.5.2
Remove idler gear for engine oil pump drive from oil pan 3.2.2.2
Remove idler gear for engine oil pump drive from intermediate frame 3.2.3.2
Remove engine oil delivery line and suction line in oil pan 12V 3.15.1.2
Remove engine oil delivery line and suction line in oil pan 16V 3.15.2.2
Remove engine oil delivery line and suction line from intermediate frame 12V 3.15.3b.2
Remove engine oil delivery line and suction line from intermediate frame 16V 3.15.3a.2
Remove engine oil pump 8V, 12V 3.15.1.2
Remove engine oil pump, 16V 3.15.2.2
Remove engine oil pump from crankcase intermediate frame 12V 3.15.1b.2
Remove engine oil pump from crankcase intermediate frame 16V 3.15.2a.2
Remove inspection port cover from crankcase intermediate frame 3.1.10.2
Remove camshaft chamber end cover 3.1.1.3
Remove camshafts 3.6.1.2
Remove pistons and conrods from crankcase with bearing caps 3.3.2.2
Remove pistons and conrods from crankcase with intermediate frame 3.3.2.2a
Remove crankshaft from crankcase with bearing caps 3.3.1.2
Remove crankshaft from crankcase with intermediate frame 3.3.1.2a
Remove oil spray nozzles 3.1.4.2
Remove cylinder liners 3.1.3.2
Remove idler gears for coolant pump and generator drive 3.2.1.2
Remove camshaft bearing bushes 3.1.5.2
Remove bearing bush for fuel injection pump drive 3.1.1.4
Remove roller tappet guide bush 3.1.1.4
Inspect and replace stress bolts for crankshaft bearing cap 3.1.2.4
Remove intermediate frame bearing cap studs 3.1.2b.2
Remove oil pipe for main oil gallery 3.1.1.4
Check and replace pins, dowel pins and studs 3.1.1.4
Work listed here which is not relevant to the respective engine version can be disregarded. –
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2.5 Engine Assembly

The sequence in which the following required procedures are listed corresponds to the order in which actual assembly
is performed.
Precise information on the individual operations is to be found in the section indicated.
Check crankcase for cracks, wear and cavitation 3.1.1.4

Install oil pipe for main oil gallery 3.1.1.4
Ensure that oilways are meticulously clean 3.1.1.4
Install camshaft bearing shells 3.1.5.6
Install bearing bush for fuel injection pump drive 3.1.1.4
Install roller tappet guide bush 3.1.1.4
Install bearing cap studs in main bearing caps 3.1.2.4
Install bearing cap studs in intermediate frame 3.1.2b.6
Pins, dowel pins and studs in crankcase 3.1.1.4
Install crankcase in roll-over assembly dolly 3.1.1.2
Install cylinder liners 3.1.3.6
Measure cylinder liners 3.1.3.7
Check crankcase for leaks 3.1.1.4
Install crankshaft bearing caps without bearing shells 3.1.2.6
Install intermediate frame without bearing shells 3.1.2b.6
Measure crankshaft main bearing bore 3.1.2.7
3.1.2b.7
Measure crankcase bores 3.1.1.4
Install and measure crankshaft bearing shells 3.3.1.6
3.3.1.6b
Install oil spray nozzles for piston cooling 3.1.4.6
Install idler gears for coolant pump and generator drives 3.2.1.6
Install crankshaft in crankcase with bearing caps 3.3.1.6
Install crankshaft in crankcase with intermediate frame 3.3.1.6b
Install camshaft with drive gear 3.6.1.6
Install camshaft chamber end cover 3.1.1.5a
Install pistons and conrods in crankcase with bearing caps 3.3.2.6
Install pistons and conrods in crankcase with intermediate frame 3.3.2.6a
Install idler gear for engine oil pump drive on oil pan 8V, 12V 3.2.2.6
Install idler gear for engine oil pump drive on oil pan 16V 3.2.2.6a
Install idler gear for engine oil pump drive on intermediate frame 3.2.2a.6
Install engine oil pump into oil pan 8V, 12V 3.15.1.6
Install engine oil pump in oil pan 16V 3.15.2.6
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Mount engine oil pump on crankcase intermediate frame 8V, 12V 3.15.1b.6
Mount engine oil pump on intermediate frame 16V 3.15.2a.6
Connect engine oil delivery and suction lines 12V 3.15.1.6
Connect engine oil delivery and suction lines 16V 3.15.2.6
Connect engine oil delivery and suction lines to intermediate frame 12V 3.15.3.6
Connect engine oil delivery and suction lines to intermediate frame 16V 3.15.3a.6
Install pressure relief valve (8V, 12V) in oil pan 3.15.5.6
Install pressure relief valve (16V) in oil pan 3.15.5.6a
Install pressure relief valve in intermediate frame 3.15.3.6b
Install oil pan 3.1.6.6
Install oil pan 3.1.6a.6
Determine TDC mark 3.5.1.4
Measure and adjust piston top clearance 3.5.1.4
Remove engine from roll-over assembly dolly 3.1.1.6
Install flywheel housing 3.1.8.6
Install oil seal carrier at driving end 3.3.5.6
Install inspection port covers on intermediate frame 3.1.10.6
Install clamp ring and grooved ball bearing on crankcase with bearing caps at driving end 3.3.4.6
Install clamp ring and grooved ball bearing on intermediate frame at driving end 3.3.4.6a
Install flywheel with track ring (order-specific) 3.3.3a.6
Install engine flange with drive member 3.3.3.6
Install roller tappets 3.6.2.6
Install cylinder heads 3.5.1.6
Install rocker bearing bushes 3.6.3.5
Install rockers and pushrods 3.6.3.6
Adjust valve clearance 3.6.3.7
Check camshaft timing/valve lift 3.6.1.7
Install valve gear housing 3.6.4.6
Install pressure limiting, pressure relief and bypass valves 3.16.5a.6
Install engine oil heat exchanger with edge-type filter element 3.16.2a.6
3.16.2b.6
3.16.3a.6
Install engine oil filter 3.16.4a.6
Install suspended oil filter 3.16.4b.6
Install electric starter 3.18.5.6
Install compressed air starter 3.18.4.6
3.18.4a.6
Install fuel injection pump drive 3.11.1.6
Install injection pump coupling at free end, IP I 3.11.3.6
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Install injection pump coupling at driving end, IP I and IP II 3.11.4.6

Install cylinder cutout 8V, 12V 3.11.8.6
3.11.8b.6
Install cylinder cutout 16V 3.11.8a.6
3.11.8c.6
Install end housing with blocking 3.11.9.6
Install rack travel indicator 3.11.10.6
Install fuel injection pump 8V, 12V 3.11.5.6
Install fuel injection pump, 16V 3.11.5a.6
Adjust fuel injection pump 8V, 12V 3.11.5.7
Adjust fuel injection pump 16V 3.11.5a.7
Install upper end cover at free end 3.1.9.6
Install air pipework 8V, 12V 3.10.2.6
Install air pipework 16V 3.10.2.6a
Install emergency air shut-off flaps 3.10.4a.6
Install intercooler 3.10.1a.6
Mount cold-start system 3.12.6.6
Install valve seat lubrication system 3.15.4.6
Connect engine oil return line to cylinder head 3.5.1.6
Install exhaust pipework 3.10.3.6
Install carrier housing with turbocharger 3.10.6a.6
Mount intake funnel and intake housing 3.10.7.6
3.10.7a.6
Install air flow control flaps for turbocharger control 3.10.7.6
Install actuator for turbocharger control 3.10.8a.6
Sequential turbocharging system 3.27.1a.6
Install fuel injection nozzles 3.11.6.6
Install starting and decompression valves 3.18.2.6
Install bearing retaining plate at free end 3.3.6.6
Install flange at free end 3.3.7.6
Install support ring at free end 3.3.7a.6
Install vibration damper, with flange at free end 3.3.8.6
Install vibration damper, with driver at free end 3.3.8a.6
Install free end cover and elbow 3.4.1.6
Install auxiliary PTO, free end (equipment-specific) 3.3.9.6
3.3.9a.6
Install air compressor drive (equipment-specific) 3.86.4.6
Install compressed air distributor 3.18.1.6
Install fuel delivery pump 3.12.4.6
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Install fuel collecting chamber with manual pump 3.12.5.6

Mount speed transmitter drive on camshaft drive gear 3.17.1.6
Install speed transmitter (camshaft drive) 3.84.2.6
Install engine speed sensor 3.84.4.6
3.84.4a.6
Install engine coolant pump 3.13.1.6
Mount speed transmitter drive on generator side (left engine side) 3.17.3.6
Install speed transmitter (left engine side) 3.84.3.6
Install engine coolant cooler 3.14.6.6
Install coolant expansion tank 3.14.5c.6
Install coolant thermostat 3.14.7b.6
Install fuel duplex filter 3.12.3.6
Install crankcase breather 8V, 12V 3.1.7.6
3.1.7c.6
Install crankcase breather 16V 3.1.7a.6
Install engine mounts 3.19.1.6
Install engine mounts on intermediate frame –
Install raw water pump 3.13.2.6
Install bilge pump 3.13.3.6
Install generator drive 3.86.3.6
Install generator coupling 3.86.2.6
Install generator 3.86.1.6
Install centrifugal oil filter 3.16.6.6
Install floating solenoid valve (leak-off fuel) 3.84.5.6
Connect engine coolant lines 3.14.1.6
Connect raw water lines 3.14.3.6
Connect vent lines 3.14.2.6
Connect drain lines 3.14.2.6
Connect engine oil lines 3.16.1.6
Connect H.P. fuel lines 3.12.1.6
Connect fuel supply and return lines 3.12.2.6
Connect leak-off fuel lines 3.12.2.6
Install cylinder head covers 3.6.4.6
Connect starting air lines 3.18.3.6
Connect compressed air line to sequential turbocharging control 3.27.1.6
Pressure-test engine coolant chambers 3.14.9
Install hydraulic fan drive (centre distance 218 mm) 3.20.1a.6
Install hydraulic fan drive (centre distance 400 mm) 3.20.1.6
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Control unit for hydraulic fan drive 3.20.3.6

3.20.3a.6
Install fan wheel 3.20.4.6

Install monitoring instruments 3.84
Install engine terminal box –
Install and connect electric cables –
Work listed here which is not relevant to the respective engine equipment can be disregarded.
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Page 1
2.6 Engine Run-In V 396 TE.4

When pistons, piston rings or cylinder liners are replaced, the engine must be run in in accordance with the applicable
running-in schedule.
Proper running-in procedures conducted according to instructions are essential for ensuring long service life and reli-
able engine operation.
Use a brake or alternator to absorb the power produced during testing.
A resilient coupling must be used to transmit power from the engine to the brake.
Setting values for
Fuel temperature before engine: 24 °C to 30 °C

Raw water temperature before engine: 24 °C to 30 °C
Coolant temperature after engine: dependent on control range of cool-
ant thermostat
Intake air temperature before engine: 24 °C to 30 °C
Exhaust backpressure after engine: 27 mbar to 33 mbar

– A = MTU Acceptance Test Record
– C = MTU Fluids and Lubricants Specification
– H = Manufacturer’s Instructions
Set up engine on test stand

Connect engine to brake or alternator
Connect air intake, exhaust, starting air, engine coolant, oil and fuel pipework
Fill expansion tank with coolant and 2 % corrosion inhibitor oil up to max. mark B
Vent coolant lines at vent valve/lines until bubble-free coolant emerges B
Check to ensure that fuel in supply/service tank conforms to specifications C
Vent fuel system with hand pump B
Fill engine with fresh oil up to max. mark B
Prior to engine start, check operation of governor and governor actuator of fuel injection pump B
Check content of compressed air tank
Check governor stop position and full-load fuel injection of fuel injection pump on shutdown housing A
Check cylinder cutout
Check operation of emergency air shut-off flaps B
Check operation of shutdown equipment
Check capacity of starting batteries H
Remove cylinder head covers B
Always build up oil pressure with priming pump before starting engine
Start engine B
Check minimum selectable no-load speed, adjust governor if necessary A
Check valve gear lubrication after 15 mins. running time
With engine at lower idling speed, check whether oil emerges uniformly from sides of rockers and B
bearings
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Check oil supply to ball sockets in adjusting screws

Check coolant, oil and fuel lines, gaskets on crankcase,
intake air system and exhaust system for leaks B
Run in engine and record measurements in accordance with running-in schedule A
Measure engine speed and brake load
Measure fuel temperature before engine/before glass gauge, specific gravity, consumption and fuel
rack travel
Measure engine oil pressure before filter, engine and measuring block
Measure engine oil temperature before and after engine
Measure coolant temperature before engine and after coolant pump
Measure coolant temperature after engine in air/coolant manifold
Measure coolant pressure before pump, after pump and after engine in manifold for
air and coolant
Measure raw water temperature before and after engine
Measure raw water pressure before pump and heat exchanger
Measure charge air temperature before engine and before cylinder
Measure intake air depression before turbocharger and charge air pressure before cylinder
Measure exhaust gas temperature after turbocharger
Measure exhaust pressure after engine (exhaust backpressure)
Check exhaust gas colour
Enter barometric pressure in Test Record A
Check engine for abnormal running noises and inspect for leaks
After engine run-in, check lowest and highest adjustable no-load speed and
stop and full-load position of governor; readjust if necessary
Recheck idle and full-load positions
Check oil filter B
After engine run-in, carry out a factory test run in accordance with MTU Acceptance Test Record
Enter operational data in factory test record provided A
Compare test data with those recorded in Acceptance Test Record A
Shut down engine B
Preserve engine in event of extended engine out-of-service periods
For sea transportation, comply with relevant protective measures
Remove engine from test stand
Install check and measuring instruments for engine monitoring B
Spray engine with protective paint
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FMP No. 396/002–94

Run-In Program BR 396
of 07.10.94
8 V 396 TC/TB/TE Name: Nolte
Engine speed 1050 2247 2775 3333 3958 4620 5303 6095 F (N)
(rpm) 4 8.5 10.5 12.6 15 17.5 20.5 23.1 pe (bar)
1000 105
1500 337 415 498 543 693 810 913
1600 444 530 632 737 863 973
1800 600 710 829 972 1097 Peff (kW)
1900 752 876 1025 1157
2000 924 1080 1217
2100 1137 1280

Wash engine Full measurement
Running time (t) 10 20 10 10 10 10 10 20 (min)

Remark: Engine measurements are only recorded at n = 1000 rpm and at final power P = F x n (kW)
(full power). X
For load ”F”,
Each final power must be driven for 20 minutes.
braking constant x = 10000
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FMP No. 396/003–94

of 07.10.94
Engine speed 1600 3367 4156 5000 5947 6925 8119 9142 F (N)
(rpm) 4 8.5 10.5 12.6 15 17.5 20.5 23.1 pe (bar)
1000 160
1500 505 625 748 890 1040 1215 1370
1600 665 796 948 1105 1295 1460
1800 900 1066 1244 1458 1645 Peff (kW)
1900 1130 1314 1538 1735
2000 1385 1620 1825
2100 1705 1920


(full measurement). X
For load ”F”,
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FMP No. 396/004–94

of 07.10.94
Engine speed 2100 4487 5544 6666 7920 92400 10824 12190 F (N)
(rpm) 4 8.5 10.5 12.6 15 17.5 20.5 23.1 pe (bar)
1000 210
1500 673 830 997 1186 1386 1620 1826
1600 887 1061 1264 1473 1726 1946
1800 1200 1420 1658 1944 2193 Peff (kW)
1900 1505 1752 2050 2313
2000 1847 2160 2433
2100 2273 2560


(full measurement). X
For load ”F”,
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2.7 Engine Installation and Initial Operation

– D = Special Publication
Open all connections, remove covers and rubber plugs

Always use lifting brackets as shown in installation drawings to suspend engine, align engine ac-
cording to centre of gravity, observe all transportation regulations and install engine in machinery
plant
Make necessary connections
Remove transportation locking device B/D
Align engine D
Fill cooling system with coolant B
Fill oil system with engine oil B
Prepare engine for operation B
Start engine B
Perform checks while engine is running B
Carry out test run B
Shut down engine B
Perform after-shutdown services B
Preservation measures are required if an extended out-of-service period is intended B
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2.8 Engine Cutaway Drawings

Engine cross-section 8V 396 TE
Engine longitudinal section, driving end 8V 396 TE
Engine longitudinal section, free end 8V 396 TE


Engine longitudinal section, free end 16V 396 TE with fan drive
The engine section drawings listed refer to general engine version and are not order-specific.
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Engine longitudinal section, free end 16V 396 TE with fan drive
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Task Description Section 3
Page 1
3 Group Summary
1 Crankcase 14 Coolant circuit

2 Gear train 15 Oil pump
3 Running gear 16 Oil system *
4 End cover on free end 17 Speed transmitter drive
5 Cylinder head 18 Starting system
6 Valve gear 19 Engine mount
7 Engine governor 20 Fan drive *
8 Governor linkage * 27 Additional control devices *
9 Exhaust turbocharger 84 Monitoring system *
10 Air intake system/exhaust system 86 Accessories (electrical, pneumatic) *
11 Injection system 87 Engine and gearbox controls *
12 Fuel system 88 Accessories (mechanical) *
13 Coolant pump
* not shown
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Task Description Section 3
Page 2
3 Group Summary
1 Crankcase 14 Coolant circuit

2 Gear train 15 Oil pump
3 Running gear 16 Oil system
4 End cover on free end* 17 Speed transmitter drive*
5 Cylinder head 18 Starting system
6 Valve gear 19 Engine mount*
7 Engine governor 20 Fan drive
8 Governor linkage * 27 Additional control devices *
9 Exhaust turbocharger 84 Monitoring system *
10 Air intake system/exhaust system 86 Accessories (electrical, pneumatic) *
11 Injection system 87 Engine and gearbox controls *
12 Fuel system 88 Accessories (mechanical) *
13 Coolant pump*
* not shown
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Page 1
3.1 Crankcase
Contents
3.1.1 Crankcase
3.1.1.2 Removal
3.1.1.3 Disassembly
3.1.1.5a Assembly
3.1.1.6 Installation
3.1.2 Crankshaft bearing cap and bearing cap studs

3.1.2.2 Removal
3.1.2.3 Disassembly
3.1.2.5 Assembly
3.1.2b Crankcase intermediate frame and stress bolts with damper

3.1.2b.1 Before-removal operations
3.1.2b.2 Removal
3.1.2b.3 Disassembly
3.1.2b.4 Inspection and repair
3.1.2b.5 Assembly
3.1.2b.6 Installation
3.1.2b.7 After-installation operations
3.1.3 Cylinder liner

3.1.3.2 Removal
3.1.4 Piston-cooling oil spray nozzle

3.1.4.2 Removal
3.1.5 Camshaft bearing bush

3.1.5.2 Removal
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3.1.6 Oil pan

3.1.6.2 Removal (6V/8V/12V/16V)
3.1.6.2b Removal (lower oil pan)
3.1.6.6 Installation (6V/8V/12V/16V)
3.1.6.6b Installation (mount lowered oil pan)
3.1.6a Oil pan

3.1.6a.1 Before-removal operations
3.1.6a.2 Removal
3.1.6a.4 Inspection and repair
3.1.6a.6 Installation
3.1.7 Crankcase ventilation

3.1.7.2 Removal
3.1.7.3 Disassembly
3.1.7.5 Assembly
3.1.7b Crankcase ventilation (version B)

3.1.7b.2 Removal
3.1.7b.5 Assembly
3.1.7c Crankcase ventilation (version C)

3.1.7c.1 Before-removal operations
3.1.7c.2 Removal
3.1.7c.3 Disassembly
3.1.7c.4 Inspection and repair
3.1.7c.5 Assembly
3.1.7c.6 Installation
3.1.8 Flywheel housing

3.1.8.2 Removal
3.1.8.3 Disassembly
3.1.8.5 Assembly
3.1.8a Flywheel housing

3.1.8a.2 Removal
3.1.8a.3 Disassembly
3.1.8a.5 Assembly
3.1.8a.7 After-installation operations
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3.1.9 Upper end cover, driving end

3.1.9.1 Before-removal operations, see 3.1.9
3.1.9.2 Removal, see 3.1.9
3.1.9.6 Installation, see 3.1.9
3.1.10 Inspection port cover on crankcase intermediate frame

3.1.10.2 Removal
20046/20 E –03.96–
Page 4
The following is a list of tools and miscellaneous materials required for the operations:
Tools from tool kits

A
S4
S 5.1
S 6.1
S 6.2
S 6.3
S 6.4
S 6.13
S 6.15
S 6.16
S 6.18
S 6.19
Auxiliary Equipment and Materials Designation Order No.

Wire brush
Spatula
Inspection lamp
Magnifier
Endoscope with cold light
Activator Loctite No. 7649 50548

Sealing paste Elastosil – N189 black 50545
Thin-film lubricant Molykote G-n plus 40041
Denaturated ethanol 40250
Liquid nitrogen – –
Surface sealant Loctite 573 40031
Cleaner P3-Solvclean KW 40022
Scale remover Sulphuric acid (10%) –
Multi-purpose grease/lubricating grease 40379
Metallic filler Permabond FE, run-proof 40210
Engine oil Shell Rotella 30 XW
Kerosene or diesel fuel
Thread-locking agent, high-strength Loctite-270 40083
Petroleum jelly Petroleum jelly, white 40317
Dry compressed air
Magnetic crack-testing equipment with fluorescent magnetic powder
Surface crack-testing equipment with red penetrant dye
Surface crack-testing equipment with fluorescent penetrant dye
Caution
When using these miscellaneous materials, it is essential to observe the manufacturers’ instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –03.96–
Page 5
Crankcase with bearing caps
1 Camshaft bearing 12 Adapter sleeve

2 Oil spray nozzle 13 Crankshaft bearing cap
3 Engine oil to cylinder head 14 Nut
4 Roller tappet guide bush 15 Locating pin
5 Engine coolant to cylinder head 16 Crankshaft bearing
6 Sealing ring 17 Crankcase
7 Cylinder liner 18 Engine oil inlet
8 Sealing ring 19 Main oil gallery
9 Gasket 20 Engine oil to distributor
10 Stress bolt 21 End cover for camshaft
11 Oil pan
20046/20 E –03.96–
Page 6
Crankcase with intermediate frame
1 Camshaft bearing 12 Gasket

2 Oil spray nozzle 13 Oil pan
3 Roller tappet guide bush 14 Cover
4 Engine oil to cylinder head 15 Crankshaft bearing
5 Engine coolant to cylinder head 16 Locating pin
6 O-ring 17 Crankcase
7 Cylinder liner 18 Engine oil inlet
8 Sealing ring 19 Main oil gallery
9 Stress bolt 20 Engine oil to distributor
10 Adapter sleeve 21 End cover for camshaft
11 Crankcase intermediate frame
20046/20 E –03.96–
Task Description Section 3.1.1
Page 1
3.1.1 Crankcase
Crankcase 8V
1 Crankcase 12 Stud
2 Protective cap 13 Stud
3 Plug 14 Camshaft bearing bush
4 Camshaft bearing bush 15 Guide bush
5 Oil pipe for oil canal 16 Bush (only for GGG crankcase)
6 Pin 17 Cover
7 Sealing ring 18 Dowel pin
8 Plug 19 Dowel pin
9 Oil pipe 20 Stud
10 Dowel pin 21 Stud
11 Bearing bush 22 Stud
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Page 2
Crankcase 12V
1 Crankcase 12 Stud
2 Protective cap 13 Camshaft bearing
3 Plug 14 Guide bush
4 Camshaft bearing bush 15 Bush (only for GGG crankcase)
5 Plug 16 Cover
7 Oil pipe for oil canal 18 Dowel pin
8 Pin 19 Stud
9 Oil pipe 20 Stud
10 Bearing bush 21 Dowel pin
11 Stud 22 Stud
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Page 3
Crankcase 16V
1 Crankcase 14 Stud
2 Protective cap 15 Camshaft bearing bush
3 Plug 16 Guide bush
4 Camshaft bearing bush 17 Bush (only for GGG crankcase)
5 Oil pipe 18 Plug
6 Oil pipe 19 Sealing ring
7 Pin 20 Cover
8 Plug 21 Dowel pin
9 Sealing ring 22 Stud
10 Oil pipe 23 Dowel pin
11 Bearing bush 24 Dowel pin
12 Stud 25 Stud
13 Stud
20046/20 E –03.96–
Page 4
Crankcase longitudinal and cross-sections
1 Crankcase A Main oil gallery

2 Camshaft bearing bush B Oilway to crankshaft
3 Cover C Oilway to camshaft bearing bush and
4 Bearing bush for grooved ball bearing to cylinder head
5 Bearing bush for drive shaft
20046/20 E –03.96–
Task Description Section 3.1.1.1
Page 1
3.1.1.1 Before-Removal Operations
A distinction must be made as to whether:

1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed
1 2 3 Operations See
x - - Remove engine 2.3

x - - Perform operations as per Disassembly Plan 2.4
- x x Removal not scheduled
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Page 1
3.1.1.2 Removal
Installing crankcase in roll-over assembly dolly
Install crankcase in roll-over assembly dolly with lifting appliance and secure.
Caution
The engine can only be swivelled in the roll-over assembly dolly up to the point where the running gear and the oil pan
are installed, i.e. without cylinder heads and other attachments.
Once the engine has been swivelled, the crankcase must be removed from the roll-over assembly dolly and positioned
on the oil pan in order to continue with the assembly process.
20038/10 E –11.92–
Page 2
20038/10 E –11.92–
Page 1
3.1.1.3 Disassembly
Remove cover from camshaft chamber
Using a mandrel, pierce cover (1) in centre.
Remove cover from bore using an extension.
Take care not to damage the bore.
1 End cover – flat version
20046/20 E –03.96–
Page 1
3.1.1.4 Inspection and Repair

Clean all parts, remove paint if necessary.
Using the surface crack-testing method and red penetrant dye, check the crankcase and main oil gallery for cracks.
Check the mating faces, top and bottom cylinder liner fits and the bores for the crankshaft bearing on the crankcase
for wear, damage and cavitation.
For advice on matters relating to cracks in the crankcase and crankcase reconditioning, please contact our Product
Support Department.
For directions on reconditioning the seating surface on the crankcase, contact MTU Friedrichshafen for Work Instruc-
tion RSM 11 11 86.
Check the seating surfaces on the crankcase partition walls for irregularities using a feeler gauge and a straightedge.
If irregularities of greater than 0.05 mm are detected, recondition the seating surfaces on the partition walls in accord-
ance with MTU specifications.
Request the relevant work instructions from MTU Friedrichshafen.
Inspecting oilways
Opening main oil gallery, driving end
Note
Plug is secured with high-strength thread-locking liquid!
Use an extended Allen key and ratchet (3) to remove

plug (1) of main oil gallery at driving end from crankcase.
Inspect main oil gallery (1) with endoscope (2) and cold
light to ensure that it is clean.
20038/10 E –03.96–
Page 2
Inspect oilways (2) leading from main oil gallery to cylin-

der heads with cold light (1) to ensure that they are
clean.
Inspect oilways (2) leading from spray nozzles to main

oil gallery with cold light (1) to ensure that they are clean.
Inspect oilways (3) leading from crankshaft bearing bore

to main oil gallery with cold light (1) to ensure that they
are clean.
20038/10 E –11.92–
Page 3
If necessary, clean oilways (2) with a bristle brush (1).

Do not use wire brushes!
After cleaning, flush oilways with a flushing system that
has a minimum working pressure of 10 bar.
Sealing main oil gallery, driving end

Before installing plug, check that threads of main oil gal-
lery and plug are in proper condition.
Clean and degrease thread and coat with ”Activator”.
Fit sealing ring on plug.
Coat thread of plug with high-strength thread-locking
liquid.
Install plug in main oil gallery at driving end.
Use torque wrench (2) and Allen key to tighten plug (1).
For torque setting, see Section 1.3.
Inspecting and replacing pins, dowel pins and studs

Inspecting pins
Remove pins only as required.
Coat pin with high-strength thread-locking liquid.
Press pin into crankcase bore.
Pins in the main bearing bore must not protrude (see
arrow).
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Page 4
Inspecting dowel pins

Remove dowel pins only as required.
Coat dowel pin with high-strength thread-locking liquid.
Press dowel pin into crankcase.
Check protrusion of dowel pin for cylinder head fixture.
Inspecting studs
Remove studs only as required.
Insert new studs with high-strength thread-locking
liquid.
Check stud length at idler gear bearings.
Studs must not protrude.
Inspecting locating pin
Note
Not applicable to crankcases with intermediate frames

Check position of locating pin (1) with respect to crank-
shaft axis.
Surface (2) of locating pin must not protrude.
Remove locating pin only as required.
20038/10 E –11.92–
Page 5
Measuring crankcase bores
Note
Measure bore only if crankshaft bearing cap is installed

and tensioned, or if crankcase intermediate frame is in-
stalled.
Crankcase bore for cylinder liner
Always measure all bores at four points.
Check upper and lower locating bores (2) in crankcase
for wear or pitting.
If badly worn or pitted, recondition bore to next repair
stage with suitable boring mill.
When reconditioning, always machine both upper and
lower locating bores.
Adjust bore gauge (1).
Measure upper and lower locating bores for cylinder
liners in crankcase.
Record values in data sheet.
For wear limits, see Tolerances and Wear Limits List.
If wear limits are exceeded, machine locating bores to
next repair stage.
Mark reconditioned crankcase on outside (3) with
punched numerals 6 mm high as follows:
Stage Marking
1 +0.2
2 +0.4
3 +0.2 dia. +0.3
4 +0.4 dia. +0.3
5 +0.4 dia. +0.6
Bearing bores for fuel injection pump drive shaft
Measure bearing bores (1) for fuel injection pump drive
shaft.
If wear limits are exceeded, replace bearing bush.
20038/10 E –11.92–
Page 6
Roller tappet guide bush

Measure bore for roller tappet (2).
If wear limits are exceeded, replace guide bush.
Camshaft bearing bush bore

Measure bore for camshaft bearing bush on crankcase
(2).
Check bearing bushes for scoring and damage.
Bearing bores for idler gear shafts, coolant pump

and generator drives
Note
Measure bore only if crankshaft bearing cap is installed

and tensioned, or if crankcase intermediate frame is in-
stalled.
Measure bore (2) for idler gear shaft of the coolant pump
and generator drives in the crankcase.
If wear limits are exceeded, fit bush in bore in accord-
20038/10 E –03.96–
Page 7
Replacing oil pipe for main oil gallery

Removing oil pipe for main oil gallery
Remove and replace oil pipe only if damaged.

To remove, saw off oil pipe at crankcase bearing wall.
Release pretensioning at roll-in point by reboring oil pipe.
Remove rest of oil pipe from crankcase.
Installing oil pipe for main oil gallery, version 6/8/12V
Y=Roll-in width
For installation, insert oil pipe in crankcase bearing wall bores.
Use device (pin in bore dia. 12 mm) to locate pipe at designated bearing wall ”A”.
Roll in oil pipe pressure-tight in all penetrations through crankcase.
Starting with a roll-in point next to bearing wall ”A”, roll in pipe progressively, first from the end, then from ”A” to the other
end of the pipe.
Roll in pipe to specified roll-in width (Y), see illustration above.
Use roll-in device only at operating temperature (warm up for 5 minutes).
Lubricate roll-in tool with high-pressure gearbox grease.
After each roll-in procedure, remove scale from tool.
The roll-in device is inserted at all roll-in points from the free end.
After rolling-in, check oil pipe for leaks with fluid. Test pressure 15 bar.
Check that there is no obstruction between oilways and oil pipe in crankcase, and that they are clean.
20038/10 E –03.96–
Page 8
Installing oil pipe for main oil gallery, version 16V
Y=Roll-in width
For installation, insert oil pipes in crankcase bearing wall bores.
Use device (pin in bore 12 mm dia.) to locate pipe at designated bearing wall ”B or C”.
Roll in oil pipes pressure-tight in all penetrations through crankcase, starting with roll-in point next to bearing wall ”B
or C”.
Roll in pipe progressively, first from one end, then starting from ”B or C”, to the other end of the pipe.
Roll in pipe to specified roll-in width (Y), see illustration above.
Use roll-in device only at operating temperature (warm up for 5 minutes).
Lubricate roll-in tool with high-pressure gearbox grease.
After each roll-in procedure, remove scale from tool.
For pipe at free end: Insertion of roll-in tool from free end.
For pipe at driving end: Insertion of roll-in tool from driving end.
After rolling-in, check oil pipe for leaks with fluid. Test pressure 15 bar.
Check that there is no obstruction between oilways and oil pipe in crankcase, and that they are clean.
20038/10 E –03.96–
Page 9
Replacing injection pump drive bearing bushes

1 Bearing bush for grooved ball bearing
2 Bearing bush for drive shaft
3 Crankcase
Removing injection pump drive bearing bushes

Use removal tool to drive grooved ball bearing bush out
of crankcase.
Using press-out tool (2), drive bearing bush (1) for drive
shaft towards driving end (V-chamber) out of crankcase.
Adjust bore gauge.
Measure crankcase bore.
Record measurement.
If bores are too large or damaged, it is possible to fit bush
or recondition them to next repair stage in accordance
with MTU specifications.
20038/10 E –11.92–
Page 10
Installing injection pump drive bearing bushes

Measure bearing bush O.D. with outside micrometer.
Record measurement.
Check that interference is within specified tolerances.
Insert installing device (3) in crankcase (5).
Tighten nuts.
Place bearing bush (2) for drive shaft on disc (1) so that
dowel pin (6) engages in recess.
Slide disc with bearing bush onto installing device.
Engage pawl (7).
Using handwheel (4), insert bearing bush all the way into
crankcase.
Attention
Check that oilway is not obstructed.

Open pawl.
Remove disc from installing device (1).
Remove nuts.
Remove installing device from crankcase.
20038/10 E –11.92–
Page 11
Caution
When using liquid nitrogen, observe the Safety Instruc-

tions in 1.5.
Chill bearing bush (1) for grooved ball bearing with
”liquid nitrogen”.
Use device to insert bearing bush all the way into crank-
case bore (2).
Attention
Bearing bush must be flush with edge of crankcase

bore.
Replacing roller tappet guide bush

Removing roller tappet guide bush
Use a suitable removal tool to withdraw guide bush from
crankcase.
Installing roller tappet guide bush
Clean new guide bush and bore in crankcase.
Adjust bore gauge.
Measure crankcase bore.
Attention

tions in 1.5.
Chill guide bush with ”liquid nitrogen” and insert into
crankcase.
Insert control mandrel (dia. 14 f7) in guide pin bore (1)
to aid in locating the bush.
Adjust bore gauge.
Measure guide bush bore.
20038/10 E –03.96–
Page 12
Replacing coolant chamber covers

Removing coolant chamber covers
Using a mandrel, pierce cover (2) in centre.
With the aid of an extension, remove cover from bore in
crankcase (1).
Take care not to damage the bore.
Installing coolant chamber covers

Fit new cover in bore as far as it will go.
Use roller expander (2) and wrench (1) to force cover
into position.
20038/10 E –11.92–
Page 13
Leak testing
Perform the leak test with the cylinder liners in place.
Position leak-test plate with guides on cylinder liners.
If leak-test plates are not available, use cylinder heads.
Tighten cylinder head nuts to specified torque. For torque setting, see Section 1.3.
Install pressure-testing device.
Caution
Coolant is hot, 80 °C – Always wear protective gloves when handling parts.

Do not exceed the prescribed test pressure. Wear protective goggles and protective clothing.
Pressure-test coolant chamber with treated water:
– Steady-state temperature 80 °C
– Test pressure 7 bar
Apply pressure to crankcase for minimum 20 minutes.
Inspect crankcase for leaks.
Relieve pressure.
Remove pressure-testing device.
20038/10 E –03.96–
Task Description Section 3.1.1.5a
Page 1
3.1.1.5a Assembly
Installing end cover for camshaft chambers – flat version

Prior to installing end cover (2), clean and degrease con-
tact surface of end cover and crankcase.
Coat mating surface (1) on new cover and on crankcase
with denaturated ethanol.
Use drift (1) to drive cover into bore of crankcase (2) until
it contacts the stop.
Make sure the cover is kept vertical to the bore.
20038/10 E –01.96–
Page 1
Removing crankcase from roll-over assembly dolly
Caution
The engine can only be swivelled in the roll-over assembly dolly up to the point where the running gear and the oil pan
are installed, i.e. without cylinder heads and other attachments.
Once the engine has been swivelled, the crankcase must be removed from the roll-over assembly dolly in order to con-
tinue the assembly process.
Secure crankcase with lifting appliance.

Remove bolts securing crankcase to assembly dolly.
Using lifting device, lift crankcase out of the assembly dolly and lower onto crankcase lower part, oil pan and/or rests.
1 Roll-over assembly dolly

1 2 3 2 Lifting device
3 Crankcase
V0010009a0
20038/10 E –03.96–
Page 1
3.1.2 Crankshaft Bearing Cap and Bearing Cap Studs
1 Long stress bolt 5 Collar nut

2 Alignment bearing cap 6 Adapter sleeve
3 Washer 7 Short stress bolt
4 Screw for alignment bearing cap 8 Crankshaft bearing cap
20038/10 E –11.92–
Page 2
Crankshaft bearing caps
1 Alignment bearing cap 5 Short stress bolt

2 Washer 6 Long stress bolt
3 Screw for alignment bearing cap 7 Adapter sleeve
4 Collar nut
20038/10 E –03.96–
Page 1


- x x Removal not scheduled -
20038/10 E –11.92–
Page 1
3.1.2.2 Removal
Removing crankshaft bearing caps
Note
The two collar nuts of a crankcase partition wall must be

released simultaneously.
To remove crankshaft bearing caps, use ratchet socket
wrench (1) and socket (2) to unscrew collar nuts.
Note
To avoid the stress bolts from becoming loose, insert re-

taining unit into splines of stress bolts and lock into posi-
tion.
Install puller (2) on crankshaft bearing cap (1).

Remove bearing cap.
20038/10 E –03.96–
Page 1
3.1.2.3 Disassembly
Removing sleeves
Remove sleeves from crankshaft bearing cap.
Note
As a rule, use bearing cap with new adapter sleeves.
20038/10 E –11.92–
Page 1

Clean all parts.
Using the magnetic crack-testing method and fluorescent magnetic powder, check the crankshaft bearing caps for
cracks, and replace as necessary.
If the crankcase bearing caps show signs of cracks, please contact our Product Support Department for advice.
Attention
If crankshaft bearing caps are replaced, they must be worked together with the crankcase.
Check crankshaft bearing cap for wear and localized galling; remove minor wear and localized galling by polishing –
if necessary recondition to MTU specifications.
Check evenness of mating faces of crankshaft bearing caps with straightedge and feeler gauge.
If irregularities greater than 0.05 mm are detected, recondition the mating faces of the crankshaft bearing cap in accord-
Inspecting and replacing crankshaft bearing cap studs.
Measure stress bolts (2) with depth gauge (1) on crank-
case (3) to max. projection.
Remove stress bolts from crankcase only if damage is
detected on screw thread or wear on separation points;
replace stress bolts also if screw projection exceeds 173
mm.
Stress bolts with identification number on the face are
secured with ”high-strength thread-locking agent ” in the
crankcase.
Attention
The stress bolts can only be removed with a socket

wrench once they are heated to 200 °C.
If stress bolts are replaced by stress bolts with identifica-
tion number on the front, the stress bolt with the same
identification number must be installed into each bolt
bore.
In the event of damage to thread in crankcase, recondi-
tion in accordance with MTU specifications.
20038/10 E –08.97–
Page 2
Prior to installing stress bolts (2) with identification

numbers, clean and degrease thread of stress bolts and
thread in crankcase and coat with ”Activator”.
Coat stud threads with high-strength thread-locking
liquid.
Prior to installing stress bolts without identification
numbers, with journal at bolt end, coat front face and
thread with ”engine oil”.
Insert stress bolts with socket wrench (1) into crank-
case.
Set stress bolts (2) with identification number on front

with depth gauge (1) on crankcase (3) so that it projects
±
169.0 mm 0.5 mm.
Insert stress bolts without identification number, with
journal at bolt end, into crankcase until it contacts the
stop and tighten with torque wrench to torque specifica-
tion 1.3.
Measure projection of 169.3 mm ±0.7 mm with depth
gauge (1).
Coat stress bolts on shaft with ”engine oil”.
20038/10 E –01.96–
Page 1
3.1.2.5 Assembly
Installing crankshaft bearing caps
Installing sleeves
Smooth mating faces of crankshaft bearing caps and
collar nuts with an oilstone.
Insert sleeves in bearing caps.
Check projection of adapter sleeves.
Note
As a rule, use bearing cap with new adapter sleeves.
20038/10 E –11.92–
Page 1
Installing crankshaft bearing caps
Install bearing caps on crankcase in accordance with
markings (1).
Attention
Take care not to damage sleeves.
Markings on crankcase and bearing caps must match

and be located on the same side of the engine.
Tap crankshaft bearing caps with plastic mallet until

joints are closed.
Check that thread and mating faces (1) of collar nuts are
clean.
Coat thread with thin-film lubrication.
Screw collar nuts down on bearing cap.
Note
The two collar nuts of a crankcase partition wall must be

tightened simultaneously.
Starting from the free end, firstly tighten all inner stress
bolts, then tighten all outer stress bolts.
Place both ratchet wrenches (3) with inserts on collar
nuts.
Engage retaining device (2) in splines of bearing cap
studs and secure.
Place measuring device (1) on crankcase mating sur-
face.
Place dial gauge feelers on bearing cap stud faces .
Set dial gauge with pretension to zero.
Tighten both collar nuts in specified order in accordance
with tightening specification 1.3.
20038/10 E –03.96–
Page 2
Coat threads and mating faces of studs and bearing

caps (2) with thin-film lubrication.
Install studs with washers in crankcase and tighten with
torque wrench (1). For torque setting, see Section 1.3
20038/10 E –11.92–
Page 1
3.1.2.7 After-Installation Operations
Measuring crankshaft bearing main bore

Use dial gauge to measure crankshaft bearing basic
bore (2) at points A, B1 and B2.
If limit values are exceeded, recondition basic bore to
next repair stage.
If crankcase mating faces are to be reconditioned, or if

crankshaft bearing caps are to be replaced, or their mat-
ing faces are to be reconditioned, recondition crankshaft
main bearing bore on fine boring mill.
Also see tolerances and wear limits list.
Transfer markings from old bearing caps to new bearing
caps using numeral punches.
20038/10 E –11.92–
Task Description Section 3.1.2.b
Page 1
3.1.2b Crankcase Intermediate Frame and Stress Bolts with Damper
1 Crankcase 6 Collar nut

2 Dowel pin 7 Stud
3 Washer 8 Adapter sleeve
4 Screw 9 Stress bolt, short
5 Crankcase intermediate frame 10 Stress bolt, long
20054/00 E –10.93–
Page 2
Crankcase and intermediate frame
1 Crankcase 4 Screw
2 Crankcase intermediate frame 5 Screw
3 Washer 6 Screw
20054/00 E –10.93–
Page 3
Crankcase longitudinal and cross-sections with intermediate frame
1 Screw 5 Collar nut

2 Crankcase intermediate frame 6 Long stress bolt
3 Washer 7 Short stress bolt
4 Screw for alignment bearing 8 Adapter sleeve
20054/00 E –10.93–
Task Description Section 3.1.2b.1
Page 1
3.1.2b.1 Before-Removal Operations

2 The engine is to be removed but no disassembled

- x x Removal not scheduled
20054/00 E –10.93–
Page 1
3.1.2b.2 Removal
Removing crankcase intermediate frame
Prior to removing crankcase intermediate frame, re-
move grooved ball bearing from crankcase bore.
Use socket and extension (1) to remove bolts for
grooved ball bearings on intermediate frame.

nuts.
studs and secure.
Use ratchet wrench to remove collar nuts.
Remove retaining device.
Place collar nuts in transport trestle and protect from
damage.
Remove all stress bolts with socket wrench from crank-

case.
Place stress bolts in transport trestle and protect from
damage.
20054/00 E –10.93–
Page 2
Remove all bolts from crankcase intermediate frame.
Install lifting device (1) on intermediate frame (2).

Mount guide pins (3) in two diagonally opposite crank-
case bores.
Remove intermediate frame with lifting gear from crank-
case.
Remove guide pins.
20054/00 E –10.93–
Page 1
Removing sleeves
Remove sleeves from crankcase intermediate frame.
Note
Replace adapter sleeves when assembling crankcase

intermediate frame.
20054/00 E –10.93–
Page 1
3.1.2b.4 Inspection and Repair

Clean all parts, remove paint if necessary.
Using the surface crack-testing method with red penetrant dye, check the crankcase intermediate frame for cracks.
Check evenness of mating faces of crankcase intermediate frame with straightedge and feeler gauge.
If unevenness is greater than 0.05 mm, recondition mating surfaces in accordance with MTU Specifications.
Check bores for crankshaft bearing, clamp ring, thrust bearing, cylindrical roller bearing, end cover and inspection port
cover for wear and localised galling.
Remove minor wear traces and localised galling by polishing; if necessary recondition bores in accordance with MTU
Specifications.
Measure fitted bores with bore gauge; for limit values, see Tolerance and Wear Limits List.
If wear limits are exceeded, recondition fitted bores in accordance with MTU specifications.
Check threaded bores for condition and ease of movement; if necessary recut or insert threaded inserts.
Check mating faces for damage, smooth as necessary.
Inspection and replacement of bearing cap studs for crankcase intermediate frame
Check stress bolts for damage and pitting; replace as necessary.
Check thread of stress bolts for condition. Replace as necessary.
Permissible overall length before installation:
– long stress bolt max. 431 mm
– short stress bolt max. 391 mm
Check rubber damper on stress bolts for damage, revulcanise as necessary and/or replace stress bolts.
Check collar nuts for cracks using magnetic crack-testing method and fluorescent magnetic powder.
Replace components exhibiting cracks.
Check collar nuts for damage, check thread for ease of movement, check mating faces for scoring and replace collar
nuts if necessary.
Replace dowel pins as necessary.
Replace adapter sleeves when reassembling.
20054/00 E –08.97–
Page 1
3.1.2b.5 Assembly
Installing sleeves
Smooth mating faces of crankcase intermediate frame
and collar nuts with an oilstone.
Insert adapter sleeves into crankcase intermediate
frame.
Check projection of adapter sleeves,
X = 9.5 mm -0.5 mm
Note
Replace adapter sleeves when assembling crankcase

intermediate frame.
20054/00 E –10.93–
Page 1
Installing crankcase intermediate frame
Note
Intermediate frame must, as a rule, be installed with new

adapter sleeves.
Smooth mating faces of crankcase and intermediate-
frame with an oilstone.
Note
If crankcase intermediate frame is installed for measur-

ing or machining purposes, do not apply any surface
sealant.
Using a paint roller, apply ”surface sealant”, max. thick-
ness 0.05 mm, to contact surfaces ”A” of crankcase in-
termediate frame.
Install lifting device (1) on intermediate frame (2).

Mount guide pins (3) in two diagonally opposite crank-
case bores.
Use lifting gear to place intermediate frame on crank-
case.
Take care not to damage sleeves.
Remove guide pins.
Remove lifting appliance.
20046/20 E –03.96–
Page 2
If crankcase intermediate frame is installed for measur-

ing or machining purposes, if possible use stress bolts
without rubber dampers as working screws.
Measure length of stress bolts prior to installation
Permissible length of long screws (2) max. 431 mm
Permissible length of short screws (1) max. 391 mm
Replace elongated screws.
Coat bores for stress bolts in intermediate frame with
”engine oil”.
Check thread of stress bolts for cleanliness and coat
with ”engine oil”.
Coat rubber buffer of stress bolts with ”engine oil”.
Drive in stress bolts via bores in crankcase intermediate

frame.
Attention
Take care not to damage rubber buffer and thread!
Screw stress bolts into crankcase.
20046/20 E –03.96–
Page 3
Tighten stress bolts with torque wrench. For torque set-

tings, see Section 1.3.
Pretightening inner collar nuts

Coat threads and mating surfaces of collar nuts with
thin-film lubricant.
Screw collar nuts onto stress bolts.
Note
Tighten collar nuts on bearing in pairs.

Fit two torque wrenches (1) with inserts on inner collar nuts
in accordance with tightening diagram on Pages 6 to 8.
studs and secure.
Pretighten collar nuts to specified torque. For torque set-
ting, see Section 1.3.
Start of tightening is always indicated on bearing wall in
centre of crankcase. Finally, tighten collar nuts at adjac-
ent bearing walls alternately in direction of free end and
driving end.
Pretightening outer collar nuts
Fit two torque wrenches (1) with inserts on outer collar
nuts in accordance with tightening diagram on Pages 6
to 8.
studs and secure.
Note
Tighten collar nuts on bearing in pairs.

Pretighten collar nuts to specified torque. For torque set-
20046/20 E –03.96–
Page 4
Tightening securing screws on crankcase inter-

mediate frame
Coat threads of bolts (2) with engine oil.
Install screws on crankcase intermediate frame.
Starting at bearing wall in centre of crankcase, use
torque wrench (1) to tighten screws to specified torque.
Finally, tighten adjacent screws diagonally and evenly
alternately in direction of free end and driving end.
Loosening inner and outer collar nuts

nuts.
Engage retaining device (2) on splines of bearing cap
studs and secure.
Note
Release the two collar nuts of a crankcase partition wall

simultaneously.
Use ratchet wrench to loosen all collar nuts.
Tightening inner bearing cap studs to specified

elongation
Note
Tighten both collar nuts on crankcase partition wall in

pairs in two stages.
Fit two ratchet socket wrenches (1) with inserts on inner
collar nuts in accordance with tightening diagram on
Pages 6 to 8.
studs and secure.
Place measuring device (3) on mating surface at crank-
case intermediate frame.
Tighten collar nuts to specified torque. For torque set-
driving end.
20046/20 E –03.96–
Page 5
Tightening outer stress bolts to specified elonga-

tion
Note
Tighten both collar nuts on crankcase partition wall in

pairs in two stages.
Fit two ratchet socket wrenches (1) with inserts on outer
collar nuts in accordance with tightening diagram on
Pages 6 to 8.
studs and secure.
Place measuring device (3) on mating surface at crank-
case intermediate frame.
Tighten collar nuts to specified torque. For torque set-
driving end.
Tightening screws for grooved ball bearings

Coat thread and seating face of screws with thin-film lu-
bricant.
Using torque wrench (1), tighten M18 screws for
grooved ball bearings to specified torque. For torque
setting, see Section 1.3.
20046/20 E –03.96–
Page 6
Tightening diagram for crankcase intermediate frame 8V
Note
The two collar nuts of a crankcase partition wall must be tightened simultaneously.
➀ ➄ to Tightening sequence of inner stress bolts, beginning with No. 1

A to E Tightening sequence of outer stress bolts, beginning with A
1 to 18 Tightening sequence of screws M12, crankcase intermediate frame on crankcase
beginning with No. 1
X Screws M18 for grooved ball bearing (thrust bearing)
20046/20 E –03.96–
Page 7
Note
I to VII Tightening sequence of inner stress bolts, beginning with No. I

A to G Tightening sequence of outer stress bolts, beginning with A
20046/20 E –03.96–
Page 8
Note
I to IX Tightening sequence of inner stress bolts, beginning with No. I

A to I Tightening sequence of outer stress bolts, beginning with A
20046/20 E –03.96–
Page 1
3.1.2b.7 After-Installation Operations

Measuring crankshaft bearing main bore
Adjust bore gauge.
Use dial gauge to measure crankshaft bearing basic
bore (2) at points A, B1 and B2.
If limit values are exceeded, recondition basic bore to
next repair stage.
If mating faces of crankcase or intermediate frame are

to be machined, or if crankcase intermediate frame must
be replaced, recondition crankshaft main bearing bore
on fine boring mill.
Also see Tolerances and Wear Limits List.
If main bearing bore in crankcase is machined, it is
necessary to increase depth of locating pin bore and
crankcase oil groove.
20054/00 E –10.93–
Page 1
3.1.3 Cylinder Liner
1 Cylinder liner 5 Spring washer

2 O-ring 6 Screw
3 Sealing ring (red) 6 Oil spray nozzle
4 Sealing ring (black) 7 Crankcase
20038/10 E –01.96–
Page 1


- - x Disable engine start Op. Man.
- - x Drain engine coolant -
- - x Drain or draw off engine oil -
- x x Disconnect H.P. fuel line 3.12.1.2
- x x Disconnect leak-off fuel line 3.12.2.2
- x x Remove valve gear housing 3.6.4.2
- x x Intake air system, remove screws at appropriate cylinder head 3.10.2b.2
- x x Exhaust pipework, remove screws at appropriate cylinder head 3.10.3a.2
- x x Disconnect engine oil return pipes from cylinder head -
- x x Remove cylinder head 3.5.1.2
- x x Remove or lower oil pan 3.1.6.2
- x x Remove piston and conrod 3.3.2.2
- x x Measure cylinder liner ID in installed condition 3.1.3.7
20058/0 E –03.93–
Page 1
3.1.3.2 Removal
Insert puller with thrust plate (1).
Take care not to damage the oil spray nozzle (2).
Make sure the puller is properly seated.
Tighten star knobs (1) to secure puller to crankcase.

Use puller to withdraw cylinder liner (2) from crankcase.
Remove puller.
20038/10 E –11.92–
Page 2
Withdraw cylinder liner (1) from crankcase (2)
20038/10 E –11.92–
Page 1

Clean all parts.
Check cylinder liner for scores or pitting, and replace if necessary.
Using the magnetic crack-testing method and fluorescent magnetic powder, check cylinder liner for cracks, and replace
if necessary.
Check cylinder liner outer surface for pitting.
In event of minor pitting, install liner turned through 90°.
In such cases, rehone the cylinder liner bore and install new piston rings.
Replace the liner if pitting is deeper than 1.5 mm.
Measure diameter of cylinder liner fits and thickness of liner collar.
Using an electronic engraver, mark collar height and cylinder no. at circumference of seating collar.
Adjust bore gauge.
Measure bore of bush at appropriate measuring point height turned through 90° twice.
For limit values, see Tolerances and Wear Limits List.
If wear limits are exceeded, replace liner.
When using new piston rings, rehone cylinder liner.
Check liner collar sealing surfaces for wear, smooth with oilstone if necessary.
Replace O-rings and sealing rings (replace in sets only).
20038/10 E –11.95–
Page 1
Installing cylinder liner
Note
Prior to installing cylinder liner, check stage or dimen-

sional accuracy in accordance with Tolerances and
Wear Limits List.
Identification mark for cylinder liner with collar chamfer:
”DS”.
Marking cylinder liner
a = Groove for stage 0-1 to 2-2 and 6
b = with etching ink stage 0-0 to 2-2 and 6
DS = Stamped on versions with collar chamfer
Note
Install O-rings in pairs only.

Install O-ring (1) in groove on cylinder liner collar. Insert
red sealing ring (3) into top groove and black sealing ring
(5) into bottom groove of bottom fit of cylinder liner (2).
Insert sealing rings with flat end (4) into groove.
Note
Ensure O-ring and sealing rings are not twisted during

installation!
Work sealing rings around in grooves to relieve any
strain.
Check projection of sealing rings.
Coat sealing rings (1) with ”petroleum jelly” (2).
Clean mating faces and check for unevenness as
necessary.
Ensure bedding pattern on liner collar and mating face
of crankcase is constant.
20038/10 E –11.95–
Page 2
Clean top and bottom guide collar in crankcase (2) and

coat with ”petroleum jelly”.
Insert cylinder liner (1) in crankcase bore.
Insert cylinder liners with pitting turned through 90°.
Use tool to press cylinder liner into position in crankcase.

Wipe off remaining ”petroleum jelly” at edges.
20038/10 E –11.95–
Page 1

Measuring cylinder liner bore
Make sure that cylinder liner (2) is properly seated on
balcony seat.
Measure bore at appropriate measuring point height
turned through 90°twice.
Note
Measure cylinder liner bore only with crankshaft cap or

crankcase intermediate frame tightened.
20038/10 E –11.92–
Page 1
3.1.4 Piston-Cooling Oil Spray Nozzle
1 Crankcase 3 Spring washer

2 Oil spray nozzle 4 Screw
20058/0 E –03.93–
Page 1


- x x Intake air system, remove screws at appropriate cylinder head 3.10.2b.2
- x x Exhaust pipework, remove screws at appropriate cylinder head 3.10.3a.2
- x x Remove piston and conrod 3.3.2.2
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Page 1
3.1.4.2 Removal
Remove screws (1) for oil spray nozzle (2) with socket.
Remove oil spray nozzle.
20038/10 E –11.92–
Page 1

Clean oil spray nozzle in diesel fuel.
Carefully blow out oilways with dry compressed air.
Check that oilways are not obstructed.
Using surface crack-testing method and red penetrant dye, check oil spray nozzle for cracks when necessary. If cracks
are detected, replace.
Check mating faces and spray nozzles for damage, replace if necessary.
20038/10 E –11.92–
Page 1
Before installing oil spray nozzle, check that mating
faces on crankcase and nozzle are smooth.
Carefully blow out oilways with compressed air.
Install oil spray nozzle (2) with screws and spring
washers in crankcase.
Use socket and torque wrench (1) to tighten screws to
specified torque. For torque setting, see Section 1.3
20054/00 E –10.93–
Page 1

Checking nozzle jet orientation
The nozzle jet orientation can be checked only after the
piston has been installed.
Place piston (1) in TDC position.
Slip alignment tool (2) over nozzle (3).
Move piston toward BDC until alignment tool tip enters
feed bore in piston.
In event of misalignment, adjust or replace nozzle.
Attention
Never bend oil spray nozzle with alignment tool.
20038/10 E –11.92–
Page 1
3.1.5 Camshaft Bearing Bush
1 Camshaft bearing bush 3 Cover

2 Camshaft bearing bush
20038/10 E –11.92–
Page 1


- - x Removal not scheduled -
- x - Mark and disconnect cables 3.84.9b.2
- x - Disconnect engine from gearbox or alternator 3.88.6a.2
- x - Remove engine terminal box and wiring 3.84.9b.2
- x - Disconnect engine coolant lines 3.14.1.2
- x - Disconnect coolant expansion tank 3.14.5b.2
- x - Remove engine coolant cooler 3.14.6.2
- x - Remove starting, control air and drain lines from cylinder head 3.18.3a.2
- x - Disconnect engine oil lines 3.16.1.2
- x - Disconnect engine oil return pipes from cylinder head 3.5.1.2
- x - Remove fuel lines 3.12.2.2
- x - Disconnect leak-off fuel line 3.12.2.2
- x - Remove cylinder head covers 3.6.4.2
- x - Disconnect H.P. fuel lines 3.12.1.2
- x - Remove fuel manifold with manual pump 3.12.5.2
- x - Remove fuel delivery pump 3.12.4.2
- x - Remove air flow control flaps and exhaust flap lever 3.10.8a.2
- x - Disconnect exhaust pipework 3.10.3.2
- x - Disconnect oil lines for valve seat lubrication 3.16.1.2
- x - Remove oil lubrication pump for valve seat lubrication 3.15.4.2
- x - Remove intake air system 3.10.2.2
- x - Remove drain line 3.10.14.2
- x - Remove compressed air distributor 3.18.1a.2
- x - Remove crankcase ventilation 3.1.7b.2
- x - Remove fuel injection pump 3.11.5a.2
- x - Remove upper cover at free end 3.1.9.2
- x - Remove drive shaft for fuel injection pump drive 3.11.1.2
- x - Remove valve gear housing 3.6.4.2
- x - Remove rocker arms 3.6.3.2
- x - Remove cylinder head 3.5.1.2
- x - Remove roller tappets 3.6.2.2
- x - Remove camshaft. 3.6.1.2
- x - Remove cover from camshaft chamber 3.1.1.3
20046/20 E –04.96–
Page 1
3.1.5.2 Removal
Note
Remove camshaft bearing bushes only when wear limits are reached or when they are damaged.
Note
Two recesses are machined on draw spindle of installation and extraction tool for left and right engine side.
Left engine side:
Use recesses on draw spindle and thrust plate for left engine side in direction of driving end.
Right engine side:
Use recesses on draw spindle and thrust plate for right engine side in direction of free end.
Mount guide element (1) without draw spindle on crank-

case, free end.
Tighten four nuts with ratchet wrench (2).
Insert draw spindle into guide (2).

Place thrust plate (1) with large recess between thrust
nut (3) and guide.
20038/10 E –11.92–
Page 2
Position bush (1) on draw spindle (3) at driving end to

serve as guide in bearing bush.
Slide thrust plate (2) for left or right side of engine into
corresponding draw spindle groove.
Each thrust plate has an engraved identifying mark for
left or right side of engine.
Removing first bearing bush A1/B1

Withdraw bearing bush (5) from crankcase (2) by turning
thrust nut (1) at free end.
At same time, slip guide bush (4) over draw spindle (3)
as far as it will go against bearing bush.
Turn thrust nut in opposite direction after first bearing
bush has been removed.
Move draw spindle towards driving end and remove
thrust plate.
Remove bush (5) from withdrawn camshaft bearing.
20038/10 E –11.92–
Page 3
Removing next camshaft bearing bush

Force bush (7) into next bearing bush (6) that is still in-
stalled.
Move draw spindle (4) by turning thrust nut (1) until
thrust plate (5) can be located on spindle at next cam-
shaft bearing (6).
Insert guide bush (3) into camshaft bearing locating bore
in crankcase (2).
Turn thrust nut to withdraw camshaft bearing bush from
crankcase.
Follow same procedure to remove other bearing
bushes.
Remove bearing bushes on right side of engine in same
way, using recesses on draw spindle that face free end.
20038/10 E –11.92–
Page 1

Inspect camshaft bearing bushes for scoring or damage.
Remove bushes from crankcase with puller if scoring or damage is identified or if wear limits are exceeded.
Measuring camshaft bearing bush locating bore

Measure locating bore (2) in crankcase.
Install next repair-size bush if specified limits are ex-
ceeded.
20038/10 E –11.92–
Page 1
Installed position of bearing bushes as viewed from engine driving end
1 Oil bore to rocker arm 4 Left engine side

2 Camshaft bearing bush 6 Right engine side
3 Assembly groove 7 Oil bore from main oil gallery
Note
For instructions on how to use installer for camshaft bearing bushes, see 3.1.5.2.
Prior to installing camshaft bearing, check stage or dimensional accuracy in accordance with Tolerances and Wear
Limits List.
Remove plug on right side of engine at driving end to enable inspection of oilway.
Plug is secured with thread-locking liquid!
20038/10 E –11.92–
Page 2
Install guide (1) without draw spindle at free end.

Secure using four nuts and ratchet wrench (2).
Insert all camshaft bearings through camshaft
chambers in crankcase with locating slots facing driving
end.
Insert draw spindle (1) into camshaft bearing bores in

crankcase (3).
Force slide (2) onto draw spindle with handgrip pointing
towards free end.
Pass slide through all loose-fitting camshaft bearings up
to free end.
Take care not to damage camshaft bearings.
To centre draw spindle (3), install guide bush (5) in cam-

shaft bearing locating bore in crankcase (2) at driving
end.
Turn thrust nut (1) to move draw spindle towards driving
end.
Slip bearing bush (7) over slide (8) for centring pur-
poses.
Slide thrust plate (6) with drawing – left or right side into
guide groove (4) of draw spindle.
Fit slide with camshaft bearing bush on thrust plate as
far as they will go.
Ensure that dowel pin on thrust plate fits into locating slot
of bearing bush.
20038/10 E –11.92–
Page 3
Turn thrust nut to pull bearing bush into crankcase until

bearing oilway is in alignment with oilway (2) in crank-
case.
Check with inspection lamp (1).
Turn draw spindle back.
Remove thrust plate.
Follow same procedure to install all other bearing
bushes in direction of free end.
After all bushes have been installed, install plug on right
side of engine at driving end and secure with thread-
locking liquid.
Measuring camshaft bearing bush bore, see 3.1.5.7
20038/10 E –11.92–
Page 1

Measuring camshaft bearing bush bore
Measure camshaft bearing bush bore in crankcase (2).
20038/10 E –11.92–
Page 1
3.1.6 Oil Pan

Oil pan (8V)
1 Oil Pan 16 Elbow

2 Flange 17 Nut
3 Gasket 18 Sealing cone
4 Spring washer 19 Locating pin
5 Socket-head screw 20 Gasket
6 Sealing ring 21 Washer
7 Plug 22 Screw
8 Sealing ring 23 Screw
9 Plug 24 Screw
11 Plug 26 Screw
12 Oil extraction pipe 27 Gasket
13 Gasket 28 Cover
14 Spring washer 29 Spring washer
15 Screw 30 Screw
20046/20 E –03.96–
Page 2
Oil pan (12V)
1 Oil Pan 19 Screw

2 Cover 20 Screw
3 Gasket 21 Screw
4 Spring washer 22 Oil extraction pipe
5 Screw 23 Elbow
6 Sealing ring 24 Gasket
7 Plug 25 Spring washer
9 Plug 27 Gasket
10 Flange 28 Cover
11 Gasket 29 Spring washer
12 Spring washer 30 Screw
13 Socket-head screw 31 Nut
14 Sealing ring 32 Sealing cone
15 Plug 33 Locating pin
16 Washer 34 Gasket
17 Screw 35 Sealing ring
18 Screw 36 Plug
20046/20 E –03.96–
Page 3
Oil pan (16V)
1 Oil Pan 17 Spring washer

3 Plug 19 Nut
4 Flange 20 Sealing cone
5 Gasket 21 Flange
6 Spring washer 22 Gasket
7 Socket-head screw 23 Spring washer
10 Oil extraction pipe 26 Gasket
11 Elbow 27 Washer
12 Gasket 28 Screw
14 Screw 30 Screw
15 Gasket 31 Screw
16 Cover
20046/20 E –03.96–
Page 1


- x - Separate engine from gearbox -
- x x Remove elbow from timing end cover and oil pan 3.4.1.2
- x x Remove electric starter 3.18.1.2
- x x Remove compressed air starter 3.18.2.2
- x x Remove oil pressure lines and elbow from oil pan to oil heat exchanger 3.16.1.2
- x x Remove elbow with connecting cable from oil pan 12V 3.16.1.2
- x x Remove elbow with connecting cable from oil pan 16V 3.16.2.2
- x x Remove free end cover 3.4.1.2
- x x Remove engine oil return lines from exhaust turbochargers 3.16.1.2
- x x Remove bottom securing screws from flywheel housing 3.1.8.2
20046/20 E –03.96–
Page 1
3.1.6.2 Removal (6V/8V/12V/16V)

Insert engine (3) in roll-over assembly dolly, secure and
turn through 180°.
Mark all bolts (differing lengths).
Unscrew bolts from oil pan (2).
Attach lifting appliance.
Lift off oil pan with lifting gear (1).
If necessary, release oil pan with plastic mallet from lo-
cating pins.
Remove attachments from oil pan according to illustra-
tion 3.1.6.
For removal of engine oil pump and oil pipe 6V, 8V, 12V,
see 3.15.1.2
16V, see 3.15.2.2
20038/10 E –06.94–
Task Description Section 3.1.6.2b
Page 1
3.1.6.2b Removal
Lowering oil pan
Attention
It is only possible to lower the oil pan with engines which

do not have intermediate frames.
Install two lowering appliances (3) at both driving and
free ends.
Secure with ratchet wrench (1).
Unscrew bolts from oil pan (2).
Operate ratchet wrenches on left and right sides of en-
gine to lower oil pan.
Engine oil pump, oil pipes, pistons and conrods can be
removed once oil pan has been lowered.
20038/10 E –11.92–
Page 1

Clean oil pan and carefully remove cleaning agent residue.
Using the surface crack-testing method and red penetrant dye, check the oil pan for cracks. Replace oil pan if cracks
are found.
Check sealing surfaces of oil pan for irregularities using straightedge and feeler gauge. Replace oil pan if irregularities
exceed 0.2 mm.
Check tapped bores for mounting oil pump, pressure lines and elbows; replace threaded inserts if necessary.
Check crankcase bore for bearing pin of oil pump idler gear for wear and cold welds. Remove smaller cold welds and
wear by polishing out; line bore if necessary.
Adjust bore gauge and measure crankcase bore for bearing pin of oil pump idler gear.
If wear limits are exceeded, fit bush in crankcase bore. For limit values, see Tolerances and Wear Limits List.
Replace locating pins, gaskets and sealing rings.
20038/10 E –06.94–
Page 1
3.1.6.6 Installation (6V/8V/12V/16V)

Oil pan installation
For installation of engine oil pump and oil pipe 6V, 8V,
12V, see 3.15.1.6
16V, see 3.15.2.6
Install attachments on oil pan according to illustration
3.1.6.
Check position of locating pin (1) with respect to crank-
shaft axis.
Surface (2) of locating pin must not protrude.
Check whether mating surfaces of crankcase (3) and oil

pan (2) are clean.
Note
Mount gaskets between crankcase and oil pan without

sealant on either side.
Gaskets coated with teflon on printed side.
Installation position: Teflon coating lying on oil pan.
To ensure sealing is correct at driving end, seal gasket
face on bore dia. 360 H8 with ”sealing paste”.
Check locating pins for damage.
Fit gaskets over locating pins on crankcase.
Screw in two mounting pins at driving and free ends.
Place oil pan (2) with lifting device (1) on crankcase.
Ensure locating pins are correctly positioned and align-
ing is correct.
Remove mounting pins.
20038/10 E –04.96–
Page 2
Screw all bolts with washers into oil pan (1).
Note
Pay attention to markings and differing bolt lengths.

Using a torque wrench (2), tighten bolts to specified
torque. For torque setting, see Section 1.3.
Install washers with larger inside diameters with two
long bolts provided with collars.
Note
After installing oil pan, cut off protruding gasket flush

with housing bore and sealing surface.
20038/10 E –04.96–
Page 1
3.1.6.6b Installation
Installing lowered oil pan
Check whether mating surfaces of crankcase and oil
pan (2) are clean.
Note
Mount gaskets between crankcase and oil pan without

sealant on either side.
Gaskets coated with teflon on printed side.
Installation position: Teflon coating lying on oil pan.
To ensure sealing is correct at driving end, seal gasket
face on bore dia. 360 H8 with ”sealing paste”.
Operate ratchet wrenches (1) on left and right sides of
engine to position oil pan on crankcase.
Ensure locating pins are correctly positioned.
Screw bolts with washers into oil pan.
Remove lowering appliances (3).
Note
Using torque wrench (2), tighten bolts to specified

Note

20038/10 E –04.96–
Task Description Section 3.1.6a
Page 1
3.1.6a Oil Pan

Oil pan for intermediate frame 8V
1 Oil pan 15 Screw

2 Flange 16 Oil extraction pipe
3 Gasket 17 Bracket
5 Socket-head screw 19 Screw
6 Sealing ring 20 Grommet
7 Plug 21 Pipe clamp half
8 Cover 22 Screw
11 Screw 25 Spring washer
12 Gasket 26 Screw
13 Washer 27 Sealing cone
14 Screw 28 Nut
20046/20 E –03.96–
Page 2
1 Oil pan 13 Plug

2 Flange 14 Gasket
5 Socket-head screw 17 Oil extraction pipe
6 Sealing ring 18 Sealing cone
7 Plug 19 Nut
8 Cover 20 Gasket
9 Gasket 21 Washer
11 Screw 23 Screw
12 Sealing ring
20046/20 E –03.96–
Page 3
1 Oil pan 19 Screw

2 Flange 20 Grommet
3 Gasket 21 Pipe clamp half
6 Sealing ring 24 Nut
7 Plug 25 Gasket
8 Cover 26 Spring washer
9 Gasket 27 Screw
10 Spring washer 28 Oil extraction pipe
11 Screw 29 Grommet
13 Washer 31 Spring washer
14 Screw 32 Screw
15 Screw 33 Sealing cone
16 Oil extraction pipe 34 Nut
17 Retainer 35 Sealing ring
18 Spring washer 36 Plug
20046/20 E –03.96–
Task Description Section 3.1.6a.1
Page 1
3.1.6a.1 Before-Removal Operations


- - x Drain or draw off engine oil Op. Man.
- x x Remove elbow from end cover and oil pan 3.4.1.2
- x x Remove elbow with connecting cable from oil pan 3.15.2.2
- x x Remove free end cover 3.4.1.2
- x x Remove engine oil return lines from exhaust turbochargers 3.16.1.2
- x x Remove oil pressure lines and elbow from oil pan to oil heat exchanger 3.16.1.2
- x x Remove guide tube for oil dipstick from crankcase intermediate frame 3.1.11
- x x Remove oil extraction pipe from oil pan 3.1.12
- x x Remove oil return lines 3.16.1.2
- x x Remove bottom securing screws from flywheel housing 3.1.8.2
20046/20 E –03.96–
Page 1
3.1.6a.2 Removal
Removing oil pan
Install lifting appliance for complete engine.
Using lifting gear, raise engine until oil pan is raised
slightly off the ground.
Remove all screws from oil pan.
Carefully raise engine with lifting gear.

Lower engine onto rests, rest oil pan on palette.
Note
For suction housing removal, see 3.15.3a.2
20046/20 E –04.96–
Page 1
3.1.6a.4 Inspection and Repair

Clean oil pan.
Carefully remove all cleaning agent residue.
Using the surface crack-testing method and red penetrant dye, check the oil pan for cracks.
Replace oil pan if cracks are found.
Check sealing surfaces of oil pan for irregularities using straightedge and feeler gauge.
Smooth sealing surfaces in event of unevenness.
Check threaded bores, replace threaded inserts as necessary.
Use new gasket.
20046/20 E –03.96–
Page 1
Installing oil pan
Note
For suction housing installation, see 3.15.5a.2

Install lifting appliance for complete engine.
Raise engine with lifting gear.
Check sealing surfaces on oil pan and crankcase inter-
mediate frame for cleanliness.
Apply a thin coat of sealing paste in dots to gasket.

Position gasket on sealing surface of oil pan.
Insert assembly pins (2) at free end and driving end of
crankcase intermediate frame.
Using lifting gear, lower engine onto oil pan until assem-
bly pins engage in bores of oil pan.
Carefully lower engine with lifting gear until there is a gap
of 1 cm between sealing surfaces.
Insert all screws with washers on oil pan.
Note

Pretighten screws with torque wrench (1).
When flywheel housing is installed, finally tighten
screws – see 3.1.8.6, in accordance with Torque Specifi-
cations 1.3.
20046/20 E –04.96–
Page 1
3.1.7 Crankcase Ventilation
1 Screw 7 Washer
2 Washer 8 Screw
3 Cover 9 Screw
4 Gasket 10 O-ring
5 Oil separator 11 Plug-in pipe
6 Breather housing
20046/20 E –03.96–
Page 2
Crankcase ventilation pipework
1 Sealing ring 17 Spring washer

2 Union 18 Spring washer
3 Pipe 19 Pipe clamp half
4 Nut 20 Screw
5 Pipe 21 Pipe
6 Nut 22 Pipe clamp half
7 Retainer 23 Screw
8 Pipe clamp half 24 Spring washer
9 Screw 25 Pipe, left
10 Washer 26 Pipe, right
11 Rubber sleeve 27 Nut
12 Clamp 28 Sealing ring
13 Retainer 29 Adaptor
14 Screw 30 Rubber sleeve
15 Screw 31 Clamp
16 Washer 32 Grommet
20046/20 E –03.96–
Page 3
Crankcase ventilation arrangement
20046/20 E –03.96–
Page 1


- - x Drain engine coolant Op. Man.
- x x Remove end cover, free end, with elbow 3.4.1.2
- x x Remove vibration damper, free end 3.3.8.2
20038/10 E –03.96–
Page 1
3.1.7.2 Removal
Unscrew vent line (4) and adapter (3) together with seal-
ing ring (2) from cover (1).
Remove screws from breather housing (1).

Withdraw housing from connecting lines.
Remove connecting lines (2) and O-rings (1) from crank-

case (3).
20038/10 E –11.92–
Page 1
3.1.7.3 Disassembly
Remove screws (1), washers (2) and cover (3) with
gasket (4).
Remove oil separator (5) and gasket from breather
housing (6).
20038/10 E –03.96–
Page 1

Clean all components.
Wash out oil separator in diesel fuel and blow out with compressed air.
Using surface crack-testing method and red penetrant dye, check vent housing and cover for cracks and replace com-
ponents as necessary.
Check sealing surfaces and bores on vent housing and cover for damage and pitting, smooth with emery cloth or oil-
stone as necessary; replace if necessary.
Check condition of tapped bores; rethread as required and/or insert thread insert.
Check connecting lines for wear and damage and replace as required.
Replace O-rings and gasket.
20038/10 E –06.94–
Page 1
3.1.7.5 Assembly
Installing oil separator
Position gasket (4) with oil separator (5) on breather
housing (6).
Install gasket with cover (3) and screws (1) and washers
(2) and tighten.
20038/10 E –03.96–
Page 1
Installing connecting lines
Check whether bores for connecting lines (2) at free end
of crankcase are clean.
Coat O-rings (1) with petroleum jelly.
Fit O-rings on connecting lines.
Insert connecting lines into crankcase bores.
Installing breather housing

Push breather housing (1) onto plug-in pipes.
Secure breather housing to end cover with screws and
washers.
Screw adapter (3) and sealing ring (2) into cover (1) and
tighten.
Attach vent line (4) leading to turbocharger to adapter in
cover.
20038/10 E –03.96–
Task Description Section 3.1.7b
Page 1
3.1.7b Crankcase Ventilation (Version B)
1 Lower section of breather housing 17 Washer

2 Top section of breather housing 18 Hex screw
3 O-ring 19 Hex screw
4 Plug-in pipe 20 Sealing ring
5 O-ring 21 Siphon
6 Spring washer 22 Oil line
7 Socket-head screw 23 Sealing ring
8 Gasket 24 Adaptor
9 Washer 25 Pipe clamp half
10 Hex screw 26 Grommet
11 O-ring 27 Spring washer
12 Oil separator 28 Hex screw
13 Cover 29 Spacer
14 Spring washer 30 Plate
15 Hex screw 31 Strainer
16 Gasket 32 Intermediate ring
20046/20 E –03.96–
Page 2
Crankcase ventilation
1 Lower section of breather housing 19 Hex screw

2 Vent housing 20 Oil separator
5 Plug-in pipe 23 Sealing ring
6 O-ring 24 Plug
7 Spring washer 25 Sealing ring
8 Socket-head screw 26 Plug
9 Hex screw 27 Sealing ring
10 Strainer 28 Siphon
11 Gasket 29 Oil line
12 Washer 30 Sealing ring
13 Hex screw 31 Union
14 O-ring 32 Pipe clamp half
15 Intermediate ring 33 Grommet
17 Washer 35 Hex screw
18 Hex screw 36 Spacer
20046/20 E –03.96–
Page 3
Vent line
1 Pipe 17 Pipe
3 Hex screw 19 Hex screw
5 Pipe 21 Pipe, left side
6 Nut 22 Pipe, right side
10 Hex screw 26 Rubber sleeve
11 Hex screw 27 Clamp
12 Washer 28 Retainer
13 Spring washer 29 Pipe clamp half
14 Spring washer 30 Hex screw
15 Pipe clamp half 31 Washer
16 Hex screw 32 Retainer
The pipe clamp halves (item 15) are installed with grommet (not illustrated).
20046/20 E –03.96–
Page 4
Vent line 16V

3 Screw 17 Pipe
4 Pipe 18 Retainer
5 Spring washer 19 Cover
6 Screw 20 Mandrel
7 Pipe clamp half 21 Nut
8 Screw 22 Pipe
9 Retainer 23 Clamp
10 Screw 24 Washer
11 Retainer 25 Washer
13 Rubber sleeve 27 Union/plug
14 Retainer 28 Elbow
Items 19 - 28 are necessary for installing injection pump/multiple disc clutch enclosure.
20046/20 E –06.96–
Page 5
20046/20 E –03.96–
Page 1


- x x Remove centrifugal oil filter 3.16.6.2
- x x Remove vent line 3.1.7b.2
- x x Disconnect oil supply and return pipes 3.16.1.2
- x x Unscrew lower retaining screws on flywheel housing 3.1.8.6
20038/10 E –03.96–
Page 1
3.1.7b.2 Removal
Removing cover with vent line and oil separator
Remove vent line (1) from cover (2).
Remove screws and washer (3) from cover.
Detach cover and oil separator from housing (4).
Remove gasket.
Removing upper section of breather housing

Remove screw (2) with washer (3) at upper section of
vent housing (1).
Detach upper section from lower section (6) of breather
housing.
Remove gaskets (7), strainer (8), O-ring (4) and inter-
mediate ring (5).
20038/10 E –11.92–
Page 2
Removing lower section of breather housing

Unscrew oil line (10) from siphon (11) and adapter (9).
Unscrew siphon from lower section (1) of breather hous-
ing.
Remove lower section of breather housing from crank-
case (5).
Remove plug-in pipes (7) with O-rings (6) and O-rings
(4) from crankcase.
20038/10 E –11.92–
Page 1
Removing oil separator from cover
Unscrew oil separator (2) from cover (1).
20038/10 E –11.92–
Page 1

Using the surface crack-test method and red penetrant dye, check the cover, vent housing upper and lower sections
for cracks, if required, and replace parts if necessary.
Check mating surfaces and bores on cover and vent housing upper and lower sections for damage and pitting; if
necessary, burnish with an emery cloth or oilstone or replace.
Check condition of tapped bores; rethread as required and/or insert thread inserts.
Check connecting lines for wear and damage and replace as required.
Visually inspect condition of oil return line and siphon and replace as required.
20038/10 E –11.92–
Page 1
3.1.7b.5 Assembly
Installing oil separator on cover
Install oil separator (2) with screws and spring washers
on cover (1).
Tighten screws.
20038/10 E –11.92–
Page 1
Installing lower section of vent housing
Check whether bores for plug-in pipe at free end of
crankcase (5) and in lower section (1) of vent housing
housing are clean.
Fit O-rings (6) on plug-in pipe (7).
Coat O-rings with petroleum jelly.
Insert plug-in pipe into crankcase.
Insert O-ring (4) into groove in lower section (1) of vent
housing.
Coat O-ring with petroleum jelly.
Push lower section of vent housing onto plug-in pipe.
Secure to free end of crankcase with screws (2) and
washers (3).
Tighten screws to specified torque. For torque setting,
see Section 1.3.
Fasten siphon (11) and sealing ring (12) with screws to
lower section of vent housing and tighten.
Connect oil line (10) to siphon (11) and adapter (9).
Installing upper section of vent housing

Place gaskets (7) and strainer (8) on sealing surface,
and intermediate ring (5) with O-ring (4) in bore, at lower
section of vent housing (6).
Fit upper section (1) with washers (3) and screws (2) on
lower section of vent housing and tighten to specified
20038/10 E –11.95–
Page 2
Installing cover with oil separator and vent line

Position gasket on sealing surface of housing (4).
Install cover and oil separator (2) on housing.
Secure with screws (3) and washers.
Attach and secure vent line (1) to cover with gasket,
screws and spring washers.
20038/10 E –11.92–
Task Description Section 3.1.7c
Page 1
3.1.7c Crankcase Ventilation Version C
1 End plate 7 Connecting line

2 Vent case 8 Gasket
3 Washer 9 Oil separator
4 Screw 10 Cover
5 Screw 11 Washer
6 O-ring 12 Screw
20046/20 E –03.96–
Page 2
Vent line

2 Adaptor 18 Spring washer
3 Pipe 19 Pipe clamp half
4 Nut 20 Hex screw
5 Pipe 21 Pipe
7 Retainer 23 Hex screw
9 Hex screw 25 Pipe, left side
10 Washer 26 Pipe, right side
14 Hex screw 30 Rubber sleeve
15 Hex screw 31 Clamp
16 Washer
The pipe clamp halves (item 19) are mounted with washer and grommet (not illustrated).
20046/20 E –03.96–
Page 3
A = Free end
B = Right side
20046/20 E –03.96–
Task Description Section 3.1.7c.1
Page 1
3.1.7c.1 Before-Removal Operations


x x x Remove centrifugal oil filter 3.16.6.2
x x x Remove oil line and siphon 3.16.1.2
x x x Disconnect oil supply and return pipes 3.16.1.2
20046/20 E –03.96–
Page 1
3.1.7c.2 Removal
Removing vent line
Unscrew vent line (1), union (2) and sealing ring (3) from
the cover (4).
Remove vent case

Unscrew screws (1) and (3) at vent housing (6) and re-
move together with washers (2).
Pull vent housing out of connecting pipes.
Lift connecting pipes (5) and O-rings off the crankcase.
20046/20 E –03.96–
Page 1
Removing oil separator
Remove screws (1), washers (2) and cover (3) with
gasket (4).
Remove oil separator (5) and gasket from vent housing
(6).
20046/20 E –03.96–
Page 1
3.1.7c.4 Inspection and Repair

Using the surface crack-test method and red penetrant dye, check the vent housing for cracks.
If cracks are detected, replace part.
Check sealing surfaces for irregularities and smooth with oilstone if necessary.
20058/0 E –03.93–
Page 1
3.1.7c.5 Assembly
Installing oil separator
Position gasket (4) with oil separator (5) on vent housing
(6).
Mount gasket with cover (3), screws (1) and washers (2)
and tighten.
20046/20 E –03.96–
Page 1
Installing vent housing
Check bores for connecting pipes (2) at crankcase, free
end, for contamination.
Coat O-rings (4) with petroleum jelly and place in
grooves of the connecting lines (5).
Insert connecting lines into crankcase bores.
Push vent housing (6) onto connecting lines.
Mount vent housing with screws (1) and (3) and washers
(2) on end plate, free end, and tighten.
Mount vent line

Screw in union (2) and sealing ring (3) to cover (4) and
tighten.
Fasten vent lines (1) to union and tighten.
20046/20 E –03.96–
Page 1
3.1.8 Flywheel Housing
Flywheel housing 8V, 12V

2 Screw 10 Plug
3 Screw 11 Flywheel housing
4 Cover 12 Clamp ring
5 Cover 13 O-ring
6 Gasket 14 Screw
8 Screw 16 Dowel pin
20046/20 E –03.96–
Page 2
1 O-ring 10 Plug
2 Dowel pin 11 Spring washer
4 Screw 13 Flywheel housing
5 Screw 14 O-ring
8 Cover 17 Socket-head screw
9 Sealing ring
20046/20 E –03.96–
Page 3
Flywheel housing 16V

2 Dowel pin 10 Screw
3 O-ring 11 Flywheel housing
4 Gasket 12 O-ring
6 Spring washer 14 Socket-head screw
7 Screw 15 Screw
8 Cover
20046/20 E –03.96–
Page 4
Flywheel housing arrangement
1 Flywheel housing 5 Grooved ball bearing

2 Screw 6 Clamp ring
4 Screw
20046/20 E –03.96–
Page 1

A disctinction must be made as to whether:

- x x Remove vent lines 3.14.2.2
- x x Disconnect engine from gearbox and alternator -
- x x Remove intercooler 3.10.1.2
- x x Remove engine coupling N060446
- x x Remove engine flange and/or flywheel 3.3.3.2
- x x Remove clamp ring with grooved ball bearing 3.3.4.2
20047/10 E –09.95–
Page 1
3.1.8.2 Removal
Removing flywheel housing
Suspend flywheel housing (2) from lifting appliance (1)
with lifting gear.
Remove all screws from flywheel housing.
Remove housing from centring ring and raise from
crankcase.
Remove O-rings from crankcase and flywheel housing.
20038/10 E –01.95–
Page 1
3.1.8.3 Disassembly
Disassembling flywheel housing in accordance
with illustration
1 Flywheel housing
2 Cover
3 Gasket
4 Cover
5 Spring washer
6 Screw
7 Gasket
8 Cover
9 Spring washer
10 Screw
11 Sealing ring
12 Plug
13 Gasket
1 Flywheel housing
2 Gasket
3 Cover
4 Spring washer
5 Screw
6 Cover
20046/20 E –03.96–
Page 1

Using red penetrant dye method, crack-test flywheel housing surfaces; replace components as necessary.
Check mating surfaces and bore of flywheel housing for damage and wear; smooth with oilstone or emery cloth if
necessary.
Metal spray locating bore according to MTU instructions when required.
Check condition of threads in flywheel and replace threaded inserts if necessary.
Replace O-rings and gaskets.
Check end cover (1) for damage.

If necessary, knock through centre of cover (1) with
mandrel and remove from bore in flywheel housing
using an extension.
Take care not to damage bore.
Coat circumference of cover with high-strength thread-
locking liquid.
Knock cover into flywheel housing (2) so that outer edge
of cover is flush with surface of flywheel housing.
Attention
The cover must never protrude over the surface of the

housing.
Check side end covers for evenness and damage, re-
move if necessary.
20038/10 E –01.95–
Page 1
3.1.8.5 Assembly
1 Flywheel housing
2 Cover
3 Gasket
4 Cover
5 Spring washer
6 Screw
7 Gasket
8 Cover
9 Spring washer
10 Screw
11 Sealing ring
12 Plug
13 Gasket
Coat gasket with sealing paste and mount with cover to
flywheel housing; secure with screws and spring
washers.
1 Flywheel housing
2 Gasket
3 Cover
4 Spring washer
5 Screw
6 Cover
Coat gasket with sealing paste and mount with cover to
flywheel housing; secure with screws and spring
washers.
20046/20 E –03.96–
Page 1
Clean mating surfaces of crankcase and flywheel hous-
ing.
Install O-rings in grooves.
Suspend flywheel housing (2) with lifting appliance (1)

and lifting gear.
Coat sealing surfaces of crankcase evenly with surface
sealant.
Install flywheel housing on crankcase.
Take care not to shear O-ring.
Attention
When installing the flywheel housing, ensure that the

cover does not protrude over the surface of the flywheel
housing.
20038/10 E –11.95–
Page 2
Coat screws with engine oil.

Use torque wrench to tighten bolts to specified torque.
Remove lifting gear.
Tightening sequence
Release screws (3) slightly on oil pan (4).
Secure flywheel housing (1) to crankcase with bolts (2).
Screw bolts (6) into flywheel housing and oil pan.
Tighten until gap (5) is sealed and then back off again by
1/2 turn.
Tighten bolts (3) to specified torque. For torque setting,
see Section 1.3.
Check gap (5).
Gap must not exceed 0.05 mm.
see Section 1.3.
20038/10 E –11.92–
Page 1
3.1.8a Flywheel Housing
1 Flywheel housing 6 End cover

2 Dowel pin 7 End cover
5 Hex screw
20046/20 E –03.96–
Page 2
Arrangement of flywheel housing with clamp ring and seal carrier
1 Flywheel housing 4 Oil pan

2 Clamp ring 5 Grooved ball bearing
3 Seal carrier 6 Crankcase
20046/20 E –03.96–
Page 1


- x x Remove intercooler 3.10.1.2
- x x Remove engine flange and/or flywheel 3.3.3.2
20046/20 E –03.96–
Page 1
3.1.8a.2 Removal
Removing flywheel housing
Suspend flywheel housing (2) from lifting appliance (1)
with lifting gear.
Remove all screws from flywheel housing.
Remove housing from centring ring and raise from
crankcase.
Remove O-ring from crankcase.
20058/0 E –03.93–
Page 1
Disassemble flywheel housing in accordance with
illustration
1 Flywheel housing
2 Cover
3 Screw
4 Spring washer
5 Cover
20046/20 E –03.96–
Page 1

Using red penetrant dye method, crack-test flywheel housing surfaces; replace components as necessary.
Check mating surfaces and bore of flywheel housing for damage; smooth with oilstone or emery cloth if necessary.
Check ease of movement of threads in flywheel and recut threads if necessary.
Check cover for damage.

If necessary, knock through centre of cover (1) with
mandrel and remove from bore in flywheel housing (2)
using an extension.
Take care not to damage bore.
Coat circumference of cover with high-strength thread-
locking liquid.
Knock cover into flywheel housing (2) so that outer edge
of cover is flush with surface of flywheel housing.
Note
The covers must never protrude over the surface of the

housing.
20058/0 E –03.93–
Page 1
3.1.8a.5 Assembly
1 Flywheel housing
2 Cover
3 Screw
4 Spring washer
5 Cover
Install cover and cap using screws and spring washers/
washer to flywheel housing. See illustration above.
20046/20 E –03.96–
Page 1
Install flywheel housing
Suspend flywheel housing (2) with lifting appliance (1)
and lifting gear.
Coat sealing surfaces of crankcase evenly with surface
sealant.
Install flywheel housing on crankcase.
Coat securing screws with engine oil and screw into fly-
wheel but do not tighten.
Tightening sequence
Slightly loosen bolts (3) in oil pan (4).
Secure flywheel housing (1) to crankcase
with bolts (2).
Tighten bolts (6) on flywheel housing and oil pan until the
gap (5) is closed; back off again for 1/2 a revolution.
see Section 1.3.
Check gap (5). Gap must not exceed 0.05 mm.
see Section 1.3.
20046/20 E –03.96–
Page 1
3.1.8a.7 After Installation Operations

Dead-centre indicator (for GG housing)
1 Dead-centre indicator
4 Spring washer
5 Screw
6 Washer
Dead-centre indicator (for GGG housing)

4 Washer
5 Spring washer
6 Screw
Setting dead-centre indicator at flywheel

housing
Mount dead-centre indicator (2) with screws, washers
and spring washers to flywheel housing.
Mount device (1) for setting TDC pointer to flywheel and
tighten.
Align dead-centre indicator with device.
Tighten screws at dead-centre indicator.
Remove device from flywheel housing.
20046/20 E –03.96–
Task Description Section 3.1.9(.)
Page 1
3.1.9 Upper End Cover, Driving End

1 Gasket
2 Plug
3 Sealing ring
4 End cover
5 Hex screw
6 Washer
7 Hex screw
8 Plug
9 Sealing ring
10 Hex screw
11 Hex screw


- x x Disable engine start Op. Man.
- x x Drain engine coolant Op. Man.
- x x Drain raw water Op. Man.
- x x Disconnect engine coolant lines 3.14.1.2
- x x Disconnect vent and drain lines 3.14.2.2
- x x Disconnect water lines 3.14.3.2
- x x Remove cooler housing with cooler insert 3.14.4.2
- x x Remove coolant expansion tank 3.14.5.2
- x x Remove engine coolant cooler 3.14.6.2
- x x Remove coolant thermostat 3.14.7.2
20046/20 E –04.96–
Page 2
3.1.9.2 Removal
Remove in accordance with illustration on Page 1.

Check end cover for cracks using surface crack-testing method with red penetrant dye; replace cover if cracks are de-
tected.
Check sealing surfaces for irregularities and smooth with oilstone if necessary.
Check condition of thread and recut if necessary.
Check plugs for ease of movement and damage; replace as required.
Smooth sealing surfaces.
Install in accordance with illustration on Page 1.
Note
Use new gasket and sealing rings.
20046/20 E –04.96–
Page 1
3.1.10 Inspection Port Cover on Crankcase Intermediate Frame
1 Crankcase 4 Cover
2 Crankcase intermediate frame 5 Spring washer
3 O-ring 6 Screw
20038/10 E –11.92–
Page 1


- x x Remove engine coolant pump 3.13.1.2
- x x Remove engine oil heat exchanger 3.16.3a.2
- x x Remove engine mount as required 3.19.1b.2
20054/00 E –04.96–
Page 1
3.1.10.2 Removal
Remove screw from inspection port cover.
Screw extraction tool (1) into inspection port cover.

Remove inspection port cover from intermediate frame
by gently tapping extraction tool against head of hex
screw.
Remove O-ring from inspection port cover.
20038/10 E –11.92–
Page 1

Using red penetrant dye method, crack-test inspection port cover surfaces; replace components as necessary.
Check thread of extraction screw in cover and recut if necessary; insert threaded insert as required.
Check cover for damage and smooth with oilstone as required.
Use new O-ring.
20038/10 E –11.92–
Page 1
Insert O-ring (1) in groove on inspection port cover and
coat with petroleum jelly.
Ensure that O-ring is not twisted when installed.
Install inspection port cover in opening in intermediate

frame by tapping gently with a plastic mallet.
When doing this, align cover so that securing holes (1)
match up.
Mount inspection port cover with screw and spring

washer to crankcase and tighten.
20038/10 E –04.96–
Page 1
3.2 Gear Train

Contents
3.2.1 Idler gears for coolant pump and generator drives

3.2.1.2 Removal
3.2.1.3 Disassembly
3.2.1.5 Assembly
3.2.2 Idler gears for engine oil pump drive on oil pan
3.2.2.2 Removal
3.2.2.3 Disassembly
3.2.2.5 Assembly 8/12V
3.2.2.5a Assembly 16V
3.2.2.6 Installation 8/12V
3.2.2.6a Installation 16V
3.2.2a Engine oil pump drive idler gear in intermediate frame

3.2.2a.2 Removal
3.2.2a.5 Assembly
20038/10 E –11.92–
Page 2

A
S4
S 5.13
S 6.2
S 6.7
S 6.15
S 6.16
S 6.19
Auxiliary Equipment and Materials Designation MTU Order No.

Magnifier
Cleaner P3 Solvclean KW 40022
Dry compressed air
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
20038/10 E –04.96–
Page 3
Gear train (crankcase with oil pan)
Gear No. Backlash

1 Camshaft drive gear, right 3 to 1 0.12 to 0.22 mm
2 Injection pump drive gear 5 to 2 0.12 to 0.22 mm
3 Camshaft drive idler gear - -
4 Camshaft drive gear, left 3 to 4 0.12 to 0.22 mm
5 Raw water pump drive idler gear 9 to 5 0.288 to 0.448 mm
6 Raw water pump drive gear 5 to 6 0.12 to 0.22 mm
7 Engine oil pump drive gear 6V, 8V, 12V 8 to 7 0.10 to 0.44 mm
7 Engine oil pump drive gear 16V 8 to 7 0.12 to 0.38 mm
8 Engine oil pump drive idler gear 6V, 8V, 12V 9 to 8 0.09 to 0.52 mm
8 Engine oil pump drive idler gear 16V 9 to 8 0.209 to 0.561 mm
9 Crankshaft gear - -
10 Coolant pump drive idler gear 9 to 10 0.293 to 0.441 mm
11 Engine coolant pump drive gear 10 to 11 0.12 to 0.22 mm
20038/10 E –04.96–
Page 4
Gear train (crankcase with intermediate frame)
Gear No. Backlash

1 Camshaft drive gear, right 3 to 1 0.12 to 0.22 mm
2 Injection pump drive gear 6 to 2 0.12 to 0.22 mm
3 Camshaft drive idler gear - -
4 Camshaft drive gear, left 3 to 4 0.12 to 0.22 mm
5 Raw water pump drive gear 5 to 6 0.12 to 0.22 mm
6 Raw water pump drive idler gear 9 to 6 0.288 to 0.448 mm
7 Engine oil pump drive gear 8 to 7 0.12 to 0.38 mm
8 Engine oil pump drive idler gear 9 to 8 0.209 to 0.561 mm
9 Crankshaft gear - -
10 Coolant pump drive idler gear 9 to 10 0.293 to 0.441 mm
11 Engine coolant pump drive gear 10 to 11 0.12 to 0.22 mm
20038/10 E –11.92–
Page 1
3.2.1 Idler Gears for Coolant Pump and Generator Drives
Engine coolant pump idler gear
1 Idler gear for coolant pump (68 teeth) 5 O-ring

2 Nut 6 Cylindrical roller bearing
3 Spring washer 7 Stress bolt
4 Bearing Flange 8 Shaft for coolant pump idler gear
20038/10 E –01.95–
Page 2
Idler gear for raw water pump and generator
1 Idler gear for raw water 5 Stress bolt

pump/generator (78 teeth) 6 Sealing cap
2 Cylindrical roller bearing 7 O-ring
3 Cylindrical roller bearing 8 Spring washer
4 Shaft for raw water pump/ 9 Nut
generator idler gear
20038/10 E –11.92–
Page 3
Engine coolant pump idler gear Idler gear for raw water pump/generator
1 Crankcase 1 Idler gear (78 teeth)

2 Idler gear (68 teeth) 2 Dowel pin
3 Stress bolt 3 Crankcase
4 Idler gear shaft 4 Cylindrical roller bearing
5 Cylindrical roller bearing 5 Idler gear shaft
6 Dowel pin 6 Crankcase
8 O-ring 8 Nut
9 Cylindrical roller bearing 9 Stress bolt
10 Bearing flange 10 Sealing cap
11 Spring washer 11 Cylindrical roller bearing
12 Nut 12 O-ring
20038/10 E –01.95–
Page 1


- x x Removal of idler gears not scheduled -
20038/10 E –11.92–
Page 1
3.2.1.2 Removal
Removing end cover/bearing flange
Unscrew nuts for securing end cover (2) for idler gear
(1).
Press the end cover with two screws (3) evenly off the
crankcase.
Installing retaining tool for idler gear

Mount retaining tool (1) on crankcase and clamp in posi-
tion.
Using a socket, unscrew stress bolts (2) at the idler
gears (3).
Remove retaining tool.
20038/10 E –01.95–
Page 2
Removing idler gear

Screw assembly screw (3) into idler gear shaft (2).
Pull shaft to the front.
Release the idler gear from the idler gear shaft by knock-
ing it lightly with a plastic mallet and simultaneously turn-
ing it.
Take the idler gear and idler gear shaft out of the gear
case
Remove the assembly screw from the idler gear shaft.
Removing cylindrical roller bearing from crankcase

Insert extractor (1) in the cylindrical roller bearing bore
in the crankcase.
Pull cylindrical roller bearing out of the crankcase.
20038/10 E –04.96–
Page 1
3.2.1.3 Disassembly
Removing cylindrical roller bearing from end cover
Insert the clamping element (2) and pressure sleeve (3)
of the removal tool (1) in the cylindrical roller bearing in
the end cover.
Note
The clamping elements for cylindrical roller bearings at

the drive for the raw water pump and for the coolant
pump are different sizes.
Clamp the end cover (3) firmly in a tensioning device.

Pull the cylindrical roller bearing (2) with extractor (1)
from the end cover.
Remove the cylindrical roller bearing inner race from the
idler gear shaft.
20038/10 E –11.92–
Page 1

Checking shaft
Check the surface of the idler gear shaft (2) for localized
galling.
Remove small sections of localized galling by polishing.
If larger areas are affected, replace the idler gear shaft.

Using the magnetic crack-testing method with fluor-
escent magnetic powder, check idler gear shaft for
cracks; replace if necessary.
Measure idler gear shaft at the bearing seat with outside
micrometer (1).
If limit values are exceeded, replace idler gear shaft. For
limit values, see Tolerances and Wear Limits List.
Check bearing seats and tightening surfaces of the idler
gear shafts for scores and wear.
Use an emery cloth to smooth polish small scores and
wear.
Check oil bores for contamination.
Checking end cover
Check the bore in the end cover (2) for localized galling.
If larger areas are affected, replace the end cover.
Measure bore in end cover.
If limit values are exceeded, replace end cover.For limit
values, see Tolerances and Wear Limits List.
Checking gear wheels
Using the magnetic crack-testing method with fluor-
escent magnetic powder, check gear wheels for cracks;
replace if necessary.
Check tooth flanks and tightening surfaces of the idler
gears for wear.
Smooth small areas of wear with oilstone or emery cloth.
Replace cylindrical roller bearing in Maintenance Eche-
lon W6.
Check bearing bore for idler gear shafts, see 3.1.1.4
20038/10 E –01.95–
Page 1
3.2.1.5 Assembly
Press-fit the inner races onto the shaft
Press-fit both inner races of the cylindrical roller bearing
with corresponding sleeve onto the idler gear shaft.
Note
Bearings that have come straight from the factory

should be cleaned only in exceptional circumstances.
The corrosion inhibitor can stay in the bearing as long as
the packaging is undamaged.
Only wipe the bore and the jacket of the bearing.
The corrosion inhibitor is usually petroleum jelly which
can be safely mixed with the bearing lubricant.
Installing the outer races in the crankcase

Coat the cylindrical roller bearing bore in the crankcase
with engine oil.
Using a mandrel (1), knock the cylindrical roller bearing
outer race into the crankcase.
The lettering on the bearing must be on the outside.
Installing outer races in the end cover

Coat the outer race of the cylindrical roller bearing with
engine oil.
Mount the cylindrical roller bearing on the bore at the end
cover.
Place the mandrel on the cylindrical roller bearing and
press-fit in the end cover as far as it will go.
20038/10 E –11.92–
Page 1
Heat idler gears on a hotplate until they are warm to
touch.
Install idler gear on right side of engine

Install idler gear (1) with 68 teeth in the gear case on the
right side of the engine.
Place the idler gear shaft (3) in the idler gear in such a
way that the dowel pin (2) engages in the bore.
Install idler gear on left side of engine

Install idler gear with 78 teeth in the gear case on the left
side of the engine.
Place the idler gear shaft in the idler gear in such a way
that the dowel pin engages in the bore.
Using a plastic mallet (2), gently knock the idler gear

shaft (1) into the idler gear on the left and right side of
the engine while simultaneously turning the idler gear.
20038/10 E –11.92–
Page 2
Fastening the idler gear to the shaft

Mount the retaining tool (1) to the crankcase.
Coat thread of stress bolts with engine oil.
Screw in the stress bolt M12 (3) for the idler gear (4) on
the left side of the engine. Using torque wrench (2)
tighten as per Tightening Specification 1.3.
Screw in the stress bolt for the idler gear on the right en-
gine side. Tighten to specified torque with torque
wrench. For torque settings, see Section 1.3.
Installing end cover to idler gear

Fit O-rings to the end cover (2).
Fit end cover with device (1) into crankcase bore.
Make sure during fitting that the rollers slide over the
inner race without any resistance.
Remove installation tool.
20038/10 E –11.95–
Page 3
Fit spring washers.

Screw in nuts (3).
Using torque wrench (2) tighten as per Tightening Speci-
fication 1.3.
Note
Tightening specifications for end cover nuts (3) are dif-

ferent for the left and right sides of engine.
20038/10 E –11.92–
Page 1

Checking radial runout
Place measuring device (2) on crankcase support sur-
face.
Place measuring roller (4) between teeth of idler gear
(1).
Place dial gauge feeler on measuring roller.
Set dial gauge (3) with preload to zero.
Measure radial runout at four points on idler gear.
Enter value in record sheet.
Permissible radial runout: max. 0.05 mm
Checking axial runout and clearance

Place measuring device (2) on support surface of gear
case on crankcase.
Place dial gauge feeler at laterally ground collar of idler
gear (1).
Set dial gauge (3) with preload to zero.
Measure axial runout at four points on idler gear.
Permissible axial runout: max. 0.02 mm
Measure axial clearance with measuring device in-
stalled in same way.
Move idler gear in axial direction, read off axial clearance
on dial gauge.
For axial clearance, see Tolerances and Wear Limits
List.
20038/10 E –11.92–
Page 2
Checking backlash
Place measuring device (2) on support surface of gear
case on crankcase.
Place dial gauge stylus on a tooth flank.
Set dial gauge with preload to zero.
Measure backlash of idler gears and drive gears (1).
For backlash, see 3.2.
Enter measurement values in data sheet.
If limit values are exceeded, check installation of idler
gears and drive gears.
Measure backlash at crankcase with intermediate

frame
Place measuring device (2) on gear case.
Place dial gauge feeler at a tooth flank of idler gear (1)
via open bore for raw water pump.
Measure backlash.
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Page 1
3.2.2 Idler Gear for Engine Oil Pump Drive on

Oil Pan
Idler gear for engine pump drive 8V, 12V
1 Idler gear I.O. 4 Washer oil pump drive

2 Snap ring 5 Bearing pin oil pump drive
3 Angular-contact ball bearing
1 Idler gear
2 Snap ring
3 Washer
4 Clamping nut
6 Oil pan
7 Stress bolt
8 Bearing pin
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Page 2
Idler gear for engine oil pump drive 16V
1 Idler gear (47 teeth) 4 Washer

2 Bearing pin 5 Snap ring
1 Idler gear
2 Snap ring
4 Bearing pin
5 Stress bolt
6 Washer
7 Washer
8 Oil pan
9 O-ring
10 Clamping nut
20038/10 E –11.92–
Page 1


- x x Remove electric starter 3.18.1.2
- x x Remove oil pan 3.1.5.2
- x x Remove elbow from timing end cover and oil pan 3.4.1.2
- x x Remove engine oil return lines from the exhaust turbochargers 3.16.1.2
- x x Remove elbow and plug-in pipe from oil pan to 3.16.5.2
engine oil heat exchanger
20038/10 E –04.96–
Page 1
3.2.2.2 Removal
Unscrew clamping nut at angular-contact ball bearing.
Remove stress bolt from bearing pin.
Mount removal tool to oil pan.
Press bearing pin and idler gear (2) out from oil pan.
If no removal tool is available, drive the bearing pin out
of the oil pan with an aluminium mandrel (1).
20038/10 E –11.92–
Page 1
3.2.2.3 Disassembly
Using a manual press, press the bearing pin out of the
idler gear.
Note
Ensure that the angular-contact ball bearing is properly

supported!
Remove both angular-contact ball bearing inner races.
Remove cages.
Remove outer races and snap ring from the idler.
20038/10 E –11.92–
Page 1

Using the magnetic crack-testing method with fluorescent magnetic powder, check idler gear, bearing pin, clamping
nut and stress bolt for cracks, replace parts if necessary.
Using a magnifying glass, check the surface condition of the idler gear tooth flanks, replace idler gear if necessary.
Using a thread gauge, check the thread pitches of clamping nut and stress bolt.
Make sure that thread moves freely.
Using an outside micrometer, measure the outside diameter of the bearing pin.
Adjust bore gauge and measure idler gear bore.
If the limit values are exceeded, metal-spray idler gear bore in accordance with MTU instructions, replace idler gear
if required.
Replace angular-contact ball bearing during Maintenance Echelon W6.
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Page 1
3.2.2.5 Assembly 8V, 12V

Installing idler gear
Press snap ring (2) with assembly sleeve into groove on
idler gear (1).
Using a suitable sleeve, press the outer races (B) of the
angular-contact ball bearing (3) into the idler gear so that
the shoulders of the outer races face inwards.
Note
When pressing the bearing into the gear, apply force

only to the bearing outer race.
Using a suitable sleeve, press-fit inner race (A) of the
angular-contact ball bearing onto the bearing pin (5) so
that the shoulder of the inner race rests against the collar
of the bearing pin.
Place the ball cage on the inner race and insert idler gear
with installed outer races.
Mount the washer (4), insert second ball cage and install
second inner race.
Press bearing pin into both inner races of the angular-

contact ball bearing.
Note
When press-fitting the bearing pin, only the bearing

inner race can be used as a support.
20038/10 E –11.92–
Page 1
3.2.2.5a Assembly 16V

Press snap ring (2) with assembly sleeve into groove on
idler gear (1).
Using a suitable sleeve, press the outer races (B) of the
angular-contact ball bearing (3) into the idler gear so that
the shoulders of the outer races face inwards.
Note
When pressing the bearing into the gear, apply force

only to the bearing outer race.
Using a suitable sleeve, press-fit inner race (A) of the
angular-contact ball bearing onto the bearing pin (4) so
that the shoulder of the inner race rests against the collar
of the bearing pin.
Place the ball cage on the inner race and insert idler gear
with installed outer races.
Mount the washer (5), insert second ball cage and install
second inner race (A).
Press bearing pin into both inner races of the angular-

contact ball bearing.
Note
When press-fitting the bearing pin, only the bearing

inner race can be used as a support.
20038/10 E –11.92–
Page 1
3.2.2.6 Installation 8V, 12V

Coat the seat surface at bearing pin with thin-film lubric-
ant.
Using the installation tool (1), pull bearing pin and idler
gear (2) into the oil pan.
Coat mating surfaces of clamping nut and stress bolt

thread with engine oil.
Fit stress bolt and screw on clamping nut.
Place the wrench (3) on the clamping nut.
Mount the measuring fixture (1), position dial gauge sty-
lus and set dial gauge with preloading to zero.
Tighten stress bolt to elongation as per Tightening
Specification 1.3.
Remove measuring fixture.
Settle the hub axially by hitting with 1000g hammer.
Check overrun of idler gear (2).
Using a dial gauge, measure the backlash (see 3.2.2.7)
and enter in the data sheet.
Using a dial gauge, check the axial clearance of the idler
gear.
List
20038/10 E –06.94–
Page 1
3.2.2.6a Installation 16V

Coat O-ring (9) with petroleum jelly.
Insert O-ring in the groove at bearing pin (4).
Push washer (7) onto bearing pin.
Insert bearing of idler gear (1) into oil pan (8).
Coat thread of stress bolt (5) with engine oil.
Screw in stress bolt and clamping nut (10).
Secure idler gear (2).

Tighten stress bolt with torque wrench (1). For torque
settings, see Section 1.3.
Settle the hub axially by hitting with 1000g hammer.
Check idler gear for ease of movement.
20038/10 E –11.95–
Page 1

Position magnetic-base indicator holder (2) with dial
gauge.
Clamp oil pump gear in place.
Install dial gauge stylus vertically on one of the gear
teeth.
Measure backlash at idler gear (1).
Using a dial gauge, check the axial clearance of idler
gear.
List.
20038/10 E –11.92–
Page 1
3.2.2a Engine Oil Pump Drive Idler Gear in Intermediate Frame
1 Idler gear for oil pump (50 teeth) 6 Bearing flange

2 Idler gear shaft 7 O-ring
4 Stress bolt 9 Nut
5 Cylindrical roller bearing
20054/00 E –01.95–
Page 2
Idler gear for engine oil pump drive

2 Shaft
3 Gear (50 teeth)
4 Dowel pin
6 Bearing flange
7 Stress bolt
8 O-ring
9 Nut
10 Spring washer
20054/00 E –01.95–
Page 1


- x x Removal of idler gears not scheduled -
20038/10 E –11.92–
Page 1
3.2.2a.2 Removal
Unscrew nuts at bearing flange.
Remove spring washers.
Using jackscrews (1), press the bearing flange off the
crankcase intermediate frame.
Remove cylindrical roller bearing from bearing flange,
see 3.2.1.3.
Secure gear.
Unscrew stress bolts from idler gear shaft (1).
Screw assembly screw into idler gear shaft.
Pull idler gear shaft forwards.
Release the idler gear from the idler gear shaft by knock-
ing it lightly with a plastic mallet and simultaneously turn-
ing it.
Pull idler gear and idler gear shaft out of crankcase inter-
mediate frame.
Remove the assembly screws from the intermediate
shaft.
Using the extractor (1), pull outer race out of crankcase

intermediate frame.
20038/10 E –04.96–
Page 1
Removing cylindrical roller bearing from bearing
flange
Insert the clamping element (2) and pressure sleeve (3)
of the removal tool (1) in the cylindrical roller bearing in
the bearing flange.
Clamp bearing flange (3) firmly in tensioning device.

Using the extractor (2), pull the cylindrical roller bearing
(1) from the bearing flange.
Remove inner race of cylindrical roller bearing with re-
moval tool from idler gear shaft.
20038/10 E –01.95–
Page 1

Using the magnetic crack-testing method with fluorescent magnetic powder, check idler gear, shaft and stress bolts
for cracks, replace parts if necessary.
Check tooth flanks and securing surfaces of the idler gear for wear and pitting.
Smooth worn sections and areas with pitting with an oilstone or emery cloth.
Check threads in idler gear for ease of movement, recut if necessary.
Replace cylindrical roller bearing in Maintenance Echelon W6.
Replace O-ring.
Checking shaft
Check the surface of the idler gear shaft (2) for localized
galling.
If larger areas are affected, replace the idler gear shaft.
Measure idler gear shaft at the bearing seat with outside
micrometer (1).
If limit values are exceeded, replace idler gear shaft.For
Check bearing seats and tightening surfaces of the idler
gear shafts for scores and wear.
Use an emery cloth to smooth polish small scores and
wear.
Check oil bores for contamination.
Check bearing flange

Check the bore in the bearing flange (2) for localized gal-
ling.
If larger areas are affected, replace the bearing flange.
Adjust bore gauge.
Measure bore in bearing flange.
If limit values are exceeded, replace bearing flange.For
Check bearing bore for idler gear shaft on crankcase in-
termediate frame, see 3.1.2b.4
20054/00 E –10.93–
Page 1
3.2.2a.5 Assembly
Press-fitting inner races
Press-fit both inner races of the cylindrical roller bearing
with corresponding sleeve onto the idler gear shaft.
Note
Clean new bearings only in exceptional circumstances.

The corrosion inhibitor can usually stay in the bearing as
long the packaging is undamaged.
Only wipe the bore and the jacket of the bearing.
The corrosion inhibitor is usually petroleum jelly which
can be safely mixed with the bearing lubricant.
Installing cylindrical roller bearing in the bearing

flange
Coat the outer race of the cylindrical roller bearing with
engine oil.
Mount the cylindrical roller bearing on the bore at the
bearing flange.
Place the mandrel on the cylindrical roller bearing and
press-fit in the bearing flange as far as it will go.
20038/10 E –01.95–
Page 1
Installing cylindrical roller bearing in crankcase in-
termediate frame
Coat the cylindrical roller bearing bore in the crankcase
intermediate frame with engine oil.
Using a mandrel (1), knock the cylindrical roller bearing
into the crankcase intermediate frame.
The lettering on the bearing must face the outside.
Installing idler gear shaft with gear in crankcase in-

termediate frame
Install gear (1) in the crankcase intermediate frame.
Place the idler gear shaft in the gear in such a way that
the dowel pin engages in the bore.
Coat thread of stress bolts with engine oil.

Screw stress bolts into shaft (1).
Secure gear.
Tighten stress bolts with torque wrench. For torque set-
tings, see Section 1.3.
20038/10 E –11.92–
Page 2
Installing bearing flange with cylindrical roller bear-

ing
Coat-ring (1) with petroleum jelly.
Insert O-ring in the groove at bearing flange.
Press bearing flange into crankcase intermediate frame.
Make sure during fitting that the rollers slide over the
inner race without any resistance.
Tighten bearing flange (1) with nuts and spring washers

on crankcase intermediate frame.
Check axial clearance of the idler gear shaft.
List.
20038/10 E –04.96–
Page 1
3.2.2a.7 After-Installation Operations

Checking backlash and axial clearance
Place measuring fixture at bearing flange.
Place dial gauge stylus on a tooth flank. Set dial gauge
with preload to zero.
Measure backlash at idler gear.Enter value in record
sheet.
Place dial gauge stylus at the side collar of the idler gear
to measure axial clearance. Set dial gauge with preload
to zero.
Move idler gear in axial direction.
Read axial clearance off the dial gauge. Enter value in
record sheet.
If the limit values are exceeded, check installation of
idler gear.
20038/10 E –01.95–
Page 1
3.3 Running Gear

Contents
3.3.1 Crankshaft
3.3.1.2 Removal from crankcase with crankcase bearing caps
3.3.1.2a Removal from crankcase with intermediate frame
3.3.1.3 Disassembly
3.3.1.5 Assembly
3.3.1.6 Installation in crankcase with crankcase bearing caps
3.3.1.6b Installation in crankcase with intermediate frame
3.3.2 Pistons and conrods

3.3.2.3 Disassembly
3.3.2.5 Assembly
3.3.2.6a Installation in crankcase with intermediate frame
3.3.3 Engine flange with drive member, driving end

3.3.3.2 Removal
3.3.3.3 Disassembly
3.3.3.5 Assembly
3.3.3a Flywheel with track ring, driving end

3.3.3a.2 Removal
3.3.3a.5 Assembly
3.3.4 Clamp ring with grooved ball bearing, driving end

3.3.4.6a Installation in crankcase with intermediate frame
20046/20 E –04.96–
Page 2
3.3.5 Seal carrier, driving end

3.3.5.2 Removal
3.3.5.3 Disassembly
3.3.5.5 Assembly
3.3.6 Bearing retaining plate

3.3.6.2 Removal
3.3.7 Flange, free end

3.3.7.2 Removal
3.3.7a Support ring, free end

3.3.7a.2 Removal
3.3.8 Vibration damper, free end, with flange

3.3.8.2 Removal
3.3.8.3 Disassembly
3.3.8.5 Assembly
3.3.8a Vibration damper, free end, with driver

3.3.8a.2 Removal
3.3.8a.5 Assembly
3.3.9 Auxiliary drive, free end

3.3.9.2 Removal
3.3.9.3 Disassembly
3.3.9.5 Assembly
3.3.9a Auxiliary drive, free end

3.3.9a.2 Removal
3.3.9a.5 Assembly
20046/20 E –04.96–
Page 3

A
S4
S 5.1
S 5.2
S 5.13
S 6.1
S 6.2
S 6.4
S 6.5
S 6.6
S 6.13
S 6.14
S 6.15
S 6.16
S 6.17
S 6.18
S 6.19

Chamois leather
Bristle brush
Polishing cloth
Inspection lamp
Magnifier
Activator Loctite 7649 50548

Ethanol, denaturated 40250
Liquid nitrogen
Varnish Molykote 3402 50250
Synthetic shot-blasting pellets MTH 608-16B 520 20098
Cleaner P3-Solvclean 40022
Cleaning agent (carbon-deposit remover) Meister Proper 40377
Engine oil SAE 10
Thread-locking compound Loctite 270 40083
Dry compressed air
Engineer’s blue blue 40641
Surface crack-testing equipment with flourescent penetrant dye
Caution
20046/20 E –04.96–
Page 4
Running gear
1 Piston 4 Crankshaft
2 Connecting rod 5 Vibration damper
3 Engine flange with ring gear
20046/20 E –04.96–
Page 1
3.3.1 Crankshaft
Crankshaft (8V)
1 Crankshaft 6 Dowel pin

2 Sealing tube 7 Crankshaft gear
3 Cover 8 Counter weight
4 Plug 9 Adapter sleeve
5 Sealing ring 10 Screw for counterweight
20046/20 E –04.96–
Page 2
Crankshaft (12V)
1 Crankshaft 6 Counterweight
2 Sealing tube 7 Adapter sleeve
3 Cover 8 Screw for counterweight
5 Plug 10 Crankshaft gear
20046/20 E –04.96–
Page 3
Crankshaft (16V)
1 Crankshaft 7 Crankshaft gear

2 Sealing tube 8 Counterweight
3 Cover 9 Counterweight
4 Plug 10 Adapter sleeve
5 Sealing ring 11 Screw for counterweight
6 Dowel pin
20046/20 E –04.96–
Page 4
Crankshaft with crankshaft bearing cap
1 Intermediate element 9 Adapter sleeve

2 Crankcase 10 Sealing tube
3 Cover 11 Crankshaft bearing
4 Bolt 12 Counter weight
5 Plug 13 Bearing cap
6 Clamp ring 14 Gear
7 Grooved ball bearing 15 Crankshaft
8 Stress bolt
20046/20 E –04.96–
Page 1


- x x Removal of crankshaft not scheduled -
20038/10 E –11.92–
Page 1
3.3.1.2 Removal from Crankcase with Crankcase Bearing Caps

Removing clamp ring, see 3.3.4.2.
Removing crankshaft bearing cap, see 3.1.2.2.
Removing oil seal carrier, see 3.3.5.2.
Removing flywheel housing, see 3.1.8.2
Slide protective sleeves (1) over studs at driving and

free ends.
Attach lifting jig for removing crankshaft.
Lift crankshaft horizontally out of crankcase with ropes
(2).
Note
Ensure that equal tension is applied to ropes!

Remove bearing shells adhering to crankshaft.
Place crankshaft in assembly dolly.
Remove protective sleeves from studs.
Remove bearing shells from crankcase bore.
Note
Fit bearing shells into suitable transport trestles and pro-

tect from damage.
20038/10 E –04.96–
Page 1
3.3.1.2a Removal from Crankcase with Intermediate Frame

For clamp ring removal, see 3.3.4.2a
For flywheel housing removal, see 3.1.8.2
For crankcase intermediate frame removal, see 3.1.2b.2
Install inner stress bolts (1) on free end and driving end.
free ends.
Attach lifting jig (3) for removing crankshaft (4).
Lift crankshaft horizontally out of crankcase with ropes.
Note
Ensure that equal tension is applied to ropes!

Remove bearing shells attached to crankcase and place
crankshaft in assembly dolly.
Remove bearing shells from crankcase bore.
Note
Fit bearing shells into suitable transport trestles and pro-

tect from damage.
Remove protective sleeves from studs.
Remove stress bolts.
20054/00 E –10.93–
Page 1
3.3.1.3 Disassembly
Removing crankshaft gear
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools for hydraulic removal.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the device annually.
1 Vent plug
2 Pressure bush
3 Support
4 Nut
5 Socket-head screw
6 Stop pin
7 Intermediate element
8 Adjusting screw
9 Puller sleeve
10 O-ring
11 Tension spring
12 Plug
Mount hydraulic puller (3) on crankshaft gear and turn

it so that locking pin (2) engages between two teeth.
Connect and secure hydraulic hand pump (4) and H.P.
line to puller.
Observe guidelines for using H.P. lines, see 1.5.
Fill hydraulic hand pump with SAE10 engine oil.
Bleed pump and line until bubble-free oil emerges.
Close valve.
Operate hand pump until a greater resistance is
achieved (approx. 200 to 300 bar) and gear is released
from crankshaft.
Remove load from hand pump.
Remove H.P. line.
Pull gear off crankshaft.
Remove puller.
20038/10 E –11.92–
Page 2
Removing counterweights
To remove counterweights, install crankshaft in a stable,
heavy-duty assembly stand.
Ensure that counterweights are numbered consecu-
tively; punch in new numbers if necessary.
Install retaining jig (3) and power amplifier (2) to release
stress bolts.
Unscrew stress bolts with ratchet (1) from counter-
weight.
Remove counterweight and set in suitable transport
trestle.
Drilling out crankpin covers

To clean oilways, remove covers, sealing tubes and
plugs from crankshaft (1).
Remove covers (2) with two-piece bore guide (4) and ex-
pander only.
Insert two-piece bore guide with O-ring (3) in cover.
Secure bore guide with M8 nut.
Adjust and secure depth limiter on twist drill at 35 mm.
Drill into cover with 4 mm drill bit.
Remove bore guide.
Drive in end cover at bore with drift dia. approx. 12 mm.
Remove cover from bore with pliers.
Note
Take care not to damage oilways and fits!

Clean crankshaft oilways with bristle brush and diesel
fuel.
Remove all deposits completely from oilways.
20038/10 E –06.94–
Page 3
Removing sealing tubes from crankpin
Note
Carry out removal of sealing tubes with hydraulic puller

only.
1 Extension pipes
2 Thrust pads
3 Retaining ring
4 Clamp ring, separated
5 Guide bush
6 Hex nut
7 Hex bolt
8 Puller
9 Lukas press 10 t
Install two-piece clamp ring (6) on crankshaft main bear-

ing journal I so that it contacts thrust bearing collar (2).
Push retaining ring (1) onto clamp ring for securing pur-
poses.
Push guide bush (3) onto spacer pins (5).
Locate guide bush on crankshaft taper.
Fit and secure hex nuts (4) on spacer pins.
Connect and secure puller (2) to guide bush (5) with hex
screws (4).
Insert extension pipe (1) with appropriate thrust pad (6)
into Lukas press and connection pipe.
Mount H.P. line on quick-action stop connector of Lukas
press (3).
Fill hydraulic hand pump with SAE 10 engine oil.
Operate pump plunger until relevant sealing tube is
forced off.
Remove sealing tube from crankshaft.
Remove puller.
20038/10 E –11.92–
Page 1

Smooth crankshaft at main and conrod bearings with fine emery cloth.
Clean crankshaft surface and oilways with cold cleaner.
Using the magnetic crack-testing method and fluorescent magnetic powder, check the crankshaft for longitudinal and
transverse cracks.
Note
Take care not to damage oil bores, bores in bearing journals, counterweight mating faces and threaded bores.
Clamp crankshaft longitudinally between jaws of test rig.
The magnetic field strength required for the test is 20 to 60 A/cm.
Notes on hot-running cracks
Hot-running cracks are characterised by running almost
only parallel to the axis.
Transverse cracks emanating from these parallel crack
lines may also occur.
Severe hot-running cracks are usually as deep as the
case-hardening.
The crankshaft must be replaced in such cases.
Crankshafts with minor hot-running cracks can be re-
paired provided that the cracks can be removed by re-
grinding to the next stage or by localised smoothing.
Consult MTU in this case.
The affected bearing journals must be carefully ground
close to a permissible repair stage, depending on crack
depth.
Minor crack damage can be removed by local grinding.
Pregrinding must be performed prior to rehardening,
otherwise hot-running cracks may be made more se-
vere, both in length and depth, by the rehardening pro-
cess.
Finish-grind the bearing journals to the repair size only
after hardening is completed.
Notes on grinding cracks
Cracks caused by incorrect grinding are characterized
by branching.
The accompanying illustration shows a bearing journal
with such cracks.
Grinding cracks arise from inadequate cooling or ex-
cessive feed during the grinding process.
20054/00 E –10.93–
Page 2
Demagnetizing crankshaft
Demagnetize crankshaft after checking for cracks; residual field strength must not exceed 2 to 4 A/cm during this pro-
cedure.
Note
A component is considered sufficiently demagnetized when a paper clip suspended from a thread is no longer attracted
by that component.
Measuring crankpins
Using an outside micrometer (3), measure main bearing
journal (1) and crankpin (2) of crankshaft at four separ-
ate points each for roundness and evenness.
If the limit value are exceeded, see Tolerance and Wear
Limits List, regrind crankshaft to the next repair stage.
20054/00 E –10.93–
Page 3
Checking shaft stub and taper

Check crankshaft stub (2) for drive gear for signs of
wear.
Measure stub with outside micrometer (1).
Record readings.
Check crankshaft taper for damage.
If necessary, recondition shaft stub for drive gear and
crankshaft taper in accordance with MTU Specifica-
tions.
Measuring crankshaft radial runout

Depending on the number of cylinders, place the sup-
ports (3) at the following main bearing journals:
– 6V at I and IV
– 8V at II and IV
– 12V at II and VI
– 16V at II and VIII
Check main bearing journals for radial runout and fly-
wheel mating surface for face runout.
Secure dial gauge (1) on adjustable dial gauge support
(2) and carry out check.
When measuring flywheel mating surface, push crank-
shaft against axial stop.
Main bearing journals with irregular wear at the circum-
ference must only be checked at the transfer of the cylin-
drical part of the journal to the radius; for this purpose,
press crankshaft against the axial stop.
If radial runout exceeds specified limit, crankshaft must
be straightened before grinding.
If a journal has to be rehardened, this has to be done be-
fore alignment.
Always consult MTU before hardening the journal and
aligning the crankshaft.
For limit values for concentricity, see Tolerance and
Wear Limits List.
20054/00 E –06.94–
Page 4
Checking crankshaft thrust collar and axial align-

ment bearing
Check thrust collar and thrust bearing inner race for
wear.
Pitting is permitted if extended over a circumference
less than 180° and is not deeper than 0.3 mm.
Note
As a rule, replace axial alignment bearings exhibiting

material pick-up.
Crankshaft Thrust bearing Reconditioning crankshaft thrust collar for axial

alignment bearing
C ±0.02 (stamped on No. of
crankshaft front, identification Recondition thrust collar to stage ”dimension C”, see
Stage driving end) grooves table, in the event of material pickup, fretting corrosion,
0 8.80 none pitting at thrust collar (1) of crankshaft which cannot be
removed by smoothing.
I 8.50 1x
II 8.20 2x
III 7.90 3x
If the thrust collar is reconditioned, a crankcase thrust

bearing with stage at outer ring (B) must be installed in
order to compensate any misalignment.
Bearings with stages are marked with identification
grooves (2) at the outer ring, see table.
Note
Stamp repair size ”C” into end face (4) of crankshaft at

driving end and note in crankshaft data sheet.
20054/00 E –10.93–
Page 5
Hardness of journal check - hardness pattern for main bearing journal and crankpin
X = Hardness pattern for inner main bearing journal – 6V, 8V, 12V, 16V – crankshaft
Y = Hardness pattern for inner main bearing journal – 16V – crankshaft (ESU quality)
Z = Hardness pattern for last main bearing journal (IV, V, VII, IX)
Check hardness of all bearing journals using rebound hardness tester.
Rehardening is required if a journal has lost its hardness due to bearing seizure.
Check journal at at least four points on the circumference with the rebound hardness tester.
When measuring, hold rebound hardness tester perfectly horizontal.
Using the hardness comparison table, convert the read-off value to Rockwell hardness.
For information on hardness, see Tolerances and Wear Limits List.
When testing hardness of main bearing journal ensure that side areas are not hardened.
Crankpin side walls and fillets are hardened.
Rub down all journals with polishing cloth.
Roughness height of all bearing surfaces = Rz 1.
All fillets and radii smooth on crankpin and main bearing journal, Rz max. 4
Oil bores rounded burrfree at inlet points.
20054/00 E –04.96–
Page 6
Checking mating face for counterweight on crank-

shaft
Check mating faces on crankshaft (1) for wear, friction
rust or cold welding.
The illustrations opposite are provided as examples to
help determine when reconditioning is necessary.
Example 1
Rest without defects, no reconditioning is required.
L8810371
Example 2
Rest with locally limited friction corrosion and localized
galling which do not exceed 5% of the mating face and
do not extend to edge of screw bores.
No reconditioning is necessary if the flatness of
mating face is still within the drawing specification
(> 0.005 mm).
L8810373
Example 2a
Assess as in example 2.
L889442
20054/00 E –01.95–
Page 7
Example 3
Mating face with intensive friction corrosion and local-
ized galling which take up more than 5% of the mating
face or that stretch to the edge of the screw bores.
Mechanical reconditioning is necessary. Check crank-
shaft beforehand for cracks as described on Page 1.
L8812113
Example 3a
Assess as in example 3.
L8812289
Reconditioning: Mechanically spot-grind mating faces

to dimension ”A” = 71.1 mm (min.).
Surface finishing quality, roughness height, flatness and
angle position must be maintained as in the illustration.
Crack testing of mating faces after reconditioning, See
Page 1.
Note
Scraping of working points or smoothing with oilstone is

not permitted.
20054/00 E –01.95–
Page 8
Inspecting counterweights and bolts

Check contact surfaces and counterweights for wear,
friction rust or cold welding.
Reconditioning: Spot-grind mating faces according to il-
lustration.
Surface finishing quality, roughness height, flatness and
angle position must be maintained as in the illustration.
Note
Individual scoring on mating face to R max. 16 depth is

permitted.
Scraping of working points or smoothing with oilstone is
not permitted.
Check counterweight bolts and counterweights themselves for cracks using magnetic crack-testing method with fluor-
escent magnetic powder.
Ensure threads in crankshaft and screws for counterweights are in perfect condition and check ease of movement; max.
permissible screw length, see Section 1.3.
Check contact surfaces for screw head contact face on counterweights with engineer’s blue for even seating, machine
grind if necessary, refer to illustration.
Inspecting crankshaft gear
Check gear for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace gear if necess-
ary.
Inspect gear for wear; rub down with oilstone or polishing cloth if necessary, otherwise replace gear.
Adjust bore gauge, measure crankshaft gear I.D. and record readings.
Inspecting main bearing shells
Check bearing shells of crankshaft for surface characteristics and wear; replace worn or broken bearing shells. Also
refer to checking and assessment of conrod bearing (grooved bearing) Section 3.3.2.4 Page 14, replace crankshaft
bearing shells at W6.
Inspecting crankshaft axial alignment bearing
Check condition of crankshaft axial alignment bearing; replace if not in perfect condition (see Page 4).
Regrinding crankshaft
When regrinding, always try to limit operations to next repair size.Adhere precisely to specified dimensions and toler-
ances. This also includes those applicable to fillets and surface condition.
Pay special attention to markings of actual value diameter for main bearing journal and crankpin of crankshafts.
The following tasks must be carried out after grinding:
– Check dimension and roughness of all journals
– Check transfer radii on journals
– Check whether oil duct outlets are perfectly rounded and smooth. Take special care when carrying out this task in order
to avoid damaging the bearing shells and to ensure perfect lubrication.
– Concentricity and flatness check
– Hardness check
– Crack check
20054/00 E –01.95–
Page 9
Marking diameter stage of main bearing journal and

crankpin
Stage 0 is not marked on crankshaft.
If individual main bearing points and crankpin bearing
points on the crankshaft are reconditioned to the next re-
pair stage, stamp the actual diameter (basic size) hori-
zontally onto the crankshaft web beside the recondi-
tioned bearing point with numerals 5 mm high and 0.5
deep.
See adjacent illustration.
Exception: Last main bearing journal at free end

In this case, stamp marking on last web at free end.
1 Marking for repair size, crankpin
2 Marking for repair size, main bearing journal
3 Crankshaft
4 Marking area on crank web
Note
Markings as viewed from driving end.
T003 620b0
20054/00 E –01.95–
Page 10
Dynamic balancing
For the purpose of balancing, the crankshaft must be assembled with crankshaft gear, sealing components and
counterweights. Seal bore diameter 14 on free end with pin (50 g) for the purpose of balancing.
Assembly, see 3.3.1.5.
Seal all oilways against dirt before balancing crankshaft!

To balance the crankshaft, position support A and B of the balancing machine at the following main bearing journals:
– 6V at I and IV
– 8V at I and V
– 12V at II and VI
– 16V on II and VIII
Dynamic balancing requires installation of a compensation weight on each crankpin.
– For 6V, compensation weight = GA 20625 g with piston weight 8900 g
– No compensation weight is required for 12V
– For 16V, compensation weight = GA 20625 g, uniformly independent of piston weight.
Crankshaft, counterweights and sealing components must be installed.
Balance crankshaft at 200 rpm.
When balancing the crankshaft, remove material by drilling radially at the counterweights only (max. 20 mm deep); ensure
the minimum width (between the individual bores, the bores and the end surfaces and/or threaded bores) is 5 mm.
Permissible residual imbalance at supports:
– When balancing initially – 0.02 Nm (200 cmg) for each support
– When checking balancing – 0.03 Nm (300 cmg) for each support
On completion of balancing, recheck numbering of counterweights and renumber if necessary.
20054/00 E –06.96–
Page 1
3.3.1.5 Assembly
Thoroughly clean all crankshaft oilways with cold cleaner or diesel fuel and suitable bristle brush.
Blow out oilways with compressed air.
Installing drive gear

Degrease surfaces of crankshaft stub and gear bore.
Dowel pin (2) for gear must be installed with 6.5 mm
-0.3 mm projection in crankshaft (1).
Check interference of gear(3)/crankshaft combination;
this must be min. 0.135 mm and max. 0.155 mm.
Heat gear in oil bath or inductive unit to approx. 200°C.
Wearing protective gloves, install gear on crankshaft
stub with collar facing crankshaft.
Dowel pin in crankshaft must fit in slot in gear collar.
Adjust spacing between crankshaft and gear with a
feeler gauge.
Space = 0.2 mm + 0.1 mm
Installation instructions for all crankpin covers

Prior to installing the crankcase cover, check the com-
plete area of bore, swaging groove and mating face for
surface damage.
Ensure that oilways are particularly clean.
Carefully smooth damaged areas on surface (e.g.
pounding damage or material lift).
Notches are not permitted; replace crankshaft if necess-
ary.
Using a drift (1), drive new covers for crankpins (2) into
bores as far as they will go, as shown in View Z (see next
illustration).
20038/10 E –06.96–
Page 2
View Z (applicable to all crankpins).

Make sure that spray hole in crankshaft cover (1) is in
correct position.
A = Centre crankpin - TDC
B = Spray hole position
Prior to rolling in, coat inside of end cover with ”thin-film

lubricant”.
Install roller expander (3) in cover as far as it will go.
Use a tap wrench, ratchet or air-operated power wrench
for installation.
Expand cover until ”go” side of plug gauge can be in-
serted.
In so doing, roller expander must be removed from cover
several times.
If the ”go” end of the plug gauge passes smoothly into
the end cover, lock the limit on the roller expander with
the locknut.
Once limit on expander has been set, roll in remaining
covers in a single operation.
1 Crankpin of crankshaft
2 Cover
3 Roller expander
4 Contact surface
5 Bolt
A Adjustment
20038/10 E –11.92–
Page 3
Check each cover after installation with plug gauge:

A = Reference dimension ∅ 42.6 mm +0.2 mm
If ”no-go” side of plug gauge marked in red can be in-
serted into cover, cover must be removed with bore
guide and replaced.
Impressions in area ”B” (caused by centre punches of
hydraulic puller) are permitted.
C = Head of roller expander
Installing sealing tubes

Ensure that oilways and oil duct are particularly clean.
Install sealing tubes (1) into main bearing journals of
crankshaft (2).
20038/10 E –11.92–
Page 4
Install and secure setting device (3) in sealing tube bore.

Use the secure setting device to set the distance 17 mm
±2 mm, see previous illustration.
Insert new sealing tube (1) into bore on crankshaft (2)
main bearing journal until it contacts the stop on the se-
cure setting device.
Rolling in sealing tubes

Install roller expander (2) in sealing tube in crankshaft
(3).
Roll in with ratchet (1).
Remove setting device (4) and expander from sealing
tube.
Roll in sealing tube from opposite end with expander.
20038/10 E –11.92–
Page 5
A = Roll-in depth 11 mm ±2 mm
X = Roller radius R1
Installing sealing plug

Ensure that oilway and oil duct are particularly clean.
Check condition of tapped bore.
Screw plug (2) with sealing ring (3) into free end of crank-
shaft.
Using torque wrench, tighten plug to specified torque.
Pressure-testing crankshaft
Mount locking device (1) on crankshaft stub at driving
end.
Seal oilways in crankshaft stub.
Insert pressure-test segments (2) into covers of crank-
shaft stub.
Mount blanking brackets (3) and (4) on main bearing
journal and crankpin in such a way that the oil bores are
covered.
Tighten clamping levers to secure clamps.
20038/10 E –11.92–
Page 6
Inserting pressure-test segment

Insert pressure-test segment into end cover in crankpin
in such a way that the position of the eyebolt is aligned
with the position of the bore, dia. 1 mm, in the end cover.
Secure pressure-test segment by tightening threaded
pin in centre of segment to 4 Nm.
Fit O-ring with threaded pin (outer centre), on bore, dia.
1 mm, on the end cover and rotate threaded pin further
to seal bore.
Connect hydraulic pressure-testing device.
Pressure-test crankshaft with engine oil (test pressure
30 bar).
Check all covers and sealing tubes for leaks.
Remove pressure-testing device and clamps.
Before removing pressure-test segments, release off-
centre threaded pin by approx. one turn and return to
1 Eyebolt
original position.
2 O-ring
3 Threaded pin, outer centre Remove pressure-test segments.
4 Threaded pin, centre
5 Pressure pin Seal all oilways with plastic plugs.
6 Pressure-test segment
7 Crankpin
8 Cover
9 O-ring
Installing counterweights
Check adapter sleeves (4) for damage.
Insert adapter sleeves into counterweight (2) so that di-
mension A = 7 mm -0.5 mm is achieved as indicated
with illustration opposite.
Note
After reconditioning crankshaft mating faces, insert

adapter sleeve into counterweight to dimension A = 6.5
mm -0.3 mm before assembling counterweights.
Degrease mating surfaces of crankshaft (1) and
counterweight.
Place counterweight in position on crankshaft.
Before each reassembly, check bolt length. For max.
permissible bolt length, see Section 1.3.
Coat threads and bolt head mating surfaces (3) with
Note
Use only bolts with identification grooves.
20038/10 E –04.96–
Page 7
Using torque wrench (1), pretighten bolts for counter-

weights to specified torque. For torque setting, see Sec-
tion 1.3.
Check distance and runout of counterweights, see next
illustration.
If the reference dimension is outside the tolerances, re-
check installation of counterweights.
After installation of counterweights (2), recheck

numbers (1) against those on crank webs.
If new counterweights have been installed, stamp in
position numbers with punch numerals 5 mm high and
0.5 mm deep. Counterweights are numbered consecu-
tively from driving end.
Stamp part no. of complete crankshaft on the counter-
weight.
Mount fixture (1) with power amplifier (3) on counter-

weight (2) and secure.
Tighten bolts to specified torque. For torque setting, see
Section 1.3.
Completely check test torque of stress bolt in tightening
direction to Tightening Specification 1.3.
Bolts must not turn beyond specified torque.
Otherwise, release bolts and retighten to specified
Dynamically balance crankshaft, see 3.5.1.4
20038/10 E –06.94–
Page 1
3.3.1.6 Installation in Crankcase with Crankcase Bearing Caps
Installation possibilities – crankshaft bearings

Illustrated: view of upper shell Old version New version
Illustrated: crankcase Illustrated: crankshaft
View of bearing bore Longitudinal section: Required
crankpins reconditioning
1. Old crankcase version In order to use new

Old crankshaft version YES NO NO crankshaft bearings, the
crankcase must receive
new sickle grooves
oil
oil oil Crankshaft must receive
angular bores at all
plane-surfaces
Note:
No sickle groove X = cross-section of oil
Locating groove Insufficient crankshaft and No crankshaft and conrod supply to crankshaft
Oil bore not on all plane sufaces conrod bearing oil supply bearing oil supply bearings
for lower shell
In order to use new
2. Old crankcase version
New crankcase version
YES NO NO crankshaft bearings, the
crankcase must receive
new sickle grooves
oil oil
oil
Note:
No sickle groove X = cross-section of oil
Insufficient crankshaft and No crankshaft and conrod supply to crankshaft
Locating groove for lower shell conrod bearing oil supply bearing oil supply bearings
Oil bore on all plane surfaces
3. New crankcase version

old crankshaft version NO NO NÃO
NO
Crankshaft must receive
angular bores on all plane
Oil supply to conrod Oil supply to conrod surfaces
bearing not constant bearing not constant
Sickle groove
Locating lug on lower
No locating groove Oil bore not on all plane surfaces shell
Note:
4. New crankcase version
New crankshaft version NO YES YES X = Cross-section of oil
supply to crankshaft
bearings
oil
Óleo oil
Sickle groove
No locating groove Oil bore on all plane surfaces Locating lug on lower shell
Turn crankcase upside down in assembly dolly.

Measuring main bearing bores, see 3.1.1.4.
Clean bores and bearing shells with chamois leather.
20038/10 E –11.92–
Page 2
Installing crankshaft bearings

Note
Check repair stage of crankshaft main bearing bore and

repair stage of bearing shells, see crankcase data sheet
and crankshaft data sheet.
Prior to installing crankshaft bearing, measure crank-
shaft bearing spreading dimension. For specified limits,
see Tolerances and Wear Limits List.
Bearing shells with no spreading must not be installed.
If main bearing bore in crankcase has been machined,
it is necessary to increase depth of locating pin bore (2)
and crankcase oil groove.
Install upper bearing shell (1) with oil groove and oilways
in main bearing bore, observing correct location of
identification number.
Install lower bearing shell (2), without oil groove, with
one butting face against corresponding face of upper
bearing shell (1).
Exert thumb pressure on shell and seat other end in
crankcase.
Make sure butting faces of shells are parallel.
The identification numbers must point towards driving
end when bearing shells are installed.
Mark new bearing shells with 2 mm punch numerals
pointing towards driving end.
Note
Top and bottom bearing shells have different part

numbers (version).
Installing crankshaft bearing cap, see 3.1.2.6.
Measuring crankshaft bearing bore
Measure crankshaft bearing bore (2).
20038/10 E –09.95–
Page 3
Measure inside diameter of installed bearing shells in

direction A and B, see Tolerances and Wear Limits List.
In direction B1 and B2 the inner diameter must be the
equal to or greater than that in direction A.
The out-of-round of the bearing is the difference be-
tween the inner dia. in direction B1 and A, or B2 and A
and must not exceed 0.075 mm.
To determine bearing clearance, use dimension in direc-
tion ”A”, see Tolerances and Wear Limits List.
If a crankshaft main bearing is excessively out-of-round,
replace bearing shells.
In most cases, it is sufficient to interchange bearing
shells within engine.
Removing crankshaft bearing cap, see 3.1.2.2.
Installing crankshaft
Remove plastic plugs from crankshaft oilways.
Use inspection lamp to inspect oil ducts and clean bear-
ings thoroughly.
Wipe bearing shells and crankshaft journals with clean
chamois leather.
Spray bearing shells with clean engine oil, making sure
that no oil film reaches bearing shell butting faces.
Install protective sleeves (1) on studs of first and last
bearings.
Attach lifting appliance to crankshaft.

Lower crankshaft horizontally into bearing shells.
Ensure that idler gears mesh correctly.
Remove protective sleeves.
20038/10 E –11.92–
Page 4
Installing lower bearing shells

bearing shell.
crankcase.
Make sure butting faces of shells are parallel.
Identification marks must point towards driving end.
Bearing cap and shell butting faces must be free of
grease.
Note
Ensure there is no gap between the bearing shells be-

fore installing the bearing cap.
Installing crankshaft bearing cap

Coat threads and mating surfaces of collar nuts with
Mount retaining device (2) on crankcase.
Position bearing cap (1) on crankcase according to
punched-in identification number.
Remove retaining device from crankcase.
Use a plastic mallet to tap bearing cap gently into
adapter sleeves.
In so doing, take care not to damage adapter sleeves.
Bearing caps must be numbered consecutively from

driving end and numbers must match those punched on
underside of crankcase.
Screw bearing cap collar nuts onto bearing cap studs.
Pretighten collar nuts with an open-end wrench.
Installing crankshaft axial alignment jig, see 3.3.4.6. Check crankshaft end float after installing flywheel/en-
Installing grooved ball bearing, see 3.3.4.6. gine coupling.
Tighten crankshaft bearing cover nuts, see 3.1.2.6 Installing oil pan, see 3.1.6.6.
Tighten screws on alignment bearing cap, see 3.1.2.6 Installing flywheel, see 3.3.3.6.
Installing engine coupling, see 3.88.
Idler gear backlash, see 3.2.
Installing clamp ring, see 3.3.4.6.
20038/10 E –06.94–
Page 1
3.3.1.6b Installation in Crankcase with Intermediate Frame

Installing crankshaft bearing
Measuring crankshaft bearing main bore,
see 3.1.2b.7
Note
Check repair stage of crankshaft main bearing bore and

repair stage of bearing shells, see crankcase data sheet
and crankshaft data sheet.
Prior to installing crankshaft bearing, measure crank-
shaft bearing spreading dimension.For specified limits,
see Tolerances and Wear Limits List.
If main bearing bore in crankcase has been machined,
it is necessary to increase depth of locating pin bore and
crankcase oil groove.
Install upper bearing shell (1) with oil groove and oilways
in main bearing bore, observing correct location of
identification number.
Install lower bearing shell, without oil groove, with one
butting face against corresponding face of upper bear-
ing shell (1).
crankcase.
Make sure that butting faces of shells are parallel.
Identification numbers (1) must point towards driving

end when bearing shells are installed.
Mark new bearing shells with 2 mm punch numerals
pointing towards driving end.
Note

numbers (version).
For crankcase intermediate frame installation, see
3.1.2b.6
20054/00 E –01.95–
Page 2
Measuring crankshaft bearing bore

Measure inner diameter of installed bearing shells.
Measure all bearings at points A, B1 and B2.

In direction B1 and B2, the inner diameter must be the
equal to or greater than that direction A; if diameter A is
larger than diameter B1 or diameter B2, replace bearing
shells.
The out-of-round of the bearing is the difference be-
tween the inner dia. in direction B1 and A, or B2 and A
and must not exceed 0.075 mm.
Use measured distance in plane A to determine bearing
play.
See Tolerances and Wear Limits List.
Replace crankshaft main bearings which are excess-
ively out-of-round.
In most case, it is sufficient to interchange bearing shells
within engine.
For crankcase intermediate frame removal, see
3.1.2b.2
20054/00 E –10.93–
Page 3
Installing crankshaft
Insert inner stress bolts (1) (assembly screws without
rubber) on driving end and free end.
free ends.
Mount top bearing shells with oil groove in crankcase,
See Page 1.
Remove plastic plugs from crankshaft oilways.
Use inspection lamp to inspect oil ducts and clean bear-
ings thoroughly.
Wipe bearing shells and crankshaft journals with clean
chamois leather.
Spray bearing shells with clean engine oil, making sure
that no oil film reaches bearing shell butting faces.
Attach lifting appliance (3) to crankshaft (4).
Lower crankshaft horizontally into bearing shells.
Ensure that gears mesh correctly.
Remove protective sleeves (2) and remove stress bolts
(1) on free end and driving end.
Installing lower bearing shells

bearing shell.
crankcase.
Make sure that butting faces of shells are parallel.
Bearing cap and shell butting faces must be free of
grease.
Note
Ensure there is no gap between the bearing shells be-

fore installing the intermediate frame.
Marking on bearing shells must point in direction of driv-
ing end, See Page 1.
For crankcase intermediate frame installation, see
3.1.2b.6
20054/00 E –10.93–
Page 4
Installing crankshaft axial locating device

Install axial locating device (1) on crankshaft (2) and free
end of crankcase (3).
Note
Do not turn crankshaft before installing axial locating de-

vice.
Install clamp ring with grooved ball bearing (thrust bear-
ing), see 3.3.4.6b
20054/00 E –10.93–
Page 1
3.3.2 Pistons and Conrods

1 Piston skirt
2 Piston crown
3 Screw
4 Hex nut
5 Rectangular-section ring
6 Taper face compression ring
7 Oil control ring
8 Piston pin
9 Backup ring
10 Snap ring
11 Spring pin
12 Spring sleeve
1 Rectangular-section ring 8 Measuring points

2 Taper face compression ring 9 Piston crown
3 Oil control ring 10 Spring pin
4 Snap ring 11 Piston crown screw
5 Bronze bushing 12 Nut, left-hand thread
6 Backup ring 13 Piston skirt
7 Piston pin
20038/10 E –11.92–
Page 2
1 Conrod bush
2 Conrod
3 Bearing shell
4 Conrod cap
5 Conrod cap bolt
6 Locating pin
1 Conrod 4 Locating pin

2 Conrod cap 5 Conrod bush
3 Conrod cap bolt
20038/10 E –11.92–
Page 1


- x x Disconnect engine coolant lines as necessary 3.14.1.2
- x x Remove starting, control air and drain lines from cylinder head 3.18.3.2
- x x Disconnect engine oil lines 3.16.1.2
- x x Disconnect engine oil return pipes from cylinder head 3.16.1.1
- x x Remove cylinder head covers 3.6.4.2
- x x Disconnect H.P. fuel lines 3.12.1.2
- x x Exhaust system: Remove screws from appropriate cylinder head 3.10.3.2
- x x Intake air system: Remove screws from appropriate cylinder head 3.10.2.2
- x x Remove rocker arms 3.6.3.2
- x x Remove inspection port cover from crankcase intermediate frame 3.1.2.3
20038/10 E –04.96–
Page 1

Installing crankshaft barring tool
Remove cover from flywheel housing.
Engage barring tool (1) in ring gear and secure to fly-
wheel housing (2).
Using barring tool, set crankpin of piston to be removed
45° after TDC to removal position.
Firmly clamp removal tool in piston crown recess.
Removing conrod cap

Remove combustion residue on bore of cylinder liners
at TDC point of piston .
Turn crankcase in assembly dolly so that the bottom
edge ”A” of the crankcase is in the removal position.
As shown in illustration, rotate crankpin of piston to be
removed to position for disassembly.
1 Locating pin on conrod cap

2 Crankshaft
3 Bearing shell
4 Conrod cap
5 Oil spray nozzle
6 Connecting rod
A Bottom edge, crankcase
20038/10 E –04.96–
Page 2
Unscrew conrod cap bolts (1) approx. 15 mm.

Tap conrod cap bolts gently to release conrod (3) from
conrod cap.
Unscrew conrod cap bolts.
Remove conrod cap (2) and bearing shells.
Note
Protect conrod cap bolts and bearing shells against

damage and place in storage frame.
Removing conrod with piston

1 A
Note
Piston and connecting rod can also be removed with oil

pan lowered, see 3.1.6.2b.
In order to remove pistons when the oil pan is lowered,
it is essential that there is a min. distance of 150 mm
from the crankcase.
With conrod installed, turn piston (1) clockwise from
working position, (A = turning position approx. 1.00 p.m.
– 2.00 p.m.), viewed towards piston crown, to avoid dam-
age to the oil spray nozzle by the conrod during the next
disassembly.
F0030018a0
Slowly push piston back into cylinder liner until long arm
of conrod contacts cylinder liner.
Using removal tool (1), drive out piston (2) and conrod
through cylinder liner.
Note
Ensure that bearing shell does not fall out of conrod.

Remove bearing shell from conrod.
20038/10 E –04.96–
Page 1

Removing conrod through assembly aperture
Rotate crankshaft (1) so that conrod (3) is in position for
removal at assembly aperture (7).
B-bank; as in illustration
A-bank; mirror-image
Unscrew conrod cap bolts (10) approx. 15 mm using a
ratchet (6) and socket wrench.
Using a plastic mallet, tap conrod cap bolts gently to re-
lease conrod (3) from conrod cap (9).
Remove conrod cap and bearing shell (8).
Note

Removing conrod in roll-over assembly dolly
Rotate crankcase in assembly dolly so that conrod (7)
is in removal position ”A”.
Rotate crankpin (1) of piston to be removed to BDC posi-
tion.
1 Crankshaft
2 Bearing shell
3 Conrod cap bolt
4 Conrod cap
5 Oil spray nozzle
6 Cylinder liner
7 Conrod
A Removal position
20038/10 E –11.92–
Page 2
Unscrew conrod cap bolts approx. 15 mm using a

ratchet and socket wrench.
Using a plastic mallet, tap conrod cap bolts gently to re-
lease conrod from conrod cap.
Remove conrod cap and bearing shells.
Note

Removing conrod with piston

1 A
working position, (A = turning position approx. 1.00 p.m.
– 2.00 p.m.), viewed towards piston crown, to avoid dam-
disassembly.
Slowly push piston back into cylinder liner until long arm
of conrod contacts cylinder liner.
F0030018a0
Using removal tool (1), drive out piston (2) and conrod
through cylinder liner.
Note
Ensure that bearing shell does not fall out of conrod.

Remove bearing shell from conrod.
Disassembly, inspection and repair and assembly of pis-
tons and conrods, see 3.3.2.3 to 3.3.2.5.
20038/10 E –04.96–
Page 1
3.3.2.3 Disassembly
Removing snap rings
Place piston and conrod on assembly bench.
Remove snap rings with snap ring pliers.
Remove backup rings.
Removing piston pin

With round piece of wood, press piston pin (2) out of pis-
ton pin boss.
Note
Do not press out piston pins with sharp-edged tools.

If too securely seated, heat piston (3) on hotplate to
60°C .
Hold conrod (1) steady and withdraw piston pin.
Remove conrod from piston.
20038/10 E –06.94–
Page 2
Removing piston rings

Remove piston rings with piston ring pliers (1).
Do not under any circumstances stretch piston rings!
Note
To avoid interchanging the piston rings, collect piston

rings of appropriate piston and mark. Protect against
damage.
Removing piston crown

Remove piston crown from piston skirt for inspection
and cleaning.
Apply suitable alignment marks to piston crown (2) and
skirt (3) prior to disassembly.
Grip piston in a vice.
Remove combustion residues on screw head of piston
crown screws.
Remove piston crown screws with socket (1).
Detach piston crown and place in a suitable storage
frame.
20038/10 E –04.96–
Page 1

Inspecting and repairing pistons
Cleaning piston crown
Remove carbon deposits from piston crown (1) and pis-
ton ring grooves (2) with decarbonizer.
Any stubborn residues can be removed with a rotating
copper or steel brush.
Note
If piston crowns are very contaminated, any residues

can be removed with a ”synthetic jet”. Cover chromium-
faced sealing surfaces and top land.
Attention
Do not direct jet at top land or annular grooves, see

Circular 06.12.94.
Checking piston crown for cracks

Check piston crown for cracks using magnetic crack-testing method with fluorescent magnetic powder.
Clamp piston crown axially in magnetic testing jig.
When checking, turn piston crown by 90° respectively.
Carefully inspect piston ring grooves for cracks.
Replace entire piston if piston crown is cracked.
Checking condition of piston crown

Check contact pattern on mating surfaces of piston crown and piston skirt.
Remove slight wear or irregularities at oil transfers and inner and outer mating surfaces by rubbing down with oilstone.
Smooth wear or pitting greater than 50 mm by reconditioning and chrome-facing sealing surfaces in accordance with
MTU Specifications.
Replace entire piston if valve pockets or edges of piston are scorched.
If scoring or pitting on top land of piston crown is only local and does not reach to the first annular groove, recondition
damage points.
Do not remove material to depth of more than 50 mm.
If scoring or pitting reaches as far as the first annular groove, replace the complete piston.
20038/10 E –01.95–
Page 2
Inspecting piston ring grooves

If carbon residues cause piston rings to stick or if rings
contact carbon residues in groove root, piston crown
must be decarbonized.
Insert new piston ring in groove.
Check axial play of piston rings with feeler gauge (1).
If specified limits are exceeded or if oil control ring has
less axial play than specified, replace piston (2).
For specified limits, see Tolerances and Wear Limits
List.
Inspecting piston rings and measuring piston ring

gap
Replace rings if first and second rings have sharp upper
edges.
If slots of oil control ring are clogged by carbon deposits,
ring must be decarbonized.
Measure piston ring gap by inserting new piston ring (3)
in cylinder liner (2) scheduled for installation.
Ensure that piston ring is inserted to uniform depth all
round.
Measure piston ring gap with feeler gauge (1).
Replace piston rings if specified limits are exceeded.
Attention
Piston rings must be replaced as a set. The cylinder liner

must be rehoned if the piston rings are replaced.
Replace piston rings during W6 overhaul.
Measure length of piston crown screws.
List.
Replace screws that are too long or damaged.
20038/10 E –11.93–
Page 3
Inspecting piston skirt

Using the surface crack-testing method and red pene-
trant dye, check the piston skirt for cracks.
Replace cracked piston skirt.
Check wear pattern on piston skirt.
Using outside micrometer, measure outside diameter on
the non-phosphated measuring points.
If the piston clearance wear limit drops below the speci-
fied minimum and if the piston shows large surface-area
wear, replace piston.
Check standpipe and spring pin for damage, replace as
necessary.
Check mating face, – see under piston crown.
Replace the piston in the event of pitting, even if only
local or covering a small area, and also in the event of
extensive and concentrated signs of contamination on
the piston skirt.
Inspecting piston pin boss

Adjust bore gauge.
Measure piston pin boss.
Replace piston if specified limits are exceeded.
Replace piston if one of the press-fitted bronze bushes
is slack or exhibits scuffing marks.
Inspecting piston pin

Check piston pin for damage using magnetic crack-test-
ing method with fluorescent magnetic powder.
Replace pins exhibiting cracks.
Remove minor traces of wear and scoring by polishing.
Replace piston pins exhibiting scuffing, indentations and
severe wear.
Using micrometer screw, measure piston pin and deter-
mine piston pin clearance, see Tolerances and Wear Li-
mits List.
Replace pin if specified limits are exceeded.
20038/10 E –11.93–
Page 4
Inspecting and repairing conrods

Clean conrods, conrod caps and conrod bolts.
Note
Clean tapped holes coated with thin-film lubricant and serrations with cold cleaner.
Using a bottle brush (cylinder wiper 40x100x300 perlon), brush threads with a turning, oscillating motion in cleaning
bath.
Brush serrations in cleaning bath until clean.
Blow dry with dry compressed air to remove all cleaning residues.
Brush conrod cap bolts in cleaning bath (cold cleaner) until clean and blow dry with compressed air to remove all clean-
ing residues.
Measure length of conrod cap bolts: max. length = 85 mm.
Polish out all traces of nicks in conrods; replace conrod if necessary.
Check conrods, conrod caps and conrod cap bolts for cracks using magnetic crack-testing method with fluorescent
magnetic powder.
Checking axial fit of conrod bush
Using test mandrel (3) and hydraulic press (1), check
axial fit of conrod bush, see Tolerances and Wear Limits
List.
If limit value is not obtained, force bush out of conrod (2)
using mandrel and hydraulic press.
20038/10 E –01.95–
Page 5
Measuring conrod bush

Adjust bore gauge.
Measure bore of conrod bush, see Tolerances and Wear
Limits List.
Replace conrod bush (1) if specified limits are ex-
ceeded.
Replace conrod bush exhibiting severe scoring, dirt,
wear and hot-running damage.
Remove light scoring by polishing with polishing cloth.
Replacing conrod bush

Press out worn or loose conrod bushes (4).
Adjust bore gauge.
Measure basic bore of conrod (1) at several points, see
Tolerances and Wear Limits List.
If specified limits are exceeded, replace conrod or ma-
chine bore to repair size.
Note
Prior to installing conrod bush, check repair stage of

conrod bore and repair stage of conrod bush.See Toler-
ances and Wear Limits List.
Stamp repair stage dimension into identification area
(5).
Cool new conrod bush in ”liquid nitrogen” and insert with-
out pressure with plastic or wooden mandrel.
Caution

tions in 1.5.
Install bush in conrod bore so that it is flush with conrod
on both sides and ensure that lubricating bores (2) and
(3) in bush are aligned with bores in conrod.
Check that bush is tightly seated and machine ID to size
with precision boring machine.
20038/10 E –02.97–
Page 6
Break edge (x) in conrod bush with triangular scraper

and smoothen with felt disc diameter 30 to 40.
Measure conrod bush ID with bore gauge.
List.
Marking conrod bushes

1 Marking Stage 1
2 Conrod bush
1+3 Marking Stage 2
none Marking Stage 0
Marking Stage
two grooves 2
one groove 1
no groove 0
20038/10 E –11.93–
Page 7
Inspecting conrod serrations and tapped bores

Grip conrod in a vice.
Using a brass-wire brush, clean serrations (1) of conrod
and conrod cap mating surfaces and blow clean with
compressed air (2).
Using oilstone, remove load traces or wear on tooth sys-
tems.
Apply engineer’s blue to check contact pattern.
Check condition of conrod and conrod cap bolt threads.
Note
Threads must not be recut (furrowed thread)!

Replace damaged conrod cap bolts.
Throroughly clean conrod, conrod cap and conrod cap
bolt.
Assemble conrod and conrod cap.
Pretightening conrod cap bolts with torque wrench
1 2 Coat threads of conrod cap bolts and bolt head seating

surfaces with engine oil.
Carefully insert cap bolts by hand until initial contact with
thread flanks is made.
Screw in bolts three full turns by hand.
Attention
Do not drop bolts into conrod cap bores; threads must

not be recut!
Initial pretightening:
Using torque wrench (1), pretighten conrod cap bolt (2)
SG03 0001a0
on short conrod arm until conrod and conrod cap serra-
tions on short and long conrod arm are closed. For
torque setting, see Section 1.3.
Then tighten conrod cap bolt on long arm.
Subsequent pretightening:
In the sequence of short connecting rod arm - long con-
necting rod arm, pretighten both conrod cap bolts with
torque wrench to tightening specification 1.3.
20038/10 E –06.96–
Page 8
Tightening conrod cap bolts with angle-of-rotation

tightening tool
Place angle-of-rotation tightening tool (2) on conrod cap
bolts.
Set pointer (1) to zero.
Tighten conrod cap bolts in the sequence of short con-
necting rod arm - long connecting rod arm to tightening
specification 1.3.
Apply checking torque 100 % in tightening direction as
specified in Section 1.3.
If bolt turns in tightening direction beyond specified
torque:
Release and retighten as specified in Section 1.3. Re-
place bolt if necessary.
Checking conrod big-end bore

Before measuring, rub down big-end bore (2) with pol-
ishing cloth.
Measure conrod big-end bore.
If the limit values are exceeded in accordance with Toler-
ances and Wear Limits List, replace conrod or rema-
chine basic bore to the next repair stage.
Check big-end bore for wear and scoring. If necessary,
replace conrod or machine bore to repair size.
If big-end bore is machined to repair size, machine locat-
ing bore to appropriate depth and replace locating pin.
20038/10 E –11.93–
Page 9
Marking repair sizes on conrod

Stamp basic size diameter of D and diameter D1 in area
”K” on conrod cap (1) with numeral punches.
List.
Installing locating pin

Positioning correctly, install locating pin to reference di-
mension 3.1 mm -0.6 mm .
If pin is not correctly seated:
Machine locating pin bore to repair size.
Install repair-size locating pin.
20038/10 E –11.93–
Page 10
Repair size markings on locating pin

1 no marking Stage 0
2 marking Stage 1
3 marking Stage 2
Check axial parallelism of connecting rod bore

Testing unit arrangement
1 Conrod
2 Test mandrel, large conrod eye
3 Securing screw for test mandrel
4 V-block
5 Spring stop
6 Locknut
7 Installation housing
8 Adjustable spring stop
9 Dial gauge for axial twist
10 Securing screw for test mandrel
11 Base plate
12 Dial gauge for axial parallelism
13 Adjustable dial gauge carrier
14 Test mandrel, small conrod eye
Clean big-end and small-end bores.

Insert alignment mandrel (3) in big-end bore.
Make sure that mandrel is installed correctly!
Wide fit side (1) of mandrel must point towards conrod
shank; narrow fit side must point towards conrod cap.
Secure mandrel by hand with adjustment screw (2).
Do not move mandrel out of its installed position.
20038/10 E –11.93–
Page 11
Insert alignment mandrel (3) in small-end bore.

Make sure that mandrel is installed correctly!
Wide fit side (1) of mandrel must point towards conrod
shank; narrow fit side must point towards oilways of
small-end bore.
Secure mandrel by hand with adjustment screw (2).
Note
Install mandrels so that narrow fits in big-end and small-

end bores lie in a plane.
Installation of test mandrels same for axial parallelism
and axial twist tests.
Checking conrod bend

Lay conrod (2) with mandrel (1) installed in big-end bore
in both V-blocks (6) of test equipment.
Position small end (3) against resilient stop (5).
Adjust resilient stop so that centreline of mandrel shaft
is approx. 2 mm below dial gauge stylus.
Adjust dial gauges so that their readings indicate ap-
prox. 2 mm preload at highest point on small-end man-
drel, and set to zero.
Turn conrod by 180° and carefully position in testing
unit.
Move small-end mandrel through dial gauge styluses at
highest point on mandrel.
Determine and record deviations from zero on dial
gauges.
20038/10 E –11.93–
Page 12
Calculating conrod bend

Test equipment is set for measuring axial parallelism
over a distance of 200 mm.
To obtain the correct measurement at a distance of 100
mm in accordance with the Tolerances and Wear Limits
List, calculate the read-off value on dial gauges as
shown in the example.
Example:
Left dial gauge A = -0.05 mm
Right dial gauge A = +0.03 mm
0.08 mm
according to example:
Axial parallelism 0.08 : 4 = 0.02 mm
For specified limit values – see Tolerances and Wear Li-
mits List.
Checking conrod twist

Use template (1) to set both dial gauges (3) for conrod
twist to zero via styluses (2).
Remove template from test equipment.
20038/10 E –11.93–
Page 13
Position conrod (2) with installed test mandrels (1) (3)

into the two V-blocks (6) of the testing unit.
Set rigid stop on adjustable resilient stop (4) so that dial
gauge styluses still have travel of approx. 2 mm.
Move small end of conrod against rigid stop.
Record readings on dial gauges (5).
The difference between the values read off the two dial
gauges is the conrod twist.
Calculating conrod twist
To obtain the measurement at a distance of 100 mm in
accordance with the Tolerances and Wear Limits List,
calculate the read-off value on dial gauges as shown in
the example.
Example:
Dial gauge 1 = 0.00 mm
Dial gauge 2 = 0.10 mm
Difference = 0.10 mm
according to example:
Axial twist 0.10 : 2 = 0.05 mm
For limit value, see Tolerances and Wear Limits List.
Release adjustment screws on alignment mandrels.
Remove mandrels from conrod bores.
20038/10 E –11.93–
Page 14
Checking and assessing conrod bearings

Criteria for grooved bearing replacement
When new, the running surface has approx. 75% galva-
a nised wear layer (a), approx. 25% light metal (b) and
b max. 5% nickle barrier (c).
Wear on the bearing running surfaces first begins in the
c
galvanised wear layer (a).
This removes the wear layer in the groove by a few
0.001 mm . In event of further wear, the difference be-
tween the light metal ridge (b) and wear layer (a) re-
mains almost constant, – i.e. at approx. 0.005 mm.
F 003 0017 a
Note
To evaluate the wear condition of the running surface more accurately, it is necessary to use a magnifying glass (mag-
nifying strength at least 5x).
In doing so, the wear layer is to be seen as the dark zone and the light-metal ridge as the light zone. The relationship
between the width of the light-metal ridge and the width of the groove and the extent of the worn area are decisive factors
when evaluating the wear condition of the grooved bearings.
The grooved bearing can still be used if the wear layer is partially missing in the grooves. Practical experience has
shown that the grooved bearing with partially empty grooves can continue to operate without negatively influencing the
function of the bearing.
Each time when evaluating the groove condition, the running surface subjected to less load (mostly new values for
groove condition) should be used for the purposes of comparison.
The groove condition is evaluated in five groups:
1. Continue to use
2. Wear
3. Borderline – wear and levelling
4. Wear layer – continuous fraction
5. Borderline case – wear layer, continuous fraction and empty grooves
Damage to bearing:
The bearing is mainly damaged by scoring by foreign bodies, indentations and embedded particles, cavitation and cor-
rosion, pitting, thermal fatigue and assembly errors.
Bearings with such damage must be replaced.
20038/10 E –01.95–
Page 15
1. Continue to use
F 003 0001 a F 003 0002 a
Condition:
The groove geometry corresponds to new condition. The wear layer is completely maintained within the grooves. Dark
dots are mainly embedded oil coke particles.
Evaluation:
The relationship of wear layer/light-metal ridge is approx. 25% to 75%. Continue to use!
F 003 0003 a F 003 0004 a
Condition:
The wear layer is uniformly removed from grooves by approx. 0.005 mm. The light-metal ridge does not show any wear.
Dark dots are mainly embedded oil coke particles.
Evaluation:
The removal of the wear layer results in the light-metal ridges appear slightly widened. Continue to use
20038/10 E –01.95–
Page 16
Continue in use
F 003 0005 a F 003 0006 a
Condition:
Minor foreign bodies distributed over the entire running surface. No great changes to the light-metal ridges.
Evaluation:
The bearing shell can continue to be used.
F 003 0007 a F 003 0008 a
Condition:
The wear layer was ”dragged” and ”lubricated” via the light-metal ridges. The light-metal ridges cannot be seen to some
extent.
Evaluation:
The bearing shell can continue to be used.
20038/10 E –01.95–
Page 17
2. Wear
3
F 003 0009 a
1 Wear layer groove 3 Wear 1:1

2 Bearing metal ridge
Condition:
The bearing is locally worn to such an extent that the bearing metal ridges and wear layer grooves have reached a ratio
of 1:1. The width of the bearing metal ridges has increased from 25% (new condition) to 50%. A wear layer is still in
the grooves.
Wear limits:
b d
a c
F 003 0010 a
a) max. 30% of circumference of shell c) max. 50% of circumference of shell

b) max. 70% of width d) max. 35% of width
Evaluation:
The bearing is suitable for operation. The bearing must be replaced for safety reasons if a wear condition similar to
that indicated in Group 3, Page 18 is expected within the next inspection interval!
20038/10 E –01.95–
Page 18
3. Borderline – wear and levelling
2
F 003 0011 a
1 Bearing metal ridges worn 2 Wear 1:1
Condition:
The bearing metal ridges are locally worn.
Wear limits:
c e
a
b d
F 003 0012 a
a) max. 20% of width d) max. 35% of circumference of shell

b) max. 5% of circumference of shell e) max. 10% of width
c) max. 10% of width f) Chamber seal
Evaluation:
The bearing must be replaced if the wear condition defined above is reached.
20038/10 E –01.95–
Page 19
4. Wear layer – continuous fraction
1
F 003 0013 a
1 Wear layer – continuous fraction
Condition:
Wear layer continuous fraction in the grooves due to local overload.
Wear limits:
b d
a c
F 003 0014 a
a) max. 25% of circumference of shell c) max. 50% of circumference of shell

b) max. 70% of width d) max. 35% of width
Evaluation:
The bearing is suitable for operation. The bearing must be replaced for safety reasons if a condition similar to that indi-
cated in Group 5, Page 20 is expected within the next inspection interval !
20038/10 E –01.95–
Page 20
5. Borderline case – wear layer, continuous fraction and empty grooves
3
F 003 0015 a
1 Wear layer – continuous fraction 3 Bearing metal ridges worn

2 Empty grooves
Condition:
Empty grooves. In certain areas, empty grooves are visible once the broken wear layer has been washed out. The
bearing metal ridges can already be locally worn.
Wear limits:
e
a c
b d
F 003 0016 a
a) max. 40% of width d) max. 40% of circumference of shell

b) max. 10% of circumference of shell e) max. 15% of width
c) max. 30% of width
Evaluation:
The bearing must be replaced if the condition defined above is reached.
20038/10 E –01.95–
Page 21
Installing bearing shells in conrod
Note
New bearing shells must be installed during W6 over-

haul.
Refer to data sheet prior to installing the conrod bearing
shells, paying special attention to diameter stage on
connecting rod and crankshaft journal.
Replace bearing shells which are worn, damaged or
scored.
Prior to installing conrod bearing shells, measure
spreading dimension of conrod bearing shell.
List.
Unscrew conrod cap bolts (5).
Remove conrod cap (1).
Install bearing shells (4) in locating bore as marked (3),
paying attention to positions of locating grooves.
The markings must point in direction of driving end, see
illustration,
A = driving end for right engine side,
B = driving end for left engine side and with
bearing shell butting face at locating pin (2).
Mark any new bearing shells with cylinder number using
electric engraver.
Note

numbers (version).
Check length of conrod cap bolt (2); max. permissible

length = 85.0 mm. Replace bolt if necessary.
1 2
Note
Use only conrod cap bolts that have identification

grooves.
Coat bolt head seating faces and threads with engine oil.
Degrease serrations on conrod and cap.
Mount conrod cap.
Using torque wrench (1), tighten conrod cap bolts to
specified torque. For torque setting, see Section 1.3.
Conrod and conrod cap have same serial number.
When assembling, ensure that numbers on components
SG03 0002a0 match.
20038/10 E –06.96–
Page 22
Applying identification marks to conrods

Mark cylinder number (1) on new conrods using electric
engraver.
Serial number is stamped into opposite side of conrod.
Measuring big-end bearing bore

Adjust bore gauge.
Measure conrod big-end bearing bore.
Measure inside diameter of installed bearing shells in
direction A and B.
Diameter b1 and diameter b2 must be equal to or greater
than diameter a.
If diameter a is greater than diameter b1 or diameter b2,
replace bearing shells and correct markings.
The out-of-round of the bearing is the maximum differ-
ence between diameter b1 and diameter a, and/or diam-
eter b2 and diameter a.
Use measured distance in plane A to determine bearing
play.
Record measured values in data sheet.
Remove conrod cap.
1 Marking of cylinder number on conrod Protect components against damage.
2 Marking of cylinder number on conrod bearing shells
3 Measuring range
20038/10 E –01.95–
Page 1
3.3.2.5 Assembly
Checking nuts in piston skirt
Prior to assembling piston crown, check hex nut (2) in
piston skirt (1) for specified tightening torque to tighten-
ing specification 1.3, retighten as necessary.
Note
Nuts have left-hand thread; observe tightening direc-

tion.
Installing nuts in piston skirt
Coat thread and mating surface with thin-film lubricant.
Screw nuts (2) into piston skirt (1).
Tighten left hand threads to specified torque. For torque
Installing standpipe and spring pin

Chill standpipe (2) in liquid nitrogen and using holder,
position correctly in register bore on piston skirt.
Note

tions in 1.5.
Measure reference dimension ”B” = 20 mm -0.3 mm;
check ease of movement ”C” to piston crown.
Insert spring pin (1) into bore on piston skirt and carefully
drive in with plastic mallet.
Do not damage mating face.
20038/10 E –11.95–
Page 2
Installing piston crown

Each piston crown and piston skirt were machined to-
gether. Do not interchange piston crowns and skirts.
Only use piston crown screws, whose max. length does
not exceed the permitted screw length in the Tolerances
and Wear Limits List.
Note
When installing the piston crown screws, take care not

to damage thread of screws (M10 or M10 x 1).
Grip piston skirt (4) in vice.
Correctly position piston crown (3) on piston skirt.
In so doing, make sure that marks applied during disas-
sembly are aligned.
Coat thread and seating face of screw (2) with thin-film
lubricant.
Using torque wrench (1), tighten piston crown screws to
initial torque. For torque setting, see Section 1.3.
Release screws and then retighten with torque wrench
to initial torque as specified in Section 1.3.
Check piston crown screws in accordance with Section
1.3.
Mount angle-of-rotation tightening tool (1) on one piston

crown screw (2) and tighten to specified torque.
Thoroughly check test torque of piston crown screw in
tightening direction with torque wrench to Tightening
Specification 1.3.
If one of screws turns when checking torque is applied,
repeat assembly procedure on all screws.
20038/10 E –06.96–
Page 3
Installing piston rings

Using piston ring pliers (1), insert piston rings into
grooves in piston crown.
To avoid breakage, do not under any circumstances
overstretch piston rings!
Replace piston rings during W6 overhaul.
Using piston ring pliers, install oil control ring in groove

III with coiled spring expander. Ends of expander spring
must be opposite oil control ring gap.
Manufacturer’s designation and MTU part number must
be legible from the top.
Note
The manufacturer’s designation and MTU part number

are engraved on the oil control ring, see illustration op-
posite.
Insert new taper face compression ring in groove II using
piston ring pliers.
The designation ”TOP3”, manufacturer’s designation
and MTU part number must be legible from the top.
Note
The designation ”TOP 3”, manufacturer’s designation

and MTU part number are engraved on the taper face
compression ring, see illustration opposite.
Insert new rectangular-section ring (1) in groove I using
piston ring pliers.
The designation ”TOP3”, manufacturer’s designation
and MTU part number must be legible from the top.
Note
The designation ”TOP 3”, manufacturer’s designation

and MTU part number are engraved on the rectangular
section ring , see illustration opposite.
20038/10 E –11.93–
Page 4
Installing conrod in piston

Insert back-up ring in piston pin bore.
Using snap ring pliers, insert snap ring into piston boss.
Make sure that snap ring is properly seated.
Install conrod (1) in matching piston (3) with long arm
positioned as shown in adjoining illustration.
Long arm (A) of conrod must face in same direction as
funnel (B) in piston.
Wipe piston pin (2) with soft chamois leather and coat
with engine oil.
Check whether piston pin moves freely in piston boss.
If piston pin is too securely seated, heat piston on hot-
plate to 60°C .
Insert piston pin until it contacts backup ring/snap ring.
If piston is a new design, insert a second backup ring.
Insert second back-up ring and install second snap ring.
Ensure that snap ring is correctly seated in groove.
20038/10 E –11.93–
Page 1

Installing conrod with piston
Rotate crankcase in assembly dolly until underside (3)
of crankcase is in a convenient position for installation.
Rotate crankshaft until crankpin of piston to be installed
is in position for installation as shown in illustration.
Note
Check repair stage of crankshaft crankpin and repair

stage of bearing shells, see crankshaft data sheet and
conrod assembly data sheet.
Clean crankpin, bearing shells and cylinder liner and
spray with engine oil.
Clean conrod big-end locating bore and mating surfaces
of bearing shells with chamois leather.
Clean serrated faces of conrod and butting faces of
bearing shells.
1 Conrod
2 Short connecting rod arm
3 Bottom edge, crankcase
4 Conrod cap
5 Bearing shell
6 Installation tool
7 Long connecting rod arm
8 Oil spray nozzle
9 Funnel in piston
Inspect backs of bearing shells for burrs; deburr if

necessary.
Install bearing shell (1), with matching number, with re-
cess engaging retaining pin (3) of installation tool (2).
Make sure that retaining pin of installation tool engages
recess.
Coat running surfaces of bearing shells with engine oil.
20038/10 E –06.96–
Page 2
Locating bearing shells with conrod cap and in-

stallation tool
1 Locating pin in assembly device ”new”

2 Locating pin in assembly device ”old”
3 Locating pin in conrod cap
a Locating bearing shell ”new bearing shell version”
b Locating bearing shell ”old bearing shell version”
Note
Because the pin plate on the installation tool can be

moved, the tool can be used to install both old and new
bearing shell versions.
Position installation tool (2) with bearing shell (1) on

crankpin and turn towards cylinder liner.
Position second bearing shell (1) on first bearing shell

(2) so that recesses of both shells are aligned.
Note
Recesses in both bearing shells must be located oppo-

site one another and face centre of crankpin.
20038/10 E –11.92–
Page 3
a Conrod bearing with old locating grooves

b Conrod bearing with new locating grooves - conrod cover side
c Conrod bearing with new locating groove - assembly
device side
Place conrod cap (1) with matching number on bearing

shells (2).
Locating pin must engage hole formed by bearing shell
recesses.
Hold bearing shells with conrod cap firmly.
Rotate conrod cap with bearing shells to assembly posi-
tion on crankpin.
Clean mating surfaces, threads and joint of conrod.

Attach protective strip (2) to long arm of conrod (1) and
insert sleeve (3) into tapped hole for conrod cap bolt.
20038/10 E –11.92–
Page 4
Turn compression ring and oil control ring until gaps are
at opposite sides of piston.
Spray piston and piston rings with engine oil.
Check that bore of assembly sleeve (3) is clean.
Slide assembly sleeve over piston (2), bevelled end first.
Position protective strip (4) with connector on conrod
(1).
With conrod installed, turn piston (1) clockwise from wor-

1 A king position, (A = turning position approx. 1o’clock –
2 o’clock), viewed towards piston crown, to avoid damage
to the oil spray nozzle by the conrod during the next as-
sembly.
F0030018a0
Slide piston (1) slowly into oiled cylinder liner.

Remove assembly sleeve (2).
After passing the oil spray nozzle, lift conrod eye in
direction of crankpin and align parallel to the crankshaft
axis.
Push piston into cylinder liner until back of conrod is
seated on bearing shell.
Remove protective strip.
20038/10 E –06.96–
Page 5
Lightly coat conrod cap bolts with ”engine oil” on bolt

head support surface and thread.
Carefully insert conrod cap bolts (1) by hand up to initial
contact on thread flanks.
Without using tools, screw bolts into conrod three full
turns.
Attention

not be recut.
Only use conrod cap bolts with identification grooves on
bolt heads.
Using torque wrench, pretighten conrod cap bolt on
short arm (2) until conrod and conrod cap serrations are
closed on both short and long arms. For torque setting,
see Section 1.3.
Then pretighten conrod cap bolt on long arm.
When tightening bolts, check whether conrod moves
freely in axial direction.
If conrod cannot move in axial direction, locating pin is
not seated in groove of conrod bearing and is stuck.
Disassemble conrod and discard damaged bearing
shells.
Attention
The crankshaft may be rotated further once the conrod

cap bolts have been initially pretightened.
Using torque wrench, pretighten conrod cap bolts to
Sequence:
Short connecting rod arm – long connecting rod arm
Check that conrod moves freely in axial direction, as de-
scribed above.
Attention
Tighten conrod cap bolts until they vibrate as little as

possible.
20038/10 E –06.96–
Page 6
Mount angle-of-rotation tightening tool (1) on conrod

cap bolt (2).
Beginning with short arm, tighten to specified torque.
If bolt turns beyond specified torque, release both bolts
and retighten as specified in Section 1.3. Replace bolts
if necessary.
Check conrod bearing axial play with feeler gauge.
Disassemble conrod if bearing has no axial play.
Discard damaged bearing shells.
Measure conrod bore again, see 3.3.2.4.
Installation with oil pan lowered

Install lowering and barring tool, see 3.3.2.2.
In order to install pistons when oil pan is lowered, it is es-
sential that there is a gap of 150 mm between oil pan and
crankcase.
Using rotator, set crankpin of crankshaft for piston to be
installed to assembly position (approx. 45° after TDC).
Firmly clamp removal tool (1) in piston crown recess.
Install pistons, bearing shells and conrod bearing caps
in the same sequence as described earlier.
Tighten conrod cap bolts with specified tool only and as
specified in Section 1.3, see also 3.3.2.6.
Detach removal tool.
Installing oil pan, see 3.1.6.6.
20038/10 E –06.96–
Page 1
3.3.2.6a Installation in Crankcase with Intermediate Frame

Installing conrod with piston in assembly dolly
Rotate crankcase in assembly dolly until underside of
crankcase is in installation position ”A”.
Rotate crankshaft until crankpin of piston to be installed
is in position for installation as shown in illustration.
Note
Check repair stage of crankshaft crankpin and repair

stage of bearing shells, see crankshaft data sheet and
conrod assembly data sheet.
Clean conrod bore and bearing shell seating surfaces
with chamois leather.
Degrease serrated conrod joints and bearing shell mat-
1 Crankshaft ing surfaces.
2 Bearing shell
3 Conrod cap bolt
4 Conrod cap
5 Oil spray nozzle
6 Cylinder liner
7 Conrod
A Installation position
Inspect backs of bearing shells for burrs; deburr if

necessary.
Install bearing shell (1), with matching number, with re-
cess engaging retaining pin (3) of installation tool (2).
Make sure that retaining pin of installation tool engages
recess.
Coat running surfaces of bearing shells with engine oil.
Note
Shell backs must be dry.
20038/10 E –06.96–
Page 2
Locating bearing shells with conrod cap and in-

stallation tool
1 Locating pin in assembly device ”new”

2 Locating pin in assembly device ”old”
3 Locating pin in conrod cap
a Locating bearing shell ”new bearing shell version”
b Locating bearing shell ”old bearing shell version”
Note
Because the pin plate on the installation tool can be

moved, the tool can be used to install both old and new
bearing shell versions.
Position installation tool (2) with bearing shell (1) on

crankpin and turn towards cylinder liner.
Position second bearing shell (1) on first bearing shell

(2) so that recesses of both shells are aligned.
Attention
Recesses in both bearing shells must be located oppo-

site one another and face centre of crankpin.
20038/10 E –11.93–
Page 3
a Conrod bearing with old locating grooves

b Conrod bearing with new locating grooves - conrod cover
side
c Conrod bearing with new locating grooves - assembly
device side
Place conrod cap (1) with matching number on bearing

shells (2); locating pin must engage hole formed by
bearing shell recesses.
Hold bearing shells with conrod cap firmly.
Rotate conrod cap with bearing shells to assembly posi-
tion on crankpin.
Clean mating surfaces, threads and joint of conrod.

Attach protective strip (2) to long arm of conrod (1) and
insert sleeve (3) into tapped hole for conrod cap bolt.
20038/10 E –11.93–
Page 4
Turn compression ring and oil control ring until gaps are
at opposite ends of piston.
Spray piston and piston rings with engine oil.
Check that bore of assembly sleeve (1) is clean.
Slide assembly sleeve over piston (2), bevelled end first.
Position protective strip with connector on conrod.
Insert piston with preassembled conrod (1) and protec-

tive strips (2) in lubricated cylinder liner.

1 A working position, (A = turning position approx. 1.00 p.m.–
2.00 p.m.), viewed towards piston crown, to avoid dam-
assembly.
F0030018a0
20038/10 E –06.96–
Page 5
Slide piston (1) slowly into oiled cylinder liner.

Remove assembly sleeve (2).
After passing the oil spray nozzle, lift conrod eye in
direction of crankpin and align parallel to the crankshaft
axis.
Push piston into cylinder liner until back of conrod is
seated on bearing shell.
Remove protective strip.
Installing conrod bearing cap

Use only conrod cap bolts up to max. 85 mm length and
with identification grooves.
Coat bolt head seating faces and threads with engine oil.
Insert guide pin (1) into bore of conrod cap bearing (2)
and into tapped bore of conrod.
Hold bearing cap firmly and push conrod completely
onto crankpin (3).
Remove guide pin.
Carefully insert conrod cap bolts by hand up to initial
contact on thread flanks.
Without using tools, screw bolts into conrod three full
turns.
Attention

not be recut (furrowed thread).
20038/10 E –06.96–
Page 6
Using torque wrench, pretighten conrod cap bolt on
short arm until conrod and conrod cap serrations are
closed on both short and long arms. For torque setting,
see Section 1.3.
Disassemble conrod and discard damaged bearing
shells.
Attention
L87_9331

Using torque wrench, pretighten conrod cap bolts to
specified torque. For torque setting, see Section 3.
Sequence:
Disassemble conrod.
Attention
Tighten conrod cap bolts until they vibrate as little as

possible.
Mount angle-of-rotation tightening tool (1) on conrod

cap bolt.
Beginning with short arm, tighten to specified torque.
if necessary.
20038/10 E –06.96–
Page 7
Installing conrod with piston through assembly ap-

erture
Rotate crankshaft as shown in illustration to installation
position for appropriate piston.
B-bank; as in illustration
A-bank; mirror-image
Clean conrod bore and bearing shell seating surfaces
with chamois leather.
Degrease serrated conrod joints and bearing shell mat-
ing surfaces.
Installation of conrod with piston, same as – Installing
conrod with piston in roll-over assembly dolly –.
Install conrod bearing and conrod cap through assembly
aperture.
1 Funnel in piston
2 Oil spray nozzle
3 Conrod
4 Crankcase
5 Short connecting rod arm
6 Crankcase intermediate frame
7 Access port B side
8 Bearing shell
9 Conrod cap
10 Installation tool
11 Long connecting rod arm
20038/10 E –11.93–
Page 8
Tightening conrod bearing cap via access port

Using socket and torque wrench (1), pretighten conrod
cap bolt at short connecting rod arm via the access port
(2) to Tightening Specification 1.3 until conrod and con-
rod cap serrationsare closed at short and long connect-
ing rod arm.
Disassemble conrod.
Note

Using torque wrench, pretighten conrod cap bolts
through assembly aperture (2) to specified torque. For
Sequence:
Check whether conrod can move slightly in axial direc-
tion.
Position of screw marking after second pretightening ”a”
(section A-A).
Tighten conrod cap bolts to specified torque in sequence
mentioned above. For torque setting, see Section 1.3.
Position of screw marking after angle of rotation tighten-
ing ”b” (section A-A).
if necessary.
Installing inspection port covers, see 3.2.5.
20038/10 E –11.93–
Page 1
3.3.3 Engine Flange With Drive Member, Driving End
1 Engine flange a Short flywheel housing

2 Clamp ring b Long flywheel housing
3 Driver
4 O-ring
20054/00 E –01.95–
Page 1


- - x Separate engine from alternator 3.88.6a.2
- - x Remove Geislinger coupling F56 N0600446
20062/00 E –04.95–
Page 1
3.3.3.2 Removal
Caution
Danger
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the flange must not be exceeded.
Pressing off engine flange
Unscrew plug at driving end of crankshaft.
Screw in draw spindle (1) of hydraulic puller as far as it
will go.
Measure reference dimension ”K” = 201 mm.
Insert and secure adapter (2) for expanding engine
flange.
20038/10 E –11.92–
Page 2
Push pressure sleeve (1) and hydraulic nut (2) onto draw
spindle (4).
Mount hex nut (3), tighten fully and back off approx.
17 mm.
Note
Before installing nut, ensure that hydraulic nut is in its in-

itial position (0 travel).
Connect and secure H.P. lines (5) and (6).
Observe guidelines for using H.P. lines, see Section 1.5.
Fill hydraulic hand pumps with SAE 10 engine oil.
Bleed pumps and lines until bubble-free oil emerges.
Close valve.
Operate hydraulic hand pump for hydraulic nut until
pressure sleeve contacts engine flange (7).
Hydraulic nut acts as a buffer and stop for engine flange
when it is released from crankshaft taper, thus prevent-
ing flange from being released suddenly from crank-
shaft.
Actuate oil pressure hand pump for expansion of engine flange until half max. expansion pressure is reached. Maintain
this pressure for approx. 5 minutes.
Increase expansion pressure in stages, waiting approx. 2 minutes between each increase, until movement becomes
noticeable at joint.
Operate pump to make up loss in expansion pressure until engine flange is released or until it is necessary to increase
pressure further.
Max. expansion pressure is stamped on engine flange: do not exceed this pressure.
Pressure in hydraulic puller increases when engine flange is released.
Gradually drain oil from hydraulic nut.
Relieve pressure in hydraulic hand pumps.
Turn hex nut to force piston of hydraulic nut to limit of travel.
Disconnect H.P. lines and remove hydraulic puller.
Remove engine flange from crankshaft taper.
20038/10 E –11.92–
Page 1
3.3.3.3 Disassembly
Removing driver from engine flange
Note
1
Remove the driver (2) only as required.

2 Rapidly heat driver to max. 180°C and remove from en-
gine flange (1).
Caution
3 Always use protective gloves to hold driver.

Remove O-ring (3).
20038/10 E –11.95–
Page 1

Clean all parts.
Check engine flange for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace flange
if cracks are detected.
Check ring gear of engine flange, replace as necessary.
Remove burrs and chipping from teeth by grinding or filing.
Check driver for indentations.
Inspect taper for wear; if necessary, use 1:50 taper mandrel to check clearance.
Distance from reference area on taper mandrel to engine flange: 12 mm –1.1 mm.
Replace engine flange if taper is expanded or reveals severe wear.
Check threaded bores for ease of movement; if necessary recut or insert helicoil threaded inserts.
Check mating surface and collar of engine flange for traces of wear and damage; recondition with oilstone as required.
Replace O-ring.
20038/10 E –07.94–
Page 1
3.3.3.5 Assembly
Shrink-fitting driver onto engine flange
Heat driver (3) to 150° +30 °C.
Using protective gloves, push driver into position all way
round.
Oil bore in driver lug (2) and engine flange (1) must be
flush.
Ensure that there is no gap at engine flange mating face.
Use fixture (1) to force driver against mating face while

it is cooling.
20038/10 E –11.92–
Page 2

Insert O-ring in groove in engine flange (2).
20038/10 E –11.95–
Page 1
Guaranteeing distance ”S”
min. 0.08 mm, max. 0.26 mm
Before installing engine flange (2) with shrink-fitted
driver (3), measure distance ”C” between grooved ball
bearing inner race (4) and crankshaft end face ”A”.
To do this, displace crankshaft (1) towards driving end
until ball bearing inner race (4) butts against crankshaft.
Measured dimension must be between 81.35 mm and
81.47 mm.
Measure distance ”B” to flange.
81.27 mm.
Protrusion ”U” of engine flange over crankshaft: max.
0.02 mm
Gap clearance ”S” = C - B + U
Alternative: Measuring with device

Attach tool (1) to driver stop.
Position depth gauge (2) on surface of engine flange and
calculate difference.
1.27 mm.
Note
Specified tool measurement = 80.00 mm.
Using tool (2), align centre of groove of ball bearing inner

race (2) with crankshaft alignment bore (3).
20038/10 E –11.92–
Page 2
Apply mark (1) to engine flange (2) using tool (3).

Displace crankshaft towards driving end until inner race
of grooved ball bearing butts against crankshaft.
Secure crankshaft in this position.
Degrease crankshaft taper and engine flange and blow
clean with compressed air.
Coat crankshaft taper with SAE 10 engine oil.
Using lifting gear and alignment tool (2), push engine

flange by hand onto crankshaft taper until seated.
Driver lug must engage into groove of grooved ball bear-
ing inner ring.
If an alignment tool is not available, installation is aided

by alignment bores (1) in engine flange and markings (2)
on crankshaft end face.
They must be aligned during installation.
20038/10 E –11.92–
Page 3
Measure reference distance ”C” with depth gauge.

Reference distance ”C” max. 17.0 mm.
If reference distance ”C” is not obtained, remove engine
flange.
Check alignment and reinstall.
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the engine flange must not be
exceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Pressing on engine flange
Screw in draw spindle (1) of hydraulic installer as far as
it will go.
Insert and secure adapter (2) for expanding engine
flange.
20038/10 E –04.96–
Page 4
Attach installer (7) for correct pressing on of engine

flange (1).
spindle (4).
Mount hex nut (5).
Connect and secure H.P. lines (2) and (3); observe
guidelines for using H.P. lines, see Section 1.3.
Close valve.
Beginning with installation pressure, alternately actuate
oil pressure hand pumps for installation and expansion
pressures and allow pressure to increase until engine
flange is flush with the crankshaft.
Select force-on pressure so that final position is reached
after approx. 5 steps.
When beginning hydraulic installation, ensure that ex-
pansion pressure is not exceeded!
Max. expansion pressure is stamped on end face of engine flange.

When press-fitting operation is completed, relieve expansion pressure and reduce force-on pressure to 270 bar.
Allow reduced force-on pressure to act on engine flange for a minimum of 60 minutes.
Relieve force-on pressure and remove hand pump and hydraulic installer.
Caution
Do not subject press fitting to operating load for at least 8 hours.

Seal end of crankshaft with plugs and sealing rings.
Tighten plugs to specified torque. For torque setting, see Section 1.3.
Measure and check projection of engine flange - crankshaft, max. 0.02 mm
20038/10 E –11.92–
Page 1

Removing crankshaft axial locating device
Remove device (1) from crankshaft (2) and crankcase,
free end (3).
Checking axial clearance

Mount measuring instrument (1) on crankcase.
Bring dial gauge stylus into contact with end face of
crankshaft (2).
Check axial clearance of crankshaft
Total axial clearance of crankshaft with engine flange in-
stalled:
- min. clearance = greater than gap clearance ”S”
- max. clearance = see Tolerances and Wear Limits List
Specified gap ”S”, see Page 3.3.3.6
20038/10 E –11.92–
Page 1
3.3.3a Flywheel with Track Ring, Driving End
1 Flywheel housing 4 O-ring

2 Flywheel 5 Track ring lug
3 Track ring
20038/10 E –04.96–
Page 1


- x x Disconnect engine from gearbox or alternator -
20038/10 E –04.96–
Page 1
3.3.3a.2 Removal
Caution
Danger
The installation pressure stamped on the tool and the expansion pressure stamped on the flywheel must not be ex-
ceeded.
Pressing off flywheel

Screw in draw spindle (1) of hydraulic puller as far as it
will go.
Insert and secure adapter (2) for expanding flywheel.
20038/10 E –11.92–
Page 2
spindle (4).
Mount hex nut (3), tighten fully and back off approx.
17 mm.
Note

Close valve.
Operate hydraulic hand pump for hydraulic nut until
pressure sleeve contacts flywheel (7).
Hydraulic nut acts as a buffer and stop for flywheel when
it is released from crankshaft taper, thus preventing fly-
wheel from being released suddenly from crankshaft.
Actuate oil pressure hand pump for expansion of flywheel until half max. expansion pressure is reached. Maintain this
pressure for approx. 5 minutes.
Operate pump to make up loss in expansion pressure until flywheel is released or until it is necessary to increase pres-
sure further.
Max. expansion pressure is stamped on flywheel; do not exceed this pressure.
Pressure in hydraulic puller increases when flywheel is released.
Remove flywheel from crankshaft taper.
20038/10 E –11.92–
Page 1
Removing track ring from flywheel
Note
Remove track ring (3) only if necessary.

Rapidly heat track ring to max. 170 °C and remove from
flywheel (1).
Remove O-ring (2) from track ring.
Caution
Always use protective gloves to hold track ring.
20038/10 E –04.96–
Page 1

Clean all parts.
Check flywheel for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace flywheel
Check ring gear of flywheel.
Remove burrs and chipping from teeth by grinding or filing.
Inspect taper for wear; if necessary, use 1:50 taper mandrel to check clearance.
Replace flywheel if taper is expanded.
Also replace flywheel is taper reveals severe wear.
Check threaded bores for ease of movement; if necessary recut or insert helicoil threaded inserts.
Check mating surface and collar of flywheel for traces of wear and damage; recondition with oilstone as required.
Check track ring for wear and check track ring lug for indentations.
Remove minor wear with emery cloth (observe track twist is in correct direction).
Replace track ring if badly worn.
If necessary, recondition indentations on track ring lug with oilstone, replace track ring if necessary.
Replace O-ring.
20038/10 E –11.92–
Page 1
3.3.3a.5 Assembly
Shrink-fitting track ring onto flywheel
Insert new O-ring (3) in groove in track ring (4).
When shrinking on, clean and degrease mating face on
track ring and flywheel for .
Heat track ring to 150°+20 °C.
Using fixture, push track ring into position all way round.
When installing track ring, oil bore (1) in flywheel and
track ring lug (2) must be flush.
Ensure that there is no gap at mating face of flywheel
flange (5).
Use fixture to force track ring against mating face while
it is cooling.
Coating flywheel end face

Position plastic ring (1) and cover disc (2) on flywheel
hub.
Coat end face with lubricating varnish (3).
Layer thickness: 0.05 mm to 0.08 mm.
Follow manufacturer’s instructions (stir before use).
Note
Keep all other surfaces free of lubricating varnish.

Keep area (4) clear of varnish.
Position is optional.
Varnish-free area serves as measuring point for layer
thickness.
Remove plastic ring and masking cover once varnish
has dried.
20038/10 E –04.96–
Page 1
Guaranteeing distance ”S”
min. 0.13 mm, max. 0.30 mm
Before installing flywheel (1) with shrink-fitted track ring
(2), measure distance ”E” between grooved ball bearing
inner race (3) and crankshaft end face.
To do this, displace crankshaft (4) towards driving end
until ball bearing inner race butts against crankshaft.
39.10 mm.
Measure distance ”F” to flange.
39.33 mm.
Note
Distance ”F” must be measured at area with lubricating

varnish coating.
Install oil seal carrier with radial oil seal and two O-rings,
see 3.3.5.6.
20038/10 E –04.96–
Page 2
Using tool (2), align centre of groove of ball bearing inner

race (2) with crankshaft alignment bore (3).
Note
Do not damage sealing lip of radial-lip shaft seal!
Apply mark (1) to flywheel (2) using tool (3).

Displace crankshaft towards driving end until inner ring
of grooved ball bearing butts against crankshaft.
Secure crankshaft in this position.
Degrease crankshaft taper and flywheel and blow clean
with compressed air.
Coat crankshaft taper with SAE 10 engine oil.
Using lifting gear and alignment tool (2), push flywheel

(1) by hand onto crankshaft taper until seated.
Driver lug must engage into groove of grooved ball bear-
ing inner ring.
20038/10 E –04.96–
Page 3
Installation aids:
If an alignment tool is not available, installation is aided
by alignment bores (1) in flywheel and markings ”A” on
crankshaft end face.
They must be aligned during installation.
Determine reference distance (max. 18.8 mm).

If reference distance is not obtained, remove flywheel.
Check alignment and reinstall.
Record reference distance.
1 Register bores
A Marking on crankshaft
Pressing on flywheel
Caution
Danger
The installation pressure stamped on the tool and the expansion pressure stamped on the flywheel must not be
exceeded.
20038/10 E –11.92–
Page 4

Screw in draw spindle (1) of hydraulic installer as far as
it will go.
Insert and secure adapter (2) for expanding flywheel.
Attach installer (3) for correct pressing on of flywheel.

spindle (4).
Mount hex nut (8).
Close valve.
Beginning with installation pressure, alternately actuate
oil pressure hand pumps for installation and expansion
pressures and allow pressure to increase until flywheel
is flush with the crankshaft.
Select force-on pressure so that final position is reached
after approx. 5 steps.
When beginning hydraulic installation, ensure that ex-
pansion pressure is not exceeded!
Max. expansion pressure is stamped on end face of fly-
wheel.
When press-fitting operation is completed, relieve ex-
pansion pressure and reduce force-on pressure to 270
bar.
Allow reduced force-on pressure to act on flywheel for
an minimum of 60 minutes.
Relieve force-on pressure and remove hand pump and
hydraulic installer.
Caution

Seal end of crankshaft with plugs and sealing rings.
Tighten plugs to specified torque. For torque setting, see Section 1.3.
20038/10 E –11.92–
Page 1

Removing crankshaft axial locating device
Remove axial locating device (1) from crankshaft (2)
and free end of crankcase (3).
Checking axial clearance

Mount measuring instrument (1) on crankcase.
Bring dial gauge stylus into contact with end face of
crankshaft (2).
Check axial clearance of crankshaft.
Total axial clearance of crankshaft with flywheel in-
stalled:
- min. clearance = greater than gap clearance ”S”
- max. clearance = see Tolerances and Wear Limits List
Specified gap ”S”, see Page 3.3.3a.6
20038/10 E –11.92–
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3.3.4 Clamp Ring with Grooved Ball Bearing, Driving End
1 Grooved ball bearing 4 O-ring

2 Clamp ring, driving end 5 Bolt
3 O-ring
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Clamp ring with grooved ball bearing
1 Flywheel housing 4 Bolt

2 Clamp ring 5 Grooved ball bearing
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Page 3
1 Grooved ball bearing 4 Spring washer

2 O-ring 5 Bolt
3 Clamp ring
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Page 4
1 Flywheel housing 5 Grooved ball bearing

2 Bolt 6 Clamp ring
4 Bolt
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Page 5
1 Grooved ball bearing 4 Spring washer

2 O-ring 5 Socket-head screw
3 Clamp ring
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Page 6
1 Flywheel housing 5 Oil pan

2 O-ring 6 Grooved ball bearing
3 Socket-head screw 7 O-ring
4 Clamp ring
20046/20 E –04.96–
Page 1


- x x Separate engine from gearbox -
- x x Remove engine coupling N 60446
- x x Remove engine flange with driver 3.3.3.2
- x x Remove flywheel with track ring 3.3.3a.2
20038/10 E –04.96–
Page 1

Removing clamp ring
Remove seal carrier, see 3.3.5.2 (order-specific)
Unscrew bolts from clamp ring (1).
Unscrew clamp ring with jackscrews from crankcase.
Remove grooved ball bearing from crankcase bore,
driving end.
Removing oil pan, see 3.1.6.2.
20038/10 E –04.96–
Page 1

Removing clamp ring
Removing oil seal carrier, see 3.3.5.2.
Unscrew bolts from clamp ring (1).
Remove clamp ring with jackscrews from crankcase and
intermediate frame.
Remove grooved ball bearing from crankcase.
Remove oil pan, see 3.1.6a.2
For crankcase intermediate frame removal, see
3.1.2b.2
20038/10 E –04.96–
Page 1

Clean all parts.
As a rule, replace axial alignment bearings exhibiting material pick-up with new grooved ball bearings.
Pitting on the front of the inner race on the thrust bearing is permissible if it extends over an area of less than 180° and
is not deeper than 0.3 mm. Also refer to 3.3.1.4
Remove material deposits by rubbing down.
Note
In order to compensate any misalignment with the thrust collar when the crankshaft thrust bearing has been recondi-
tioned, a crankshaft thrust collar with repair stage on outer ring (B) must be installed. For repair stages and marking,
see Table.
Crankshaft Thrust bearing
C± 0.02
(stamped on No. of identifica-
crankshaft front, driving tion grooves
Stage end)
0 8.80 none
I 8.50 1x
II 8.20 2x
III 7.90 3x
If a crankshaft axial alignment bearing with a repair size is installed, it is essential to install a clamp ring with an identifica-
tion groove.
Check clamp ring for cracks using magnetic crack-testing method with fluorescent magnetic powder.
If cracks are detected, replace clamp ring.
Check clamp ring for damage and flatness, recondition if necessary, replace as necessary.
If an engine is being repaired, the original clamp ring can be removed, machined to size and marked with an identifica-
tion groove (see circular 10 11 90).
Replace O-ring.
20038/10 E –10.95–
Page 1

Before installing grooved ball bearing, mount axial locat-
ing device (1) on crankshaft (2) and free end of crank-
case (3).
Note
Do not re-turn crankshaft before installing axial locating

device.
Installing grooved ball bearing

Observe repair size before installing grooved ball bear-
ing, see 3.3.1.4.
Slide grooved ball bearing (1) into bearing cap at driving
end in crankcase bore.
Using plastic mallet, drive ball bearing home into bearing
cap.
Align the alignment bearing caps in such a way that the
fit diameter and the contact surface for the grooved ball
bearing are flush with the crankcase and bearing cap.
Tighten alignment bearing cap nuts and screws, – see
3.1.2.6
Check crankshaft axial play after installation of flywheel/
engine coupling.
Installing oil pan, see 3.1.6.6.
Installing flywheel, see 3.3.3a.6.
Install engine coupling
Idler gear backlash, see 3.2.
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Page 2
Installing clamp ring

Insert O-ring in the groove on clamp ring (1) and coat
with petroleum jelly.
Install clamp ring with screws (3) (without spring
washers) on crankcase and alignment bearing caps, –
see Arrangement 3.3.4
Check inner ring of grooved ball bearing for ease of
movement by turning by hand.
Note
Mount O-ring only after oil pan has been installed.
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Page 1
3.3.4.6a Installation in Crankcase with Intermediate Frame

Before installing grooved ball bearing, mount axial locat-
ing device (3) on crankshaft (1) and free end of crank-
case (2).
Note
Do not re-turn crankshaft before installing axial locating

device.

Observe repair size before installing grooved ball bear-
ing, see 3.3.1.4.
Slide grooved ball bearing (1) into crankcase bore at
driving end.
Using plastic mallet, drive ball bearing home into inter-
mediate frame.
Installing clamp ring

Insert O-rings in grooves in clamp ring.
Coat O-ring and sealing surface on crankcase and inter-
mediate frame with ”petroleum jelly”.
Install clamp ring in housing with bolts.
Installing flywheel housing, see 3.1.8.6.
Measuring crankshaft axial play after installation of en-
gine coupling, see 3.3.3.7.
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3.3.5 Seal Carrier, Driving End
1 O-ring 4 Seal carrier

3 Radial-lip shaft seal 6 Bolt
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Seal carrier, driving end
1 Seal carrier 4 O-ring

2 Shaft seal 5 Spring washer
3 O-ring 6 Bolt
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Page 3
Seal carrier for flywheel with taper

1 O-ring
2 Hex bolt
3 Spring washer
4 O-ring
5 Seal carrier
6 Radial-lip shaft seal
Seal carrier for coupling/alternator

1 Seal carrier
2 Track ring
3 Shaft seal
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- x x Separate engine from gearbox -
- x x Remove engine flange 3.3.3.2
- x x Remove flywheel 3.3.3a.2
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3.3.5.2 Removal
Unscrew bolts from oil seal carrier (1).
Use three jackscrews to press carrier off clamp ring.
Remove O-ring and jackscrews from carrier.
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3.3.5.3 Disassembly
Press oil seal (1) out of carrier (2) using a suitable thrust
plate and hand press.
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Clean oil seal carrier and check for distortion.
Adjust bore gauge and measure bore for radial-lip oil seal.
Replace component if carrier is distorted.
Replace component if specified limits are exceeded.
Replace O-ring.
Replace radial-lip shaft seal.
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3.3.5.5 Assembly
Installing oil seal
Coat rubberized outer casing of oil seal with denaturated
ethanol.
Denaturated ethanol serves as a lubricant and must not
be wiped off with a cloth or blown away with compressed
air.
Clean and degrease bore for shaft seal in seal carrier (2)
and blow out with compressed air.
Using a press-in plate (1) and manual press, press shaft
seal with lip facing inwards into seal carrier.
Oil seal must be correctly seated on bore collar.
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Page 1
Insert O-rings in grooves in oil seal carrier.
Coat lip on shaft seal with ”petroleum jelly”.
Mount oil seal carrier (1) on clamp ring using bolts and
spring washers.
Tighten screws with torque wrench. For torque settings,
see Section 1.3.
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3.3.6 Bearing Retaining Plate
1 Bearing retaining plate 7 Intermediate element

2 Plug 8 O-ring
3 Crankshaft bearing (one-piece) 9 O-ring
4 Plug 10 Washer
5 Sealing ring 11 Hex bolt
6 Sealing ring
20038/10 E –11.92–
Page 2
1 Plug
2 Washer
3 Hex bolt
4 O-ring
5 O-ring
6 Crankshaft bearing (one-piece)
7 Crankshaft
8 Bearing retaining plate
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Page 1


- x x Remove cover, free end, with elbow removal 3.4.1.2
- x x Remove vibration damper 3.3.7.2
- x x Remove flange for vibration damper 3.3.7.2
- x x Remove auxilary PTO, free end (order-specific) 3.3.9.2
20038/10 E –07.94–
Page 1
3.3.6.2 Removal
Using ratchet wrench (2), remove bolts from bearing re-
taining plate (1).
Release retaining plate from fitted pins using two pry
bars and remove.
Remove O-ring from groove.
Remove intermediate element (1) from bore on crank-

case.
Remove O-rings (2) from grooves.
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Remove plugs and clean bearing retaining plate.
Using the surface crack-testing method with red penetrant dye, check bearing retaining plate for cracks; replace com-
ponent if cracks are found.
Adjust bore gauge and measure crankshaft bearing bore.
Replace crankshaft bearing if limit values are exceeded.
For specified limits, see Tolerances and Wear Limits List.
Replace crankshaft bearing until it reveals signs of damage, scoring, indentations or cavitation.
Using mandrel and hydraulic press, remove crankshaft bearing from retaining plate.
Adjust bore gauge and measure locating bore in retaining plate.
If limit value is exceeded, machine locating bore to repair size and install repair-size crankshaft bearing.
Note
Replace crankshaft bearing during W6 overhaul.

Check intermediate piece for damage and scoring; rub down as required with oilstone or polishing cloth.
Replace O-rings.
20038/10 E –11.92–
Page 2
Installing crankshaft bearing in retaining plate

Blow oilways in retaining plate clear with compressed
air.
Chill crankshaft bearing in liquid nitrogen.
Caution

tions in 1.5.
Heat bearing retaining plate (1) to 80°C.
Caution
Always use protective gloves to hold bearing retaining

plate.
Place on a flat surface so that when it is installed, crank-
shaft bearing cannot project beyond face of retaining
plate.
Using retaining unit, insert crankshaft bearing (2) in ac-
cordance with stamped 0-marking into bearing retaining
plate.
Ensure that the 0-markings on bearing retaining plate
and crankshaft bearing are aligned.
Cool bearing retaining plate to 20°C.
Measure crankshaft bearing bore with bore gauge.
1 0-marking on bearing retaining plate and crankshaft bearing
2 Crankshaft bearing
20038/10 E –11.95–
Page 1
Insert O-rings (2) in grooves in intermediate piece (1).
Insert intermediate piece in crankcase bore so that re-
cess in collar engages dowel pin in crankcase.

Rub down mating faces of crankcase and retaining plate
(2) with oilstone.
Insert O-ring (1) in retaining plate.
Install O-ring in groove at guide collar.
Coat threads of retaining plate securing bolts (1) with en-

gine oil.
Fit washers (2) on bolts.
Clean and degrease sealing surface (A) for bearing re-
taining plate (4) and crankcase and coat with ”surface
sealant”.
Before installing retaining plate, make sure that idler
gear mounting studs and nuts do not project beyond
seating surface of retaining plate.
Install retaining plate in crankcase bore.
Take care to ensure that O-ring (3) does not shear.
20038/10 E –04.96–
Page 2
Screw bolts and washers into retaining plate (1).

Attention
Bearing retaining plate and crankcase are machined as

a pair and must not be replaced individually.
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Page 1
3.3.7 Flange, Free End
Version 559 030 05 94
1 Flange, free end

2 Fitted pin
3 O-ring
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Flange, free end - version 556 031 01 46
1 Flange
20038/10 E –04.96–
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Flange, free end - 559 030 05 94

2 Fitted pin
3 Crankshaft
4 Flange
Flange, free end - 556 031 01 46

2 Flange
3 Crankshaft
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- x x Remove vibration damper, free end 3.3.8.2
20038/10 E –04.96–
Page 1
3.3.7.2 Removal
Caution
Danger
Use only specified and tested equipment for hydraulic removal.
Pressing off flange, free end
Unscrew plug at free end of crankshaft (1).
Screw draw spindle (2) of hydraulic puller into crank-
shaft as far as it will go and secure.
Measure reference dimension ”B” = 260 mm.
20038/10 E –11.92–
Page 2
Fit intermediate ring (4) on draw spindle (9); for this pur-
pose insert centering bushing (3) over pin (2).
Insert adapter (10) for expanding flange (1).
Push pressure sleeve (5) and hydraulic nut (6) with
carrier (7) onto draw spindle.
Mount hex nut (8) on draw spindle until it contacts the
stop and back off approx. 12 mm to 15 mm (A).
Note

A Setting 12 mm to 15 mm
B Reference dimension 260 mm
Connect and secure H.P lines to adapter and hydraulic nut.
Close valve.
Operate hydraulic hand pump for hydraulic nut until pressure sleeve contacts flange.
Hydraulic nut acts as a buffer and stop for flange when it is released from crankshaft taper, thus preventing flange from
being released suddenly from crankshaft.
Actuate oil pressure hand pump for expansion of flange until half max. expansion pressure is reached. Maintain this
Operate pump to make up loss in expansion pressure until flange is released or until it is necessary to increase pressure
further.
Max. expansion pressure is stamped on flange: do not exceed this pressure.
Pressure in hydraulic puller increases when flange is released.
Remove flange from crankshaft taper (11) and O-rings from flange.
Take care not to damage crankshaft bearing.
Removing bearing retaining plate, see 3.3.6.2.
20038/10 E –04.96–
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Check flange for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace component
Check running surface of flange for scoring, rust, indentations and damage.
Smooth minor wear with emery cloth; in event of major damage, grind running surface to repair size, see Tolerances
and Wear Limits List.
Machining of running surface and gauging on flange can only be performed with flange installed.
Stamp repair stage dimensions on front of flange.
Check tapered bore for wear; use tapered gauge 1:50 if necessary. Replace component if tapered bore has expanded.
Check condition of tapped bores and recut as required.
Replace O-rings.
20038/10 E –04.96–
Page 1
Degrease crankshaft bearing (1) and contact surfaces
(2) of flange and crankshaft.
Coat contact surfaces of crankshaft taper and crank-
shaft bearing with SAE 10 engine oil.
Push flange (1) onto crankshaft taper (2).

Measure distance (A) from end of crankshaft to flange
face.
Record measurement.
Specified force-on distance and maximum expansion
pressure are stamped on flange face.
Maximum force-on pressure is stamped on hydraulic in-
staller.
Caution
Danger
Use only specified and tested equipment for hydraulic installation. Check the equipment annually (draw spindle crack
test). The installation pressure stamped on the tool and the expansion pressure stamped on the flange must not be
exceeded. During the installation procedure, make sure that nobody is standing behind the tool.
20038/10 E –11.92–
Page 2

Screw draw spindle (9) of hydraulic installer into crank-
shaft as far as it will go.
Fit intermediate ring (4) on draw spindle and insert
centering bushing (3) over fitted pin (2).
Insert adapter (10) for expanding flange (1).
Mount hex nut (8) on draw spindle and tighten fully.
A = push–on distance
Connect and secure H.P. line to adapter and hydraulic nut.

Close valve.
Actuate oil pressure hand pumps to increase installation pressure and expansion pressure alternately, starting with
installation pressure, until installation dimension stamped on flange is reached and flange front face is flush with crank-
shaft front face.
Select force-on pressure so that final position is reached after approx. 5 steps.
When beginning hydraulic installation, ensure that expansion pressure is not exceeded!
Max. expansion pressure is stamped on flange face.
Allow reduced force-on pressure to act on flange for a minimum of 60 minutes.
Relieve force-on pressure.
Remove hand pump and hydraulic installer.
Note

Seal end of crankshaft with plug and sealing ring. For torque setting, see Section 1.3.
Recheck force-on distance with depth gauge.
20038/10 E –04.96–
Page 1
3.3.7a Support Ring, Free End
1 Bearing retaining plate 3 Support ring

2 Crankshaft bearing (one-piece) 4 Crankshaft
A = Distance 89.5 mm +0.2 mm
-0 mm
20038/10 E –04.96–
Page 1


- x x Remove auxiliary PTO, free end (order-specific) 3.3.9.2
20038/10 E –11.92–
Page 1
3.3.7a.2 Removal
Caution
Danger
Forcing off support ring, free end
shaft as far as it will go and secure.
20038/10 E –11.92–
Page 2
Push-on dimension A 7.1 mm to 9.4 mm

Reference distance B 260 mm
Block dimension C 89.5 mm +0.2 mm
-0
Push pressure sleeve (4) onto draw spindle (8).

Screw adapter (3) for expansion pressure into face of
support ring (2) and secure.
Push hydraulic nut (5) with carrier (6) onto draw spindle.
Mount hex nut (7) on draw spindle, tighten fully and back
off approx. 10 mm (A).
Note

itial position (0-travel).
Connect and secure H.P. lines to adapter and hydraulic nut.

Close valve.
Operate hydraulic hand pump for hydraulic nut until pressure sleeve contacts support ring.
Hydraulic nut acts as a buffer and stop for support ring when it is released from crankshaft taper, thus preventing support
ring from being released suddenly from crankshaft.
Actuate oil pressure hand pump for expansion of support ring until half max. expansion pressure is reached. Maintain
this pressure for approx. 5 minutes.
Operate pump to make up loss in expansion pressure until support ring is released or until it is necessary to increase
pressure further.
Max. expansion pressure is stamped on support ring: do not exceed this pressure.
Pressure in hydraulic puller increases when support ring is released.
Remove support ring from crankshaft taper, taking care not to damage crankshaft bearing.
20038/10 E –04.96–
Page 1

Check support ring for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace compo-
nent if cracks are detected.
Check running surface of support ring for scoring, rust, indentations and damage.
Smooth minor wear with emery cloth; in event of major damage, grind running surface to repair size.
Machining of running surface and gauging on support ring can only be performed with support ring installed.
Stamp repair stage dimensions on front of support ring.
Check tapered bore for wear; use tapered gauge 1:50 if necessary. Replace component if tapered bore has expanded.
Check condition of threads in tapped bores and recut as required.
20038/10 E –11.92–
Page 1
Degrease crankshaft bearing (1) and contact surfaces

(2) of flange and crankshaft.
Coat crankshaft taper and crankshaft bearing with SAE
10 engine oil.
Push support ring (1) onto crankshaft taper (2).

Measure distance from end of crankshaft to support ring
face.
Record measurement.
Specified force-on distance and maximum expansion
pressure are stamped on support ring face.
A = 89.5 mm +0.2 mm
-0
20038/10 E –04.96–
Page 2
Caution
Danger
Use only specified and tested equipment for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the support ring must not be
exceeded.
Pressing on support ring, free end
shaft as far as it will go.
20038/10 E –11.92–
Page 3
Push-on dimension A 7.1 mm to 9.4 mm

Reference distance B 260 mm
Block dimension C 89.5 mm +0.2 mm
-0
Push pressure sleeve (4) onto draw spindle (8).

Screw adapter (3) for expansion pressure into support
ring face (2) and secure.
Push hydraulic nut (5) with carrier (6) onto draw spindle.
Connect and secure H.P. line to adapter and hydraulic
nut.
Fill hydraulic hand pumps with SAE 10 engine oil and
bleed pumps and lines until bubble-free oil emerges.
Close valve.
Beginning with installation pressure, alternately actuate oil pressure hand pumps for installation and expansion pres-
sures and allow pressure to increase until push-on distance stamped on support ring has been reached.
When beginning hydraulic installation, ensure that permissible expansion pressure is not exceeded!
Max. expansion pressure is stamped on support ring face.
When press-fitting operation is completed, relieve expansion pressure and reduce force-on pressure to 270 bar. Allow
reduced force-on pressure to act on support ring for a minimum of 60 minutes.
Relieve force-on pressure and remove hand pumps and hydraulic installer.
Seal end of crankshaft with plug and sealing ring. For torque setting, see Section 1.3.
20038/10 E –04.96–
Page 1
3.3.8 Vibration Damper, Free End, with Flange

Version 559 030 11 03
1 Flange, free end 5 Intermediate ring

2 O-ring 6 Stress bolt
3 Vibration damper 7 Crankshaft bearing (one-piece)
4 Fitted pin
20038/10 E –11.92–
Page 2
Vibration damper with flange

1 Vibration damper
2 O-ring
3 Fitted pin
4 Fitted pin
5 Crankshaft
6 Intermediate ring
7 Stress bolt
8 Flange
1 Vibration damper
2 Inner side plate
3 Driver
4 Bolt
5 Inertia member
6 Outer side plate
7 Pin
8 Sleeve spring
20038/10 E –10.95–
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20038/10 E –11.92–
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3.3.8.2 Removal
Unscrew stress bolts (3) from vibration damper (1) with
extension wrench (1).
Force intermediate ring (4) off flange on crankshaft
using jackscrews.
Screw two mandrels (2) into flange.

Force vibration damper (1) off flange using jackscrews
and remove with lifting gear.
Remove auxiliary mandrels from flange.
20038/10 E –11.92–
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3.3.8.3 Disassembly
Remove bolts from outer side plate (1).
Detach side plate from inertia member.
By raising vibration damper from drive member (3) with

lifting gear, inner side plate is released from inertia
member.
Pay attention to spring pin.
Remove stroke limiters (1) by hand from sleeve springs
(2).
Knock out sleeve springs with removal mandrel.
Remove drive member from inertia member.
20038/10 E –11.92–
Page 1

Check surfaces of sleeve spring bores in inertia and drive members for signs of wear; smooth surfaces with polish-
grinding machine if necessary.
Check stroke limiter surfaces and groove flanks in drive member for wear; rub down with oilstone and polishing cloth
if necessary.
In event of wear on groove edges of driver, recondition groove edges to dimension 24.5 H11 and then harden edges,
– also refer to MTU Circular.
Check side plates, inertia member with driver for indentations and working points on contact surfaces; smooth with
oilstone as necessary.
Check threads and recut if necessary.
Take sleeve spring packs apart individually and visually inspect for cracks.
Replace sleeve springs if cracked.
Sleeve springs cannot be replaced individually.
Replace sleeve springs during W6 overhaul.
Check intermediate ring for damage and irregularities; recondition if necessary.
Check length of stress bolts; max. length = 68.0 mm.
Check threads and hexagon heads for damage; replace stress bolts if necessary.
Check stress bolts for cracks using magnetic crack-testing method with fluorescent powder; replace bolts if cracks are
found.
Check spring pin on driver and inertia member; replace as necessary.
20038/10 E –10.95–
Page 1
3.3.8.5 Assembly
Position inertia and drive members on inner side plate.
Pay attention to spring pin.
Rotate drive member so that markings (1) are in align-
ment.
Coat sleeve springs (2) individually with thin-film lubric-

ant.
Use installation tool (1) to insert sleeve spring packs into
vibration damper.
New sleeve spring packs have already been treated with
lubricant and must not be cleaned.
Use drift (1) to drive sleeve springs (2) into vibration

damper.
20038/10 E –11.92–
Page 2
Place stroke limiters (1) in sleeve springs.
Notes on assembly:
Before installing outer side plate, check serial numbers
of inertia and drive members.
These numbers must be the same.
A = serial number.
Check projection ”A” and ”B” = 5 mm –0.5 mm of spring

pins (1) and (3) on driver (2) and inertia member (4).
If necessary, install new spring pins.
20038/10 E –10.95–
Page 3
Fit outer side plates on inertia member.

Coat threads of bolts with engine oil and install bolts.
20038/10 E –10.95–
Page 1
Use plastic mallet to drive fitted pins (1) into crankshaft
(3) and flange (2) so that pins are in alignment as shown
in adjoining illustration.
Clean seating surfaces of vibration damper (1) and

flange (5) and blow clear with compressed air.
Ensure that oil feed bore in flange remains clean.
Install O-rings (2) in grooves in flange.
Ensure that O-rings do not become twisted.
Screw two mandrels into flange.
Push vibration damper onto mandrels with rope and lift-
ing gear.
In so doing, pay attention to locating bore.
Push vibration damper onto flange.
Ensure that fitted pin (3) engages locating bore provided
in damper.
Push intermediate ring (6) onto flange so that fitted pin
(4) engages locating bore provided.
Coat threads and heads of stress bolts (7) with engine
oil.
Secure vibration damper to flange with two stress bolts.
Remove auxiliary mandrels from flange.
20038/10 E –10.95–
Page 2
Measure length of stress bolts (2).

Max. length = 68.0 mm.
Replace stress bolts if max. length is obtained.
Coat threads and heads of stress bolts with engine oil.
Secure vibration damper to flange with stress bolts.
Screw stress bolts into vibration damper (3) and pre-
tighten diagonally and evenly to specified torque with
torque wrench (1). For torque setting, see Section 1.3.
Tighten stress bolts to final torque.
20038/10 E –11.92–
Page 1
3.3.8a Vibration Damper, Free End, with Driver

Version 556 030 05 03
1 Outer side plate 8 Sleeve spring

2 Reactor 9 Hex bolt
3 Driver 10 Socket-head screw
4 Sealing plug 11 Sealing washer
5 Inertia member 12 O-ring
6 Inner side plate 13 Vibration damper
7 Pin
20038/10 E –11.92–
Page 2
Vibration damper, free end, with driver – Version 556 030 04 03
1 Side plate 9 Sleeve spring

2 Reactor 10 Spring pin
3 Driver 11 Hex bolt
4 Sealing plug 12 Socket-head screw
5 Inertia member 13 Sealing washer
6 Inner side plate 14 O-ring
7 Dowel pin 15 Fitted pin
8 Pin for sleeve spring 16 Vibration damper
20038/10 E –10.95–
Page 3
Vibration damper, free end, with driver – Version 556 030 10 03
1 Outer side plate 8 Sleeve spring

2 Reactor 9 Bolt
3 Driver 10 Bolt
4 Sealing plug 11 Sealing washer
5 Inertia member 12 O-ring
6 Inner side plate 13 Vibration damper
7 Pin
20038/10 E –04.96–
Page 4
Vibration damper with driver – Version 556 030 04 03

1 Vibration damper
2 O-ring
3 Sealing washer
4 Crankshaft
5 Socket-head screw

1 Vibration damper
2 O-ring
3 Sealing washer
4 Crankshaft
5 Socket-head screw
20038/10 E –10.95–
Page 5

1 Vibration damper
2 O-ring
3 Sealing washer
4 Crankshaft
5 Socket-head screw
6 Bell housing
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.- - x Drain engine oil Op. Man.
20038/10 E –11.92–
Page 1
3.3.8a.2 Removal
Removing sealing disc
Remove socket head screws.
Force sealing ring (1) off drive member using jack-
screws (2).
Remove O-ring from sealing disc.
Pressing off vibration damper
Caution
Danger
The installation pressure stamped on the tool and the expansion pressure stamped on the driver must not be exceeded.
shaft (1) as far as it will go and secure.
Push intermediate ring (3) onto draw spindle.
Insert adapter (4) for expanding drive member (2).
stop and then back off approx. 12 mm to 15 mm (dis-
tance ”A”).
Note

A Setting 12 mm to 15 mm
20038/10 E –11.92–
Page 2
Connect and secure H.P. lines (1) and (4) to adapter (3)
and hydraulic nut (2).
Close valves.
Operate hydraulic hand pump for hydraulic nut until pressure sleeve contacts drive member.
Hydraulic nut acts as a buffer and stop for vibration damper when it is released from crankshaft taper, thus preventing
damper from being released suddenly from crankshaft.
Actuate oil pressure hand pump for expansion of driver until half max. expansion pressure is reached. Maintain this
Operate pump to make up loss in expansion pressure until vibration damper is released or until it is necessary to in-
crease pressure further.
Max. expansion pressure is stamped on drive member: do not exceed this pressure.
Pressure in hydraulic puller increases when vibration damper is released.
Relieve pressure in hydraulic hand pump.
20038/10 E –11.92–
Page 3
Insert eyebolt (1) into vibration damper (2).

Attach lifting rope.
Lift vibration damper off crankshaft with lifting gear.
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Page 1
Position vibration damper on assembly ring.
Remove bolts from outer side plate (1) with ratchet
wrench (2).
Detach side plate.
Note
On vibration damper 556 030 04 03, the outer side plate

is located with spring pin and dowel pin .
By raising vibration damper from drive member (2) with

lifting gear, inner side plate is released from drive and in-
ertia members.
Remove stroke limiters (3) by hand from sleeve springs
(1).
Knock out sleeve springs with removal mandrel.
Remove drive member from inertia member.
20038/10 E –10.95–
Page 1

Clean all parts.
Using the magnetic crack-testing method with fluorescent magnetic powder, check driver and inertia member for
cracks. If cracks are detected, replace parts.
Drive and inertia members are machined and marked as a single unit and may only be replaced as such.
Check running surface of drive member for scoring, corrosion, indentations and damage.
Smooth minor wear with emery cloth.
If more severe damage is found, grind running surface to repair size.
Driver reconditioning and measuring can only be carried out when driver is fitted (push-on dimension for conditioning
10.9 mm +0.2 mm).
The repair stage dimension is stamped on the face of the driver.
Inspect taper bore in drive member for wear and check with 1:50 taper mandrel if necessary.
If the tapered bore has expanded, replace component.
Check surfaces of sleeve spring bores in inertia and drive members for signs of wear; smooth surfaces with polish-
grinding machine if necessary.
Check stroke limiter surfaces and groove flanks in drive member for wear; rub down with oilstone and polishing cloth
or replace if necessary.
Check side plates, inertia member with driver for indentations and wear on contact surfaces; smooth with oilstone as
necessary.
Take sleeve spring packs apart individually and visually inspect for cracks.
Replace sleeve springs if cracked.
Sleeve springs cannot be replaced individually.
Replace sleeve springs during W6 overhaul.
Check threads and tapped bores for ease of movement and recut if necessary.
Ensure that oil bores are particularly clean.
Check dowel pin and spring pin for damage, replace as necessary.
20038/10 E –10.95–
Page 1
3.3.8a.5 Assembly
Ensure that oil bore in drive member is particularly clean
and seal with plug (2).
Observe distance 1.3 mm.
Coat thread of restrictor (1) with high-strength pipe
thread sealant and screw into drive member as far as
end of thread.
Using insertion tool, drive spring pin (1) into driver (2).
Note: Dimension A = 5 mm –0.5 mm
Drive dowel pin (3) into inertia member (4).
Note: Dimension A = 5 mm –0.5 mm
Note
Spring pin and dowel pin are installed on vibration

damper 556 030 04 03.
Check oil bore in drive member for obstructions using

compressed air.
20038/10 E –10.95–
Page 2
Position inner side plate (4) on assembly ring (3).

Place drive member (2) on inner side plate.
Install two guide mandrels (1).
Position inertia member (1) on inner side plate.

Pay attention to position of countersink marking (see
next illustration).
Countersink markings (A) on drive and inertia members

must be in alignment.
Check serial numbers (B) of drive and inertia members.
These numbers must be the same.
20038/10 E –10.95–
Page 3
Coat sleeve springs (1) all over with thin-film lubricant.

Grip sleeve springs with tool (2) and insert into vibration
damper.
Pay attention to installation positions of sleeve springs.
New sleeve spring packs have already been treated with
lubricant and must not be cleaned.
Use drift (1) to drive sleeve springs (2) into vibration

damper.
20038/10 E –11.92–
Page 4
Place stroke limiters (1) in sleeve springs.

Use feeler gauge to check gap (S) all round between
drive and inertia members.
Distance (S) ≥ 0.25 mm
Fit outer side plates on inertia member.

Remove guide mandrels (1).

Insert screws and tighten with torque wrench (2) to
Tightening Specification 1.3.
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Page 1
Installing bearing retaining plate, see 3.3.6.6.
Degrease contact surfaces of crankshaft (2) and vibra-
tion damper.
Coat crankshaft taper and crankshaft bearing (1) with
SAE 10 engine oil.
Insert eyebolt (1) into vibration damper (2).

Attach lifting rope.
Raise vibration damper with lifting gear and push onto
crankshaft taper.
Measure distance from end of crankshaft to face of drive
member.
Record measurement.
Specified force-on distance and max. expansion pres-
sure are stamped on face of drive member.
Remove suspension rope and eyebolt.
20038/10 E –07.94–
Page 2
Pressing on vibration damper
Caution
Danger
Use only specified and tested equipment for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the driver must not be exceeded.
shaft (1) as far as it will go and secure.
Push intermediate ring (3) onto draw spindle.
Insert adapter (4) for expanding drive member (2).
A Push-on dimension 12 mm to 15 mm
Connect and secure H.P. lines (1) and (4) to adapter (3)
and hydraulic nut (2).
Close valves.
20038/10 E –11.92–
Page 3
Actuate oil pressure hand pump to increase installation pressure and expansion pressure alternately, starting with in-
stallation pressure, until installation dimension stamped on driver is reached and driver front face is flush with crankshaft
front face.
Ensure that expansion pressure is not exceeded!
Max. expansion pressure is stamped on face of drive member.
Allow reduced force-on pressure to act on drive member for a minimum of 60 minutes.
Relieve force-on pressure and remove hand pump and hydraulic installer.
Note

Installing sealing disc

Provide sealing disc (1) with a new O-ring.
Insert O-ring into drive member of vibration damper.
Rotate sealing disc so that bores are in alignment with
tapped bore in vibration damper.
Insert socket-head screws (2) and tighten in two stages,
diagonally and evenly, to Tightening Specification 1.3.
Note
The initial sealing washer version is designed with

12 bores. Insert securing screws (3) and in two stages,
diagonally and evenly, to Tightening Specification 1.3.
20038/10 E –04.96–
Page 1
3.3.9 Auxiliary Drive, Free End
1 Bell housing (order-specific) 8 Intermediate flange

2 Bell housing 9 Plug
3 Washer 10 O-ring
4 Bolt 11 Bolt
5 Seal carrier 12 O-ring
6 Radial-lip shaft seal 13 Vibration damper
7 Track ring
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Page 1


- - x Remove resilient coupling (order-specific) -
- x x Remove hydraulic pump (order-specific) -
- x x Remove hydraulic pump drive (order-specific) -
20038/10 E –04.96–
Page 1
3.3.9.2 Removal
Removing seal carrier
Unscrew bolts (2) from oil seal carrier (6).
Remove screws and washers (3).
Force oil seal carrier out of bell housing (1) using jack-
screws.
Remove plug (5) from intermediate flange (4).
Removing track ring

Mount removal tool (4) with screws (5) on track ring (2)
and tighten.
Fix thrust pad (3) on intermediate flange (1).
Insert Lukas cylinder (6) into removal tool.
Connect H.P. line to quick connector (7).
Actuate pump plunger until track ring is released from in-
termediate flange.
Remove removal tool.
Remove track ring and remove O-ring (8) from track
ring.
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Page 2
Removing intermediate flange

Unscrew bolts (2) from intermediate flange.
Press off intermediate flange (1) with jackscrews from
driver (3) of vibration damper.
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Page 1
3.3.9.3 Disassembly
Disassemble seal carrier
Remove radial-lip shaft seal (2) with suitable drift from
seal carrier (3).
Remove O-ring (1) from seal carrier.
20038/10 E –04.96–
Page 1

Check intermediate flange, track ring and stress bolt for cracks using magnetic crack-testing method with fluorescent
magnetic powder.
Replace components if cracks are found.
Using the surface crack-testing method and red penetrant dye, check seal carrier for cracks.
Replace carrier if cracks are found.
Measure bores in intermediate flange, track ring and oil seal carrier with bore gauge.
Check locating bores and mating surfaces of intermediate flange and oil seal carrier for indentations and damage; rub
down with oilstone or polishing cloth if necessary.
Check oil seal carrier for distortion and replace as required.
Check running surface of track ring for wear, indentations and corrosion.
Smooth minor wear with emery cloth; if necessary respray in accordance with MTU Specifications.
Check length of stress bolt shanks; see Section 1.3.
Replace O-rings and radial-lip oil seal.
20038/10 E –11.92–
Page 1
3.3.9.5 Assembly
Installing track ring on intermediate flange
Prior to shrinking track ring onto intermediate flange,
clean and degrease joint surfaces of components.
Heat track ring to 150 °C (do not exceed temperature of
180 °C).
Thinly coat O-ring (3) with ”petroleum jelly” and insert
into groove in track ring (2).
Wearing protective gloves, force track ring with O-ring
onto intermediate flange (1) as far as it will go. Ensure
that there is no gap at intermediate flange mating face.
Note
When replacing radial-lip oil seal, install track ring so that

sealing lip does not come into contact with old running
race.
Assembling seal carrier

Clean and degrease radial-lip shaft seal (2) on outer di-
ameter and coat with ”denaturated ethanol”.
Coat sealing lip with ”petroleum jelly”.
Use an appropriate mandrel to install oil seal in oil seal
carrier (3) as far as it will go.
Insert O-ring in groove in oil seal carrier.
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Page 1
Installing intermediate flange
Fit intermediate flange (1) on driver (4).
Note
When reinstalling, only use bolts which do not exceed

mm in length.
Coat thread of screws (3) with ”engine oil” and insert on
intermediate flange.
Using torque wrench, pretighten bolts diagonally and
evenly to specified torque.
Then tighten to final torque. For torque settings, see
Section 1.3.
To check tightening of bolts, apply checking torque in
tightening direction as specified in Section 1.3.
If a bolt does turn beyond specified torque, release all
bolts and retighten as specified in Section 1.3.
Screw plug (2) into intermediate flange and tighten with
torque wrench to specified torque. For torque setting,
see Section 1.3.
Installing oil seal carrier
Coat running surface of radial-lip shaft seal on track ring
(4) with ”engine oil”.
Mount seal carrier (5) with screws (2) and washers (3)
on bell housing (1) and tighten.
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Page 1
3.3.9a Auxiliary Drive, Free End
1 Bell housing (order-specific) 8 Plug

2 Bell housing 9 O-ring
3 Washer 10 Shaft seal
4 Bolt 11 Seal carrier
5 Track ring 12 O-ring
6 Hub 13 Vibration damper
7 Sealing ring 14 Bolt
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Page 1


- - x Remove resilient coupling (order–specific) -
20038/10 E –04.96–
Page 1
3.3.9a.2 Removal
Caution
Danger
The installation pressure stamped on the tool and the expansion pressure stamped on the hub must not be exceeded.
Pressing off hub
Unscrew plug (1) from hub (4).
Remove plug (2) from intermediate flange (3).
Screw draw spindle (6) of hydraulic puller into intermedi-

ate flange (1) as far as it will go and secure.
Fit pressure bush (3) on draw spindle (6) and insert con-
nector (9) to expand hub (2) or (8) (order-specific).
Fit hydraulic nut (4) on draw spindle.
stop and back off approx. 10 mm to 12 mm (A).
Note

A Adjustment
B Reference distance
7 Dial gauge for pushing on
20038/10 E –04.96–
Page 2
Mount H.P. lines on connector and hydraulic nut and tighten.

Close valve.
Operate hydraulic hand pump for hydraulic nut until pressure sleeve contacts hub.
Hydraulic nut acts as a buffer and stop for hub when it is released from intermediate flange taper, thus preventing hub
from being released suddenly from crankshaft.
Actuate oil pressure hand pump for expansion of hub until half max. expansion pressure is reached. Maintain this pres-
sure for approx. 5 minutes.
Operate pump to make up loss in expansion pressure until hub is released or until it is necessary to increase pressure
further.
Max. expansion pressure is stamped on hub: do not exceed this pressure.
Pressure in hydraulic puller increases when hub is released.
Remove hub from intermediate flange.
Remove screws (2) and washers (3) from seal carrier
(4).
Force oil seal carrier out of bell housing (1) using jack-
screws.
20038/10 E –04.96–
Page 3
Removing track ring

Mount removal tool (3) with screws (5) on track ring (2)
and tighten.
Fix thrust pad (4) on intermediate flange (1).
Insert Lukas cylinder (6) into removal tool.
Connect H.P. line to quick connector (7).
Actuate pump plunger until the track ring is released
from intermediate flange.
Remove track ring and remove O-ring (8) from track
ring.

Unscrew bolts (3) from intermediate flange.
Press off intermediate flange (1) with jackscrews from
hub (2) on free end.
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Page 1
Disassembling seal carrier
Press oil seal (2) out of carrier (3) using a suitable thrust
plate and hand press.
Remove O-ring (1) from seal carrier.
20038/10 E –04.96–
Page 1

Clean all parts.
Check intermediate flange, track ring, hub and stress bolt for cracks using magnetic crack-testing method with fluor-
Using the surface crack-testing method and red penetrant dye, check seal carrier for cracks.
Replace carrier if cracks are found.
Measure bores in intermediate flange, track ring and oil seal carrier with bore gauge.
Check locating bores and mating surfaces of intermediate flange and oil seal carrier for indentations and damage; rub
down with oilstone or polishing cloth if necessary.
Check tapered bore on intermediate flange and hub for wear; if necessary check with tapered gauge 1:30.
Check oil seal carrier for distortion and replace as required.
Check running surface of track ring for wear, indentations and corrosion.
Smooth minor wear with emery cloth; if necessary respray in accordance with MTU Specifications.
Check length of stress bolt shanks; see Section 1.3.
Replace O-rings and radial-lip oil seal.
20038/10 E –04.96–
Page 1
3.3.9a.5 Assembly
Installing track ring on intermediate flange
Prior to shrinking track ring onto intermediate flange,
clean and degrease joint surfaces of components.
Heat track ring to 150 °C (do not exceed temperature of
180 °C).
Thinly coat O-ring (3) with ”petroleum jelly” and insert
into groove in track ring (2).
Wearing protective gloves, force track ring with O-ring
onto intermediate flange (1) as far as it will go. Ensure
that there is no gap at intermediate flange mating face.
Note
When replacing radial-lip oil seal, install track ring so that

sealing lip does not come into contact with old running
race.
Assembling seal carrier
Clean and degrease radial-lip shaft seal (2) on outer di-
ameter and coat with ”denaturated ethanol”.
Use an appropriate mandrel to install oil seal in oil seal
carrier (3) as far as it will go.
Insert O-ring in groove in oil seal carrier.
20038/10 E –04.96–
Page 1
Fit intermediate flange (1) on flange (2) of free end.
Coat thread of screws (3) with ”engine oil” and insert on
flange.
Note
When reinstalling, only use bolts which do not exceed

81.5 mm in length.
Using torque wrench, pretighten bolts diagonally and
evenly to specified torque.
Then tighten to final torque. For torque settings, see
Section 1.3.
To check tightening of bolts, apply checking torque in
tightening direction as specified in Section 1.3.
If a bolt does turn beyond specified torque, release all
bolts and retighten as specified in Section 1.3.
Installing oil seal carrier

Coat sealing lip on shaft seal with ”petroleum jelly”.
Coat running surface of radial-lip shaft seal on track ring
(4) with ”engine oil”.
Mount seal carrier (5) with screws (2) and washers (3)
on bell housing (1) and tighten.
20038/10 E –04.96–
Page 2
Caution
Danger
Use only specified and tested equipment for hydraulic installation. Check the equipment annually (draw spindle crack
test). The installation pressure stamped on the tool and the expansion pressure stamped on the hub must not be ex-
ceeded. During the installation procedure, make sure that nobody is standing behind the tool.
Pressing on hub
Fit hub (2) on intermediate flange (1).
Measure distance from front of hub to front of intermedi-
ate flange and record measurement.
Screw draw spindle (6) of hydraulic installation tool into
intermediate flange(1) as far as it will go and secure.
Fit pressure bush (3) on draw spindle (6) and insert con-
nector (9) to expand hub (2).
Fit hydraulic nut (4) on draw spindle.
Note

A – Push-on dimension
B – Reference distance
Connect and secure H.P. line to adapter and hydraulic nut.
Close valve.
Fit measuring device on crankcase, position dial gauge stylus of dial gauge (7) with preload on front of hub (8) to
measure push-on dimension.
Actuate oil pressure hand pumps to increase installation pressure and expansion pressure alternately, starting with
installation pressure, until installation dimension stamped on hub is reached and hub (2) front face is flush with inter-
mediate flange front face (1).
When beginning hydraulic installation, ensure that expansion pressure is not exceeded!
Max. expansion pressure is stamped on face of hub.
Allow reduced force-on pressure to act on flange for a minimum of 60 minutes and release installation pressure.
20038/10 E –04.96–
Page 3
Remove measuring device, oil pressure hand pump and installation tool.
Note
Blow out with compressed air to remove oil from expan-

sion bore.
Fit sealing ring on plugs (1) and (2).
Coat thread of plugs with ”engine oil”.
Insert plugs into hub (4) and intermediate flange (3).
Using torque wrench, tighten plugs to specified torque.
20038/10 E –04.96–
Page 1
3.4 End Cover, Free End

Contents
3.4.1 End cover with elbow, free end

3.4.1.2 Removal
20054/00 E –10.93–
Page 2

A
S4

Sealing paste Elastosil – N189 black 50545
Engine oil
Dry compressed air
Caution
20054/00 E –10.95–
Page 1
3.4.1 End Cover with Elbow, Free End
End cover with elbow
1 Plug-in pipe 10 Washer

3 Elbow 12 Sealing ring
4 Gasket 13 Plug
5 Washer 14 O-ring
6 Bolt 15 Cover
8 Bell housing 17 Bolt
9 Dowel pin
20046/20 E –05.96–
Page 2
End cover at free end with elbow
1 Elbow (order-specific version) 8 Dowel pin

2 O-ring 9 Washer
4 Hex bolt 11 Sealing ring
5 Plug-in pipe 12 Plug
6 O-ring 13 Pointer (order-specific version)
7 Bell housing (order-specific version)
20046/20 E –05.96–
Page 3
1 Plug-in pipe 6 Hex bolt

2 O-ring 7 O-ring
3 Elbow 8 Bell housing
4 Gasket 9 Washer
5 Washer 10 Socket-head screw
20046/20 E –05.96–
Page 4
1 Plug-in socket pipe 7 O-ring

2 O-ring 8 Cover
4 Gasket 10 Plug
5 Washer 11 Washer
6 Bolt 12 Bolt
20046/20 E –05.96–
Page 5
1 Plug-in socket pipe 7 O-ring

2 O-ring 8 Cover
4 Gasket 10 Plug
5 Washer 11 Washer
6 Bolt 12 Bolt
20046/20 E –05.96–
Page 1


- x x Remove hydraulic pump (order-specific) 3.30.1.2
- x x Remove hydraulic pump drive (order-specific) 3.88.1.2
20046/20 E –05.96–
Page 1
3.4.1.2 Removal
Unscrew bolts (3) securing end cover (1).
Use two pry bars to detach end cover from bearing re-
taining plate.
Remove plug-in pipe with O-rings.
Unscrew elbow (2) from oil pan.
Remove O-ring and gasket.
Note
Remove other versions as shown in illustrations 3.4.1.
20046/20 E –05.96–
Page 1

Clean end cover, elbow and plug-in pipe.
Check end cover for cracks using surface crack-testing method with red penetrant dye.
Repair minor cracks by machining and distortion-free welding; replace end cover if necessary.
Check sealing surfaces, plug-in pipe bore and and bolt-head seating faces for damage; rub down with oilstone if necess-
ary or replace as required.
20038/10 E –11.92–
Page 1
Install O-ring (1) in groove in bearing retaining plate.
Mount elbow (6) with O-ring (7) and gasket on oil pan.
Insert O-ring (2) in the grooves on plug-in pipe (3) and
Insert plug-in pipe in elbow.
Mount cover (1) on bearing retaining plate.

Install socket head screws (3) with washers in cover.
Tighten socket-head screws with torque wrench.
Secure elbow (2) to oil pan with bolts and washers.
Note
Install other versions as shown in illustrations 3.4.1.
20046/20 E –05.96–
Page 1
3.5 Cylinder Head

Contents
3.5.1 Cylinder head

3.5.1.2 Removal
3.5.1.3 Disassembly
3.5.1.5 Assembly
20038/10 E –11.92–
Page 2

A
S4
S 5.1
S 5.3
S 5.13
S 6.16
S 6.19

Inspection lamp
Steel brush roller
Magnifier
Cylinder wiper with brass brushes

Ethanol, denaturated 40250
Liquid nitrogen
Cleaner P3 Solvclean KW 40022
Engine oil
Decarbonizer (cleaner) Meister Proper 40377
High-strength thread-locking liquid Loctite 270 40083
Emery paste
Dry compressed air

Caution
20038/10 E –08.97–
Page 3
Cylinder head
1 Valve stem seal 12 Exhaust valve

2 Pressure sleeve 13 Valve guide
3 Thrust screw 14 Protective sleeve
4 Injector 15 Inlet valve
5 O-ring 16 Valve seat insert, inlet
6 Spring retainer
7 Valve collet a Engine coolant
8 Valve spring, outer b Engine oil
9 Valve spring, inner c Exhaust gases
10 Valve rotator d Air
11 Valve seat insert, exhaust
20038/10 E –11.92–
Page 1
3.5.1 Cylinder Head
6V 8V 16V
12V
ET05013717B
1 End plate, driving end 12 O-ring 23 Oil line

2 End plate, free end 13 O-ring 24 O-ring
3 End plate, free end 14 Clamp 25 Usit ring
4 Bolt 15 Spacer plate 26 Banjo union
5 Support plate 16 Lifting bracket. 27 Double banjo union
6 Cylinder head gasket 17 Screw M20 x 248 28 Banjo screw
7 Transfer pipe 18 O-ring 29 Usit ring
8 Sealing ring 19 Screw M18 x 229 30 Double banjo union
9 Oil transfer pipe 20 Screw M18 x 200 31 Banjo screw
10 O-ring 21 Screw M18 x 257
11 Sleeve 22 Oil line
20038/10 E –07.94–
Page 2
Inlet and exhaust valves with valve guides and protective sleeve
1 Cylinder head
2 Valve rotator
3 Inlet valve
4 Exhaust valve
5 Valve spring, outer
6 Valve spring, inner
7 Spring retainer, top
8 Valve collet
9 Valve stem seal, inlet
10 Sealing ring
11 Plug
1 Cylinder head
2 Protective sleeve
3 O-ring
4 Cover
5 Cover
6 Cover
7 Sealing ring
8 Plug
9 Sealing ring
10 Plug
11 Valve guide, exhaust
12 Valve guide, inlet
13 Valve seat insert, inlet
14 Valve seat insert, exhaust
20038/10 E –05.96–
Page 3
Cylinder head with supporting plate and cylinder head gasket
1 Cylinder head cover 18 Crankcase

2 Gasket 19 Cylinder liner
3 Adjusting screw 20 Valve seat insert, exhaust
4 Nut 21 Valve seat insert, inlet
5 Rocker, Inlet 22 Sealing ring for coolant transfer
6 Gear case 23 Support plate
7 Rocker shaft 24 Cylinder head gasket
8 Ball stud 25 Coolant transfer pipe
9 O-ring 26 Exhaust valve
10 Rocker shaft 27 Valve rotator
11 Push rod 28 Valve spring, inner
12 Stress bolt for cylinder head 29 Valve spring, outer
13 Inlet valve 30 Stress bolt for cylinder head
14 Valve guide 31 Valve spring retainer, top
15 O-ring 32 Valve collet
16 Sleeve 33 Rocker, exhaust
17 O-ring 34 Valve stem seal
20038/10 E –11.92–
Page 1


- x x Disconnect starting air lines 3.18.3.2
- x x Intake air system: Remove screws at appropriate cylinder head 3.10.2b.2
- x x Exhaust pipework: Remove screws at appropriate cylinder head 3.10.3a.2
- x x Remove rockers and pushrods 3.6.3.2
20058/0 E –05.96–
Page 1
3.5.1.2 Removal
Removing cylinder head bolts
Prior to removing cylinder heads, remove engine oil re-
turn line from cylinder head.
Using ratchet (1) and extension, remove bolts securing
cylinder head in diagonally opposite sequence.
Remove clamps (2) with shims.
Remove lifting bracket.
Detach end plates from end cylinders.
Remove cylinder head.
Remove O-rings from crankcase.
Removing cylinder head gasket

Remove cylinder head gasket (2) and supporting plate
(3) with coolant transfer pipes and sealing rings.
If cylinder head gaskets are to be reused, they must be
marked with respective cylinder numbers.
Remove sleeves (1) with O-rings for valve tappets and
oil transfer pipes.
20038/10 E –11.92–
Page 1
3.5.1.3 Disassembly
Removing valve springs
Removing fuel injector, see 3.11.5.2.
Before removal, use electric engraver to apply identify-
ing marks to valve heads.
Insert securing screw of valve spring compressor (1)
into tapped bore of cylinder head.
Position cylinder head on workbench so that valve
heads are seated.
Compress valve springs with valve spring compressor
and remove valve collets.
Remove upper valve spring retainer (2).
Caution
Spring tension
Remove outer and inner valve springs (1) and (2).
20038/10 E –02.95–
Page 2
Remove valve stem seals (1) from inlet valves.
Turn cylinder head on its side.

Remove inlet valves (2) and exhaust valve (1) from
valve guides.
It is advisable to use a storage rack (1) to protect valves

against damage.
20038/10 E –11.92–
Page 3
Remove valve rotators (1) from valve guides.
Removing protective sleeve

Remove protective sleeve (3) for fuel injection nozzle
from cylinder head (1) using pronged wrench.
Make sure that wrench is correctly engaged in sleeve re-
cess.
Remove O-ring (4) from cylinder head.
20038/10 E –11.92–
Page 1

Clean mating faces, valve seats, inlet and exhaust valves with ”cold cleaner”.
If necessary, pretreat oil carbon deposits on valvess and cylinder heads with ”decarbonizer”; for this purpose, place
components in a container filled with ”decarbonizer” – dwell time depends on degree of contamination.
Note
Add enough solvent to cover valve seats.
Caution
Decarbonizer must only be used in conjunction with a extraction system.

Always wear gloves and protective goggles.
Observe Manufacturer’s Instructions!
After the solution bath, flush or spray cylinder heads and valves with warm water, approx. 60 °C to 80 °C.
Clean valve seats in cylinder head and valves with a rotary steel-wire brush.
Clean bores of inlet and exhaust valve guides with cylinder wiper with brass bristles.
Check cylinder head bolts for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace
bolts if cracks are found.
Check protective sleeve for cracks using surface crack-testing method with fluorescent penetrant dye; replace sleeve
if cracks are found.
Check contact surface of protective sleeve in cylinder head for scoring and wear; recondition if necessary starting from
present actual size.
Attention
The contact surface of the protective sleeve in the cylinder head can only be remachined once.
Check valve collets for indentations and replace as required.
Check valve rotator for ease of movement by turning in direction of rotation; for this purpose, press against the lower
section. Replace valve rotator if sluggish or as part of every W6 major overhaul.
Clean cylinder head gaskets and sandblast as necessary. Check for flateness.
Check sealing surface for scoring and damage, if necessary nickle-plate and/or replace cylinder head gaskets.
Clean support plates, check for flatness and damage and replace as necessary.
Check condition of oil transfer pipes, sleeves, end plates, clamping elements and spacer plates, replace components
as necessary.
Check transfer pipes for engine coolant for damage, replace as necessary.
Using surface-crack test procedure, check lifting bracket for cracks, replace component if cracks are detected.
Check oil return pipes for damage, replace as necessary.
Replace sealing rings, O-rings and valve stem seals.
Inspecting cylinder head face
Check cylinder head face and valve seats for cracks using surface crack-testing method with red penetrant dye.
Cracks in cylinder head face can be removed by machining concentrically to limit size.
Repeat crack test after machining.
Replace cylinder head if further cracks are found.
Replace valve seats if cracked.
20038/10 E –01.96–
Page 2
Using a straightedge or measuring jig, check seating face of cylinder head for irregularities and indentations.
Indentations can be removed by concentric machining on a lathe. Machine towards centre of cylinder head.
Attention
Do not remove more material than is necessary in order to obtain a perfect seating face; see Tolerances and Wear
Limits List.
If corrosion indentations remain in vicinity of high-pressure seal once cylinder head has been machined, seating face
can be chrome-plated in vicinity of high-pressure seal to MTU specifications.
Attention
When reconditioning the cylinder mating face, the mating face of the cylinder liner on the crankcase must also be
checked and reconditioned if necessary.
The height difference between neighbouring cylinder heads must not exceed max. 0.5 mm.
This also applies between cylinder head and end plate on the corner cylinders.
After concentrically reconditioning the mating face, check the depth 28 mm +0.1 mm at the pushrod penetrations.
Bores must be milled is this value is not obtained, see MTU Circular.
Checking clearance between seating face of cylinder head and face of valve head, see Page 7.
Checking cylinder head for leaks

Installing protective sleeve in cylinder head before leak
test, see 3.5.1.5.
Hydraulic pressure-testing procedure:
Install pressure-testing fixtures (1) and (2).
Pump water at approx. 80°C through cylinder head until
head is warm.
If possible, add 1% corrosion inhibitor oil to water.
Close shut-off valve in vent line.
Pressure-test cylinder head at 4 bar water pressure.
Check cylinder head for leaks.
Pressure must be maintained for at least 30 minutes.
Replace leaking sealing caps.
Pneumatic pressure-testing procedure:
Immerse cylinder head in water bath at 80°C and allow
head to warm up.
Pressure-test cylinder head at 0.5 bar air pressure; ob-
serve safety precautions.
Check cylinder head for leaks.
Pressure must be maintained for at least 30 minutes,
during which time no air bubbles should be visible.
Replace leaking sealing caps.
Remove pressure-testing equipment.
20038/10 E –01.96–
Page 3
Removing sealing caps

When removing a sealing cap (2), take care to prevent
it from falling into bore.
Never drill caps to facilitate removal.
Swarf in coolant chambers could cause localized cylin-
der head overheating.
Using a drift (1), carefully tap rim of cap inwards on one
side until cap tilts so that it can be grasped with pliers and
removed.
Do not damage bore, as otherwise new cap will not form
a perfect seal.
Installing sealing caps
Attention
Use only new sealing caps.

Clean and degrease cylinder head bore and seating sur-
face at new end cover (2).
Dry seating surface with compressed air.
Coat seating surface of cap with high-strength thread-
locking liquid (1).
Using suitable drift (1), drive cap (2) into cylinder head
bore.
Rim of cap must be recessed to a depth of approx. 1 mm
in cylinder head bore.
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Page 4
Inspecting and removing valve guides

Clean valve guide bores in cylinder head.
Adjust bore gauge.
Measure bores in inlet and exhaust valve guides (1) and
(2) in measuring planes A-B-C as shown in adjoining il-
lustration.
Check ends of valve guides protruding into inlet and ex-
haust ports for cracks using surface crack-testing
method with red penetrant dye.
Check that inlet and exhaust valve guides are securely
seated in cylinder head.
Replace damaged valve guides.
Check valve guide bores with control mandrel (1).

Control mandrel’s own weight must be enough to cause
”go” end of mandrel to slide through installed valve
guide.
Valve guide must be replaced if ”no-go” end (marked
with a red ring) can be inserted.
If values obtained for valve guides and clearance be-
tween valve and valve guide are greater than or less
than limits specified in Tolerances and Wear Limits List,
valve guides in cylinder head (2) must be replaced.
Using extractor mandrel, press valve guides out of cylin-
der head.
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Page 5
Measuring locating bore for valve guide

Clean bore for valve guide in cylinder head (2) with cylin-
der wiper, or ream bore carefully.
Measure locating bores in cylinder head.
If the limit values are exceeded, ream bores for valve
guides in cylinder head to next stage.
For wear limits, see Tolerances and Wear Limits List
Installing valve guides

Exhaust valve guide designation
I Exhaust valve guide, finish machining of
ID
X Finish machining by reaming, stage 0,1,1a,2
X1 Finish machining by honing, stage 0,1,1a,2
Y Groove only for stage 1 and 2
II Exhaust valve guide finish guide
X2 operational valve guide-without recondition-
ing ID
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Page 6
Inlet valve guide designation

I Inlet valve guide, finish machining of
ID
X Finish machining by reaming, stage 0,1,2
X1 Finish machining by honing, stage 0,1,2
II Inlet valve guide finish guide
X2 Operational valve guide-without
reconditioning ID
Attention
Different valve guides! Pay attention to installation posi-

tion and installation point. Do not reuse valve guides (2)
and (3) once they have been removed.
Heat cylinder head in water bath to approx. 80°C.
Chill new valve guides in liquid nitrogen.
Caution

tions in 1.5.
Mount assembly device with four locating pins for instal-
ling exhaust valve guides on cylinder head.
Note locking pin on installation jig.
Clamp exhaust valve guides (2) in retaining mandrel (1)
and insert into bore in cylinder head until the stop on lo-
cating pins of assembly device.
Insert inlet valve guides (3) with retaining mandrel into
cylinder head until the stop on locating pins of assembly
device.
Note
It is not permitted to drive or press in the valve guides.

Rehone valve guide with manual honing unit, Pemamon
model 1040, to finished dimension, see Circular 06 04 92.
20038/10 E –01.95–
Page 7
1 Exhaust valve guide

2 Assembly device
3 Inlet valve guide
A Exhaust duct
E Inlet duct
a = Distance, 48 mm 0.2 mm±

gray cast iron exhaust valve guide
a = Distance, 44 mm 0.2 mm±
Bronze exhaust valve guide
b = Distance, 50 mm ± 0.2 mm
gray cast iron inlet valve guide
Check bore of valve guides with control mandrel (1) – the

”go”-end length of the mandrel must correspond to the
length of the valve guide.
Control mandrel’s own weight must be enough to cause
”go” end of mandrel to slide through installed valve
guide.
Valve guide must be replaced if ”no-go” end (marked
with a red ring) can be inserted.
Note
When the finished valve guides are installed, using a

control mandrel, check from the compression side and
control side of the cylinder head.
Measuring valve seat recess

Install new valve into cylinder head.
Using depth gauge, measure distance from cylinder
head face to valve head.
Install new valve seat inserts if specified limits are ex-
ceeded.
20038/10 E –07.94–
Page 8
Removing valve seat inserts with removal tool
1 To remove valve seat insert, insert extractor sleeve (2)

into valve seat so that the claws (3) grab the valve seat.
2 Using Allen key (1), tighten stress bolt in extractor

sleeve; for this purpose locate extractor sleeve on valve
3 seat.
Note
For exhaust and inlet valve seat rings, the diameters of

the extractor sleeve vary.
L94_005_01
Insert head spindle (1) into extractor sleeve (2) and turn
until stop on dowel pin.
1
3
2
L94_005_2
20038/10 E –07.94–
Page 9
Turn handle (1) to remove valve seat from cylinder head.

Measure bore for valve seat insert in cylinder head with
1
bore gauge.
List.
Machine to repair size as required.
L94_005_3
Removing valve seat inserts with auxiliary equip-

ment
Prepare two old valves as tools for pressing out valve
seat inserts. Lathe a valve on OD of valve head by 10
mm – used as extractor mandrel (1).
Mill 15 mm off two opposing sides of second valve head
(2).
Regrind the remaining OD corresponding to projecting
edge of cylinder head.
Insert drift into valve guide.
Introduce second prepared valve at an oblique angle
into valve seat bore and position against protruding
edge of valve seat insert.
Using manual press and drift (1), force valve seat insert
out of cylinder head.
Measure bore for valve seat insert, see above.
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Page 10
Installing valve seat inserts

Measure OD of valve seat inserts.
Check interference against Tolerances and Wear Limits
List.
Heat cylinder head in water bath to approx. 80°C.
Chill new valve seat inserts (2) in liquid nitrogen.
Caution

tions in 1.5.
Install in cylinder head with drift (1).
Remachining valve seats

Clean valve guide before inserting pilots with cylinder
wiper and coat with a thin film of ”engine oil”.
Insert pilot (1) from compression surface into valve
guide as far as it will go.
Screw pilot (3) from opposite side into pilot (1).
Secure with spindles (2).
Remove spindles.
Clamp cutting tool (2) 45° in support (1) of valve lathing

tool.
20038/10 E –01.95–
Page 11
Mount valve lathing tool (3) on pilot (5).

Release locknut (2) on rapid adjuster (1).
Turn rapid adjuster until cutting tool (4) is positioned at
centre of valve seat face.
Secure rapid adjuster with locknut.
Carefully push valve lathing tool down onto pilot until cut-
ting tool contacts centre of valve seat.
Release locking screw (2) on knurled nut (3).

Press down pilot rest (1) until it is seated on pilot.
Tighten locking screw of knurled nut.
Turn knurled nut counterclockwise until cutting tool no
longer contacts valve seat face.
Mount steady rest (3) on cylinder head.

Secure steady rest eye (2) to crutch (1).
Attention
The valve tool must be able to turn easily.
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Page 12
Refacing valve seats
Attention
The valve seat face is machined from the inside out-

wards.
To adjust cutting tool (6):
Release locknut (5) on rapid adjuster (4).
Turn rapid adjuster until the cutting tool is positioned at
ID of valve seat surface (7).
Tighten locknut on rapid adjuster.
To set rate of cut:
Set rate of cut with knurled nut (2).
Secure with locking screw (3).
Grip knurled screw (8) securely.
Turn crank (1) clockwise until cutting tool moves freely.
When refacing valve seats, do not remove more ma-
terial than is necessary to obtain perfect seats.
List.
Rework refaced valve seats in cylinder head with cutting
tool or countersink.
Remove lathing tool, steady rest and pilots.
Inpsecting valves
Measure valve stem (2) with outside micrometer (1).
Replace valves if specified limits are exceeded.
Check valves for damage, pitting, scoring and indenta-
tions on stem, plate, neck and pressure surface.
Replace valve if chrome plating is damaged or worn
through, if indentations are found, if valve stem reveals
scores or if pitting is found at transition from valve head
to valve stem.
Remove severe indentations at pressure face of valve
by machining to MTU specifications. Replace valve if
necessary.
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Page 13
Regrinding valve head

Do not remove more material than is necessary to obtain
a perfect seat.
If a valve grinding machine is not available, machine
valve on a valve turning machine.
Measure height of valve lip.
Replace valve if specified limits are exceeded (see Tol-
erances and Wear Limits List).
Check valves for cracks using surface crack-testing
method with fluorescent penetrant dye; replace if
necessary.
Protect valves from damage and place in transport

trestle (1).
Measuring valve recess

Thoroughly clean valve guide bores and valves.
Install valves in cylinder head.
Measure distance from cylinder head face to valve
head.
Replace valves if specified limits are exceeded.
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Page 14
Checking valve springs

Test valve springs (2) with spring tester (1).
Replace springs if specified limits are exceeded.
Check valve springs for indentations, flats, burrs and
surface irregularities.
Flats of up to 0.2 mm on inner diameter of end coils are
permissible.
Surface irregularities and burrs on windings can be re-
moved and springs then reused.
Replace valve springs if necessary.
Determining TDC mark

Determing TDC position
To determine TDC, mount timing pointer (1) on crank-
case.
Mount swivel head (3) with screws at free end of crank-
shaft.
Tighten screws.
Mount graduated disc (2) on swivel head.
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Page 15
Determining TDC position on vibration damper

Remove plug from cover (3) of vibration damper (2), free
end; in doing so the TDC pointer (1) is visible.
Bar crankshaft with barring tool in direction of engine
rotation until piston A1 is at firing TDC.
Roller tappets must not be in overlap position.
Mount magnetic dial gauge holder with dial gauge (2) on

crankcase.
Bring piston to TDC.
Roller tappets must not be in overlap position.
With stylus touching piston crown at outer edge (3), set
dial gauge to zero with preload.
Move piston up and down several times past TDC until
dial gauge shows its maximum reading.
Set dial gauge to zero.
Rotate crankshaft to 6° before TDC.
Read dial gauge and record reading.
Continue rotating crankshaft to approx. 10° after TDC
(to take up play).
Then rotate crankshaft in opposite direction to 6° after
TDC.
Read dial gauge and record reading.
Example:
Piston to 6° before TDC = 0.50 mm
Piston to 6° after TDC = 0.42 mm
Both measurements = 0.92 mm
Mean value = 0.46 mm

Position piston so that dial gauge reads 0.46 mm. Adjust
graduated disc to 6° after TDC and secure.
Check:
The absolute TDC point is reached if the dial gauge be-
fore and after TDC displays the same values at the same
degree.
20038/10 E –07.94–
Page 16
Measuring and adjusting piston top clearance
1 Piston crown surface A Thickness of cylinder head gasket 2.0 mm

2 Cylinder liner B Crankcase surface – piston surface
3 Cylinder head gasket C Piston gap
4 Support plate D Projection of liner collar
E Gap ”S” before tightening cylinder head screws
F Thickness of support plate
Bring piston to TDC (check with dial gauge).
Measure projection B of piston above crankcase.
Record reading in data sheet.
Mark cylinder number on cylinder head gasket and supporting plate with electric engraver.
Check:
Piston top clearance ”C” must be at least 1.40 mm in every case.
Selecting cylinder head gasket
Measured projection ”B” from 8.16 mm to 8.52 mm
Required gasket thickness ”A” 2.0 mm
Set piston gap ”C” from 1.4 mm to 1.9 mm
Example:
Calculate dimension of piston gap ”C” = A + D – B
Projection of cylinder liner collar ”D” + 8.05 mm
Thickness of cylinder head gasket ”A” + 2.00 mm
= 10.05 mm
Projection of piston over crankcase ”B” = –8.15 mm

Dimension of piston gap ”C” = 1.90 mm
Selection of support plate with reconditioned crankcase
Measured bush projection ”D” 8.04 mm to 8.06 mm
Required thickness of support plate ”F” 7.95 mm to 7.97 mm
Gap ”S” 0.090 mm – 0.130 mm/0.70 mm – 0.110 mm
20038/10 E –07.94–
Page 17
Measuring piston gap and setting for pistons with epsilon = 15.5
1 Piston crown surface A Thickness of cylinder head gasket 2.0 mm

2 Cylinder liner B Crankcase surface – piston surface
3 Cylinder head gasket C Piston gap
4 Support plate D Projection of liner collar
E Gap ”S” before tightening cylinder head screws
F Thickness of support plate
Bring piston to TDC (check with dial gauge).
Measure projection B of piston above crankcase.
Record reading in data sheet.
Mark cylinder number on cylinder head gasket and supporting plate with electric engraver.
Check:
Piston top clearance ”C” must be at least 1.40 mm in every case.
Selecting cylinder head gasket
Applicable for piston E = 15.5
Measured projection ”B” 8.35 mm to 8.54 mm 8.55 mm to 8.74 mm 8.75 mm to 8.98* mm
Required gasket thickness ”A” 2.0 mm 2.2 mm 2.4 mm
Set piston gap ”C” 1.42 mm to 1.79 mm 1.42 mm to 1.79 mm 1.40 mm to 1.79 mm
*For dimensions between 8.96 mm and 8.98 mm, use gasket with minimum thickness 2.34 mm!
Also see Tolerances and Wear Limits List.
Set support plate with reconditioned crankcase
Measured bush projection ”D” 8.04 mm to 8.06 mm
Required thickness of support plate ”F” 7.95 mm to 7.97 mm
Gap ”S” 0.090 mm – 0.130 mm/0.70 mm – 0.110 mm
Using electric engraver, write cylinder number on cylinder head gasket and on side of support plate.
20038/10 E –05.96–
Page 1
3.5.1.5 Assembly
Installing protective sleeves
Check that tapped bores in cylinder head and threads of
protective sleeves (3) are clean.
Blow groove for O-ring (4) in cylinder head clear with
compressed air and check that it is clean.
Insert new O-ring into groove. Coat O-ring with ”petro-
leum jelly”.
Coat thread of protective sleeve with engine oil.
Install sleeve in cylinder head with pronged wrench (2).
Tighten sleeve with torque wrench to specified torque.
When tightening sleeve, make sure that pronged
wrench is correctly engaged in sleeve recess.
Once sleeves have been installed, check cylinder head
for leaks, see 3.5.1.4.
Installing valves
Clean valve guides with suitable cylinder wiper and fuel.
Thoroughly clean valves and spray with engine oil.
Install exhaust valves (1) and inlet valves (2).
20038/10 E –11.95–
Page 2
Installing valve rotators

Turn cylinder head over and place on suitable work-
bench so that valve heads are seated.
Install valve rotators (1) on valve guides.
Note
Install valve rotators so that ribbed faces contact cylin-

der head.
Install new rotators during W6 overhaul.
Installing valve stem seals

Before installing valve stem seal, spray upper valve
guide seat (1) with denaturated ethanol.
Slip assembly sleeves (2) onto both inlet valve stems.
Fit dry valve stem seals (1) over assembly sleeves onto
valve stems.
Remove assembly sleeves.
20038/10 E –11.92–
Page 3
Use installation tool (1) to push seals onto inlet valve

guides.
Installing valve springs

Install inner and outer valve springs (1).
Make sure that wider coil spacing is at top.
Top (2) of spring is coloured green.
Use only valve springs with this green marking.
20038/10 E –11.92–
Page 4
Install securing screw of valve spring compressor (1) in

tapped bore in cylinder head.
Place upper spring retainers (2) on valve springs.
Operate valve spring compressor to force springs down.
Install valve collets in valve spring retainers.
Caution
Spring tension
Relieve pressure on valve spring compressor and re-
move.
Place cylinder head on its side and tap valve stem lightly
with plastic mallet to settle valve collets correctly on
valve stem.
Check valve recess.
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Page 1
Installing support plate with coolant transfer pipes
and sealing rings
Check supporting plate (1) for surface irregularities and
ensure that it is clean; replace plate if necessary.
Clean mating face for support plate on crankcase.
Position supporting plate with matching number on
crankcase.
Insert coolant transfer pipes (3) into bores in supporting
plate.
Mount new sealing rings (2) on coolant transfer pipes.
Installing cylinder head gasket and pushrod

sleeves
Check that bores for sleeves (1) in crankcase are clean.
Mount new O-rings on sleeves.
Coat O-rings with ”petroleum jelly”.
Insert sleeves into crankcase.
Insert O-rings (4) for cylinder head screws in crankcase
and coat with ”petroleum jelly”.
Place new cylinder head gasket (2) of correct thickness
or with appropriate marking on supporting pl ate (3).
20038/10 E –05.96–
Page 2
Note
Cylinder head gaskets with silver colour (chemically

nickle-plated) must be used for cylinder liners with
double chamfer and designation ”DS” (1) .
Cylinder head gaskets with silver colour (chemically
nickle-plated) must be used for cylinder heads with chro-
mium-faced compression base.
Installing oil transfer pipes for cylinder head

Mount new O-rings (2) on oil transfer pipes (1).
Insert oil transfer pipes into crankcase bores.
Installing cylinder head

Insert guide pins (4) into cylinder head (1).
Ensure that cylinder head mating face is clean; rub down
and clean as required.
Check that cylinder head gasket (2) and coolant transfer
pipes (3) are correctly seated.
Position cylinder head on crankcase.
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Page 3
Installing end plates

Coat O-rings (1) with petroleum jelly and place in bores
of end plate.
Install end plates (1) on free end and driving end with
socket-head screws M10 (2), – only fit screws only but
do not tighten.
Install lifting bracket with screws M18, – only fit screws
but do not tighten.
Note
Ensure that screw lengths and threads are correct, see

3.5.1.
Tightening cylinder heads

Check threads of stress bolts (2) for damage and blow
clean with compressed air.
Replace damaged stress bolts.
Coat thread, bolt head contact surface and stem of
stress bolts M18 for cylinder heads with ”engine oil” and
insert into crankcase.
Fit clamping elements with spacer plates and insert
stress bolts M20.
Screw in stress bolts.
Note
Ensure that screw lengths and threads are correct, see

3.5.1.
Mount and secure alignment jig (1) on exhaust ports of
cylinder heads.
Carefully align cylinder heads as warping or cracks in
the exhaust housing and/or intake housing could occur.
20038/10 E –05.96–
Page 4
First pretightening:
Pretighten all cylinder head screws on all cylinder heads
with torque wrench (1) in accordance with tightening
specification 1.3 and tightening diagram for individual
cylinder head, see next Page.
Pretighten stress bolts M20 for clamps with torque
wrench in accordance with tightening specification 1.3
in sequence as shown in tightening diagram for individ-
ual cylinder head, see next Page.
Second pretightening:
Pretighten cylinder head screws M18 with torque
wrench in accordance with tightening specification 1.3
in sequence as shown in tightening diagram, see next
Page.
Pretighten all cylinder head screws M20 (clamp screws)
with torque wrench in accordance with tightening spec-
ification 1.3 in sequence as shown in tightening diagram,
see next Page.
Torque angle tightening:

Tighten cylinder head screws M18 with torque angle
measuring tool (1) in accordance with tightening specifi-
cation 1.3 in sequence as shown in tightening diagram.
Tighten cylinder head screws M20 (clamp screws) with
torque angle measuring tool in accordance with tighten-
ing specification in sequence as shown in tightening dia-
gram.
If an angle-of-rotation tightening tool is not available,
mark a line on head of each stress bolt.
Tighten each stress bolt through specified angle.
Tighten bolts on end plates with torque wrench to speci-
fied torque. For torque settings, see Section 1.3.
Remove alignment jigs.
Seal inlet and exhaust ports with end plates.
Checking cylinder heads for leaks, see 3.14.9.
Install fuel injection nozzle, see 3.11.6.6
20038/10 E –07.94–
Page 5
Tightening diagram: Cylinder head, 6V, 8V, 12V, 16V and individual cylinder head
Installing oil return line on cylinder head

Insert O-ring (4) into groove on banjo union (1) and on
oil return line (5) and coat with ”petroleum jelly”.
Insert banjo union into oil return line and install in crank-
case (7).
Connect and secure oil return line to cylinder head (6)
with banjo bolt (2) and Usit rings (3).
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Page 1
3.6 Valve Gear

Contents
3.6.1 Camshaft
3.6.1.2 Removal
3.6.2 Roller tappets

3.6.2.2 Removal
3.6.2.3 Disassembly
3.6.2.5 Assembly
3.6.3 Rockers and pushrods

3.6.3.2 Removal
3.6.3.3 Disassembly
3.6.3.5 Assembly
3.6.4 Gear case, cylinder head cover

3.6.4.2 Removal
20038/10 E –01.95–
Page 2

A
S4
S 6.7
S 6.15
S 6.16
S 6.18
S 6.19

Polishing cloth
Inspection lamp
Ink-check plate
Magnifier
Liquid nitrogen
Engine oil
Dry compressed air

Caution
20038/10 E –08.97–
Page 3
Valve gear
1 Roller tappets 7 Ball stud

2 Locating pin 8 Rocker shaft
3 Stop 9 Rocker, inlet
4 Drive gear 10 Rocker, exhaust
5 Camshaft 11 Adjusting screw
6 Pushrod
20038/10 E –11.92–
Page 1
3.6.1 Camshaft
1 Camshaft, left side 5 Screw

2 Camshaft, right side 6 Drive gear, camshaft
3 Camshaft bearing 7 Driver
20038/10 E –11.92–
Page 1


- - x Removal not scheduled -
- x - Mark and disconnect cables -
- x - Remove terminal boxes and wiring -
- x - Drain engine coolant Op. Man.
- x - Disconnect engine coolant lines 3.14.1.2
- x - Remove coolant expansion tank 3.14.5a.2
- x - Remove engine coolant cooler 3.14.6.2
- x - Disconnect starting air lines 3.18.3.2
- x - Disconnect engine oil lines 3.16.1.2
- x - Disconnect engine oil return pipes from cylinder head -
- x - Remove fuel lines 3.12.2.2
- x - Disconnect leak-off fuel lines 3.12.2.2
- x - Remove cylinder head covers 3.6.4.2
- x - Disconnect fuel pressure lines 3.12.1.2
- x - Remove fuel manifold with manual pump 3.12.5.2
- x - Remove fuel delivery pump 3.12.4.2
- x - Remove intercooler 3.10.1a.2
- x - Separate engine from gearbox -
- x - Remove engine coupling 3.3.3c.2
- x - Remove end cover and/or exhaust connecting line 3.10.11.2
- x - Disconnect exhaust pipework 3.10.3a.2
- x - Remove actuating cylinder 3.10.8a.2
- x - Remove actuator for turbocharger control 3.10.8a.2
- x - Remove intake funnel and intake housing 3.10.7.2
- x - Remove carrier housing with exhaust turbocharger 3.10.6a.2
- x - Remove oil pump for valve seat lubrication 3.15.4.2
- x - Disconnect oil lines for valve seat lubrication 3.16.1.2
- x - Remove intake air system 3.10.2b.2
- x - Remove flywheel housing 3.1.8.2
- x - Remove starting-air distributor 3.18.1.2
- x - Remove crankcase ventilation 3.1.7b/c.2
- x - Remove fuel injection pump 3.11.5.2
- x - Remove upper cover at free end 3.1.9.2
- x - Remove drive shaft with injection timer 3.11.1.2
- x - Remove valve gear housing 3.6.4.2
- x - Remove rocker arms 3.6.3.2
- x - Remove cylinder heads 3.5.1.2
- x - Remove roller tappets 3.6.2.2
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3.6.1.2 Removal
Setting crankshaft to firing TDC of cylinder A1
Turn crankshaft until markings (1) on camshaft (3) and
crankcase (2) are aligned.
Installation and removal of injection timer and camshaft
are carried out when crankshaft is in this position (firing
TDC position of piston of cylinder A1).
Attaching retaining device

Install retaining device (1) with retaining pin on driving
end on camshafts.
Removing drive gear

Remove stress bolts (1) from drive gear (2) of camshaft.
Remove driver and camshaft drive gear from camshaft.
Remove retaining device on driving end from cam-
shafts.
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Removing alignment bearing

Remove screws for alignment bearing (1) with socket
(2).
Remove alignment bearing.
Install guide sleeve

Install guide sleeve (1) with screws on camshaft (2),
driving end.
Tighten screws so that guide sleeve can be centred with
camshaft.
Attention
Never install or remove camshaft without guide sleeve

as this could damage camshaft bearing.
Remove camshaft.
Carefully remove camshaft (2) with guide sleeve (1)
from crankcase in direction of free end.
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Clean camshaft, drive gear and driver.
Flush oil bores with as high a pressure as possible and blow out with compressed air.
Prepolish bearings and cams with emery cloth.
Using the magnetic crack-testing method with fluorescent magnetic powder, check camshaft, drive gear and driver for
cracks, replace parts if necessary.
Check components for damage or excessive wear; if necessary, recondition in accordance with MTU information and
or replace.
Check camshaft alignment bearing for scoring and wear; for limit values see Tolerances and Wear Limits List.
Check radial runout of journal with dial gauge.

If necessary, straighten camshaft on work bench.
Measure camshaft bearing and cam with outside micro-

meter.
If limit values are exceeded, recondition camshaft in ac-
cordance with instructions from MTU; replace camshaft
if necessary.
Replace damaged dowel pins.

When installing, observe projection dimension of 6 mm
-1 mm.
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Installing camshaft
Attention
Ensure reconditioned journals are correctly paired with

bearings!
Attach guide sleeve (1) to camshaft (2) in such a way
that guide sleeve is centred on camshaft.
Rub journal and guide sleeve with chamois leather and
spray with ”engine oil”.
Insert camshaft on free end into bearing.
Insert long camshaft on left engine side and short cam-
shaft on right engine side.
Remove guide sleeve
Installing alignment bearing

Install camshaft alignment bearing (2).
Coat screws with ”engine oil”.
Insert screws and spring washers.
Using torque wrench (1), tighten screws on camshaft
alignment bearing to tightening specification 1.3.
Check camshaft for ease of movement.
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Page 2

Install retaining device with retaining pins on camshaft,
driving end, see 3.6.1.2
Fit drive gear (4) on camshaft (1).
Fit driver (2).
Dowel pin of camshaft must engage in bore of drive
gear.
Note
Replace stress bolts in pairs only for drive gear installa-

tion.
Coat thread of stress bolts (3) with ”engine oil”.
Insert stress bolts for drive gear and, using torque
wrench, tighten diagonally and evenly to tightening
specification 1.3.
Remove retaining device, driving end, from camshaft.
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3.6.1.7 After-installation Operations

Checking axial clearance of camshaft
Install measuring device (1) on camshaft.
Move camshaft (2) on drive gear in axial direction.
Read off axial clearance of camshaft on dial gauge.
If limit values are exceeded, remove drive gear and
alignment bearing of camshaft.
List
If axial clearance is too small:

Recondition camshaft alignment bearing (1) with fine
emery cloth (2) on ink-check plate.
If axial clearance is too large:
Replace camshaft alignment bearing for an alignment
bearing near the top manufacturing limits.
Checking camshaft timing/valve lift

For determining TDC, see 3.5.1.4
Turn crankshaft in direction of engine rotation to firing
TDC, A1 or B1.
Set valve clearance, see 3.6.3.7
When checking valve lift, feeler gauges (1) and (2) must
be installed between adjusting screw (3) and one inlet
and one exhaust valve.
No valve play must be present to obtain correct measur-
ing values and settings.
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Mount measuring device (1) on cylinder head with wing

screw (2) and tighten.
Mount both dial gauge styluses with 1 mm preload on
inlet and exhaust valve spring retainers.
Use dial gauges with 30 mm measuring distance.
Set dial gauge on inlet valve to zero.
Turn crankshaft in direction of engine rotation by 360°
until valve overlap in TDC.
Read off dial gauge at inlet valve and record in data
sheet.
Specified dimension: 1.72 mm + 0.4 mm
– 0.5 mm
Set dial gauge on exhaust valve to zero.
Continue to turn crankshaft in engine direction of rota-
tion until dial gauge on exhaust valve comes to a stand-
still and roller tappet is in base circle of cam.
Read off dial gauge at exhaust valve and record in data
sheet.
Specified dimension: 1.47 mm + 0.3 mm
– 0.25 mm
Remove measuring device and remove feeler gauges.
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3.6.2 Roller Tappets

1 Snap ring
2 O-ring
3 Guide pin
4 Bush
5 Pin
6 Roller
7 Roller tappet
8 Guide bush
9 Crankcase
10 Push rod
1 Roller tappet 7 Guide pin

2 Tappet 8 O-ring
3 Complete roller tappet repair kit 9 Circlip
4 Pin 10 Stop
5 Roller 11 Spring washer
6 Bush 12 Screw
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- x x Disconnect fuel pressure lines 3.12.1.2
- x x Disconnect starting air lines 3.18.3.2
- x x Intake air system: Remove screws from appropriate cylinder 3.10.2b.2
- x x Exhaust system: Remove screws from appropriate cylinder 3.10.3a.2
- x x Disconnect engine oil return pipe from cylinder head -
- x x Remove rockers 3.6.3.2
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3.6.2.2 Removal
Remove screw (1) from stop (2).
Remove stop from guide pin.
Press guide pin (1) out of crankcase by hand.

Remove O-ring and circlip from guide pin.
Remove roller tappet (1) from crankcase.
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3.6.2.3 Disassembly
To press out guide pin, insert roller tappet (2) between
two V-blocks (3) so that there is sufficient support on
either end of pin bore.
Using mandrel (1), press guide pin out of tappet.
Insert bush, roller, pin and tappet into protective basket
and protect against damage.
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Wash roller tappet.
Using the magnetic crack-testing method with fluorescent magnetic powder, check for cracks; replace components if
necessary.
Measure tappet OD and pin OD with outside micrometer.
Adjust bore gauge and measure tappet bore for pin.
If limit values are exceeded, replace parts.
In event of scoring, wear and indentations, smooth components with emery cloth.
If wear is found on one side of pin, reinsert pin by turning by 180°.
Replace components in event of chipping and damage.
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3.6.2.5 Assembly
Heat tappet (1) on heating plate to approx. 80 °C to
120 °C.
Chill pin (2) in liquid nitrogen.
Insert bush (4) into roller (3).
Caution
Always use protective gloves to hold tappet.

Insert bush with roller (3) into tappet (2).
Insert tappet into device (1).
Locate with spring-loaded guide pin (4) into bores of
tappet.
Caution

tions in 1.5.
Insert bush (4) into roller (3).
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Insert pin (2) with retaining pliers (4) into bore on tappet
(1).
Using mandrel (3), press in pin by hand until the stop.
Once tappet has cooled to room temperature, check
ease of movement and axial clearance of roller.
Using outside micrometer, measure roundness of
tappet.
Axial clearance: 0.6 mm to 0.7 mm
Check axial interference fit of pin in complete roller

tappet (5) with test mandrel (3) and hydraulic press (4).
For checking load, see Tolerances and Wear Limits List.
Insert roller tappet into suitable V-Block (1) with groove.
For the purposes of checking axial play, a shim (2) (0.6 mm
thick) is inserted between roller and tappet.
Press fit must not slip at either pin fit.
Check recess of pin.

X = 1 mm
Set roller tappet in transport trestle and protect against
damage.
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Spray roller tappet (1) with ”engine oil” and insert into
guide bush in crankcase.
Fit O-ring (2) and circlip (1) on guide pin and coat with
”engine oil”.
Insert guide pin into bore in crankcase until the stop on
circlip.
Friction surfaces must engage in guide slot of roller
tappet.
To check ease of movement, turn camshaft of roller
tappet to be checked into base circle.
When raised, the roller tappet must fall back into its bot-
tom initial position through its own weight.
When all roller tappets are installed, bar camshaft sev-
eral times by hand.
Ensure that all roller tappets fall back to their initial posi-
tion due to their own weight.
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To locate guide pin for cylinders A1, B1 and end cylin-

ders on free end, install stop (2) with screws and spring
washers (1) and tighten.
Remaining guide pins are secured by installing charge
air manifold.
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3.6.3 Rockers and Pushrods
1 Rocker, inlet 13 Rocker

2 Rocker 14 Bush
3 Bush 15 Bush
4 Bush 16 Ball
5 Ball 17 Ball stud
6 Ball stud 18 Adjusting screw
7 Adjusting screw 19 Locknut
8 Locknut 20 Rocker shaft, exhaust
9 Rocker shaft, inlet 21 Stress bolt
10 Carrier 22 Push rod, inlet
11 Stress bolt 23 Push rod, exhaust
12 Rocker, exhaust
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Rocker, inlet
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Rocker, exhaust
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- x x Remove cylinder head cover 3.6.4.2
- x x Disconnect leak-off fuel lines 3.12.2.2
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3.6.3.2 Removal
Unscrew stress bolts (2) from rocker shafts (1).
Remove carrier with rocker (1) from cylinder head.

Remove locknuts from rocker.
Remove adjusting screws.
Store rocker in transport trestle and protect against
damage.
Remove push rods (1) from roller tappets.
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3.6.3.3 Disassembly
Remove rocker shaft (1) from inlet rocker (2) at side with
installed spring pin (arrow).
Remove rocker shaft (4) from exhaust rocker (3) on side
with chamfer (arrow).
Store rockers and rocker shafts in transport trestle and
protect against damage.
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Clean all parts.
Using magnetic crack-testing procedure with fluorescent magnetic powder, check rocker shafts, rockers, ball heads,
push rods and pans for cracks; replace components as necessary.
Smooth rocker shafts with minor wear and scoring with emery cloth.
Remove minor scoring, indentations and wear on bearing bushes with emery cloth; replace as necessary.
Measure rocker shafts with outside micrometer.
Adjust bore gauge.
Measure bores of rocker bearing bushes, see Tolerances and Wear Limits List.
Record measurements and determine bearing clearance.
Check threaded bores in rockers and locknuts for ease-of-movement, rechase with tapped bore if necessary.
Check hex of locknut for damage, replace if necessary.
Check condition of adjusting screw threads and replace if necessary.
Check screw slot for damage.
Check pushbutton caps for clearance and pitting; replace as necessary.
Check ball stud on rocker for wear and damage; press out and replace as necessary.
Turn pushrod end and top to check if securely seated.
Check pushrod seat and ball head for wear; replace as necessary.
Check push rod for wear; up to max. 0.3 mm permitted.
Check carrier for rocker shaft for flatness and damage; smooth with oilstone if necessary.
Replacing rocker bearing bushes
Using extraction mandrel (1), press bearing bushes out
of rocker (2).
Ensure that rocker is perfectly seated!
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Page 2
Adjust bore gauge.

Measure bore in rocker.
List.
Chill new bearing bushes (3) and (4) in ”liquid nitrogen”
and beginning with long bearing bush (3), insert into
rocker (1).
Oil bores (2) in rocker and bearing bush must be aligned.
Bearing bushes should have clearance ”A” and ”B” = 2
mm + 0.5 mm from bore edge on rocker.
Caution

tions in 1.5.
After inserting rocker bearing bushes, mill on fine boring
mill, to specified dimension.
Adjust bore gauge.
Measure bore of bearing bush.
After processing, carefully clean oil bores and deburr if
necessary.
Replacing ball stud
Check that oil bore on rocker (1) and ball stud (2) is per-
fectly clean.
Chill ball stud with ”liquid nitrogen” and insert into bore
on rocker.
Caution

tions in 1.5.
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3.6.3.5 Assembly
Check oil bores in rocker, ball stud and shaft for cleanli-
ness and blow through with compressed air.
Air must emerge at ball stud!
Insert adjusting screws into threaded bores of rocker.
Ensure adjusting screws can move easily!
Fit locknuts on adjusting screws.
Coat rocker shafts with ”engine oil”.
Insert rocker shaft (1) with installed spring pin (see
arrow) into inlet rocker (2).
Insert rocker shaft (4) with chamfer (see arrow) without
spring pin into exhaust rocker (3).
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Coat ball heads of push rods (1) with ”engine oil”.
Insert push rods into roller tappet with ball head end.
Exhaust push rod 260 mm long
Inlet push rod 273 mm long
Check contact surfaces on cylinder head and carrier for

evenness; smooth with oilstone as necessary.
Set appropriate cylinder to firing TDC.
Position rocker (2) with shaft for exhaust valves on cylin-
der head.
Wider mating face on rocker shaft for exhaust valves
must contact carrier.
Position rocker with shaft and carrier for inlet valves on
cylinder head.
Note
When positioning rocker on cylinder head, ensure that

push rod (1) is inserted into ball head.
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Securing rocker
Check long stress bolts for inlet rockers.
Max. screw length 81 mm
Check short stress bolts for exhaust rockers.
Max. screw length 51 mm
If max. screw length is achieved before installation,
replace stress bolts.
Coat thread of stress bolts (2) with engine oil.
Insert stress bolts into cylinder head and pretighten with
torque wrench (1) to tightening specification 1.3.
Using angle-of-rotation measuring tool (2), tighten

stress bolts (1) for inlet and exhaust rockers to tightening
specification 1.3 .
Note
Stress bolts for inlet and/or exhaust rockers have differ-

ent angles of further rotation.
If no angle-of-rotation measuring tool is available,
tighten stress bolt in accordance with markings made on
screw head corresponding to specified angle of rotation.
1 Stress bolt, long

2 Cylinder head
3 O-ring
4 Oil transfer pipe
5 O-ring
6 Crankcase
7 Stress bolt, short
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Checking and adjust valve clearance
Remove cover from flywheel housing.
Engage engine barring tool (1) in ring gear and secure
to flywheel housing (2).
Turn crankshaft in engine direction of rotation until pis-
ton of cylinder A1 is in firing TDC.
In firing TDC, both valves must be closed and both
rocker arms unloaded and free to move.
Determine crank angle before TDC, see 3.11.5.7
Note
For engines with F56 coupling, the TDC can be deter-

mined by means of the TDC mark A1 on the ring gear
of the coupling.
Remove end cover on both ends of the flywheel housing.
Mount engine barring tool on right side of flywheel hous-
ing.
Turn crankshaft in engine direction of rotation until mark-
ing on left side of bearing housing is aligned with TDC
mark A1 on ring gear.
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Page 2
Remove end cover, free end, from fuel injection pump

drive.
Secure ring with large internal hexagon socket and
socket-head screw (1) to stress bolt of fuel injection
pump drive.
Insert relevant adjusting shim (2) with clamp ring (4) into
ring.
Secure timing pointer (3) to bearing cap.
Secure adjusting shim with clamp ring so that marking
for cylinder A1 is aligned with point of timing pointer.
Check that adjusting shim is securely seated; insert sec-
ond adjusting shim if necessary.
Insert feeler gauge (2) between pushrod seat and valve.

For valve clearance, see 1.4
Using valve clearance adjusting tool (1), set adjusting
screw so that feeler gauge can still just be pulled
through.
In this position, securely hold adjusting screw and
tighten locknut.
When tightening locknut, the adjusting screw must not
turn.
After locking locknut, check valve clearance again.
Note
If it is difficult to set valve clearance (lack of room), use

commercially available box wrench A/F 17 and short
screwdriver C 1.2 x 8.
To check and adjust remaining valves, turn crankshaft
until next piston (according to firing order, 1.4) is in firing
TDC.
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Page 3
V6 Setting valve clearance in two crankshaft positions
Note
Only experienced assembly employees should set

valve clearance at two crankshaft positions.
Normally cylinders should be adjusted individually.
Check and set valves as shown in illustration opposite.
I = Firing TDC for cylinder A1
II = Overlap TDC for cylinder A1
A Exhaust valves
E Inlet valves
V8
V12
20038/10 E –07.94–
Page 4
V16
After setting valve, remove adjusting shim and pointer from fuel injection pump drive on free end.
Install end cover.
Remove engine barring tool from flywheel housing.
Install cylinder head cover, see 3.6.4.6
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3.6.4 Gear Case, Cylinder Head Cover
ET 06 134 1
1 Gear case 6 Cylinder head cover

2 O-ring 7 Collar screw
3 Screw 8 Clamping ring
4 Washer 9 O-ring
5 Cylinder head cover 10 Gasket
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3.6.4.2 Removal
Remove cylinder head cover
Remove gasket.
Remove internal leak-off fuel line.
Disconnect H.P. fuel line
Remove collar screw as necessary.
Remove screws and washers from gear case.

Remove gear case and O-ring.
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Page 1

Check gear case and cylinder head cover for cracks using surface crack-testing method with fluorescent penetrant dye;
replace components if cracks are found.
Weld gear case with chipped sealing ring groove and recut groove with milling cutter.
Repair gear case with damaged threaded inserts with threaded bushes.
Secure threaded bushes with ”high-strength thread-locking agent”.
Check cylinder head cover for flatness and damage; replace as necessary.
Check collar screw for damage and check condition of threads; replace if necessary.
Check thickness of rubber and condition of gasket.

If a gasket is damaged, porous, cracked or less than 3
mm thick (dimension A), replace gasket.
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Page 1
Smooth contact surfaces on cylinder head and gear
case with oilstone and clean.
Insert O-ring in groove on gear case.
Position gear case on cylinder head.
Insert screws with washers and tighten with torque
wrench (1) to tightening specification 1.3.
Check ease-of-movement of rockers.
Install internal leak-off fuel line and H.P. fuel line.
Install leak-off fuel collecting line with new sealing rings.
Coat cylinder head cover in sealing area with ”petroleum

jelly”.
Press gasket onto cylinder head cover.
Mount cylinder head cover onto gear case.
Tighten collar screws with torque wrench to tightening
specification 1.3.
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3.7 Engine Governor

Engine governor, see Special Publication.
Install / remove engine governor actuator together with fuel injection pump, see 3.11.5.2.
For governor actuator disassembly and assembly, see Special Publication.
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3.8 Regulating Unit

See Special Publications for fuel injection pump and governor
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3.9 Exhaust Turbocharger

Removal, see 3.10.6.2
Installation, see 3.10.6.6
Carry out exhaust turbocharger disassembly and assembly in accordance with Assembly Instructions appropriate to
the respective engine model.
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Page 1
3.10 Air/Exhaust System

Contents
3.10.1a Intercooler
3.10.1a.2 Removal
3.10.1a.5 Assembly
3.10.2 Air system

3.10.2.2 Removal (6V, 8V, 12V)
3.10.2.2a Removal (16V)
3.10.2.6 Installation (6V, 8V, 12V)
3.10.2.6a Installation (16V)
3.10.3 Exhaust system

3.10.3.2 Removal
3.10.3.3 Disassembly
3.10.3.5 Assembly
3.10.4a Emergency air shut-off flaps

3.10.4a.2 Removal
3.10.4a.5 Assembly
3.10.6a Carrier housing with exhaust turbocharger and exhaust elbow

3.10.6a.2 Removal
3.10.6a.3 Disassembly (without exhaust flow control flap)
3.10.6a.3a Disassembly (with exhaust flow control flap)
3.10.6a.5 Assembly (without exhaust flow control flap)
3.10.6a.5a Assembly (with exhaust flow control flap)
3.10.7 Intake funnel and intake housing with turbocharger control

3.10.7.2 Removal
3.10.7.5 Assembly
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Page 2
3.10.7a Intake funnel and intake housing without turbocharger control

3.10.7a.2 Removal
3.10.8a Actuator for turbocharger control

3.10.8a.2 Removal
3.10.8a.5 Assembly
3.10.11a Exhaust connecting line

3.10.11a.2 Removal
3.10.11a.5 Assembly
20046/20 E –05.96–
Page 3

A
S4
S 5.7
S 5.7.1
S 5.13
S 6.1
S 6.19

Ink-check plate
Spray gun
Inspection lamp
Magnifier

Sealing paste Elastosil N189 50545
Silicone-base grease
Corrosion preventive Caramba 40090
Synthetic abrasive MTH 608 Type 2 16/2 20098
Assembly paste Ultratherm - MTU 50547
Engine oil
Decarbonizer (cleaner) Meister Proper 40377
High-strength pipe thread sealant Loctite No. 586 40033
High-strength thread-locking liquid Loctite No. 270 40083
Thread-locking varnish RAL 4001 lilac red 40664
Engineer’s blue 40641
Dry compressed air
Antifriction bearing grease AEROShell Grease 15A 50190

Caution
20046/20 E –05.96–
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Air/exhaust system (8V)
1 Exhaust turbocharger 4 Charge air manifold

2 Intercooler 5 Exhaust pipe
3 Emergency air shut-off flap
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1 Exhaust turbocharger A 6 Exhaust flow control flap

2 Intercooler 7 Exhaust turbocharger B
3 Emergency air shut-off flap 8 Air flow control flap
4 Charge air manifold 9 Exhaust connecting line
5 Exhaust pipe
20046/20 E –05.96–
Page 6
1 Exhaust turbocharger A 6 Exhaust pipe

2 Intercooler 7 Exhaust flow control flap
3 Emergency air shut-off flap 8 Exhaust turbocharger B
4 Charge air manifold 9 Air flow control flap
5 Expansion line 10 Exhaust connecting line
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3.10.1a Intercooler
1 Left carrier 5 Right carrier

2 Spring pin 6 Intercooler
3 Spring washer 7 Sleeve
4 Hex bolt 8 Hex bolt
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Cover for air inlet and air outlet on intercooler
1 Drain valve 13 Plug

2 Cover 14 Gasket
3 Gasket 15 Washer
4 Washer 16 Hex bolt
5 Hex bolt 17 Stud
6 Stud 18 Hex nut
7 Hex bolt 19 Spring washer
8 Hex nut 20 Hex bolt
9 Sealing ring 21 Plug-in sleeve
10 Plug 22 O-ring
11 Cover 23 O-ring
12 Sealing ring
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Intercooler
1 Complete block 12 O-ring

2 Connection chamber 13 Socket-head screw
3 Diverter chamber 14 Washer
4 Gasket, connection chamber 15 Stud
5 Gasket, diverter chamber 16 Stud
6 Plug 17 Nut
9 Sealing ring carrier 20 Washer
10 O-ring 21 Bolt
11 O-ring 22 Washer
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- x x Remove direct-current magnet and limit switch 3.10.4a.2
- x x Remove exhaust connecting line 3.10.11a.2
- x x Disconnect air intake system between intercooler and exhaust turbocharger 3.10.2b.2
- x x Disconnect drain line 3.14.2.2
- x x Disconnect engine coolant and vent lines 3.14.1.2
3.14.2.2
- x x Disconnect oil lines for valve seat lubrication 3.16.1.2
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3.10.1a.2 Removal
Removing intercooler
Unscrew screws (1) securing intercooler (2) on carrier
(3).
Install lifting eyes (2) in intercooler (1).

Attach intercooler to rope and lifting gear
Push in direction of driving end using installation tool and
lift from carriers.
Remove plug-in sleeve and O-rings.
Removing carrier
Prior to removing carrier, remove elbow and plug–in pipe
from right carrier, see 3.14.1.2 and 3.14.3.2.
Unscrew screws (2) from carrier (1).
Remove carrier from flywheel housing.
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Removing air inlet cover
Release screws (1) and (5) and spring washers (2) from
cover (6).
Remove cover and gasket (3) from intercooler (4).
Removing air outlet cover

Release screws (4) and spring washers (3) from cover
(2).
Remove cover and gasket (5) from intercooler (1).
Check cooler core for contamination; if necessary,
check for leaks
In the case of severe contamination, e.g. sand, sludge,
foreign bodies, or thick lime layer, disassemble inter-
cooler.
In the event of leaks, send to MTU/manufacturer.
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Page 2
Disassembling intercooler (GEA)

Label all parts before disassembly.
Unscrew nuts (2), (5) and washers from connection
chamber (1) and cover (6).
Release studs (4) only if necessary.
Unscrew plugs (3) and sealing ring from connection
chamber.
Removing connection chamber

Remove securing screws (2), (4) and (6) from top con-
nection chamber (3).
Remove connection chamber with jackscrews from in-
tercooler (5).
Remove gasket (1).
Note
The chamber frames have threaded bores to accomo-

date the jackscrews.The chamber securing screws can
be used as jackscrews.
Chamber frames which are sealed against the tube
bundle do not, in general, need to be removed. They
must be secured against falling out during cleaning.
Release securing screws (1) from cooler core (3).

Remove connection chamber (2) with jackscrews from
intercooler (5).
The chamber frames have threaded bores to accomo-
date the jackscrews.
The chamber securing screws can be used as jack-
screws.
Remove connection chamber with gasket (6) from
cooler core (3). Do not damage locating pin in tube plate.
To remove the chamber frame (4), release screws (5).
20046/20 E –05.96–
Page 3
Removing diverter chamber

Remove securing screws (3) from cover (6). Remove
cover.
Release diverter chamber (8) securing screws (7) from
cooler core (1).
Remove diverter chamber with jackscrews from inter-
cooler (1).
The chamber frames (2) have threaded bores to acco-
modate the jackscrews.
The chamber securing screws can be used as jack-
screws.
Remove diverter chamber with gasket (4) and O-ring (5)
from cooler core.
Remove gasket and O-ring.
Observe instructions given in ”Connection Chamber Re-
moval”.
Remove cover (5) (8V).
Release securing screws (4) and (6) from diverter
chamber (3).
Remove diverter chamber with jackscrews from cooler
core (1).
moval”.
Remove gasket (2) and O-ring (7).
Remove cover (5) (12V, 16V)

Release securing screws (6) from diverter chamber (4).
Remove diverter chamber with jackscrews from cooler
core (1).
moval”.
Do not damage locating pin (3) when removing diverter
chamber.
Remove locating pin only as required.
Remove gasket (2) and O-ring (7).
20046/20 E –05.96–
Page 1

Cleaning
The cleaning may be mechanical, hydraulic or chemical.
Mechanical cleaning of the coolant side
Mechanical cleaning means cleaning with nylon brushes which are fitted to extended handles to clean the cooler tubes.
A chamber must be removed for the purposes of cleaning, see 3.10.1a.3
Clean the cooler tubes with the nylon brush thoroughly when wet. Never pierce the cooler tubes or use sharp tools.After
cleaning, the cooler tubes must be flushed with water until residue no longer emerges.
Hydraulic cleaning of the coolant side
For hydraulic cleaning, high-pressure cleaning equipment with special nozzles is used to release the dirt by means of
high-pressure water jets.
Chemical cleaning of the coolant side
Chemical cleaning is necessary if mechanical or hydraulic cleaning fails to provide the required standard of cleanness.
The coolant chambers must be removed and cleaned separately.
If there are greasy scale deposits, the water side must first be degreased. Immerse the cooler core in a cleaning bath
containing a dissolved cleaning agent. Buffered alkaline agents such as, for example, a 3 to 5% P3 FD solution supplied
by Henkel are suitable cleaning agents.When preparing the cleaning bath, the manufacturer’s instructions must be ob-
served. The immersion period depends on the condition and temperature of the bath and on the type and degree of
contamination.
A decalcifying agent which is not agressive to the metal surfaces (e.g. P3 T288 from Henkel or amidosulphonic acid
Euron 1308 from Hoechst) must be used to remove scale deposits. With extremely stubborn deposits, it may be
necessary to use a 10% hydrochloric acid solution. In this case, an appropriately inhibited acid must be used (e.g. Euron
1144 from Hoechst). After cleaning, the system must be flushed with water until the pH values of fresh water and flush-
ing water approximately correspond (permissible difference: 1 pH). Normal coolant can be used for flushing purposes.
If results of cleaning are not sufficient, the procedure must be repeated or performed using glass bead peening on cool-
ant side.
Check internal pipe surfaces of cooling tubes with endoscope and cold light source for impermissible corrosion pits.
Permitted value for impermisssible corrosion pits ≥ 80 mm deep.
In the event of impermissible corrosion pits in the cooling tubes, internal pipes must be inserted in accordance with MTU
instructions and/or it is recommended that repair work be carried out by MTU or the manufacturer.
20058/0 E –05.96–
Page 2
Hydraulic cleaning of the air side

The coolant chambers are removed for cleaning purposes, see 3.10.1a3. The same cleaning equipment as used for
hydraulic cleaning of the water side can be used. A nozzle diameter of 3 mm is recommended.
If the water jet strikes the cooler tubes vertically, i.e. parallel to the fins, cleaning work can be carried out with a spray
pressure of 120 bar from 2 m distance. P3 Grato from Henkel is a suitable cleaning agent.
Chemical cleaning of the air side
The coolant chambers are removed for cleaning purposes, see 3.10.1a 3. Cleaning agent and procedure as for the
water side.
Note
After cleaning the air side, blow out and dry with dry compressed air.
Checking connnection between cooler tubes and tube plate for leaks
Seal cooler core without coolant chambers on air side with stable plates and rubber seals. One of the inspection plates
must be equipped with a connection for pressure-testing with compressed air.
Immerse cooler core in a testing tank filled with water at approx. 60 – 80°C. With a reduced test pressure of 0.5 bar
(pay attention to accident prevention regulations), check water side for leaks. Leaking connections between tube and
tube plate are indicated by air bubbles emerging.
Turn cooler core 180° about its transverse axis to test second tube plate
If tube plate leaks are detected, return intercooler to the manufacturer or to MTU Friedrichshafen for repair.
Checking intercooler for leaks
Note
To carry out this inspection, the connection and diverter

chambers must be installed, see 3.10.1a.5.
Plug coolant ports with flanges (2) and seal (3).
Connect compressed air line to one of the flanges.
Immerse intercooler in a testing tank filled with water at
approx. 80 °C.
Open compressed air valve and adjust pressure reducer
(1) to approx. 0.5 bar.
Check cooler for leaks. No air bubbles must emerge.
Turn cooler 180° about its transverse axis and repeat
test.
If leaks are detected in the cooler core or cooler tubes,
return intercooler or preheater to the manufacturer or to
MTU-Friedrichshafen for repair.
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Page 1
3.10.1a.5 Assembly
Assembling intercooler (GEA)
Clean all sealing surfaces, smooth with oilstone if
necessary.
Note
Refer to labels on parts to ensure proper reassembly!

Installing connection chamber
Install connection chamber (1) with gasket (4) on cooler
core (3) and secure with socket-head screws (5) and
washers.
Do not damage locating pin (2) when installing connec-
tion chamber.
Secure connection chamber (3) with socket–head

screws (2), (4), (6) and washer diagonally and evenly.
Cut off any protruding gaskets (1).
Prior to installing side components, coat sealing sur-

faces with surface sealant.
Install chamber frame (4) with socket-head screw (5)
and washers on cooler core (3) and tigten uniformly to
tightening specification 1.3.
Tighten screws (1) on connection chamber (2) diag-
onally and evenly to tightening specification 1.3.
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Page 2
Installing diverter chamber and cover

Mount diverter chamber (4) with gasket (2) and O-ring
(7) on cooler core (1) and secure with socket-head
screws (6) and washers.
When installing diverter chamber, do not damage locat-
ing pin (3).
Prior to installing cover (5), coat sealing surfaces with
surface sealant.
8V
Mount bottom diverter chamber (3) with gasket (2) and
damping ring (7) on cooler core (1).
Tighten socket-head screws (4), (6) and washers diag-
onally and evenly to tightening specification 1.3.
For cover installation, also refer to bottom illustration.
Before installation, coat sealing surfaces of side compo-

nents and cover with surface sealant.
Install cover (3) and tighten with socket head screws (1)
and washers to chamber frame (2) diagonally and uni-
formly. For torque settings see Section 1.3.
Note
Cut off any protruding gaskets.
20046/20 E –05.96–
Page 3
Fit nuts (2), (5) and washers on studs (4) on connection

chamber (1) and cover (6) and tighten to tightening
specification 1.3.
Insert plugs (3) and sealing ring on connection chamber
and tighten.
Check intercooler for leaks, – see 3.10.1a.4.
Installing air inlet cover

Clean sealing surfaces, smooth with oilstone if necess-
ary.
Install cover (6) and gasket (3) with screws (1), (5) and
washers (2) on intercooler (4) and tighten.
Note
Depending on the order, the air inlet cover is installed on

the intercooler using only sealing paste.
Installing air outlet cover

ary.
Install cover with emergency air shut-off flaps (2) and
new gasket (5) with screws (4) and spring washers (3)
on intercooler and tighten.
Note
Cut off any protruding gaskets.
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Page 1
Installing intercooler carriers
Check spring pins for damage and replace as necess-
ary.
Install intercooler carriers (2) on right and left engine
sides with screws and spring washers (1) and tighten.
Installing plug-in sleeves on charge air manifold

Check plug-in sleeves (1) for wear and replace as
necessary.
Coat O-rings with ”petroleum jelly” and insert into
grooves plug-on in sleeves.
Check plug-in bores on the charge air manifold for
cleanliness and insert plug-in sleeves up to stop.
Prior to installing intercooler, mount lube oil pump for
valve seat lubrication with oil supply line and install con-
nector with oil lines for exhaust turbocharger and injec-
tion pump lubrication, see 3.15.4.6 and 3.16.1.6.
Installing intercooler
Check sealing surfaces and mating faces on intercooler
(1) for cleanliness.
Screw lifting eyes (2) into intercooler.
Use rope and lifting gear to place intercooler on the
carrier on the flywheel housing. Push in direction of free
end.
Do not damage plug-in sleeves and O-rings when insert-
ing into bores in the intercooler.
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Page 2
Install intercooler (1) with screws (2) and sleeves (3) on

carrier (4) and tighten.
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3.10.2 Air System
Air/coolant manifold (8V, 16V)
1 Manifold 18 Hex screw

2 Gasket 19 Sealing ring
3 O-ring 20 Plug
4 Washer 21 Cover
5 Socket-head screw 22 O-ring
7 Plug 24 Hex screw
8 Sealing ring 25 Sealing ring
9 Plug 26 Plug
10 Threaded bush 27 Cover
11 Sealing ring 28 Cover (order-specific)
12 Plug 29 Gasket
13 Threaded bush 30 Washer
14 Sealing ring 31 Hex screw
15 Plug 32 Cover
16 Washer 33 Gasket
17 Hex screw 34 Cover
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Page 2
Air/Coolant manifold (12V)
1 Manifold 18 Cover
2 Gasket 19 O-ring
3 O-ring 20 Washer
6 Sealing ring 23 Plug
7 Plug 24 Cover
8 Sealing ring 25 Cover (order-specific)
9 Plug 26 Gasket
10 Threaded bush 27 Washer
12 Plug 29 Cover
13 Threaded bush 30 Cover
15 Plug 32 Washer
17 Plug 34 Hex screw
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Air/Coolant manifold (16V)
1 Manifold, left A1 - A4 9 Washer

2 Manifold, right B1 - B4 10 Socket-head screw
3 Sleeve 11 Sealing ring
4 O-ring 12 Plug
5 Sleeve 13 Sealing ring
6 O-ring 14 Plug
8 O-ring 16 Plug
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Page 4
Air intake system between intercooler and exhaust turbocharger (8V, 12)
1 Sleeve 6 Flange
2 Sleeve 7 Flange
3 O-ring 8 O-ring
4 O-ring 9 Washer
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Page 5
Air intake system between intercooler and exhaust turbocharger 16V
1 Sleeve 5 Flange
2 O-ring 6 O-ring
3 O-ring 7 Washer
4 Flange 8 Bolt
20046/20 E –05.96–
Page 1


- - x Drain or draw off engine coolant Op. Man.
- x x Disconnect monitoring devices 3.84
- x x Remove monitoring devices and measuring block 3.84
- x x Remove terminal boxes and wiring --
20042/10 E –07.94–
Page 1
3.10.2.2 Removal (6V, 8V, 12V)

Removing manifolds
Remove screws and washers from covers (1) with
socket wrench (2).
Remove air/coolant manifold cover.
Remove O-ring from cover.
Remove screws from air/coolant manifold (1).

Remove manifold from cylinder heads.
Remove O-rings (1) and gaskets (2) from cylinder

heads.
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Page 2
Removing connecting line for intercooler/exhaust

turbocharger
Unscrew screws (5) and washers (4) on intermediate
flanges (1) and (3) from intercooler (10).
Remove intermediate flanges from intercooler and
plug-in pipe (8) from exhaust turbocharger (6).
Remove O-rings (2), (7) and (9).

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Page 1
3.10.2.2a Removal (16V)

Removing manifolds
Remove screws and washers from covers (1) with
socket wrench (2).
Remove air/coolant manifold cover.
Remove screws on second section of air/coolant mani-

fold (1).
Remove second section (1) of manifold from cylinder

heads.
Remove sleeves (3) with O-rings from first section (2) of
manifold.
Remove O-rings from sleeves.
20054/00 E –05.96–
Page 2
Remove screws on first section of air/coolant manifold

(1).
Remove manifold from cylinder heads.
Remove O-rings (1) and gaskets (2) from cylinder

heads.
Removing connecting line for intercooler/exhaust

turbocharger
20054/00 E –05.96–
Page 1

Wash air/coolant manifold, connecting lines, sleeves, plug-in pipes and elbow with cleaning agent.
Using the surface crack-testing method and red penetrant dye, check the manifold for cracks. Replace component if
cracks are found.
Check manifold sealing surfaces and screw interfaces for evenness and damage, smooth with oilstone if necessary.
Check bores for sleeves on manifolds for wear and damage, smooth slight wear and damage with polishing cloth, if
necessary line in accordance with MTU regulations.
Check condition of threaded inserts and bushes on manifolds, replace if necessary.
Check connecting lines, elbow, sleeves and plug-in pipes for damage and wear, smooth with polishing cloth or oilstone
if necessary, replace parts as required.
Pressure-test air-carrying parts of manifolds at room temperature with air in water bath.
Test pressure 0.5 bar (observe accident prevention regulations!).
Pressure-test coolant-carrying part of manifold with air in water bath. Test pressure 4.5 bar
Note
Water used for pressure-testing must contain an anti-corrosion agent.

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Page 1
3.10.2.6 Installation (6V, 8V, 12V)

Installing manifolds
Smooth cylinder head and air/coolant manifold sealing
surfaces with oilstone.
Check that manifold is clean.
Coat gaskets (2) with ”sealing paste” and O-ings (1) with
”petroleum jelly”.
Install gaskets and O-rings on cylinder heads.
Coat threads of screws with engine oil.

Install manifold (1) with screws and washers.
Use torque wrench (2) to secure manifold to cylinder
head. For torque settings, see Section 1.3.
Before installing cover (1) on manifold, pressure-test the

engine with water (see 3.1.4).
Mount cover with gasket, screws and spring washers on
manifold and tighten with torque wrench (2).
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Page 2
Installing connecting line for intercooler/exhaust

turbocharger
After installing exhaust turbocharger (6), insert O-rings
(2) and (7) into groove on plug-in pipe (8) and on com-
pressor housing of exhaust turbocharger and coat with
Insert O-rings (2) into groove of flanges (1) and (3) and
Fit flanges on plug-in pipe.
Fit plug-in pipe with flanges on compressor housing on
exhaust turbocharger.
Mount flanges on intercooler (10) with screws (5) and

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Page 1
3.10.2.6a Installation (16V)

Installing manifolds
Smooth cylinder head and air/coolant manifold sealing
surfaces with oilstone.
Check that manifold is clean.
Coat gaskets (2) with ”sealing paste” and O-rings (1)
with ”petroleum jelly”.
Install gaskets and O-rings on cylinder heads.
Coat threads of screws with engine oil.

Install first section (1) of manifold with screws and
washers.
Insert O-rings into grooves of plug-in sleeves (1) and (2)

Insert sleeves in manifold bores.
20054/00 E –05.96–
Page 2
Insert second section of manifold in sleeves and install

with screws and washers on cylinder.
Use torque wrench (1) to secure manifold to cylinder
head. For torque setting, see Section 1.3.
Before installing cover (1) on manifold, pressure–test

the engine with water (see 3.14.4).
Mount cover with gasket, screws and washers on mani-
fold and tighten with torque wrench (2).
Installing connecting line for intercooler/exhaust

turbocharger
spring washers (7) and tighten.
20054/00 E –05.96–
Page 1
3.10.3 Exhaust System

Housing and plug-in pipes
1 Housing for exhaust 13 Hex bolt ”SB”

3 Washer 15 Shim
4 Bolt 16 Tab washer
5 Constant-pressure manifold half 17 Hex bolt
6 Constant-pressure manifold half 18 Cover for exhaust manifold
7 Constant-pressure manifold half 19 O-ring
8 Constant-pressure manifold half 20 Washer
9 Hex bolt ”SB” 21 Hex bolt
10 Hex nut ”SB” 22 Hex bolt
11 End cover 23 Sealing ring
12 Washer 24 Plug
20046/20 E –05.96–
Page 2
Flanges with plug-in pipe

2 Flange 10 Hex bolt
3 O-ring 11 Washer
4 O-ring 12 Hex bolt
5 Flange 13 Plug-in pipe
6 O-ring 14 O-ring
7 O-ring 15 Protective tube
8 O-ring 16 O-ring
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Page 3
Housing for exhaust manifold, carrier housing - end cover
1 Constant-pressure manifold 16 Hex bolt

2 Housing for exhaust manifold 17 Washer
3 Shim 18 O-ring
4 Locating pin 19 O-ring
5 Tab washer 20 Hex bolt and washer
6 Rectangular-section ring 21 Flange
7 O-ring 22 Plug-in pipe
8 O-ring 23 Flange
9 O-ring 24 O-ring
10 Protective tube 25 Hex bolt and washer
11 Carrier housing 26 Hex bolt
12 Connection housing 27 End cover
13 Hex bolt 28 Washer
14 Washer 29 Hex bolt ”SB”
15 Cover
±
A = Distance = 2.0 mm 0.5 mm
±
B = Distance = 3.4 mm 0.5 mm
C = Position of protective tube
20046/20 E –05.96–
Page 4
Exhaust system - housing for exhaust manifold, carrier housing, connection housing
1 Constant-pressure manifold 13 O-ring

2 Housing for exhaust manifold 14 Hex bolt and washer
3 Shim 15 Flange
4 Locating pin 16 Plug-in pipe
5 Rectangular-section ring 17 Flange
6 O-ring 18 O-ring
7 O-ring 19 Hex bolt and washer
9 Protective tube 21 End cover
10 Carrier housing 22 Washer
11 Connection housing or flap housing 23 Hex bolt ”SB”
12 O-ring
±
A = Distance = 2.0 0.5 mm
±
B = Distance = 3.4 0.5 mm
C = Position of protective tube
20046/20 E –05.96–
Page 1


x - – Perform operations as per Disassembly Plan 2.4
– - x Disable engine start Op. Man.
– - x Drain engine coolant Op. Man.
- x x Disconnect or remove electric cable 3.84.9a.2
- x x Disconnect coolant lines 3.14.1.2
- x x Remove actuating cylinder 3.10.8a.2
- x x Remove actuator for turbocharger control 3.10.8a.2
- x x Remove intake funnel and intake housing (only if necessary) 3.10.7.2
20046/20 E –05.96–
Page 1
3.10.3.2 Removal
Removing exhaust manifold cover
Remove screws (1) securing flange (2) to housing for
exhaust manifold (3).
Unscrew securing screws from cover for exhaust mani-
fold (4).
Remove cover (2) from housing for exhaust manifold

(1).
Remove O-rings.
Removing cover from carrier housing

Unscrew securing screws (1).
Remove cover (2) from carrier housing (3).
Remove O-rings.
20054/00 E –10.93–
Page 2
Remove securing screws (3) of flanges (4) on cover (1)

and carrier housing (2).
Unscrew securing screws from cover.
Remove cover from carrier housing. Remove flanges
with plug-in pipe and protective tube.
Remove O-rings.
Removing constant-pressure manifold halves

Remove screws securing constant-pressure manifold
halves (2) to exhaust manifold housing (1).
Note
When removing constant-pressure manifold halves

from housing for exhaust manifold, the corner connec-
tions must not be released.
If, for technical reasons, the corner connection screws
are released, the screws and hex nuts must be replaced.
Pay special attention to screws and nuts with marking
”SB”.
Remove constant-pressure manifold halves (1) with

screws and shims (4) from exhaust manifold housing
(3).
Check locating pin (2) for damage, remove if necessary.
20054/00 E –10.93–
Page 3
Removing cover
Remove screw securing cover (1).
Remove cover.
Removing exhaust manifold housing

Remove screws (2) securing exhaust manifold housing
(1) to cylinder heads.
Remove housing
20054/00 E –10.93–
Page 1
Disassembling connecting flange
Press flanges (1) off protective tube (2).
Press plug-in pipe out of flanges.
Remove O-rings.
Removing constant-pressure manifold half

Release and remove screws (1) from hex nuts.
Remove constant-pressure manifold half (2).
Note

are released prior to W6 major overhaul, the screws and
hex nuts must be replaced.
Pay attention to screw and nut ”SB” designations.
Always replace screws and hex nuts during W6 over-
haul.
20054/00 E –10.93–
Page 1

Insert exhaust elbow, constant-pressure manifolds, housing and cover into container with ”decarboniser” for approx.
12 to 24 hours.
Caution
”Decarbonizer” must only be used in conjunction with a fume extraction system.

Pay attention to manufacturer’s safety instructions.
After cleaning, rinse parts until they are free from residues.
Stubborn soot deposits can also be treated later by spraying ”synthetic abrasive” MTH 608 (rated grain 16 to 20); cool-
ant inlets and outlets must be sealed for this purpose.
Using surface crack-testing method and red penetrant dye, check plug-in pipes, constant-pressure manifolds, exhaust
elbow, diverter housing and cover for cracks.
If cracks are detected, replace parts.
Check plug-in pipes, constant-pressure manifolds, exhaust elbows, diverter housing, housing for exhaust manifold and
cover for wear, pitting and distortion; recondition and/or replace as necessary.
Check thread and thread inserts for damage. Check sealing surfaces, sealing ring grooves and bores for plug connec-
tions for damage.Replace damaged thread inserts. Smooth sealing surfaces and bores with polishing cloth and oil-
stone.
Check that all screws and nuts are in perfect condition; check for ease of movement; make sure correct type of screw
is used ; replace if necesary. Replace securing screws, corner joint screws and nuts for constant-pressure manifold
halves during a W6 overhaul.
Replace sealing rings and tab washers.
Replace Rotatherm ring.
Pressure-test water-carrying components.
Pressure-testing specifications:
Liquid test pressure = 7.0 bar with water
Air test pressure = 0.5 bar in water bath at 80 °C
20054/00 E –10.93–
Page 1
3.10.3.5 Assembly
Preassembling connecting flange
Insert O-ring (7) into flange (9).
Insert O-ring (4) into flange (1).
Insert two O-rings (6) into grooves of plug-in pipe (8).
On cover side, insert screw (5) with washer into flange
(1).
Fit flanges (1) and (9), with coolant side facing outwards,
onto plug-in pipe (8) so that small coolant transfers (3)
on flanges are flush.
Fit flanges flush with plug-in pipe on protective tube (2).
Note
Ensure installation position (A) of recess on protective

tube is correct.
Insert O-rings (2), (3) and (4) into flange (1) on coolant
side and coat with ”petroleum jelly”.
Preassembling constant-pressure manifold halves

Support constant-pressure manifold halves (1) in suit-
able device in centre bores with locating pin.
Coat screw thread with ”assembly paste”.
Connect at corners with four new screws and nuts (3).
Note
Pay attention to ”SB” screw and nut markings.
20054/00 E –05.96–
Page 2
Tighten corner-joint screws (1) to specified torque. For

torque setting, see Section 1.3. Pay attention to position
of screw head (2) (insert screw in direction shown by
arrow.)
Note

are released prior to W6 major overhaul, the screws and
hex nuts must be replaced.
Pay attention to screw and nut ”SB” designations.
Always replace screws and hex nuts during a W6 over-
haul.
20054/10 E –10.93–
Page 1
Installing exhaust manifolds, left and right engine
sides
Before installing exhaust manifold housing (1), check
that all cylinder heads on one engine side are mounted
flush using a steel ruler (permissible deviation: 0.1 mm).
Coat screw threads (2) and washer mating face with ”as-
sembly paste”.
Evenly coat sealing surfaces of housing for exhaust
manifold on flange surface with ”sealing paste”.
Install housing with screws and washers on cylinder
heads.
see Section 1.3.
Installing cover
Install cover (1) on exhaust manifold housing (2).
Coat screw threads (3) and washer mating face with ”as-
sembly paste”.
Pay attention to correct installation of cover (4).
Using torque wrench, tighten screw to specified torque.
For torque setting see Section 1.3.
Note
Pay attention to ”SB” screw markings.
Installing constant-pressure manifold halves

If required, install new locating pin (2) in exhaust mani-
fold housing (3).
Coat thread of screws (4) with ”assembly paste”.
Install preassembled constant-pressure manifold
halves with shims, tab washers and screws in exhaust
manifold housing.
Note
Make sure they are located correctly.

Mount last constant-pressure manifold half on driving
end only once preassembled flange has been mounted
on housing for exhaust manifold.
20054/00 E –05.96–
Page 2
Tighten screws securing constant-pressure manifold

halves (2) to exhaust housing (1) to specified torque. For
Insert rectangular-section ring (2) into groove of housing

for exhaust manifold (1).
Carefully fit rectangular-section ring (2) over protective

tube on preassembled flanges (1).
20054/00 E –05.96–
Page 3
Insert preassembled flanges (1) with O-rings between

carrier housing (2) and housing for exhaust manifold (3).
Mount flanges with screws and washers (4) on carrier
housing and housing for exhaust manifold and tighten.
Mount preassembled constant-pressure manifold half
on driving end.
Clean sealing surfaces on cover (1) and housing.

Coat O-rings (2) with ”assembly paste” and install in
grooves on cover. Check O-ring pretension.
Apply an even, thin coat of ”sealing paste” to exhaust
manifold housing sealing surfaces.
Note
On account of O-ring pretension, apply only a thin coat

to sealing surfaces.
Install cover (2) on exhaust housing (1).

Align cover until sealing surface on driving end side is
flush.
see Section 1.3.
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Page 4
Mount flange (2) with securing screws (1) on housing for

exhaust manifold (3) and cover (4).
Tighten securing screws after installing cover on carrier
housing.
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Page 1
3.10.4a Emergency Air Shut-Off Flaps
1 Grease nipple 9 Bearing bush

2 Limit switch 10 Spiral spring
3 Pull rod 11 Lever, right-hand side
4 Lever, left-hand side 12 Intercooler cover
5 Trip lever
6 Flap A Emergency air shut-off flaps closed
7 Solenoid B Emergency air shut-off flaps open
8 Shaft
20046/20 E –05.96–
Page 2
Emergency air shut-off flaps

2 Flap 16 Bolt
3 Key 17 Pull rod
4 Shaft 18 Pull rod, right-hand side
5 Grease nipple 19 Pull rod, left-hand side
6 Bearing bush 20 Pin
7 Shaft seal 21 Swivel head
8 Washer 22 Nut
9 Snap ring 23 Shim
10 Sleeve 24 Split pin
11 Spiral spring 25 Pin
12 Lever, left-hand side 26 Shim
13 Lever, right-hand side 27 Split pin
14 Dowel pin
20046/20 E –05.96–
Page 3
Solenoid and limit switch for emergency air shut-off flap

2 Cover 18 Hex bolt
3 Spring washer 19 Hex bolt
4 Hex bolt 20 Limit switch
5 Carrier 21 Holder
6 Lever 22 Spring washer
7 Axle 23 Hex nut
8 Grease nipple 24 Hex bolt
9 Cam roller 25 Spring washer
11 Hex nut 27 Plug
12 Spring washer 28 Hex nut
15 Solenoid 31 Stud
16 Flange
20046/20 E –05.96–
Page 1


- - x Drain coolant Op. Man.
- x x Disconnect wire from solenoid and proximity switch -
- x x Disconnect vent line 3.14.2.2
- x x Disconnect coolant connections from intercooler 3.14.1.2
- x x Disconnect air intake system between intercooler and exhaust turbocharger 3.10.2b.2
- x x Remove intercooler 3.10.1a.2
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Page 1
3.10.4a.2 Removal
Removing solenoid
Remove flange (4) for securing solenoid.
Remove solenoid (3) from carrier (5).
Twist grease nipple (1) out of shaft (2).
Unscrew shaft on lever (6) from carrier.
Remove lever with shaft from holder.
Removing carrier for solenoid

Release screws (3).
Remove carrier (2) on cover (1) for emergency air shut-
off flaps.
Removing limit switch

Remove limit switch (1) with bracket (2) on cover (3) for
emergency air shut-off flap.
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Page 2
Remving cover with emergency air shut-off flaps

Remove cover (1) with emergency air shut-off flaps from
intercooler.
Remove gasket.
Remove intercooler, see 3.10.1a.2
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Page 1
Disassembling cover with emergency air shut-off
flaps
Release and pull out split pin (4).
Remove adjusting shim (3).
Press pin (2) out of lever (5).
Remove pull rod (1).
Remove lubricating nipple (1) from shaft.
Support emergency air shut-off flap shaft with support

device (1).
Use suitable drift punch to drive dowel pin (arrow) out of
lever.
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Page 2
Release hex bolt on lever (1).

Remove lever from emergency air shut-off flap shaft.
Remove spiral spring (2), sleeve (3) and washer (1).
Note
Remember that spiral springs are torsionally tensioned.
Remove snap ring (1) on emergency air shut-off flap

shaft.
Remove washer (2).
Press bearing bushes (3) with jackscrews out of cover
(4).
Press shaft seals out of bearing bushes.
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Page 3
Drive shaft (1) out of flap (3) in direction of arrow with

plastic mallet.
Remove shaft with flap from cover.
Press shaft out of flap.
Remove key (2) from shaft.
Disassembling lever
Remove lockwashers (5) from pin (2).
Place back-up washer for pressing out pin in cutout on
lever (1).
Use mandrel to press pin out of short lever side.
Note
Register bores on lever have different tolerances.

Remove adjusting shims (4) from lever.
Remove bush (3) with mandrel.
Release nut (8) and remove with washer (7).
Remove cam roller (6) from lever.
Removing pull rod from solenoid

Hold flat section of pull rod (3) and release nut (2).
Unscrew pull rod with nut and remove from solenoid (1).
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Page 4
Disassembling pull rod

Release nuts (2) from pull rods (3) and (4).
Unscrew joints (1) from pull rods.
Release and remove split pin (7) from pin (5).
Remove shim (6) from pin.
Remove pin from pull rod.
Separate pull rods.
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Page 1

Clean all parts.
Check sealing surfaces of flap seat for damage and unevenness, smooth with oilstone if necessary.
Check bores for plug-in sleeves on cover for pitting and damage, smooth with emery cloth if necessary. Replace cover
as necessary.
Check sealing lip of rubber strip on flap for damage and unevenness, replace flap if necessary.
Measure bores for bearing bushes and outside diameter of shafts. If limit values are exceeded, replace parts.For speci-
fied limits, see Tolerances and Wear Limits List.
Check key grooves on shafts and flaps, if grooves are worn replace parts.
Check lever, bush, pin and cam roller for wear, replace if necessary.
Check condition of spring.
Check pull-rod for solenoid and roller contact surface on lever for wear; recondition if necessary and replace as re-
quired.
Check pull-rod ends between emergency air shut-off flaps and pull-rod connecting pins for wear, replace if necessary.
Replace grease nipple as required.
Replace shaft seals and O-rings.
If required, carry out crack-testing procedure.
Check function of solenoid – see 3.86.7
Check function of limit switch – see 3.84.6.4
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Page 1
3.10.4a.5 Assembly
Assembling emergency air shut-off flaps
Insert keys (1) into shaft grooves.
Coat shaft (1) with ”engine oil”.

Check shaft and flap (2) for slide fit when removed, re-
condition key if necessary.
Drive shaft with plastic mallet into flap so that the shaft
slightly projects on the opposite side of the flap.
Coat bearing bush on fit with ”engine oil”.

Fit bearing bush (2) on cover.
Locate bearing bush with pin (1).
The position of bore dia. 3.5 mm on collar of bearing
bush must be aligned with bore in cover.
Press bearing bush with suitable mandrel into cover.
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Page 2
Insert emergency air shut-off flap (2) with shaft (1) into
cover.
The sealing lip of rubber strip must face flap seat.
Coat shaft (2) and bearing bush with ”engine oil”.

Use a suitable pipe (5) to support cover (4).
Fit guide bush (3) over shaft and insert into cover.
Use press (1) to install shaft in flap in direction of arrow.
Remove guide bush.
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Page 3
Coat mating surface of lower bearing bush (2) with ”sur-

face sealant”.
Insert bearing bush with press (1) and suitable mandrel
into cover (3) until the stop.
Coat shaft seals (1) on sealing lip with ”petroleum jelly”.

Fit shaft seals on emergency air shut-off flap shaft and
drive into bearing bushes with suitable sleeve (2).
Take care not to damage the shaft seal.
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Page 4
Fit washer (2) on shaft end and secure with snap ring (1).
Fit washer (1), sleeve (3) and flexible spring (2) on shaft.
End of flexible spring must engage in bore on collar of
bearing bush.
Fit lever (1) in correct installation position on shaft.

Apply preload to flexible spring.
Locate lever by inserting drift (2).
Tighten hex bolt with spring washer on lever.
Withdraw drift from bore.
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Page 5
Support emergency air shut-off flap shaft with support

device (1).
Drive dowel pin (2) into lever.
Insert grease nipple (1) into shaft.

Check flap for ease of movement and lubricate with
”antifriction bearing grease”.
Assembling pull-rod
Install nuts (2) on joints (1).
Screw joints in pull-rods (3) and (4). Fill pull-rods 2/3 full
with grease.
Assemble both pull-rods with pin (5), shim (6) and split
pin (7).
Adjust joints to lengths ”A” and ”B”.
Dimension ”A” = 297.5 mm 6V, 8V, 12V
Dimension ”B” = 368.5 mm ±0.5 mm 6V, 8V, 12V
Dimension ”B” = 267.5 mm ±0.5 mm 16V
Dimension ”A” = 196.5 mm 16V
Pay special attention to surface parallelity of swivel
heads and position of pins.
Check length of pull rod when removed in accordance
with illustration; reset as necessary.
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Page 6
Installing pull-rod
Install pull rod (1) with pins (2) on lever (5) of emergency
air shut-off flap.
Position adjusting shim (3) on pin, insert split pin (4) in
pin and secure.
Assembling lever
Press bush (1) with mandrel into lever (2).
Insert two adjusting shims (2) and one back-up ring (3)
for pin (1) installation into fork of lever.
Insert pin on short lever side.
Note
Bores for pin on lever have different tolerances.
Secure pin on both sides with lockwashers.
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Page 7
Check projection ”X” = 3.8 mm ± 0.2 mm of pin to lever.
Install cam roller (1) with spring washer (3) and hex nut
(4) on long lever arm (2).
Tighten nut to tightening specification 1.3.
Installing pull-rod on solenoid

Fit nut (2) on pull rod (3).
Insert pull rod on solenoid (1) and set to dimension 51
mm ± 0.3 mm.
Secure pull-rod with nut on solenoid.
Tighten nut.
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Page 1
Installing cover with emergency air shut-off flaps
Clean sealing surfaces on intercooler (3) and cover (1),
smooth with oilstone if necessary.
Place gasket (2) on intercooler.
Coat sealing surfaces (2) with sealing paste. (Order-
specific)
Install cover with emergency air shut-off flaps in inter-
cooler using screws and spring washers.
Tighten screws diagonally and evenly.
For intercooler installation – see 3.10.1a.6
Installing carrier for solenoid

Install carrier (2) on cover (1) using screws (3) and
spring washers.
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Page 2
Installing solenoid
Coat axle threads (2) with ”thread-locking liquid”.
Place lever (6) on carrier. Install and secure axle (2) in
carrier (5).
Install lubricating nipple (1) in axle.
Place solenoid (3) in carrier in such a way that slot in pull
rod points towards axle.
Insert solenoid in carrier and install with flange (4),
screws and spring washers.
Installing retainer for limit switch (closed signal)

Install retainer (2) on cover (1) with screws and spring
washers then secure.
Installing limit switch

Install limit switch (2) on retainer (3) with screws (1),
spring washers (6), washers (4) and nuts (5).
Only pretighten nuts.
Installation of Miltac microswitch and proximity switch is
identical.
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Page 3
Adjusting Miltac microswitch

With shut-off flap open, adjust Miltac microswitch (open
signal) (2) clearance between stop on lever and Miltac
microswitch to 3 mm (A).
Tighten Miltac microswitch.
Adjusting proximity switch

With closed emergency air shut-off flaps, adjust clear-
ance between proximity switch (2) and lever (1) to (A)
= 1.5 mm 0.5 mm.
Tighten proximity switch.
Check function of emergency air shut-off flaps.

After installing solenoid and limit switch, check function
of emergency air shut-off flaps and limit switch in both
directions.
Using a grease gun, lubricate all emergency air shut-off
flap bearings at lubricating nipples.
See description for grease type and lubrication points.
1 Pull rod
x closed
y open
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Page 1
3.10.6a Carrier Housing with Exhaust Turbocharger and Exhaust Elbow
1 Coolant jacket upper section 6 Hex bolt ”GA”

2 Coolant jacket upper section 7 Washer
3 Exhaust elbow 8 Exhaust turbocharger, right
4 Clamp 9 Carrier housing, left
5 Carrier housing, right 10 Exhaust turbocharger, left
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Page 2
Exhaust system with carrier housing, coolant jacket and cover
1 Carrier housing, left 29 O-ring

2 Dowel pin 30 Washer
6 Flange 34 Plug
8 Hex bolt 36 Plug
9 Threaded sleeve 37 Flange
10 Washer 38 Washer
11 Tab washer 39 Hex bolt
12 Hex bolt ”GA” 40 Sealing ring
13 Connection housing, left 41 Sealing ring
14 Cover, left 42 Sleeve
15 Dowel pin 43 Cover
16 Hex bolt 44 O-ring
19 Hex bolt 47 Carrier housing, right
21 O-ring 49 Plug
22 Drain valve 50 Connection housing, right
23 Sealing ring 51 Cover
24 Plug 52 Plug
25 Floating exhaust pipe joint 53 Sealing ring
26 Coolant jacket upper section 54 Sealing ring
28 Plug
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Page 3
Carrier housing with connection housing and exhaust flow control flap
1 Carrier housing, left 8 Tab washer

2 Floating exhaust pipe joint 9 Hex bolt ”SB”
3 Threaded sleeve 10 Flap housing, right
4 Connection housing, left 11 Hex bolt ”GA”
5 Carrier housing, right 12 Washer
6 Flap 13 Tab washer
7 Bearing bush 14 Rod
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Exhaust system and turbocharging without turbocharger control
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Exhaust system and turbocharging, left side, without turbocharger control
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Exhaust system and turbocharging, right side, without turbocharger control
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Exhaust system and turbocharging, left side, with turbocharger control
T0100770a0
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Page 8
Exhaust system and turbocharging, right side, with turbocharger control
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Exhaust system and turbocharging, right side, with turbocharger control
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Page 1


- x x Disconnect electric cable -
- x x Remove cover and/or exhaust connecting line 3.10.11.2
- x x Remove intake funnel and intake housing 3.10.7.2
- x x Remove intercooler 3.10.1a.2
- x x Remove cover from carrier housing 3.10.3a.2
- x x Remove flanges and first constant-pressure manifold 3.10.3a.2
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Page 1
3.10.6a.2 Removal
Remove securing screws (3) of flanges (4) on cover (1)
and carrier housing (2).
Remove cover from carrier housing.
Remove flanges with plug-in pipe and protective tube.
Remove O-rings.
Removing flange
Remove flange (1) securing screws.
Remove flange.
Removing coolant jacket upper section

Remove screws (4) securing exhaust turbocharger (5)
to coolant jacket upper section (2).
Remove screws (3) and (6) for securing coolant jacket
upper section.
Remove coolant jacket upper section above elbow (1).
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Page 2
Removing exhaust elbow and exhaust turbo-

charger
Release clamp (1) on turbine housing (2) of exhaust
turbocharger via access port on carrier housing (4) with
screwdriver (5).
Remove exhaust elbow (3) from exhaust turbocharger
(6).
Remove screws securing exhaust turbocharger from
carrier housing.
Remove exhaust turbocharger with retaining rope and
lifting gear from carrier housing.
Remove screws (2) with washers and rubber sealing

ring with sleeve (1) from carrier housing (3).
Remove exhaust pipe joint (1) from connection housing

(2).
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Page 3
Removing carrier housing

Insert screws (3) as disassembly aid into carrier.
Remove securing screws (1) from carrier housing (2).
Remove assembly screws and remove carrier housing.
Check dowel pins for damage and replace if necessary.
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3.10.6a.3 Disassembly (without Exhaust Flow Control Flap)

Disassembling carrier housing
Release tab washer (5).
Remove securing screws (3) with washers (4) from
carrier housing (1).
Remove connection housing (2) from carrier housing.
Disassembling connection housing

Clamp connection housing (2) in appropriate retaining
unit (vice) – do not press in!
Release threaded sleeve (1) on collar and remove from
connection housing.
Note
For exhaust turbocharger disassembly and assembly,

see Special Publication.
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Task Description Section 3.10.6a.3a
Page 1
3.10.6a.3a Disassembly (with Exhaust Flow Control Flap)

Disassembling carrier housing
Release tab washer (5).
Remove securing screws (3) with washers (4) from
Remove connection housing / flap housing (2) from
carrier housing.
Disassembling connection housing

Release threaded sleeve (1) on collar and remove from
connection housing.
Disassembling right flap housing

Clamp flap housing (7) in appropriate retaining unit
(vice) – do not press in!
Remove threaded sleeve (1) from flap housing.
Release tab washers (4).
Remove screws (3) from bearing bush (5).
Remove tab washers.
Remove bearing bushes from flap housing (7) and sim-
ultaneously remove flap (2) in flap housing.
Using mandrel, press rod (6) out of flap housing.
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Page 1

Prior to crack testing and visual inspection, clean parts with cold cleaner.
Jet-clean exhaust elbow, exhaust flow control flap, joint and connection housing with ”plastic abrasive” MTH 608 (rated
grain 16 - 20).
If excessively dirty, treat components with ”decarbonizer”. Place parts to be treated in a container with ”decarbonizer”.
Treatment time is dependent on degree of contamination.
Caution
”Decarbonizer” must be used only in conjunction with a fume extraction system.

After cleaning, rinse parts until they are free from residues.
Using surface crack-testing procedure with flourescent penetrant dye, check coolant jacket top section, carrier housing,
connection housing, cover and flange for cracks.If cracks are detected, replace parts.
Check mating faces of carrier housings and coolant jacket top sections, cover and flanges for flatness and damage.
Smooth with oilstone as necessary.
Check water transfers for cavitation, if necessary recondition in accordance with MTU specifications.
Check exhaust pipe joints, exhaust flow control flap, threaded sleeve, clamps and connection housing for wear and
replace as necessary.
Check thread inserts for ease of movement, replace if necessary.
Clean coolant chambers with scale-removing compound.
Pressure-test coolant-carrying and oil-carrying components. Pressure-testing specifications:
– Liquid test pressure = 4.5 bar with water
– Air test pressure = 0.5 bar in water bath at 80 °C.
Individual chambers must be tested separately.
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Page 1
3.10.6a.5 Assembly (without Exhaust Flow Control Flap)

Assembling connection housing
Coat threaded sleeve (1) on thread with ”assembly
paste”.
Insert into connection housing and secure.
Install threaded sleeve on flap housing by pressing in

collar.
Assembling carrier housing

Install connection housing (2) with tab washer (5),
washer (4) and securing screws (3) in carrier housing
(1).
Tighten securing screws to tightening specification 1.3.
Note
Only use screws marked ”GA” on screw head!

Secure screws with tab washer.
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Page 1
3.10.6a.5a Assembly (with Exhaust Flow Control Flap)

Assembling right flap housing
Clamp flap housing (7) in appropriate retaining unit
(vice) – do not press in!
paste” and insert into flap housing (7) and tighten.
Install threaded sleeve on flap housing by pressing in
collar.
Coat rod (6) with ”assembly paste”, insert into flap hous-
ing and drive in with mandrel and mallet.
Coat bearing bushes (5) with ”assembly paste” and in-
sert a bearing bush into flap housing.
Insert flap (2) into bearing bush in flap housing.
Insert second bearing bush into flap housing and con-
nect with flap.
Mount bearing bushes (5) with tab washer (4) and
screws (3), tighten and secure.
Assembling connection housing

paste”.
Insert into connection housing and secure.
Install threaded sleeve on connection housing by pres-
sing in collar.
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Page 2
Assembling carrier housing

Install connection housing (2) with tab washer (5),
washer (4) and securing screws (3) in carrier housing
(1).
Tighten securing screws to tightening specification 1.3.
Note

Secure screws with tab washer.
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Page 1
Installing carrier housing
Note
Prior to installing right carrier housing, mount coolant

elbow on carrier, see 3.14.1
Insert preassembled carrier housing (1) into carrier (2).
Insert assembly screws (1) into carrier (3) to fix carrier

housing (4).
Mount carrier housing on carrier with screws (2) and
washers.
Tighten screws using torque wrench.
Do not damage dowel pins.
Remove assembly screws.
Coat exhaust pipe joint (1) with ”assembly paste” and in-
sert into connection housing (2).
20058/0 E –05.96–
Page 2
Coat sleeve with rubber sealing ring (1) with ”petroleum

jelly” and insert into oil drain bore on carrier housing
(3).Coat screws with washers (2) with ”assembly paste”
and insert up to bore end on carrier housing.
Note
Installing exhaust turbocharger
Note
Exhaust turbochargers for left and right are not the

same.
Observe information on nameplate:
Right turbocharger (B) and left turbocharger (A)
Secure installation tool (1) to bearing housing (2) of ex-
haust turbocharger.
Position exhaust turbocharger with lifting gear into sup-
port saddle of carrier housing (4) and insert into exhaust
pipe joint.
Note
Do not damage rubber sealing ring and sleeve (5) for oil
return.
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Page 3
Insert retaining screws (1) of installation tool (6) on

carrier housing.
Locate exhaust turbocharger (3).
Position exhaust turbocharger on carrier wall.
Tighten retaining screws.
Using hand wheel of installation tool (2), press exhaust
turbocharger into support of carrier housing (5).
Insert securing screws (4) and tighten with torque
wrench to tightening specification 1.3 .
Release hand wheel and retaining screws.
Coat mating face for exhaust elbow with ”assembly

paste”.
Attack clamp (1) on collar of turbine housing (2).
Insert O-rings (4) into grooves of coolant transfers on
Insert O-ring (3) into groove on oil supply of exhaust
turbocharger.
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Page 4
Installing exhaust elbow

Mount exhaust elbow (3) with clamp (1) on exhaust
housing (2) of exhaust turbocharger (6).
Pretighten clamp via access port on carrier housing (4)
with screwdriver (5).
Installing coolant jacket upper section

Smooth sealing surface on coolant jacket upper section
(1) with oilstone.
Coat screws with washers (2) with ”assembly paste” and
install in coolant jacket upper section bores.
Note
Mount cooling jacket top section (2) on carrier housing

and secure with screws and washers (3) and (6).
Preassemble exhaust turbocharger (5) with securing
screws and washers (4).
Align exhaust elbow (1) in transverse direction and using
torque wrench, tighten clamp via access port in carrier
housing to tightening specification 1.3.
Tighten securing screws for exhaust turbocharger to
tightening specification 1.3. Seal access port with plug
and sealing ring.
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Page 5
Installing flange
Mount flange (2) on cooling jacket top section.
Check gap (S) intermediate flange and exhaust elbow
(1).
S = 0.5 mm to 2.0 mm
Installing cover
Clean sealing surfaces on cover (1) and carrier housing
(2).
Apply ”sealing paste” to sealing surfaces of cover for
carrier housing.
Mount cover on carrier housing
Note
Ensure that sealing surface of free end is flush with

carrier housing and cover.
Using torque wrench (1), tighten screws on cover (2) to

Tighten securing screws of flange (3) on carrier housing
and cover.
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Page 1
3.10.7 Intake Funnel and Intake Housing with Turbocharger Control

Intake housing for exhaust turbocharger A and B sides
1 Intake housing, right side 13 Cover plate (transportation protection)

2 O-ring 14 Intake housing, left side
3 O-ring 15 O-ring
4 Washer 16 O-ring
6 Sealing ring (order-specific) 18 Hex bolt
7 Union (order-specific) 19 Sealing ring
8 Sealing ring 20 Union
9 Union 21 Sealing ring
10 O-ring 22 Union
12 Support plate 24 Cover plate (transportation protection)
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Page 2
Intake Housing, A Side, with Connector for Turbocharger Speed
1 Intake housing, A side 4 Toothed washer

2 Connector 5 Socket-head screw
3 Gasket
Intake funnel for intake housing

1 Intake funnel
2 Sealing ring
3 Plug
4 Washer
5 Hex bolt
6 Hex bolt
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Page 3
Air flow control flap for exhaust turbocharger B side
1 Intake housing B side 9 O-ring

2 Suction flap 10 O-ring
3 Shaft 11 Spring washer
4 Key 12 Hex bolt
5 Snap ring 13 Stop
6 Shim 14 Washer
7 Flange bush 15 Castle nut
8 Flange bush 16 Split pin
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Page 1


- x x Release electric connection on connectors -
- x x Remove actuator for turbocharger control 3.10.8a.2
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Page 1
3.10.7.2 Removal
Removing intake funnel
Remove intake funnel (1) from housing (2).
Remove backing plate (1) with sealing ring and O-ring

(2) from housing.
Note
When removing intake funnel on A side, remove gasket

from housing.
Removing intake housing, B side

Unscrew housing (1) with intake flap from compressor
housing (2).
Remove O-ring from turbocharger/housing.
Note
Remove intake housing, A side, similarly.
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Page 1
Disassembling intake housing with suction flap, B side

Remove screws (12) with spring washers (11) from flanged bushes (10) and (3).
Removed flanged bushes from intake housing (2).
Withdraw shaft (8) and, at the same time, remove intake flap (1) and shim (9).
Remove O-rings (4) and (5) from flanged bushes.
20038/10 E –05.96–
Page 2
Remove split pin (4) from nut (3).

Unscrew nut with washer (2) from stop (5).
Remove stop for flap (1) from housing (6).
Removing socket
Remove socket-head screws (5) with toothed washers
(4) from socket (2).
Remove connector with gasket (3) from intake housing
(1).
Unsolder connections.
Note
Remove socket only if faulty.
20038/10 E –11.92–
Page 1

Clean all components and if necessary clean coolant chambers with scale remover.
Check suction housing, intake funnel and suction flap for cracks using surface crack-testing method with fluorescent
penetrant dye.
Check shaft for cracks using magnetic crack-testing method and fluorescent magnetic powder. If cracks are detected,
replace parts.
Check sealing and mating surfaces on intake funnel, intake housing and flap for damage and unevenness, smooth with
oilstone if necessary.
Check bores for flanged bushes on intake housing for indentations and wear, smooth with polishing cloth if necessary.
Check key grooves on shaft and flap.
Measure locating bores in intake housing, flap and flanged bushes with bore gauge.
Measure diameter of shaft and flanged bushes with outside micrometer.
Pressure-test coolant-carrying components as necessary or pressure-test with engine.
Liquid test pressure: 4.5 bar with coolant
Replace support plate with sealing ring as part of every W6 major overhaul.
Replace stop in intake housing as part of every W6 major overhaul.
Check socket for damage and indentations, replace as required.
20038/10 E –05.96–
Page 1
3.10.7.5 Assembly
Assembling intake housing, B side

Insert stop (14) into intake housing (13) and tighten nut (16) with washer (17).
Secure nut with split pin (15).
Install keys (7), shim (5) and snap ring (6) on shaft (8).
Insert suction flap (1) into intake housing and insert shaft into intake housing and into suction flap.
For installation position, see illustration.
Fit O-rings (3) and (4) on flange bushes (2) and (10) and coat with ”petroleum jelly”.
Coat flange bushes and shaft with ”antifriction bearing grease” at points marked with arrow.
Install adjusting shim (9) with flange bush (10) and flange bush (2) into intake housing.
Tighten with two screws (11) and spring washers (12).
Check intake flap for ease of movement. Flap must fall onto stop under its own weight at position marked (see illustra-
tion).
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Page 2
Installing socket
Install connections in socket.
Coil 1: Pin A = yellow; Pin B = brown
Coil 2: Pin D = yellow; Pin E = brown
Install socket (5) with gasket (2) on intake housing (1).
Pay attention to correct position of groove ”X”.
Secure with screws (3) and toothed washers (4).
20038/10 E –11.92–
Page 1
Installing intake housing, B side
Coat O-ring (2) and (3) with ”petroleum jelly” and insert
into grooves on compressor housing (1).
Install housing (1) with nuts and washers on compressor

housing (2) and tighten.
Note
Install intake housing, A side, similarly.
Installing intake funnel

Insert backing plate (1) with sealing ring (3) and O-ring
(2) in housing.
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Page 2
Install intake funnel (1) with screws and washers on

housing and tighten.
Note
Mount intake funnel on A side with gasket.
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Page 1
3.10.7a Intake Funnel and Intake Housing without Turbocharger Control
Intake housing for exhaust turbocharger A and B sides
1 O-ring 5 Sealing ring

2 O-ring 6 Union
3 Washer 7 Gasket
4 Bolt 8 Transportation protection
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Intake funnel for intake housing

1 Intake funnel
2 Sealing ring
3 Plug
4 Washer
5 Hex bolt
6 Hex bolt
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3.10.7a.2 Removal
Removing intake funnel
Remove intake funnel (1) from housing (2).
Remove gasket from housing.
Removing intake housing

Remove screws (6) and washers (5) from intake hous-
ing (4).
Remove intake housing from exhaust turbocharger (1).
Remove O-ring (2) and (3) from grooves a compressor
housing.
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Clean all components and if necessary clean coolant chambers with scale remover.
Check suction housing and intake funnel for cracks using surface crack-testing method with fluorescent penetrant dye.
Check sealing and connection surfaces on intake funnel, intake housing for damage and unevenness, smooth with
oilstone if necessary.
Pressure-test coolant-carrying components as necessary or pressure-test with engine.
Liquid test pressure: 4.5 bar with coolant
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Installing intake housing
Coat O-ring (2) and (3) with ”petroleum jelly” and insert
into grooves on compressor housing (1).
Install housing (1) with nuts and washers on compressor

Installing intake funnel

Install intake funnel (1) with gasket (6), screws (2), (4)
and washers (3) on intake housing (5) and tighten.
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3.10.8a Actuator for Turbocharger Control
1 Retaining plate 17 Hex bolt

3 Hex bolt 19 Air flap lever, right
4 Spring washer 20 Key
5 Actuating cylinder 21 Spring washer
6 Reduction union 22 Hex bolt
7 Sealing ring 23 Control rod
8 Mounting bracket 24 Bush
10 Hex bolt 26 Hex nut
11 Hex bolt 27 Shim
12 Washer 28 Split pin
13 Spring washer 29 Accumulator link
14 Spring washer 30 Castle nut
15 Exhaust flap lever, right 31 Split pin
16 Key
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Flap actuation arrangement
1 Exhaust turbocharger B side 5 Air flap lever

2 Solenoid valve 6 Intake housing with air flow control flap
3 Actuating cylinder 7 Accumulator link
4 Accumulator link 8 Exhaust flap lever
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Actuator for turbocharger control
1 Retainer 18 Bolt
2 Bolt 19 Spring washer
3 Bolt 20 Air flap lever, right
4 Bolt 21 Key
6 Actuating cylinder 23 Bolt
7 Union 24 Control rod
8 Sealing ring 25 Bush
9 Bolt 26 Bolt
10 Spring washer 27 Nut
11 Retainer 28 Shim
12 Spring washer 29 Split pin
13 Bolt 30 Control rod
14 Spring washer 31 Castle nut
15 Bolt 32 Split pin
16 Exhaust flap lever, right 33 Shim
17 Key
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Flap actuation arrangement
1 Exhaust turbocharger B side 6 Intake housing with air flow control flap
2 Solenoid valve/distributor 7 Control rod
3 Actuating cylinder 8 Exhaust flap lever, right
4 Accumulator link 9 Diverter housing
5 Air flap lever
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- x x Remove compressed air lines for actuating cylinder 3.10.8a
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3.10.8a.2 Removal
Removing accumulator link
Remove split pin from castle nuts (4).
Unscrew castle nuts and accumulator link (2) from air
flap lever (1) and exhaust flap lever (3).
Removing air flow control flap lever and exhaust

flap lever and accumulator link
Remove split pin (5) and adjusting shim (6) from exhaust
flap lever (7).
Remove accumulator link (4) between connector (3)
and/or pull rod and exhaust flap lever.
Release clamping screw (1) on air flow control flap lever
(2) and clamping screw (8) on exhaust flap lever (7).
Remove both levers from shafts.
Remove keys from grooves on shafts.
Removing actuating cylinder

Unscrew screws (1) securing actuating cylinder (2) and
screws (4) securing mounting bracket (3) on retaining
plate (5).
Remove actuating cylinder from retaining plate.
Remove mounting bracket from actuating cylinder and
retaining plate from diverter housing.
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Removing boot and connector from actuating cylin-
der
Release clamp (2) with pliers on boot (5) and remove
boot and clamp.
Release hex nut (3) on plunger (6) from connector (1).
Remove connector from plunger.
For actuating cylinder disassembly, see 3.86.9.3
Disassembling control rod
Release hex nuts (3) and (11) on swivel heads (1) and (12) and unscrew swivel head from rod (4) and end element
(10).
Unscrew end element from spacer tube (9) and remove compression spring (13) from spacer tube.
Remove rod with intermediate element (7) from spacer tube. Remove guide bush (6) with scraper (5) from spacer tube
and remove intermediate element from rod only if necessary.
Remove scraper from guide bush.
L1 = setting dimension
L2 = setting dimension
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Disassembling accumulator link (short)
Note
The clevis link should be disassembled only after an

operation and condition check.
Remove clevis link (1) from threaded bush (3).
Remove pin (2) from strap (8).
Remove guide element (7) from threaded bush.
Remove compression spring (4) and spring retainer (5)
from pin.
Remove O-ring (6) from guide element.
* secured with ”high-strength pipe-thread sealant”
L = setting dimension
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Clean all parts.
Use the surface crack-testing method with red penetrant dye to check air flow control flap lever, exhaust flap lever and
mounting bracket for elements.
Use the magnetic surface crack-testing method with fluorescent magnetic powder to check connector, link, clevis link,
pin and rod for cracks. If cracks are detected, replace parts.
Check pin and bores on air flow control flap lever and exhaust flap lever for wear; replace components as necessary.
Measure locating bores on link, clevis link and connector with bore gauge.
Check pressure springs for wear, check spring pressure on spring balance as required, and replace pressure springs
if necessary.
Check ball joints for wear, replace if necessary.
Check all threads for ease of movement and rechase as necessary. Check wrench surfaces for damage; recondition
and/or replace components as necessary.
Replace boot in event of damage and hardening.
Replace clamps in event of damage and extreme warping.
Check condition of spacer tube, rod, guide bush, intermediate element, end element and nut; replace components as
necessary.
Replace scraper and O-ring.
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3.10.8a.5 Assembly
Boot and connector on actuating cylinder
Install hex nut (3) and connector (1) on plunger (6).
Set dimension ”A” = 95 mm ±0.3 mm.
Lock connector with hex nut.
Ensure installation position of connector is correct.
Fit boot (5) with clamps (2) on actuating cylinder (4) and
connector and secure clamps with pliers.
Assembling short accumulator link

Install O-ring (6) in groove of guide element (7).
Coat guide element, link (8) and pin (2) on sliding sur-
faces marked with xxxx with ”petroleum jelly”.
Join guide element and link.
Provide pin with spring retainer (5) and pressure spring
(4).
Coat thread on link with ”Activator” and ”high-strength
pipe-thread sealant”.
Insert preassembled pin in link.
Coat threaded bush (3) on sliding surfaces with ”petro-
leum jelly”.
Insert preassembled guide element into threaded bush.
Coat second thread of threaded bush and thread of cle-
vis link (1) with ”Activator” and ”high-strength pipe-
thread sealant”.
* secured with ”high-strength pipe-thread sealant”
Insert clevis link into threaded bush to dimension ”L” =
±
140 mm 1 mm.
After screw-locking compound has hardened, check
that clevis link can be both extended and compressed
by approx. 10 mm.
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Assembling long accumulator link
Press scraper (5) into guide bush (6) and insert rod (4) with insertion sleeve into guide bush.
Install intermediate element (7) on rod and tighten with hex nut (8) to specified torque. For torque setting, see Section
1.3.
Note
Always replace hex nut after every disassembly.

Coat spacer tube (9) on sliding surfaces marked with arrow and rod with ”petroleum jelly” .
Install pressure spring (13) on end block (10).
Screw preassembled rod and end block in spacer tube and tighten.
Equip swivel head (12) with hex nut (11) and insert into end element to length ”L2” = 32 mm ±0.5 mm.
Lock swivel head with hex nut.
Fit hex nut (3) and swivel head (1) on rod and insert to length ”L1” = 385 mm ±0.5 mm for version 556 090 03 25.
Lock swivel head with hex nut.
Lubricate swivel heads on tapered grease nipple (2) with grease.
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Installing actuating cylinder
Install retaining plate (5) on diverter housing and tighten.
Install mounting bracket (3) on actuating cylinder (2) and
tighten.
Mount actuating cylinder with securing screws (1) and
(4) and tighten.
Installing air flow control flap lever and exhaust flap

lever and accumulator link
Insert keys in grooves on shafts for air and exhaust flow–
control flaps.
Fit air flow control flap lever (2) and exhaust flap lever
(7) on shafts and tighten with clamping screws (1) and
(8).
Installing accumulator link (4) on exhaust flap lever.
Mount adjusting shim (6) on pin and secure with split pin
(5).
Mount accumulator link and/or pull rod with screw,
bushes and nut on connector (3) of actuating cylinder
and tighten.
Installing accumulator link

Fit accumulator link (2) on pins on air flow control flap
lever and exhaust flap lever (1) and (3).
Install castle nut (4) and tighten; secure with split pin.
Note
Check operation and position of air and exhaust flow-

control flaps (see Description and Operation Manual).
If flaps do not close properly, check length of accumula-
tor link and change length by adjusting swivel head.
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3.10.11a Exhaust Connecting Line
1 Diverter housing, top 11 Hex bolt

3 Plug-in pipe 13 Bush
4 O-ring 14 Diverter housing, bottom
5 O-ring 15 Coolant line
6 Exhaust elbow 16 Plug-in pipe
7 Washer 17 O-ring
8 Hex bolt ”GA” 18 O-ring
9 Plug-in pipe 19 Washer
10 Dowel pin 20 Hex bolt
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Exhaust flow-control flap and connection housing
1 Rod 7 Bearing bush

2 Flap 8 Seal carrier
3 Bearing bush 9 Rotatherm ring
4 Tab washer 10 Connection housing, left
5 Hex bolt 11 Flap housing, right
6 Shaft
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Carrier housing and diverter housing arrangement, bottom
1 Carrier housing 6 Washer

2 Connection housing or flap housing 7 Hex bolt
3 Hex bolt ”GA” 8 Washer
4 Washer 9 Diverter housing, bottom
5 Hex bolt 10 Exhaust elbow
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Exhaust system and turbocharging, left side, with turbocharger control
T0100770a0
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- x x Remove exhaust flap lever 3.10.8a.2
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3.10.11a.2 Removal
Removing shaft of exhaust flow-control flap
Remove seal carrier (1) for shaft of exhaust flow-control
flap (3) from right diverter housing (5).
Remove Mototherm ring (2).
Remove shaft (3) from diverter housing.
Remove bush (4).
From diverter housing, remove securing screws which
reach into cover of exhaust manifold (6).
Removing diverter housing and connecting cable

Remove diverter housing (1), right and left, with exhaust
elbow from carrier housing (2).
Remove securing screws from top diverter housing (6).

Using lifting rope and lifting gear, remove plug-in pipes
(5) with diverter housing (4) and (6) from intercooler (1).
Remove bush (3) from carrier housing (2).
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Disassembling diverter housing and connecting
cable
Disconnect diverter housing (1) from plug-in pipe (4).
Disconnect diverter housing (7) from plug-in pipe (5).
Disconnect plug-in pipe (5) from plug-in pipe (4).
Remove O-rings (2) and (6), check dowel pins (3) for
damage and remove as necessary.
Release screws (4) and remove with washers (3).

Remove exhaust elbow (2) from diverter housing (1).
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Insert exhaust elbow into container with ”decarboniser” for approx. 12 to 24 hours.
Caution
”Decarbonizer” must be used only in conjunction with a fume extraction system.

After cleaning with ”carbon-deposit remover”, rinse components in water until no further residues are washed off.
Cleaning jets with ”synthetic abrasive” (grain 16 to 20) can also be used to remove stubborn soot deposits. For this
purpose, the engine coolant inlets and outlets must be sealed.
Using surface crack-testing method and red penetrant dye, check plug-in pipes, exhaust elbows and diverter housing
for cracks.
Check plug-in pipes, exhaust elbows and diverter housing for wear, pitting and distortion; recondition and /or replace
as necessary.
Check thread and thread inserts for damage. Check sealing surfaces, sealing ring grooves and bores for plug connec-
tions for damage. Replace damaged thread inserts. Smooth sealing surfaces and bores with polishing cloth and oil-
stone.
Check that all screws and nuts are in perfect condition; check for ease of movement; make sure correct type of screw
is used ; replace if necessary.
Check condition of drive shaft and bearing bush for exhaust flow-control flap.
Replace sealing ring and tab washers.
Replace Mototherm ring.
Pressure-test water-carrying components.
Liquid pressure: 7.0 bar with coolant
Air test pressure: 0.5 bar in water bath at 80 °C
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3.10.11a.5 Assembly
Assembling diverter housing and connecting line
Insert exhaust elbow (2) into diverter housing (1).
Mount exhaust elbow with hex bolts (4) and washers (3)
on diverter housing.
Tighten bolts to specified torque. For torque setting, see
Section 1.3.
Pay attention to ”GA” screw markings.
Insert dowel pins (3) into plug-in pipe (4).

Insert O-rings (2) into grooves on plug-in pipe (5).
Insert O-rings (6) into grooves in diverter housing (1)
and (7).
Fit plug-in pipe (5) on plug-in pipe (4).
Note
Dowel pin (3) for locating inner plug-in pipe (5) on bottom
diverter housing (7) not applicable for second version.
Insert plug-in pipe (2) and (4) into diverter housing (1).
Note
Dowel pin (3) must be inserted into guide groove in div-

erter housing.
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Installing exhaust connection, left and right engine
side
Insert bush (3) into bore on carrier housing (2).
Mount plug-in pipes (5) with diverter housing (6) on inter-
cooler (1), and/or with diverter housing (4) on carrier
housing (2).
Fit screws with washers.
Note
Only tighten screws once cover is installed on carrier

housing.
Installing shaft of exhaust flow-control flap

Insert bush (4) into right diverter housing (5).
Coat shaft of exhaust flow-control flap (3) with ”assem-
bly paste”.
Insert shaft of exhaust flow-control flap into diverter
housing and connect with exhaust flow-control flap in
Apply a thin coat of ”sealing paste” to seal carrier (1).
Fit Mototherm ring (2) on shaft (3).
Mount seal carrier with washers and screws on diverter
housing and tighten.
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Page 1
3.11 Fuel Injection Equipment

Contents
3.11.1 Fuel injection pump drive

3.11.1.2 Removal
3.11.1.5 Assembly
3.11.2 Drive gear

3.11.2.2 Removal
3.11.2.5 Assembly
3.11.2a Injection timer

3.11.2a.2 Removal
3.11.2a.5 Assembly
3.11.2b Injection timer

3.11.2b.2 Removal
3.11.2b.5 Assembly
3.11.2b.7 After-installation operations
3.11.3 Fuel injection pump coupling, free end

3.11.3.2 Removal
3.11.3.5 Assembly
3.11.4 Fuel injection pump coupling IP I, driving end and IP II

3.11.4.2 Removal
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3.11.4a Fuel injection pump coupling IP I, driving end and IP II

3.11.4a.2 Removal
3.11.5 Fuel injection pump 8V, 12V

3.11.5.2 Removal
3.11.5a Fuel injection pump 16V

3.11.5a.2 Removal
3.11.5a.5 Assembly
3.11.5a.7a After-installation operations
3.11.6 Fuel injection nozzle with nozzle holder

3.11.6.2 Removal
3.11.7 End housing with locking device

3.11.7.2 Removal
3.11.7.5 Assembly
3.11.8 Cylinder cutout, fuel injection pump 8V/12V

3.11.8.2 Removal
3.11.8a Cylinder cutout, fuel injection pump II, 16V

3.11.8a.2 Removal
3.11.8b Cylinder cutout, fuel injection pump 8V/12V with 4/2-way solenoid valve
3.11.8b.2 Removal
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3.11.8c Cylinder cutout, fuel injection pump II, 16V

3.11.8c.2 Removal
3.11.9 Connecting housing, fuel injection pump I, 16V

3.11.9.2 Removal (see 3.11.9)
3.11.9.6 Installation (see 3.11.9)
3.11.10 Rack travel indicator

3.11.10.2 Removal
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Page 4

A
S4
s 4.1
S 5.1
S 5.8
S 5.13
S 6.9
S 6.10
S 6.19

Ink-check plate
Magnifier
Activator No. 7649 50548

Ethanol, denaturated
40250
Liquid nitrogen
Long-lasting lubricant grease Long-Term 2 Plus 40337
Engine oilKerosene or diesel fuel
Thread-locking varnish RAL 4001 red/purple 40664
Dry compressed air
Petroleum jelly
Petroleum jelly, white 40317
Caution
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Page 1
3.11.1 Fuel Injection Pump Drive

Fuel injection pump drive (without injection timer)
1 Bolt 10 Grooved ball bearing

2 Washer 11 Collared bush
3 End cover (open and closed version) 12 Locknut (2x)
4 O-ring 13 Thrust washer
5 Shaft seal 14 Drive gear
6 Bearing flange, complete 15 Drive shaft
8 Stress bolt (with and without sealing ring version) 17 Nut
9 Collared bush
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Fuel injection pump drive (IIb injection pump) with drive gear
1 Nut 13 Crankcase
2 Spring washer 14 Centering ring
3 Bearing flange 15 Grooved ball bearing
4 O-ring 16 Washer
5 Stress bolt 17 Bolt
6 Drive gear 18 O-ring
7 Camshaft idler gear 19 Cover
8 Drive shaft 20 Stress bolt
9 Bearing bush 21 Shaft seal
10 Thrust washer 22 Collared bush
11 Locknut 23 Bearing bush
12 Collared bush
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Fuel injection pump drive (IId injection pump) – with injection timer or drive gear
1 End cover 12 Drive gear (rigid drive)

2 Injection timer 13 Thrust washer
3 Idler gear – camshaft drive 14 Locknut (2x)
4 Bearing bush 15 Crankcase
5 Plug-in sleeve 16 Centering ring
6 Coupling 17 Collared bush
7 Coupling sleeve 18 Stress bolt
8 Washer 19 Cover
9 Nut 20 Grooved ball bearing
10 Plug-in sleeve 21 Bearing bush
11 Drive shaft 22 Bearing flange
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Fuel injection pump drive (IIb injection pump) with injection timer
1 Stud 12 Spring washer

2 Bearing flange 13 Bolt
3 O-ring 14 O-ring
4 Injection timer 15 End cover (alternative to16)
5 Drive shaft 16 Stress bolt (alternative to 15)
6 Bearing bush 17 Shaft seal (order-specific)
7 Idler gear – camshaft 18 Collared bush
8 Drive gear 19 Grooved ball bearing
9 Thrust washer 20 Nut
10 Locknut (2x) 21 Washer
11 Collared bush
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Page 5
Fuel injection pump drive (with injection timer)

3 End cover (closed version) 11 Locknut (2x)
5 Bearing flange, complete 13 Injection timer
6 O-ring 14 Drive shaft
7 Stress bolt (version without shaft seal) 15 Spring washer
8 Collared bush 16 Nut
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Page 1


- x x Drain or draw off engine oil Op. Man.
- x x Disconnect electrical lines and remove 3.84.1.2
- x x Remove engine terminal box 3.84.3.2
- x x Remove crankcase vent lines 3.1.7.2
- x x Remove coolant level monitor 3.84.2.2
- x x Remove cooler housing with cooler insert 3.14.2.2
- x x Remove fuel lines 3.12.2.2
- x x Remove H.P. fuel lines with damping tape 3.12.1.2
- x x Remove fuel injection pumps and governor 3.11.4.2
- x x Remove upper cover at free end 3.1.9.2
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Page 1
3.11.1.2 Removal
Removing drive gear
If only the drive gear is replaced or repaired, the piston
of cylinder A1 must firstly be set to firing TDC.
Both markings on camshaft on driving end must be
aligned with markings on crankcase (3.11.1.4)
Remove end cover from bearing flange of injection pump
drive and remove O-ring.
Release stress bolt for drive shaft by one rotation.
Using a plastic mallet, tap ring side of screw head so that
lock ring is released.
Remove stress bolt (2).

Remove collared bush (1).
Remove bearing flange from crankcase.
Using plastic mallet, drive drive shaft 5 to 10 mm in direc-

tion of driving end.
Insert a suitable mandrel (2) or stress bolt into bore of
drive shaft so that lock ring and collared bush do not fall
into gear case when drive gear (1) is removed.
Move drive shaft in direction of driving end and, using
mandrel or stress bolt, catch lock ring and collared bush.
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Page 2
Install removal tool (1) on drive gear (2).

When removing drive shaft (3), simultaneously remove
drive gear vertically from above from gear case.
In doing so, drive gears of camshafts are turned out-
wards if they are engaged in idler gear.
Indicate the position of camshaft marking on driving end
with scriber on crankcase.
Remove removal tool from drive gear.
Marking (2) and (3) matched to drive gear position rela-

tive to cams.
Marking (1) for removal and installation position of cam-
shaft and/or firing TDC A1
Removing grooved ball bearing

Install internal extractor (2) with support frame (3) on
grooved ball bearing (1).
Remove grooved ball bearing from crankcase.
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Page 3
If no removal tool is available, the grooved ball bearing

(2) can be pressed out of crankcase with two pry bars
(1).
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Disassembling bearing flange
Remove O-ring (2) from bearing flange (1).
Remove dished washers with centering ring (3) from
bearing flange.
Disassembling end cover

Remove O-ring (2) from end cover (1).
Using a suitable mandrel, press shaft seal (3) out of end
cover.
Note
End cover with shaft seal is order-specific. For arrange-

ment, see 3.11.1
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Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check drive shaft, stress bolts and collared
bush for cracks.
Check thread of stress bolts and drive shaft, rechase as necessary.
Measure length of stress bolt; max. screw length prior to assembly 165 mm.
Check lock ring for wear; replace as necessary.
Check driver on collared bush for pitting and wear; recondition minor pitting, smooth wear with an oilstone or replace
component as necessary.
Check end cover and bearing flange for damage and flatness; smooth with an oilstone or replace as necessary.
Replace grooved ball bearing as part of every W6 Maintenance Echelon.
Replace O-rings and shaft seal.
Adjust bore gauge (1) and measure bearing bush bore

(2) for grooved ball bearing in crankcase.
Measure bearing bore for drive shaft in crankcase, see
3.1.1.4
If wear limits are exceeded, replace bearing bushes.For
specified limits, see Tolerances and Wear Limits List.
Measure bearing seats on drive shaft (2) with outside

micrometer (1).
List.
Smooth minor wear and scoring on bearings with emery
cloth.
If necessary diameter 67 on drive shaft can be reground
to next repair stage.
If drive shaft is reconditioned, the bearing bush in crank-
case must be installed at appropriate stage.
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Page 1
3.11.1.5 Assembly
Assembling end cover

Clean and degrease bore in end cover (1) and seating
surface of shaft seal (3).
Coat shaft seal on seating surface with ”surface seal-
ant”.
Using installation mandrel, insert shaft seal with sealing
lip facing inwards into end cover.
Coat O-ring (2) with ”petroleum jelly” and insert into
groove on end cover.
Note
End cover with shaft seal is order-specific. For arrange-

ment, see 3.11.1
Assembling bearing flange

Fit four dished washers (3) into groove of bearing flange
(1).
Insert centering ring (2).
Ensure that bore edges of dished washers face in direc-
tion of grooved ball bearing.
Centering ring must be flush with bearing flange surface.
Max. clearance 0.2 mm
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Page 1
Installing adjusting shim with swivel head and
pointer
Mount swivel head with screws on free end of crank-
shaft.
Tighten screws.
Mount adjusting shim (2) on swivel head and timing
pointer (1) on crankcase.
Determine TDC mark, see 3.5.1.4
Prior to installing drive gear for fuel injection pumps, set

marking (3) matched to drive gear relative to camshafts
(2).
Marking (1) for removal and installation position of cam-
shaft and/or firing TDC A1

Turn crankshaft to firing TDC A1.
Insert drive gear (1) of fuel injection pump into gear case
on crankcase.
Idler gear of camshaft drive must simultaneously en-
gage on both sides in drive gears of camshafts.
Drive gears must turn regularly inwards.
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Page 2
Once tooth flanks engage, markings on drive gear (1)

must be aligned with markings (2) on crankcase.
Drive gear of fuel injection pump is correctly installed if

markings (1) and (3) on both fronts are aligned.
Marking (2), cam position.
Installing drive shaft

Coat drive shaft (3) and bearing bore in crankcase with
”engine oil”.
Insert drive shaft through drive gear (2) into bearing
bore.
Remove installation device (1).
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Installing thrust washer and lock ring

Fit thrust washer (1) on drive shaft.
Coat lock ring (1) with ”engine oil” and fit on drive shaft
(2).
Ensure lock ring is installed in correct position.
Fit collared bush (1) on drive shaft.
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Insert grooved ball bearing (1) with insertion sleeve in
bearing bush (2).
Ensure grooved ball bearing is positioned correctly.
Installing bearing flange with centering device

Smooth sealing surfaces with oilstone.
Insert O-ring into groove on bearing flange (1) and coat
Install bearing flange with O-ring, centering ring and
dished washer on crankcase (for installation position,
see next illustration).
Coat thread of studs with ”engine oil”, fit spring washer
on stud and tighten nuts to tightening specification 1.3
with torque wrench.
When installing the bearing flange, the cast-on identifi-

cation arrow must point vertically upwards.
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Page 5
Installing collared bush and stress bolt

Coat thread and bolt head contact surface of stress bolt
(2) with ”thin-film lubricant”.
Insert collared bush (1) with stress bolt into drive shaft.
Insert collared bush into groove of drive shaft.
Note
Collared bush has displaced driver claws and can be in-

stalled in only one position.
Insert stress bolt in drive shaft and pretighten.
Only tighten stress bolt (2) once start of delivery has
been set.
Check distance (A) between stress bolt (2) on drive gear

(1) of camshaft and drive gear (3) of injection timer.
”A” = min. 1 mm
Installing end cover

groove in end cover (5).
Coat running surface on stress bolt (4) with ”thin-film lu-
bricant”.
Mount end cover with screw (2) and spring washer (3)
on bearing flange (1).
Take care not to damage shaft seal when installing.
Using torque wrench, tighten screw to specified torque.
For torque setting see Section 1.3.
Note
Stress bolt with collar for shaft seal and end cover with
shaft seal is order-specific.
20054/00 E –06.96–
Page 1
3.11.2 Drive Gear

3 End cover (open and closed version) 12 Locknut (2x)
5 Shaft seal 14 Drive gear
6 Bearing flange, complete 15 Drive shaft
8 Stress bolt (with and without sealing ring version) 17 Nut
9 Collared bush
20038/10 E –06.96–
Page 2
Drive gear with fuel injection pump drive (IIb injection pump)
1 Nut 13 Crankcase
2 Spring washer 14 Centering ring
3 Bearing flange 15 Grooved ball bearing
4 O-ring 16 Washer
5 Stress bolt 17 Bolt
6 Drive gear 18 O-ring
7 Camshaft idler gear 19 Cover
9 Bearing bush 21 Shaft seal
10 Thrust washer 22 Collared bush
11 Locknut 23 Bearing bush
12 Collared bush
20038/10 E –06.96–
Page 3
Fuel injection pump drive (IId injection pump) with drive gear
1 End cover 12 Thrust washer

2 Drive gear (rigid drive) 13 Locknut (2x)
3 Idler gear – camshaft drive 14 Crankcase
4 Bearing bush 15 Centering ring
5 Plug-in sleeve 16 Collared bush
6 Coupling 17 Stress bolt
7 Coupling sleeve 18 Cover
8 Washer 19 Grooved ball bearing
9 Nut 20 Bearing bush
10 Plug-in sleeve 21 Bearing flange
20038/10 E –07.97–
Page 1


- x x Remove coolant expansion tank 3.14.5a.2
- x x Remove coolant cooler 3.14.6.2
- x x Remove crankcase ventilation 3.1.7.2
- x x Remove fuel injection pumps 3.11.4.2
20046/20 E –06.96–
Page 1
3.11.2.2 Removal
See 3.11.1.2
20038/10 E –11.92–
Page 1
Disassembling drive gear
If idler gear (2) or drive gear (1) must be replaced, re-
lease stress bolts (3) and remove.
Remove idler gear from drive gear.
Remove spring pin (4) as necessary.
20038/10 E –11.92–
Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check drive gear, idler gear and stress bolts
for cracks.
Check running and contact surfaces on drive gear for wear, scoring and pitting.
Check tooth flanks and gears for wear, scoring and pitting.
Smooth minor wear, scoring and indentations with emery cloth or oilstone. In the event of severe damage, replace com-
ponents.
Check thread of stress bolts, rechase as necessary.
Length of stress bolts for idler gear prior to assembly 38 mm; replace longer stress bolts.
Adjust bore gauge and measure interior diameter of fitted bores on drive gear. If limit values are exceeded, replace
parts. For specified limits, see Tolerances and Wear Limits List.

Measure bearing bore of drive gear (2).
List.
Check tooth flanks and mating faces for wear.
Smooth minor wear with oilstone or emery cloth; replace
drive gear or idler gear.
Check threaded bores.
20038/10 E –08.94–
Page 1
3.11.2.5 Assembly
Assembling drive gear
Note
Prior to installing idler gear (2), measure length of stress

bolts (3).
Max. length prior to assembly 38 mm.
Replace longer stress bolts.
When assembling, ensure position of spring pin (4) is
correct. Assemble idler gear (2) and drive gear (1) with
stress bolts (3).
Coat threads and heads of stress bolts with engine oil.
Tighten stress bolts to tightening specification 1.3.
20038/10 E –08.94–
Page 1
See 3.11.1.6
20038/10 E –11.92–
Page 1
3.11.2a Injection Timer
1 Drive gear for injection pump 11 Spring pin

2 Companion flange 12 Compression spring
3 Idler gear 13 Compression spring
4 Control weight 14 Flyweight
5 Stress bolt 15 Guide pin
6 Stress bolt 16 Sleeve
7 Spacer sleeve 17 Guide pin
8 Spacer sleeve 18 Spring pin
9 Cam 19 Dowel pin
10 Cam 20 Spring retainer
20038/10 E –11.92–
Page 2
Injection timer
1 Stress bolt 10 Guide pin

2 Stress bolt 11 Flyweight
3 Spacer sleeve 12 Guide pin
4 Spacer sleeve 13 Compression spring
5 Companion flange 14 Sleeve
6 Dowel pin 15 Spring retainer
7 Idler gear 16 Cam
8 Drive gear 17 Compression spring
9 Cam S MTU part number
20038/10 E –11.92–
Page 1


20046/20 E –06.96–
Page 1
3.11.2a.2 Removal
See 3.11.1.2
20038/10 E –11.92–
Page 1
Disassembling injection timer
Note
If a cover disc is still installed on injection timer, it is de-

structively removed; see Circular 151091.
Carefully grind cover disc at outer edge, taking care not
to damage drive gear.
Using two assembly levers, press cover disc off drive
gear.
Scrap cover disc.
Removing companion flange

Insert injection timer in retaining unit.
Lever companion flange (1) with screwdriver (2) out of
drive gear, paying particular attention to preload of com-
pression springs.
Caution
Spring tension
Remove compression springs and control weights.
20038/10 E –10.95–
Page 2
Removing flyweight and guide pin

Remove guide pin from drive gear.
Using drift (1), drive sleeve (2) from exterior side of gear
in direction of flyweight.
Using assembly lever (1), lift sleeve (2).

Remove flyweight with sleeve, spring retainer and com-
pression spring from guide pin.
Note
Guide pin is inserted chilled into hub on drive gear.
Using drift (1), drive guide pin (2) out of hub of drive gear.
20038/10 E –11.92–
Page 3
Removing cams
Remove stress bolts for cams (1) from drive gear.
Using plastic mallet, gently tap cams to release them
from drive gear and remove.
Remove dowel pin.
Removing idler gear for camshafts

Remove stress bolts (1) for idler gear from drive gear (2).
Remove drive gear and idler gear from retaining unit.
Using screwdriver, press idler gear off spring pin on drive
gear.
20038/10 E –11.92–
Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check drive gear, idler gear, companion
flange, cams, guide pin and control weights for cracks.
Check running and contact surfaces on companion flange and drive gear for wear, scoring and pitting.
Check cams, guide pin, flyweight and control weights for wear and flatness.
Smooth minor wear, flatness, scoring and indentations with emery cloth or oilstone. In the event of severe damage,
replace components.
Note
If the removed guide pin is used again and if there is no chamfer on the outer edge of the pin, rework in accordance
with Circular 15 10 91 (provide a chamfer) to achieve better lubricating and sliding conditions and to avoid edge carriers.
Check compression springs with spring test unit; if limit values are exceeded, replace compression springs.
Adjust bore gauge and measure interior diameter of fitted bores on companion flange. If limit values are exceeded,
replace parts. For specified limits, see Tolerances and Wear Limits List.
Check thread and length of stress bolts; max. length 38 mm prior to assembly.
20038/10 E –11.92–
Page 1
3.11.2a.5 Assembly
Prior to assembly, clean all components, ensuring they are perfectly clean.
Installing cam
Chill dowel pin (1) in ”liquid nitrogen”.
Caution

tions in 1.5.
Using pliers, insert dowel pin into installation tool (2) and
press into drive gear so that it is flush with drive gear
mating face.
Ensure that dowel pin is correctly installed.
Insert installation mandrel (1) for cam (2) into threaded

bore of drive gear.
Heat individual cam on hotplate to approx. 150 to
170 °C.
Caution
Always wear protective gloves to hold heated compo-

nents!
Fit heated cam via guide of assembly mandrel on the
dowel pin (3) which is still cooled.
Press cam (2) onto dowel pin.

Remove assembly mandrel (1).
Coat threads and heads of stress bolt with engine oil.
Insert stress bolt and tighten by hand.
20038/10 E –06.96–
Page 2

Insert spring pin (1) into drive gear to locate idler gear
(2).
Mount idler gear on drive gear and locate.

oil.
Insert stress bolts with spacer sleeves (1) and tighten by
hand.
Insert drive gear in retaining unit.

Using torque wrench (1), pretighten stress bolts (2) to
tightening specification 1.3 with torque wrench (1).
20038/10 E –06.96–
Page 3
Install angle-of-rotation measuring tool (2) with guide el-

ement (3).
Set pointer to zero position and using torque wrench (1),
tighten stress bolts to tightening specification 1.3.
Remove angle-of-rotation measuring tool and guide el-
ement.
Installing flyweight
1 Flyweight
2 Spring retainer
3 Compression spring
4 Sleeve
Chill sleeve (1) in ”liquid nitrogen”.
Caution

tions in 1.5.
Fit together compression spring (2), spring retainer,
chilled sleeve and flyweight (3).
20038/10 E –06.96–
Page 4
Coat sliding surface ”A” on drive gear (1) with ”thin-film

lubricant” .
Install assembled flyweight (2) into drive gear.
Press flyweight with screwdriver (3) into centering bore
on drive gear.
Chill guide pin in liquid nitrogen.
Caution

tions in 1.5.
Insert installation tool (2) into hub of drive gear.
Using pliers (3), insert chilled guide pin (1) into guide
groove of installation tool.
Using insertion tool (1), drive guide pin via guide groove,
hub and flyweight into sleeve until it contacts the stop.
Check clearance of guide pin to hub of drive gear.
Check flyweight for ease of movement.
20038/10 E –06.96–
Page 5
Using insertion mandrel (1), drive spring pins (2) into

cams (3).
Installing cams
Note
Prior to installing cams, check version of all cams (parts

number is stamped on cam).
Insert cams (2) into drive gear (3).
Gently tap cams with a plastic mallet (1) to fit cover on
surface

oil.
Insert stress bolts and tighten by hand.
Insert drive gear into retaining unit and pretighten stress
bolts to tightening specification 1.3 with torque wrench
(1).
20038/10 E –06.96–
Page 6

ement (3).
Set pointer to 0 and using torque wrench (1), tighten
stress bolts to tightening specification 1.3.
Remove angle-of-rotation measuring tool with guide el-
ement.
Remove drive gear from retaining unit.
Installing flyweight
Coat sliding surfaces of flyweight (2) and control weights
(1) with ”thin-film lubricant”.
Insert control weights into drive gear to hub.
Pay special attention to installation position:
Control weight with large groove (3) facing upwards.
Installing guide pin

Coat guide pin (2) on sliding surface with ”thin-film lubric-
ant” and fit on flyweight (1) in drive gear (3).
20038/10 E –11.92–
Page 7
Installing companion flange

Coat sliding surfaces on companion flange (1) with ”thin-
film lubricant”.
Fit companion flange on control weights.
Installing compression springs

Insert injection timer in retaining unit (1).
Insert compression springs (3) in companion flange (2)
and cams.
Fit twisting device (2) on companion flange (1) and se-

cure with pin (3) via hub of twisting device.
Using twisting device and ratchet, twist companion
flange against spring pressure; in doing so, simulta-
neously press lever (4) downwards until companion
flange contacts hub of drive gear and compression
springs engage.
Caution
Spring tension
Note
During installation, compression springs must not be

compressed to block length.
Length dimension: min. 38 mm
Remove twisting tool.
Check injection timer for ease-of-movement.
20038/10 E –10.95–
Page 1
See 3.11.1.6
20038/10 E –11.92–
Page 1

Check function of injection timer
Mount box wrench on hex of collared bush (1) of fuel in-
jection pump drive.
Twist injection timer in clockwise direction, against its
spring pressure, until it contacts the stop.
In doing so, the injection timer must not jam and must
automatically spring back to its initial position.
20038/10 E –11.92–
Page 1
3.11.2b Injection Timer
1 Drive gear for injection pump 8 Cam

2 Companion flange 9 Spring pin
3 Camshaft idler gear 10 Spring pin
4 Control weight 11 Compression spring
5 Stress bolt 12 Torsion spring (radial)
6 Stress bolt 13 Dowel pin
7 Spacer sleeve
20047/10 E –10.95–
Page 2
Injection timer
1 Torsion spring (radial) 8 Camshaft idler gear

2 Dowel pin 9 Stress bolt
3 Compression spring 10 Spacer sleeve
4 Cam 11 Stress bolt
5 Control weight 12 Companion flange
6 Spring pin
7 Injection pump drive gear S MTU part number stamped
20047/10 E –10.95–
Page 1


20046/20 E –06.96–
Page 1
3.11.2b.2 Removal
For injection timer removal, see 3.11.1.2
20047/10 E –10.95–
Page 1
1 Injection pump drive gear
2 Companion flange
3 Camshaft idler gear
4 Control weight
5 Stress bolt
6 Stress bolt
7 Spacer sleeve
8 Cam
9 Spring pin
10 Spring pin
12 Torsion spring (radial)
13 Dowel pin
Removing companion flange

Insert injection timer in retaining unit.
Using screwdriver (2), lever companion flange (1) out of
drive gear, ensuring that preload of compression springs
is correct.
Caution
Spring tension
Remove compression springs and control weights.
Removing cams
Remove stress bolts for cams (1) from drive gear.
Using plastic mallet, gently tap cams to release them
from drive gear and remove.
Do not damage spring pin; remove only if necessary.
20047/10 E –10.95–
Page 2
Removing torsion spring and dowel pin

Remove torsion spring (1) from dowel pin (2).
Remove dowel pin from drive gear (3) with drift as
necessary.
A = Distance 20 mm –0.5 mm
Removing idler gear for camshafts

Remove stress bolts (1) for idler gear from drive gear (2).
Remove drive gear and idler gear from retaining unit.
Using screwdriver, press idler gear off spring pin on drive
gear.
Remove spring pin as necessary.
20047/10 E –10.95–
Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check drive gear, idler gear, companion
flange, cams and control weights for cracks.
Check running and contact surfaces on companion flange and drive gear for wear, scoring and pitting.
Check cams and control weights for wear and flatness.
Smooth minor wear, flatness, scoring and indentations with emery cloth or oilstone. In the event of severe damage,
replace components.
Check compression springs with spring test unit; if limit values are exceeded, replace compression springs.
Check condition of torsion springs (radial); replace as necessary.
Adjust bore gauge and measure interior diameter of fitted bores on companion flange. If limit values are exceeded,
replace parts. For specified limits, see Tolerances and Wear Limits List.
Check thread and length of stress bolts; max. length 38 mm prior to assembly.
Replace dowel pin and spring pins as necessary.
20047/10 E –10.95–
Page 1
3.11.2b.5 Assembly
Prior to assembly, clean all components, ensuring they
are perfectly clean.
Preassemble drive gear
1 2 3
Chill dowel pin (1) in ”liquid nitrogen”.
Caution

tions in 1.5.
Using pliers, insert dowel pin into guide washer (2) and
press into drive gear (3) so that it is flush with the sup-
port.
When inserting dowel pin without guide washer, the dis-
0
tance is 20 mm –0.5 mm must be maintained, see
SG11 0001a0
3.11.2b.3 page 2.
s

Using insertion tool, drive spring pin (2) into drive gear
(1) to locate idler gear.
1
SG11 0002a0
Mount idler gear (1) on drive gear (2) and locate in posi-
1 2 tion.
SG11 0003a0
20047/10 E –11.95–
Page 2

oil.
1
Insert stress bolts (1) with spacer sleeves (2) into drive
gear (3) and tighten manually.
3 2
SG11 0005a0
Insert drive gear in retaining unit.

1
Using torque wrench (1), pretighten stress bolts (2) to
tightening specification 1.3 with torque wrench (1).
SG11 0006a0

1 2 3 ement (1).
Set pointer to zero position and using torque wrench (3),
tighten stress bolts (4) to tightening specification 1.3.
Remove angle-of-rotation measuring tool.
SG11 0007a0
20047/10 E –11.95–
Page 3
Insert torsion springs (1) via dowel pin (2), ensuring that
installation position is correct, see arrangement 3.11.2b.
1 2 1
SG11 0008a0
Installing cams
Using insertion mandrel (1), drive spring pins (2) into
1
cams (3).
3
2
SG11 0010a0
Note
Prior to installing cams, make perfectly sure that cam

version used is correct!
Insert cams (1) into drive gear (2).
1
Gently tap cams with a plastic mallet to fit on contact sur-
face.
1 2
SG11 0012a0
20047/10 E –11.95–
Page 4

oil.
1
Insert stress bolts and pretighten with torque wrench (1)
to tightening specification 1.3 .
SG11 0013a0

1 2 3 ement (1).
Set pointer to 0 and tighten stress bolts (4) to tightening
specification 1.3 with torque wrench (2) .
Remove angle-of-rotation measuring tool with guide el-
ement.
Remove drive gear from retaining unit.
4
SG11 0014a0
Installing control weight

1
Note
2
Prior to installing control weights, ensure that the correct
control weight version is used!
Coat sliding surfaces of cams and control weights (2)
with ”thin-film lubricant”.
Insert control weights into drive gear to hub (1).
Ensure installation position is correct:
Control weights installed with large groove (2) facing up-
2 wards, see illustration 3.11.2b.
SG11 0015a0
20047/10 E –11.95–
Page 5
Installing companion flange and compression

springs
1 2
Insert drive gear into assembly device (2).
Coat sliding surfaces on companion flange (1) with ”thin-
3 film lubricant”.
Fit companion flange on control weights.
Insert compression springs (3) in companion flange (2)
and cams.
SG11 0016a0
Fit twisting device (2) on companion flange (1) and se-

cure with pin (3) via hub of twisting device.
Using twisting device and ratchet, twist companion
flange against spring pressure; in doing so, simulta-
neously press lever (4) downwards until companion
flange contacts hub of drive gear and compression
springs engage.
Remove twisting tool.
Check injection timer for ease-of-movement.
20047/10 E –11.95–
Page 1
See 3.11.1.6
20047/10 E –11.95–
Page 1
3.11.2b.7 After-Installation Operations

Check function of injection timer
Mount angled box wrench on hex of collared bush (1) of
fuel injection pump drive.
Twist injection timer in clockwise direction, against its
spring pressure, until it contacts the stop.
In doing so, the injection timer must not jam and must
automatically spring back to its initial position.
20047/10 E –11.95–
Page 1
3.11.3 Fuel Injection Pump Coupling (Two-Part), Free End

1 Injection pump I
2 Housing with locking screw
3 Coupling half
4 Nut
1 Plug-in sleeve
2 Coupling sleeve
3 Hex nut
4 O-ring
5 Coupling half
20042/10 E –08.94–
Page 2
Coupling half with connection housing 6V, 12V
1 Injection pump 12 Washer

2 Housing 13 Bolt
3 Compression spring 14 Bolt
4 Locating pin 15 Bolt
5 Spring retainer 16 Driver
6 Circlip 17 Coupling half
7 Threaded connection 18 Tapered flange
8 Sealing ring 19 Spring pin
9 Locking screw 20 Nut
10 O-ring 21 Sealing wire
11 Gasket 22 Two-hole seal
20042/10 E –08.94–
Page 3
Coupling half with connection housing 8V, 16V
ET 11 255 13
1 Injection pump I 14 Hex bolt

2 Housing 15 Hex bolt
3 Compression spring 16 Driver
4 Locating pin 17 Coupling half
5 Spring retainer 18 Tapered flange
6 Circlip 19 Spring pin
7 Threaded connection 20 Hex nut
8 Sealing ring 21 Flange
9 Locking screw 22 Spring washer
11 Gasket 24 Sealing wire
12 Washer 25 Two-hole seal
13 Hex bolt
20042/10 E –08.94–
Page 1


- x x Disconnect electrical cables and remove -
- x x Remove engine terminal box -
- x x Detach Flexatrol actuator Op. Man.
- x x Remove end housing with locking device 3.11.7.2
20046/20 E –06.96–
Page 1
3.11.3.2 Removal
Removing coupling half, fuel injection pump I
Insert retaining unit (2) into teeth of coupling half of injec-
tion pump.
Ensure injection pump (3) and retaining unit are secure!
Clamp retaining unit securely.
Remove nut on coupling half with box wrench (1).
Remove retaining unit from teeth of coupling half.
Install removal tool on coupling half.
Remove coupling half from camshaft of injection pump;
for this purpose, hold removal tool in position.
Remove removal tool from coupling half.
For removal of connection housing with locking device,
see 3.11.7.2
20038/10 E –08.94–
Page 1
Disassembling coupling half
Press tapered flange (2) with suitable assembly levers
off coupling half (3).
Remove spring pin (1) from coupling half.
X – Taper surface
S – Distance 1 mm – 0.3 mm
20038/10 E –08.94–
Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check coupling half and tapered flange for
cracks.
Check teeth on coupling half for wear.
If necessary, recondition with oilstone or replace.
Check threads on tapered flange for ease of movement, recut if necessary.
Check taper surfaces for fretting corrosion.
If necessary, remove with emery cloth or replace component.
Replace spring pin.
20038/10 E –08.94–
Page 1
3.11.3.5 Assembly
Assembling coupling half
Insert spring pin (1) into tapered flange (2).
Clean taper surfaces ”X” with ”denaturated ethanol”.
Place dry and degreased coupling half (3) on tapered
flange; locate with spring pin.
Press coupling half onto tapered flange with a press-on
force of 200 N to 500 N.
Note
When pressing on, support tapered flange beneath tap-

ered surface.
Gap: Check ”S” = 1 mm – 0.3 mm .
20038/10 E –11.95–
Page 1
Installing coupling half, fuel injection pump I
For installation of connection housing with locking de-
vice, see 3.11.7.6
When injection pump is newly delivered from manufac-
turer, with the aid of locating device, the camshaft of in-
jection pump is located with locating pin (2) at pump tim-
ing.
Set/check start of delivery, see 3.11.3.7
Insert locking screw (1) with preload outwards and

screw in approx. 5 mm with screwdriver.
20038/10 E –11.92–
Page 2
Clean taper on injection pump camshaft and in coupling

half with ”denaturated ethanol”.
Fit coupling half (2).
Pay special attention to recess for locating pin (1).
Fit nut manually.
Load locating pin (1) by screwing in locking screw.
Note
If no locating device is available for tightening nut, use

retaining unit as for coupling half removal, see 3.11.3.2.
Use torque wrench to tighten nut to secure coupling half

to tightening specification 1.3.
Secure with ”screw locking paint”.
Remove retaining unit from teeth of coupling half.
Remove locating pin (1) from guide of locating device.
20038/10 E –08.94–
Page 3
Injection pump remains locked by means of locking

screw (1) until installed in engine.
Release nut securing locating device (1) on taper of in-

jection pump camshaft and remove with washer.
Remove locating tool with removal tool (2).
Remove flange (1) for locating tool.

Set start of delivery, see 3.11.3.7
20038/10 E –11.92–
Page 1

Checking start of delivery (injection pump removed)
Remove locking screw (1).
Remove constant-pressure valve assembly from fuel in-

jection pump.
6V, 8V, 12V: last pump barrel, engine cylinder A1.
16V: Injection pump I, last pump barrel, engine cylinder
A5.
16V: Injection pump II, last pump barrel, engine cylinder
A1.
Unscrew securing link (1).
Unscrew constant-pressure valve assembly (2) with
serrated wrench and extension from fuel injection pump.
20038/10 E –08.94–
Page 2
Using dial gauge, insert adjusting jig instead of constant-

pressure valve assembly into fuel injection pump and
tighten by hand.
Clamp dial gauge .
Turn camshaft of injection pump until pointer of dial
gauge displays ’Minimum’.
Secure minimum position by raising and releasing dial
gauge rod several times or by fully pressing down dial
gauge rod.
Set digital sheet of dial gauge to ”0”.
0-setting is at base circle of injection cam.
Turn camshaft of injection pump in direction of rotation
until locking screw (1) with locating pin can turn in recess
of coupling half.
Read off prestroke on dial gauge and compare with
value stamped on injection pump.
If values deviate, release coupling half and set to speci-
fied value. For coupling half removal, see 3.11.3.2.
Release nut securing locating device (1) on taper of in-

jection pump camshaft and remove with washer.
Remove locating tool with removal tool (2).
Remove flange (1) for locating tool.

Mount constant-pressure valve assembly on injection
pump, see 3.11.5a.7
20038/10 E –11.95–
Page 1
3.11.4 Fuel Injection Pump Coupling IP I, Driving End and IP II

Multiple disc clutch and coupling flange for fuel injection pump I and II, 16V
1 Connecting housing 13 Hex bolt

2 Gasket 14 Flange
3 Washer 15 Woodruff key
5 Flange 17 Hex nut
6 Woodruff key 18 Cover plate
7 Spring washer 19 Cover plate
8 Hex nut 20 Hex bolt
9 Disc pack 21 Spring washer
10 Intermediate element 22 Washer
11 Washer 23 Cut-out control housing
12 Spring washer
20038/10 E –08.94–
Page 1


- x x Disconnect electrical cables and remove 3.84.1.2
- x x Remove engine terminal box Op. Man.
20046/20 E –06.96–
Page 1
3.11.4.2 Removal
Removing intermediate element, disc pack and coupling flange, fuel injection pump I
Removing intermediate element
Remove securing screws (2) and spring washers (1)
from intermediate element.
Remove intermediate element (3) from disc pack.
Removing disc pack

Unscrew disc pack (1) on coupling flange and remove.
Do not disassemble disc pack.
Avoid contaminating disc pack.
Removing coupling flange

Install retaining unit (1) on coupling flange.
Release nut securing coupling flange (2).
Remove nut and spring washer.
Remove coupling flange (1) with removal tool.
Remove woodruff key from taper of injection pump
shaft.
20054/00 E –10.93–
Page 2
Removing disc pack, coupling flange, fuel injection pump II

Removing disc pack
Unscrew disc pack (1) on coupling flange and remove.
Do not disassemble disc pack.


shaft.
20054/00 E –10.93–
Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check coupling flanges and intermediate el-
ement for cracks.
Check mating faces, fit of coupling flange for wear and damage.
If necessary, smooth with oilstone or replace.
If necessary, remove with emery cloth or replace components.
Check mating faces and fits of intermediate element for wear and damage; smooth with oilstone and/or replace as
necessary.
Insert woodruff key into taper of injection pump cam-

shaft, pump I and II.
Fit coupling flange (1) onto camshaft of injection pump
(3).
Check clearance between woodruff key and coupling
flange with feeler gauge (2).
Max. clearance max. 0.2 mm
Replace woodruff key as necessary.
Clean disc pack only if severely contaminated.

Visually inspect condition of disc packs; replace as necessary. Do not disassemble!
20054/00 E –10.93–
Page 1
Installing coupling flange, disc pack and intermediate element, fuel injection pump I
Install flange (1) with screws and spring washers on in-
jection pump.
Installing coupling flange

Insert coupling flange (1) in retaining unit (2).
Pay particular attention to marking (3).
Clean and degrease taper on injection pump camshaft
and in coupling flange (1) with ”denaturated ethanol”.
Insert woodruff key (1) into injection pump camshaft.
20054/00 E –10.93–
Page 2
Fit coupling flange via woodruff key onto taper.

Coat thread and mating face of nut with ”engine oil”.
Fit spring washer and screw on nut.
Screw retaining unit with screw (1) on injection pump
Use torque wrench to tighten nut to secure coupling
flange to tightening specification 1.3.
Installing disc pack

New disc packs are coated with oil when delivered.
Do not remove grease/oil prior to assembly.
If disc packs had to be cleaned, assemble free from oil.
Check tightening torque of self-locking nut on disc pack,
see tightening specification 1.3
Install disc pack (1) on coupling flange with screw and
spring washer and tighten with torque wrench to tighten-
ing specification 1.3.
Installing intermediate element

Install intermediate element (3) with thicker flange side
on disc pack (4).
Tighten screws (2) and spring washers (1) to tightening
specification 1.3 with torque wrench.
Markings on coupling flange and intermediate element
must be aligned.
20054/00 E –10.93–
Page 3
Installing coupling flange and disc pack, fuel injection pump II

Insert woodruff key (1) into injection pump camshaft.

Tighten nut with spring washer by hand.
Install retaining unit (1) on coupling flange (2).

20054/00 E –10.93–
Page 4

Install disc pack (1) on coupling flange with screw and
spring washer and tighten with torque wrench to tighten-
20054/00 E –10.93–
Page 1
3.11.4a Fuel Injection Pump Coupling IP I, Driving End and IP II
Multiple disc clutch, coupling flange and dirt-proof enclosure for fuel injection pump I and II, 16V
1 Flange 17 Gasket
2 O-ring 18 Clamp
3 Washer 19 Clamp
4 Bolt 20 Mandrel
5 Flange 21 Nut
6 Woodruff key 22 Pipe
7 Spring washer 23 Elbow
8 Nut 24 Sealing ring
9 Disc pack 25 Union
10 Intermediate element 26 Clamp
11 Bolt 27 Washer
12 Washer 28 Bolt
13 Protective tube 29 Bolt
14 Gasket 30 Bolt
15 Cover 31 Washer
16 Stop
20046/20 E –06.96–
Page 2
Arrangement of dirt-proof enclosure on injection pumps I and II, 16V
1 Connecting housing 10 Stop

2 Injection pump I 11 Clamp
3 Bolt 12 Gasket
4 Union for vent line 13 Flange
5 Cover 14 O-ring
6 Plug-in pipe 15 Flange
7 Plug-in pipe flange 16 Disc pack
8 Shutdown housing 17 Intermediate element
9 Injection pump II 18 Protective tube
A Clearance crankcase/shutdown housing: 9.5 mm - 1mm E Nick on protective tube

B Thick flange F Window in protective tube
C Thin flange G Nick on cover
D Vertical shutdown housing surface H Nick on protective tube
20046/20 E –06.96–
Page 1


- x x Remove engine terminal box Op. Man.
- x x Remove vent line from protective tube -
20046/20 E –06.96–
Page 1
3.11.4a.2 Removal
Removing protective tube, intermediate element, disc pack, coupling flange and flange from fuel injection
pump I and II
Removing protective tube
1 Remove protective tube (2) from flange of injection

pump II (1).
SG110018a0
Removing intermediate element

Remove securing screw (1) from intermediate element
(3), holding intermediate element in position with secur-
ing device (4).
1 2 Remove intermediate element from disc pack (2).
SG110019a0
20046/20 E –06.96–
Page 2
Removing disc pack

Remove securing screw (2) from coupling flange.
Remove disc pack (1) from coupling flange.
1 Do not disassemble disc pack.
Remove disc pack from injection pump I in same se-
quence.
2
SG110020a0
Removing coupling flange from injection pump II

shaft.
Remove screws from coupling flange.
1
SG110021a0
Removing flange from injection pump II

Remove securing screws (1) from flange (2).
Remove flange from injection pump.
Remove O-ring (3) from flange.
1 3
SG110022a0
20046/20 E –06.96–
Page 3
Removing coupling flange from injection pump I

Insert locking screw in end housing and/or mount retain-
ing unit on coupling half.
1
shaft.
Remove screws (2) from coupling flange.
SG110023a0
Removing flange from injection pump I

Remove flange from injection pump.
Remove O-ring (2) from flange.
1
SG110024a0
20046/20 E –06.96–
Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check coupling flanges and intermediate el-
ement for cracks.
Check mating faces, fit of coupling flange and flanges for wear and damage; smooth with oilstone and/or replace as
necessary.
If necessary, remove with emery cloth or replace components.
Check mating faces and fits of intermediate element for wear and damage; smooth with oilstone and/or replace as
necessary.
Check fits of protective tube for wear and damage; smooth damaged areas and/or replace protective tube as necess-
ary.
Check fits on both sides of protective tube for roundness.
Insert woodruff key into taper of injection pump cam-
shaft, pump I and II.
Fit coupling flange (1) onto camshaft of injection pump
(3).
Check clearance between woodruff key and coupling
flange with feeler gauge (2).
Max. clearance max. 0.2 mm
Replace woodruff key as necessary.
Clean disc pack only if severely contaminated.

Visually inspect condition of disc packs; replace as necessary. Do not disassemble!
20046/20 E –06.96–
Page 1
Installing coupling flange, flange, disc pack, intermediate element and protective tube on fuel injection pump
I and II
Installing flange on injection pump II

Mount flange (2) with securing screws (1) and washers
on bearing cap of injection pump and tighten.
Insert O-ring (3) into groove of flange, ensuring O-ring
does not get twisted.
Coat O-ring with ”petroleum jelly”.
1
1 3
SG110022a0
Installing coupling flange on injection pump II
Note
Prior to installing coupling flange, insert four screws (1)

1 ±
of length 23.8 mm 0.2 mm into flange apertures.
2 Clean and degrease taper on injection pump camshaft
3 Insert woodruff key into injection pump camshaft.
Mount nut (3) and spring washer and tighten hand-tight
only.
1
SG110025a0
20046/20 E –06.96–
Page 2
Install retaining unit (1) on coupling flange (2).

SG110021a0

1
Install disc pack (1) on coupling flange with screw (2)
and tighten with torque wrench to tightening specifica-
tion 1.3.
Install disc pack on injection pump I in same sequence.
2
SG110020a0
Installing intermediate element

Install intermediate element (2) with ”thicker flange side”
on disc pack (4) of injection pump II with screws (3).
1 2
Markings (1) on coupling flange and intermediate el-
ement must be aligned.
4 3
SG110026a0
20046/20 E –06.96–
Page 3
Tighten screws (1) on intermediate element (3) with

torque wrench to tightening specification 1.3.
Using securing device (4), hold intermediate element
securely in position.
1 2
SG110019a0
Installing protective tube
1 Coat fit of protective tube (2) with ”petroleum jelly”.

Fit protective tube on flange of injection pump (1) so that
nick (arrow) on protective tube is aligned with vertical
surface on shutdown housing.
SG110018a0
Installing flange on injection pump I

Mount flange (3) with securing screws (1) and washers
on bearing cap of injection pump and tighten.
Insert O–ring (2) into groove of flange, ensuring O–ring
1 does not get twisted.
Coat O–ring with ”petroleum jelly”.
SG110024a0
20046/20 E –06.96–
Page 4
Installing coupling flange on injection pump I
Note
Prior to installing coupling flange, insert four screws (2)

1 ±
of length 23.8 mm 0.2 mm into flange apertures.
Insert woodruff key into injection pump camshaft.
Mount nut and spring washer and tighten hand-tight
only.
2
Insert locking screw in end housing and/or mount retain-
ing unit on coupling half.
SG110023a0
Install disc pack as for injection pump II.
20046/20 E –06.96–
Page 1
3.11.5 Fuel Injection Pump
Fuel injection pump 8V
1 Fuel injection pump 8V
20046/20 E –06.96–
Page 2
Fuel injection pump 12V
1 Fuel injection pump 12V
20046/20 E –06.96–
Page 3
Injection pump with drive 8V/12V
1 Injection pump drive with injection timer 6 Shutdown lever

2 Housing 7 Electrical actuator
3 Locking screw 8 Bracket
4 Injection pump 9 Coupling half
5 Intermediate housing 10 Coupling sleeve
1 O-ring
2 Plug-in sleeve
3 Snap ring
4 Coupling sleeve
20046/20 E –06.96–
Page 1


- x x Remove engine terminal box 3.84.9.2
20058/0 E –03.93–
Page 1
3.11.5.2 Removal
Using a socket (2), remove screws from the injection
pump (1).
Mount the lifting appliance (1) to the pressure pipe con-

nections of the injection pump (2).
Raise the injection pump at the electronic governor or in-
termediate housing.
Pull the bracket from the plug-in connection.
Using the assembly lever, withdraw the injection pump
out of the coupling sleeve in the direction of the driving
end.
Lift the injection pump out of the engine saddle.
Remove lifting appliance from the injection pump.
20042/10 E –08.94–
Page 2
Removing coupling sleeve and plug-in sleeve

Pull the plug-in sleeve (2) out of the crankcase upper
section.
Remove O-rings (1) from the grooves in the plug-in
sleeve.
Remove coupling sleeve (1) from the drive shaft.

Using circlip pliers, remove the snap ring from the
groove in the coupling sleeve.
20042/10 E –08.94–
Page 1

Overhaul fuel injection pump is accordance with Special Publication M040073 (IP–IIB) and M040095 (IP–IID).
Using the magnetic crack-testing method and fluorescent magnetic powder, check the coupling sleeve for cracks and
Check splines on coupling sleeve for pitting, smooth with an oilstone if required, replace if necessary.
Check plug-in sleeve for pitting at the fit, replace if necessary.
Replace O-rings.
20038/10 E –08.94–
Page 1
Engage barring tool (2) in ring gear (1) and secure to fly-
wheel housing.
As a control, check the freedom of movement of the
rocker arm at cylinder A1.
Both rocker arms must be unloaded and free to move.
Release bearing cap stud at the collared bush by one

rotation.
Using a soft-metal pin and steel hammer, knock the front
side of the screw head several times until the lock ring
slackens and the rigid connection between the drive
gear and injection pump is loosened.
20038/10 E –11.92–
Page 2
Using a box wrench, rotate the collared bush (1) until the
appropriate marking is facing upwards.
Example:
Marking ”8” at 8V
Marking ”12” at 12V
Using the locking screw (1), lock the injection pump.

Take the recess at the drive gear into account.
The locking screw must engage in the recess at the drive
gear.
20038/10 E –11.92–
Page 3
Coat O-rings (1) with ”petroleum jelly” and insert into

grooves in plug-in sleeve (2).
Insert plug-in sleeve into crankcase.
Installing coupling sleeve

Using circlip pliers, insert snap ring (1) into coupling
sleeve.
Fit coupling sleeve (1) onto drive shaft with snap ring
pointing to drive shaft.
20038/10 E –06.96–
Page 4
Insert O-rings (1) into grooves on bracket (2) and coat

Insert bracket into intermediate housing (3) of injection
pump.
Insert blocked injection pump (2) with lifting device (1)

into engine saddle.
Carefully insert injection pump into coupling sleeve and
plug-in sleeve.
20038/10 E –06.96–
Page 5
Align injection pump (2) in the centre with alignment tool

(1).
Fit alignment tool on crankcase Vee chamber on mating
faces and centre over pressure pipe connection of injec-
tion pump.
Note
If no alignment tool is available, the injection pump can

be centred with aid of measuring tape.
Coat thread of securing screws with ”engine oil”.

Insert screws with washers to secure injection pump (2)
and tighten to tightening specification 1.3 with torque
wrench (1).
Set start of delivery, see 3.11.5.7
Tightening sequence for injection pump securing

screws
1. Fit all screws (with battery screwdriver).
2. Screws in sequence: Pretighten 1 to 4/6/8 in accord-
ance with arrangement opposite.
3. Carry out final tightening in same sequence.
For tightening specification, see 1.3.
20038/10 E –07.97–
Page 1

Removing locking device from injection pump
Remove locking screw (1), turn by 180°, install with seg-
ment and tighten.
Note
When removing locking screw, ensure that spring lock-

ing pin in cut-out control housing disengages.
Check whether crankshaft rotates freely.
Checking start of delivery

On left engine side, remove cover from flywheel hous-
ing.
wheel housing.
To check whether piston is in firing TDC, remove cylin-
der head cover from cylinder A1 and check rockers.
Both rockers must be unloaded and free to move.
Turn crankshaft approx. 45° counterclockwise.
Turn crankshaft in engine direction of rotation to start of
delivery, e.g. 20° before firing TDC A1.
For start of delivery, see acceptance test record.
For determining crank angle before TDC – see Page 5
Note
For engines with Geislinger coupling F56 and tapered

flywheel, the TDC point can be determined by means of
the degree scale of coupling and/or tapered flywheel.
Remove both end covers from flywheel housing.
Disconnect H.P. fuel line from cylinder A1 on injection
pump.
For arrangement of H.P. fuel lines, see 3.12.1
20038/10 E –08.94–
Page 2
Removing constant-pressure valve assembly, cyl-

inder A1
serrated wrench and extension from injection pump.
Install adjusting jig with dial gauge (1) into injection

pump, cylinder A1 and tighten manually (do not tighten
fully).
Clamp dial gauge.
Release stress bolt from collared bush by one rotation.

Using soft-metal pin and steel hammer, knock the front
When lock rings are released, turn drive shaft of injec-
tion pump with collared bush AF50 by approx. 10°
against engine direction of rotation (counterclockwise)
until pointer of dial gauge displays ’Minimum’.
Check/secure minimum position by raising and releas-
ing dial gauge rod several times or by fully pressing
down dial gauge rod.
Set digital sheet of dial gauge to ”0”. (0-setting of dial
gauge is at base circle of injection cam.)
20038/10 E –08.94–
Page 3
Turn drive shaft of injection pump at collared bush in en-

gine direction of rotation (clockwise) until dial gauge dis-
plays prestroke actual dimension stamped on injection
pump with pressure valve for associated cylinder A1.
For example 4.70 mm.
Example:
Prestroke actual dimension (1) stamped on surface of
fuel injection pump.
Hold collared bush in this position with box wrench and

pretighten stress bolt to tightening specification 1.3 with
torque wrench.
Turn crankshaft against engine direction of rotation by
approx. 45°.
Using plastic mallet, tap screw head of stress bolt sev-
eral times to set control weights of injection timer to their
initial position.
Turn crankshaft in engine direction of rotation until
pointer of dial gauge displays prestroke actual dimen-
sion stamped on injection pump housing.
Check position of crankshaft; it must be at start of deliv-
ery (for specified value, see acceptance test record);
correct setting of start of delivery if necessary.
When start of delivery setting is correct, hold collared
bush of drive shaft securely in position with box wrench,
check pretightening torque of stress bolt and retighten
to specified value.
Tighten stress bolt by angle of further rotation to tighten-
Check start of delivery again.
Check 0 position of dial gauge – see Page 3.
Check checking torque of stress bolt in tightening direc-
tion to tightening specification 1.3.
Unscrew adjusting jig and dial gauge from fuel injection
pump.
20038/10 E –11.92–
Page 4
Installing constant-pressure valve assembly

Insert O-ring into groove of constant-pressure valve as-
sembly (2) and coat with ”petroleum jelly”.
Insert constant-pressure valve assembly into injection
pump and tighten to tightening specification 1.3 with ser-
rated wrench.
Fit securing link (1) and tighten with nut, washer and
spring washer.
Remove barring tool from flywheel housing and install
cover.
Determining crank angle before TDC

Remove cover from flywheel housing (2).
Mount engine barring tool (1) on driving end, left engine
side and tighten.
Ensure that pinion of engine barring tool engages in
coupling ring gear.
20038/10 E –06.96–
Page 5
Remove cylinder head covers

Remove fuel injector of cylinder A1.
Insert measuring device into nozzle bore and tighten.
Note
If installation of measuring device (cylinder A1) proves

difficult, firstly insert measuring device without dial
gauge, then insert dial gauge into device and clamp in
position.
Measuring procedure
Turn crankshaft in engine direction of rotation; when
doing so determine greatest reading on dial gauge.
Piston is at firing TDC if both rockers have play.
Set dial gauge to 0.
Turn crankshaft counterclockwise until stroke to be set
is exceeded by a few mm – see Page 3.
stroke to be set is achieved.
1 Piston in firing TDC

(Inlet and outlet valves closed)
2 Piston 40° before TDC = 26.865 mm piston stroke
A Piston stroke
20038/10 E –11.92–
Page 6
Arrangement for start of delivery setting

Crank angle before TDC to mm piston stroke before TDC
Crank angle corresponds to piston stroke

(mm)
7.0 0.876
8.0 1.143
9.0 1.446
10.0 1.784
11.0 2.157
12.0 2.564
13.0 3.006
14.0 3.483
15.0 3.993
16.0 4.538
17.0 5.116
18.0 5.727
19.0 6.372
20.0 7.049
21.0 7.759
22.0 8.501
23.0 9.274
24.0 10.079
25.0 10.915
26.0 11.718
27.0 12.678
28.0 13.604
29.0 14.559
30.0 15.544
31.0 16.556
32.0 17.597
33.0 18.665
34.0 19.760
35.0 20.831
36.0 22.028
37.0 23.201
38.0 24.398
39.0 25.619
40.0 26.865
Arrangement of compressed air distributor

(mm)
4.0 0.286
after firing TDC, cylinder B1
20038/10 E –07.97–
Page 1
3.11.5a Fuel Injection Pump 16V
1 Fuel injection pump I

2 Fuel injection pump II
20038/10 E –11.92–
Page 2
Injection pumps IIB with drive 16V
1 Injection pump drive with injection timer 7 Flange

2 Locking screw 8 Disc pack
3 Injection pump I 9 Intermediate element
4 Connecting rod with swivel head 10 Coupling half
5 Cylinder cutout 11 Coupling sleeve
6 Injection pump II
20038/10 E –07.96–
Page 3
Injection pumps IID with drive 16V
1 Injection pump drive with injection timer 6 Flange

2 Injection pump I 7 Disc pack
3 Connecting rod 8 Intermediate element
4 Shutdown housing with cylinder cutout 9 Coupling half
5 Injection pump II 10 Coupling sleeve
A = zero dimension, injection pump I
20038/10 E –07.96–
Page 4
Fuel injection pump II with electric actuator 16V
1 Cut-out control housing, cylinder cutout 5 Electric actuator

2 Injection pump II 6 Bracket
3 Intermediate housing 7 Flange
4 Shutdown lever 8 Disc pack
20038/10 E –07.96–
Page 5
Connecting linkage with plug-in pipe and connectors
ET 11/274A
1 Complete tie rod 12 Pin

2 Tie rod 13 Eccentric screw
3 Swivel head 14 Split pin
4 Hex nut 15 Plug-in pipe
5 Connector 16 O-ring
6 Hex bolt 17 Snap ring
7 Spring washer 18 Plug-in pipe flange
8 Castle nut 19 Gasket
9 Split pin 20 Hex bolt
11 Locating spring 22 Plug
20038/10 E –07.96–
Page 1


- x x Disconnect Flexatrol actuator (order-specific) Op. Man.
- x x Remove vent line from protective tube (order-specific) -
- x x Disconnect solenoid (order-specific) -
20046/20 E –07.96–
Page 1
3.11.5a.2 Removal
Removing fuel injection pump II
Remove snap ring on plug-in pipe (4) with circlip pliers
from groove.
Insert plug-in pipe into plug-in pipe flange (2).
Remove split pin from securing screw of connecting rod
(1) to injection pump I.
Unscrew nut with ratchet wrench.
Remove screws from cover plate (3) and remove cover
plate.
Remove plug-in pipe flange (3) with plug-in pipe (2) from
cut-out control housing (4).
Remove intermediate element (1) from disc pack (2).
20046/20 E –07.96–
Page 2
Removing fuel injection pump II with dirt-proof en-

1 2 1 3 closure
Remove plug-in pipe, plug-in pipe flange and connecting
rod as described on page 1.
Release clamps (1) on protective tube (3) and remove.
Remove cover (2) and gasket from protective tube.
SG110027a0
Release clamp (1) on protective tube (4) and remove.

Remove stop (2) and gasket (3) from protective tube.
1 2
4 3
SG110028a0
Unscrew screws (4) and washers (3) from disc pack (1)
1 2 3 4 5 by means of window of protective tube (5) on intermedi-
ate element (2).
Note
Protective pipe can be turned to facilitate removal.
SG110029a0
20046/20 E –07.96–
Page 3
Remove screws from injection pump II.
Note
Release screws on injection pump I to remove injection

pump II with dirt-proof enclosure.

Raise injection pump on intermediate housing.
Pull the bracket from the plug-in connection.
Remove disc pack, see 3.11.4.2/3.11.4a.2
After raising injection pump with dirt-proof enclosure,

use assembly lever and/or assembly device to remove
1 2 3 injection pump II (1) and protective tube (2) from injec-
tion pump I (3).
Use lifting gear to raise injection pump from engine
saddle.
Remove dirt-proof enclosure, see 3.11.4a.2
SG110030a0
20046/20 E –07.96–
Page 4
Removing fuel injection pump I
Using a socket (2), remove screws from the injection

pump (1).

Raise injection pump.
Using assembly lever, withdraw injection pump from
coupling sleeve in direction of driving end.
Lift injection pump out of engine saddle.
Remove coupling sleeve and plug-in sleeve.
Remove lifting appliance from injection pump.
Remove intermediate element from disc pack, see
3.11.4.2/3.11.4a.2
20046/20 E –07.96–
Page 1
Removing connecting rod with swivel head
Release split pin (6) on eccentric screw (2) and remove.
Remove eccentric screw from connector (5) and swivel
head of connecting rod (1) to injection pump I.
Remove connecting rod.
Remove pin (3) and locating spring (4) from connector.
Disassembling connecting rod

Release nuts (2) on connecting rod (3).
Unscrew swivel heads (1) from connecting rod.
A = Setting dimension 217.5 mm ±0.3 mm
B = Setting dimension 23 mm
Remove shutdown housing, see 3.11.7a.2
Remove connecting housing, see 3.11.9
20038/10 E –07.96–
Page 1

Overhaul fuel injection pump is accordance with Special Publication M040073 (IP–IIB) and M040095 (IP–IID).
Using the magnetic crack-testing method and fluorescent magnetic powder, check the coupling sleeve for cracks and
Check splines on coupling sleeve for pitting, smooth with an oilstone if required, replace if necessary.
Check plug-in sleeve for pitting at the fit, replace if necessary.
Replace O-rings.
Check swivel heads of connecting rod for wear and replace as necessary.
Check connecting rod and nuts for damage; recondition or replace components as necessary.
Check thread in connecting rod for ease of movement; rechase or replace as necessary.
Check eccentric screw and pin for pitting and wear; replace as necessary.
Check cover plate for warping and damage; correct or replace as necessary.
20038/10 E –08.94–
Page 1
3.11.5a.5 Assembly
Assembling connecting rod
Fit nuts (2) on swivel heads (1).
Insert swivel heads into connecting rod (3) and set to
setting dimensions ”A” and ”B”.
Lock nuts on connecting rod.
Note
Ensure position of swivel heads is correct (90° ± 3°).

±
A = 217.5 0.3 mm
B = 23 mm
For installation of connection housing with locking de-
vice, see 3.11.7.6
For installation of connecting housing, see 3.11.9
For installation of rack travel indicator, see 3.11.10.6
Insert connecting rod with swivel head (1) into connector

(5), paying particular attention to arrangement.
Insert locating spring (4) and pin (3) into connector.
Insert eccentric screw (2) and secure with split pin (6).
20038/10 E –11.95–
Page 1
Installing fuel injection pump I
wheel housing.
As a control, check freedom of movement of rockers at
cylinder A5.

20046/20 E –07.96–
Page 2
appropriate marking ”FB” is pointing vertically upwards.
appropriate marking is facing upwards.
Example:
Marking ”6” for 6V
Marking ”8” for 8V and 16V IP I
Marking ”12” for 12V
Marking ”16” for 16V IP II
Installing plug-in sleeve

Coat O-rings (1) with ”petroleum jelly” and insert into
grooves in plug-in sleeve (2).
Insert plug-in sleeve into crankcase and/or fit onto bear-
ing flange of injection pump I.

Using circlip pliers, insert snap ring (1) into coupling
sleeve.
20046/20 E –07.96–
Page 3
Fit coupling sleeve with marking (1) and (2) onto gear of
drive shaft until both markings are aligned.
Using the locking screw (1), lock the injection pump.

Pay special attention to recess on drive gear.
Carefully insert locking screw (spigot first) until injection
pump shaft is locked free of play.
(Start of delivery setting of injection pump I).
20046/20 E –07.96–
Page 4
Mount lifting device (1) on pressure pipe connections of

injection pump (2).
Insert injection pump with lifting gear into engine saddle.
Carefully insert injection pump into coupling sleeve and
plug-in sleeve.
Insert screws with washers to secure injection pump.
Align injection pump (2) in the centre with alignment tool

(1).
Fit alignment tool on crankcase Vee chamber on mating
faces and centre over pressure pipe connection of injec-
tion pump.
Note
If no alignment tool is available, the injection pump can

be centred with aid of measuring tape.
Removing locking device from injection pump

Remove locking screw (1), turn by 180° C, install with
segment and tighten.
Note
When removing locking screw, ensure spring locating

pin disengages from groove of coupling half.
Set start of delivery, see 3.11.5a.7.
20046/20 E –07.96–
Page 5
Installing fuel injection pump II

Insert O-rings (1) into grooves on bracket (2) and coat
Insert bracket into intermediate housing (3) of injection
pump.
For installation of disc packs and intermediate element,

see 3.11.4.6.
Mount lifting device (1) on pressure pipe connections of
injection pump (2).
Insert injection pump with lifting gear into engine saddle.
Insert bracket into its seat in engine saddle.
Insert screws with washers to secure injection pump.
Insert four spacer brackets (1) on disc packs.

Using assembly lever, press injection pump II in direc-
tion of free end onto disc packs.
20046/20 E –07.96–
Page 6
Align injection pump in the centre with alignment tool or

measuring tape.
Pressure pipe connection unions from injection pump I
and II must be aligned flush to one another.
Use torque wrench to tighten screws for securing injec-
tion pump diagonally and evenly to tightening specifica-
tion 1.3.
For tightening sequence, see 3.11.5.6.

Mount intermediate element (2) with screws, spring
washers and washers on disc pack, pump II and tighten
to tightening specification 1.3 with torque wrench (1).
Note
When installing intermediate element, markings (see il-

lustration) must be flush with one another.
20046/20 E –07.96–
Page 7
Installing fuel injection pump II with dirt-proof en-

closure
3
Coat fits of protective tube (1) with ”petroleum jelly”.
Insert bracket into intermediate housing as described on
2 page 5.
1
Pay special attention to markings (2) on intermediate el-
ement; re-turn injection pump II (3) if necessary.
For installation of protective tube on injection pump, see
3.11.4a.6.
SG110031a0
Using lifting gear, insert injection pump II (1) into engine

saddle as described on page 5 and with protective tube
1 2 3 (2) fit on flange of injection pump I (3).
Note
Release screws on injection pump I to install injection

pump II with dirt-proof enclosure.
SG110030a0
Insert screw (4) and washer (3) by means of window of

1 2 3 4 5 protective tube (5) on intermediate element (2) in disc
pack (1) and pretighten.
Note
Protective tube can be turned to facilitate installation.

When installing injection pump II on injection pump I,
markings on intermediate element and flange must be
flush, see illustration on page 6.
Align injection pump I and tighten as described on page
4.
Insert remaining screws and washers and tighten to
SG110029a0
20046/20 E –07.96–
Page 8
Align injection pump II in the centre with alignment

tool (1) or measuring tape
1
Pressure pipe connection unions from injection pump I
and II must be aligned flush to one another.
Use torque wrench to tighten screws for securing injec-
tion pump diagonally and evenly to tightening specifica-
tion 1.3.
For tightening sequence, see 3.11.5.6.
SG110032a0
Set protective tube (4) to correct installation position;

nicks (arrow) with vertical surface on shutdown housing
must be aligned.
Install stop (2) with gasket (3) on protective tube and se-
1 2 cure with clamp (1).
4 3
SG110028a0
Mount cover (2) and gasket on protective tube (3) by

1 2 1 3 means of window and secure with clamps (1).
SG110027a0
20046/20 E –07.96–
Page 9

grooves on plug-in pipe (2).
Insert plug-in pipe into plug-in pipe flange (3) and mount
1 2 3 4
on cut-out control housing (4) with gasket, screws and
spring washers.
SG110033a0
Carefully insert register knurled-head screws (2) to lo-

cate control racks (1) in injection pump I and II.
Use pump calibre to measure zero dimension value on
1 2 driving end of injection pump I.
Note
Zero dimension is stamped on lateral surface of injection

pump housing.
Remove register knurled-head screw from injection
pump I.
SG110034a0
Using allen key (1), turn eccentric screw until connecting

screw for control rack on injection pump I can be in-
serted.
1
Note
If connecting screw can still not be inserted after adjust-

ing eccentric screw, the length of connecting rod (2) can
be adjusted for coarse setting.
SG110035a0
20046/20 E –07.96–
Page 10
Using pump calibre (1), check zero dimension value on

1 driving end of surface of injection pump I (2) and readjust
control rack connection if necessary.
SG110036a0
Fit nut with spring washer on connecting screw of link (2)

and tighten.
1 2 3
Secure nut with split pin.
Insert plug-in pipe (3) into housing (1) and secure with
snap ring.
SG110037a0
Installing cover plate for fuel injection pump drive

without dirt-proof enclosure
Install cover plate (1) over multiple disc clutch.
Note
Each time securing screws are released, the control

racks on one of the two injection pumps must be read-
justed.
20046/20 E –07.96–
Page 1

Setting start of delivery with dial gauge, injection pump I
On left engine side, remove cover from flywheel hous-
ing.
wheel housing.
Turn crankshaft approx. 45° counterclockwise.
Turn crankshaft in engine direction of rotation to start of
delivery, e.g. 18° before firing TDC.
For determining crank angle before TDC – see Page 7
Note

Remove both end covers from flywheel housing.
For engines with degree scale on vibration damper, re-

move plug from end cover on free end (3); in doing so
TDC pointer becomes visible.
For engines without degree scale, determine crank
angle before TDC – see Page 7.
Remove H.P. fuel line from cylinder A5 on injection pump
I and from cylinder A1 on injection pump II.
For arrangement of H.P. fuel lines, see 3.12.1
20038/10 E –11.95–
Page 2

inder A5 from injection pump I
Insert adjusting jig with dial gauge (1) into injection pump
(2) cylinder A5 and tighten manually (do not tighten se-
curely).
Clamp dial gauge.

Using soft-metal pin and steel hammer, knock the front
When lock rings are released, turn drive shaft of injec-
tion pump with collared bush AF50 by approx. 10°
against engine direction of rotation (counterclockwise)
until pointer of dial gauge displays ’Minimum’.
Set digital sheet of dial gauge to ”0”. 0-setting of dial
gauge is at base circle of injection cam.
Turn drive shaft of injection pump at collared bush in en-
gine direction of rotation (clockwise) until dial gauge dis-
plays prestroke actual dimension stamped on injection
pump with pressure valve for associated cylinder.
20038/10 E –08.94–
Page 3
Example:
Prestroke actual dimension (1) stamped on surface of
fuel injection pump.

torque wrench.
approx. 45°.
initial position.
ery (for specified value, see acceptance test record);
correct setting of start of delivery if necessary.
When start of delivery setting is correct, hold collared
bush of drive shaft securely in position with box wrench,
check pretightening torque of stress bolt and retighten
to specified value.
Check start of delivery again.
Check 0 position of dial gauge – see Page 2.
Unscrew adjusting jig and dial gauge from fuel injection
pump.
20038/10 E –08.94–
Page 4
Installing constant-pressure valve assembly, cylin-

der A5, into injection pump I
rated wrench.
spring washer.
Setting start of delivery, injection pump II

inder A1 from injection pump II
Insert adjusting jig with dial gauge (1) into injection pump
(2) cylinder A1 and tighten manually (do not tighten se-
curely).
Clamp dial gauge .
20038/10 E –11.95–
Page 5
For installation of barring tool (2) on flywheel housing –

see Page 1
Turn crankshaft counterclockwise until pointer of dial
gauge displays ”Minimum”.
Set digital sheet of dial gauge to ”0”. 0-setting of dial
gauge is at base circle of injection cam.
Set crankshaft in engine direction of rotation to start of
delivery in accordance with acceptance test record, e.g.
16° before firing TDC.
Release screws securing intermediate element (1) on

disc pack (2), injection pump II.
Hold intermediate element in position.

Turn camshaft on coupling flange of injection pump II in
elongated holes of intermediate element in engine direc-
tion of rotation until dial gauge displays prestroke actual
dimension stamped on injection pump housing.
20038/10 E –11.92–
Page 6
Example:
Prestroke actual dimension is stamped on injection
pump.
Secure multiple disc clutch in this position with a screw.

Coupling flange and/or camshaft of injection pump must
not be able to turn.
approx. 45°.
initial position.
Check zero position of dial gauge as described on
Page 5.
ery (for specified value, see acceptance test record).
Use torque wrench to tighten all screw securing inter-
mediate element (2) on disc pack, injection pump II to
Installing constant-pressure valve assembly, cylin-

der A1, into injection pump II
rated wrench.
spring washer.
20038/10 E –11.95–
Page 7
Determining crank angle before TDC

Remove cover from flywheel housing (2).
Mount engine barring tool (1) on driving end, left engine
side and tighten.
Ensure that pinion of engine barring tool engages in
coupling ring gear.
Remove cylinder head covers

Remove fuel injector of cylinder A1.
Insert measuring device into nozzle bore and tighten.
Note
If installation of measuring device (cylinder A1) proves

difficult, firstly insert measuring device without dial
gauge, then insert dial gauge into device and clamp in
position.
Measuring procedure
Turn crankshaft in engine direction of rotation; when
doing so determine greatest reading on dial gauge.
Piston is at firing TDC if both rockers have play.
Set dial gauge to 0.
Turn crankshaft counterclockwise until stroke to be set
is exceeded by a few mm – see Page 8.
stroke to be set is achieved.
1 Piston in firing TDC

2 Piston 40° before TDC = 26.865 mm piston stroke
A Piston stroke
20038/10 E –08.94–
Page 8
Arrangement for start of delivery setting

Crank angle before TDC to mm piston stroke before TDC

(mm)
7.0 0.876
8.0 1.143
9.0 1.446
10.0 1.784
11.0 2.157
12.0 2.564
13.0 3.006
14.0 3.483
15.0 3.993
16.0 4.538
17.0 5.116
18.0 5.727
19.0 6.372
20.0 7.049
21.0 7.759
22.0 8.501
23.0 9.274
24.0 10.079
25.0 10.915
26.0 11.718
27.0 12.678
28.0 13.604
29.0 14.559
30.0 15.544
31.0 16.556
32.0 17.597
33.0 18.665
34.0 19.760
35.0 20.831
36.0 22.028
37.0 23.201
38.0 24.398
39.0 25.619
40.0 26.865
Arrangement for compressed air distributor

(mm)
4.0 0.286
after firing TDC, cylinder B1
20038/10 E –07.96–
Page 1
3.11.5a.7a After-Installation Operations

Setting start of delivery in accordance with blocking method, injection pump I
wheel housing.
Using barring tool, turn crankshaft in engine direction of
rotation to start of delivery mark of cylinder A5 corre-
sponding to start of delivery of injection pump.
As a control, check freedom of movement of rockers at
cylinder A5.
Both rockers must be unloaded and free to move; valves
are closed (firing TDC).
To set pump timing, injection pump must be secured with
all screws and control rack must contact full-load stop.
For determining crank angle before TDC – see
3.11.5a.7, Page 7
Note

To readjust injection pump, release stress bolt on col-

lared bush by one revolution.
20038/10 E –11.95–
Page 2
appropriate marking ”8” on collared bush is pointing
vertically upwards.
Note
Collared bush must only be turned if injection pump is

not locked!
Remove locking screw (1).

Using locking screw (preload inwards), apply pressure
on spring locating pin (2) to determine whether start of
delivery position of injection pump is achieved.
In doing so, injection pump can be readjusted by care-
fully turning pump with collared bush, see illustration
above.
Insert locking screw until injection pump shaft is locked
free of play in groove of coupling half (3). Check by
means of collared bush.
20038/10 E –11.95–
Page 3

initial position.
torque wrench.
Remove locking screw (1), turn by 180°, install with seg-

ment and tighten.
Note
When removing locking screw, ensure spring locating

pin (2) disengages from groove of coupling half (3).
20038/10 E –11.95–
Page 4

Check start of delivery again – see 3.11.5a.7
When randomly checking start of delivery, the stamped
prestroke value, measured on pump barrel 8 (engine
±
cylinder A5) can deviate by a max. of 0.08 mm.
Set start of delivery at injection pump II – see 3.11.5a.7
20038/10 E –11.95–
Page 1
3.11.6 Fuel Injection Nozzle with Nozzle Holder
1 Cylinder head 4 Pressure sleeve

2 Thrust screw 5 Nozzle holder with nozzle
3 O-ring 6 Support ring
7 CE ring
20038/10 E –11.95–
Page 2
Fuel injection nozzle with nozzle holder
1 H.P. fuel line 5 O-ring

2 Leak-off fuel line 6 CE-ring and support ring
3 Nozzle holder 7 Protective sleeve
4 Thrust screw 8 Pressure sleeve
20038/10 E –11.95–
Page 1


- x x Remove cylinder head covers
20038/10 E –11.92–
Page 1
3.11.6.2 Removal
Removing leak-off fuel line
Unscrew cap nut (2).
Remove sealing ring and leak-off fuel line (1) from banjo
union.
Remove leak-off fuel line (1) from nozzle holder (2).

Remove O-ring from groove of seal carrier.
20038/10 E –11.92–
Page 2
Removing nozzle holder

Release thrust screw (1) with removal tool (3) by a few
rotations.
Using removal tool, release nozzle holder (2) from cylin-
der head.
Completely remove thrust screw.
Remove nozzle holder and pressure sleeve (5).
Removing support ring and CE-ring

Remove support ring (2) and CE-Ring (1) with wire hook
from cylinder head.
20038/10 E –11.92–
Page 1

Check pressure sleeve for straightness and ensure that it is in perfect condition in area of groove and sealing surfaces.
Replace damaged or deformed pressure sleeves.
For disassembly, cleaning, assembly and inspection of fuel injectors, see Engine Operating Instructions.
Replace support ring, CE ring and O-rings.
Clean leak-off fuel lines, visual inspect condition and check for damage and replace indented or corroded seal carriers
and banjo unions.
20038/10 E –11.95–
Page 1
Installing nozzle holder
Fix support ring and CE ring with ”lubricating grease” on
nozzle holder so that, when installing, the gap between
nozzle and protective sleeve is sufficiently filled with
grease.
Insert nozzle holder into cylinder head.
Locating pin must engage in groove in cylinder head.
Coat O-rings (1) with ”petroleum jelly”.

Insert O-rings into grooves of thrust screw (2).
Coat front of pressure sleeve (4) with ”engine oil”.
Fit thrust screw with pressure sleeve over nozzle holder
(3) and screw into cylinder head, taking care not to dam-
age support ring and CE-ring (5).
Using device (3), insert thrust screw (1) into cylinder

head and tighten evenly wit h torque wrench to tighten-
When tightening thrust screw, ensure that annular gap
between nozzle holder (2) and thrust screw (1) is uni-
form throughout (central seat of injection nozzle).
If this is not the case, slightly turn nozzle holder against
the direction of tightening with an open-end wrench at
flattened section at top of nozzle holder.
Note
If specified torque is not achieved when tightening, re-

place pressure sleeve.
20038/10 E –11.95–
Page 2
Installing leak-off fuel line

Insert new O-ring into groove of seal carrier.
Coat O-ring with ”petroleum jelly”.
Insert leak-off fuel line (1) into nozzle holder (2).
Mount leak-off fuel line (1) on banjo union with sealing

rings.
Fit cap nut (2) and tighten.
20038/10 E –11.95–
Page 1
3.11.7 End Housing with Locking Device
1 Injection pump 10 Gasket

2 Housing 11 Washer
3 Compression spring 12 Bolt
4 Locating pin 13 Bolt
5 Spring retainer 14 Bolt
6 Circlip 15 Driver
7 Threaded connection 16 Coupling half
8 Locking screw 17 Sealing ring
9 O-ring 18 Nut
20038/10 E –11.92–
Page 2
Connection housing with locking device, fuel injection pump I 8V, 12V, 16V
1 Locking screw 4 Complete coupling half

2 Injection pump 5 Locating pin
3 Hex nut 6 Housing
20038/10 E –07.96–
Page 1


- x x Remove fuel injection pump 3.11.4.2
20038/10 E –11.92–
Page 1
3.11.7.2 Removal
Remove securing screws for end housing (1).
Remove end housing with gasket and O-ring.
20038/10 E –11.92–
Page 1
Removing locking device from housing
Remove locking screw (1) from housing (8).
Remove sealing ring (2).
Remove O-ring (9) from housing.
Note
Do not disassemble locating pin (4) with circlip (5), com-

pression spring (7) and spring retainer (6); threaded
connection (3) is secured with ”pipe-thread sealant”.
If, due to technical reasons, the locking device must be
disassembled, threaded connection must be heated to
approx. 180 °C.
20038/10 E –11.92–
Page 1

Using the surface crack-testing method with red penetrant dye, check housing for cracks; replace component if cracks
are found.
Check mating faces and fitted bores for wear and pitting; smooth with emery cloth if necessary.
Check locking screw for damage and replace as necessary.
Replace sealing ring, gasket and O-ring.
20038/10 E –08.94–
Page 1
3.11.7.5 Assembly
Installing locking device in housing
Insert circlip (5) into groove on locating pin (4).
Coat locating pin with ”thin-film lubricant”.
Fit spring retainer (6) and compression spring (7) on lo-
cating pin.
Insert locating pin with compression spring in housing
(8).
Coat threaded connection (3) with ”pipe-thread sealant”
and insert into housing bore until the stop.
Ensure locating pin is free to move.
housing groove.
Fit sealing ring (2) on thread on short end of locking
screw (1).
Insert locking screw into housing and tighten.
20038/10 E –11.95–
Page 1
Mount end housing (1) with gasket, O-ring, screws and
washers on injection pump.
Check control rack for ease of movement.
Note
If control rack is sluggish, release securing screws and

nut for end housing again and realign end housing.
20038/10 E –11.92–
Page 1
3.11.8 Cylinder Cutout, Fuel Injection Pump 8V/12V
1 Injection pump 4 Compression spring

2 Grooved ring 5 Oil supply sleeve
3 Oil supply sleeve
20038/10 E –11.92–
Page 2
Cylinder cutout with end housing 12V
1 Injection pump
2 End housing with cylinder cutout
3 Control rack
20038/10 E –11.92–
Page 1


20038/10 E –11.92–
Page 1
3.11.8.2 Removal
For removal of end housing, see 3.11.7.2
Remove oil supply sleeves (2) and (3) with compression
spring (1).
Remove grooved rings (1) from end housing (2).
20038/10 E –11.92–
Page 1

Check oil supply sleeves for wear.
Smooth sliding surfaces with emery cloth or replace components as necessary.
Check compression spring for pitting and friction.
Check compression spring when unloaded for length 13 mm .
Using spring balance, press compression spring to length 7 mm and check spring pressure 10 N±2 N.
If length and spring pressure are not achieved or if major friction and pitting is visible on compression spring, replace
compression spring.
Replace grooved rings.
20038/10 E –07.96–
Page 1
Make sure components are perfectly clean.
Fit oil supply sleeves (2) and (3) with compression spring
(1) on control rack.
Coat grooved rings (1) with ”petroleum jelly” and insert

in end housing (2).
Note
For installation position of grooved rings, see 3.11.8
For installation of end housing (1), see 3.11.7.6

Note
If control rack is sluggish: Release securing screws and

nuts for end housing again and realign end housing.
20038/10 E –07.96–
Page 1
3.11.8a Cylinder Cutout, Fuel Injection Pump II, 16V
1 Hex bolt 10 Cut-out control housing

3 Cover 12 Grooved ring
4 Gasket 13 Connector
5 Plug 14 Circlip
6 Sealing ring 15 Oil supply sleeve
7 Hex bolt 16 Compression spring
8 Spring washer 17 Oil supply sleeve
9 Hex nut
20038/10 E –11.92–
Page 2
Cylinder cutout with cut-out control housing 16V
1 Control rack 3 Cut-out control housing

2 Injection pump II 4 Connector
20038/10 E –11.92–
Page 1


- x x Remove control rack connection 3.11.4.2
- x x Remove oil lines 3.16.1.2
20038/10 E –11.92–
Page 1
3.11.8a.2 Removal
Unscrew securing screws and nuts for cut-out control
housing (1).
Remove cut-out control housing and gasket.
Remove snap ring for connector (1) and remove con-

nector.
Remove oil supply sleeves (2) and (3) with compression

spring (1).
20038/10 E –11.92–
Page 2
Remove grooved rings (1) from cut-out control housing

(2).
20038/10 E –11.92–
Page 1

Check cut-out control housing for cracks using surface crack-testing method with red penetrant dye.
Check mating faces and bore for pitting and wear; if necessary, smooth with emery cloth or replace components.
Check threads for ease of movement; rechase or replace threaded bushes as necessary.
Check oil supply sleeves and connectors for wear.
Check fitted bores on connector for pitting and concentricity; replace as necessary.
compression spring.
Replace snap ring if warped or damaged.
Replace grooved rings and gasket.
20038/10 E –11.92–
Page 1
Fit oil supply sleeves (2) and (3) with compression spring
(1) on control rack.
Push back oil supply sleeve (1) and insert connector (2)
with snap ring (3).
Press snap ring for connector (1) into groove of oil sup-
ply sleeve.
20038/10 E –11.92–
Page 2
Coat grooved rings (1) with ”petroleum jelly” and insert

into cut-out control housing (2).
Note
For installation position of grooved rings, see 3.11.8a
Mount cut–out control housing (2) with gasket (1), nuts,

screws and spring washers on injection pump.
Note

nuts for cut-out control housing again and realign cut–
out control housing.
20038/10 E –11.95–
Page 1
3.11.8b Cylinder Cutout, Fuel Injection Pump 8V/12V

with 4/2-Way Solenoid Valve
1 Injection pump I 10 Washer

2 O-ring 11 Bolt
3 Guide sleeve 12 Bolt
4 Compression spring 13 Sealing wire
5 Spring retainer 14 Two-hole seal
6 Guide sleeve 15 O-ring
7 Circlip 16 4/2-way solenoid valve
8 Stop 17 Socket-head screw
9 O-ring
20046/20 E –07.96–
Page 2
Cylinder cutout with end housing 8V, 12V
1 Injection pump 3 4/2-way directional control valve

2 End housing with cylinder cutout 4 Control rack
20046/20 E –07.96–
Page 3
Cylinder cutout
1 Cut-out control housing 11 Snap ring

2 Bore for ventilation and oil return T 12 Sleeve
3 Bore for compressed oil A to hydraulic cylinder 13 Compression spring
4 Bore for compressed oil P from engine oil system 14 Hydraulic cylinder
5 Bore for compressed oil B to hydraulic cylinder 15 Fuel injection pump
6 Spring retainer 16 Circlip
7 O-ring 17 Ventilation and oil return T via cut-out control housing
8 Power piston 18 Stop
9 Shutdown rod with hydraulic cylinder 19 4/2-way solenoid valve
10 Main rod 20 Compressed oil inlet
20046/20 E –07.96–
Page 1


20058/0 E –03.93–
Page 1
3.11.8b.2 Removal
Unscrew securing screws for housing (1) and remove
with washers.
Remove housing with O-rings.
Remove circlip (1) from groove of actuator cylinder.

Remove stop, spring retainer, guide sleeves and com-
pression spring from actuator cylinder.
Unscrew securing screws for 4/2-way directional control

valve (2) with Allen key (1).
Remove 4/2-way directional control valve with O-rings.
20058/0 E –03.93–
Page 1

Check guide sleeves, spring retainer and connector for wear.
compression spring.
Replace circlip if warped or damaged.
Replace O-ring.
20046/20 E –07.96–
Page 1
Attention

Fit guide sleeve (1), compression spring (2) and spring
retainer (3) on actuator cylinder.
Fit guide sleeve (1) and spring retainer (2) on actuator

cylinder.
Fit circlip (2) on stop (1).

Insert stop into actuator cylinder.
20058/0 E –03.93–
Page 2
Using two screwdrivers (1), insert circlip into groove of

actuator cylinder.
Coat components of cutout system with ”engine oil”.
Fit 4/2-way directional control valve (2) with O-rings on

housing.
Tighten securing screws with Allen key (1).
Coat O-rings with ”petroleum jelly” and insert into hous-

ing (1).
Mount housing with screws and washers on injection
pump (2).
Then push control rack over entire control rod travel
position (at least 5 times) so that spring retainers are
aligned with control cylinder.
In doing so, oil pressure must not be applied to shutdown
equipment.
Note
If control rack is sluggish, release securing screws for

end housing again and realign end housing.
20058/0 E –07.96–
Page 1
3.11.8c Cylinder Cutout, Fuel Injection Pump II, 16V
1 Guide sleeve 9 Washer

2 Compression spring 10 Nut
3 Spring retainer 11 Bolt
4 Guide sleeve 12 O-ring
5 Circlip 13 Sealing ring
6 Connector 14 Plug
7 O-ring 15 4/2-way solenoid valve
8 Cut-out control housing 16 Socket-head screw
20047/10 E –11.95–
Page 2
Cylinder cutout with cut-out control housing 16V

valid to engine no. 5591216
1 Control rack of injection pump 1 14 O-ring

2 Plug-in pipe 15 Sleeve
3 Connecting linkage 16 Power piston
4 Plug-in pipe flange 17 Collar
5 Connector 18 Hydraulic cylinder
6 Cut-out control housing 19 Compression spring
7 4/2-way solenoid valve 20 Circlip
8 Control rack of injection pump 2 21 Ventilation and oil return T via cut-out control housing
9 Bore for ventilation and oil return T
10 Bore for compressed oil B to hydraulic cylinder I Fuel injection pump 1
11 Bore for compressed oil P from engine system II Fuel injection pump 2
12 Bore for compressed oil A to hydraulic cylinder P Compressed oil from engine oil system
13 Spring retainer
20047/10 E –11.95–
Page 1


- x x Remove control rack connection 3.11.4.2
- x x Remove oil lines 3.16.1.2
- x x Remove fuel injection pump II 3.11.5a.2
20047/10 E –11.95–
Page 1
3.11.8c.2 Removal
Removing cut-out control housing
Unscrew securing screws and nuts for cut-out control
housing (1).
Remove cut-out control housing and O-ring (2).
Remove circlip (1) with screwdriver (3) from groove of

actuator cylinder (2) on injection pump.
1 2
SG11 0017a0
Remove connector (6), circlip (5), spring retainer (3),

and guide sleeves (1) and (4) and compression spring
(2) from actuator cylinder on injection pump.
20047/10 E –11.95–
Page 2
Unscrew securing screws for 4/2-way directional control

valve (2) with Allen key (1).
Remove 4/2-way directional control valve with O-rings.
20047/10 E –11.95–
Page 1

Check guide sleeves, spring retainer and connector for wear.
compression spring.
Replace circlip if warped or damaged.
Replace O-ring.
20047/10 E –11.95–
Page 1
Note

When installing components on injection pump, first re-
move control rack locating tool and inner snap ring.
Fit guide sleeve (1), compression spring (2) and spring
retainer (3) on actuator cylinder.
Fit guide sleeve (1) and spring retainer (2) on actuator

cylinder.
Fit circlip (2) on connector (1).

Fit connector on actuator cylinder.
1 2
SG11 0009a0
20047/10 E –11.95–
Page 2
Using two screwdrivers (1), insert circlip into groove of

actuator cylinder.
1 Note
Insert circlip in such a way that butt is not positioned in

groove of guide sleeve.
Coat components of cutout system with ”engine oil”.
SG11 0011a0

bores on 4/2-way solenoid valve (2).
Fit 4/2-way solenoid valve with O-rings on housing (4)
and tighten with securing screws (1).

housing (1).
Mount cut-out control housing (1) with O-ring, nuts,
screws and washers on injection pump.
Note

nuts for cut-out control housing again and realign cut-out
control housing.
20047/10 E –11.95–
Page 1
3.11.9 Connecting Housing, Fuel Injection Pump I, 16V

1 Fuel injection pump I
2 Gasket
3 Connecting housing
4 Spring washer
5 Hex bolt


- x x Remove connecting linkage with plug-in pipe 3.11.4.2
- x x Remove engine oil lines 3.16.1.2
3.11.9.2 Removal
Remove hex bolts from connecting housing. Remove connecting housing with gasket.

Check end housing for cracks using surface crack-testing method with red penetrant dye. If cracks are detected, re-
place parts.
Check fitted bore for plug-in pipe for pitting and wear; smooth with emery cloth or replace as necessary.
Check mating faces on connecting housing for flatness and smooth with emery cloth as necessary.
Replace gasket.
Mount connecting housing with gasket, spring washers and hex bolts on fuel injection pump I.
20038/10 E –11.92–
Page 1
3.11.10 Rack Travel Indicator
1 Lower section 7 Nut

2 Guide pin 8 Rack travel indicator
3 Cover 9 Gasket
4 Gasket 10 Bolt
5 Bolt 11 Washer
6 Spring washer
20042/10 E –08.94–
Page 2
Rack travel indicator

1 Housing
2 Spring pin
3 Pointer
4 Dowel pin
5 Scale plate
6 Cover plate
7 Spring washer
8 Bolt
20042/10 E –08.94–
Page 3
Rack travel indicator arrangement
1 Scale plate 3 Pointer

2 Housing 4 Driver
20042/10 E –11.95–
Page 1


20042/10 E –08.94–
Page 1
3.11.10.2 Removal
Remove cover (1) from lower section.
Remove screws securing rack travel indicator (1).

Remove rack travel indicator and gasket.
Remove lower section (3) and gasket (2) from end hous-
ing (1).
20042/10 E –08.94–
Page 2
Remove driver (2) from control rack (1).
Remove scale plate (2) and cover plate (1) from rack
travel indicator (3).
Remove pointer from housing of rack travel indicator
only if necessary.
Note
Dowel pin for pointer is secured with ”thread-locking

agent”.
20042/10 E –08.94–
Page 1

Check housing, cover, cover plate and lower section for damage and warping; smooth with oilstone if necessary.
Check threaded bores for ease of movement; rechase or insert HC thread insert as necessary.
Check driver and pointer for pitting and replace as necessary.
Check scale plate for cleanliness and damage, replace as necessary.
Replace gaskets.
20038/10 E –11.92–
Page 1
Mount scale plate (2) and cover plate (1) with screws on
rack travel indicator (3).
Pointer of rack travel indicator must be free to move.
Mount driver (2) on control rack (1).
Fit lower section (3) with gasket (2) on threaded pin of

end housing (1).
20042/10 E –08.94–
Page 2
Insert knurled screw (1) to locate control rack in injection

pump.
Mount rack travel indicator (1) with gasket (2) on lower

section (3).
Note
Ensure pointer engages driver of injection pump cor-

rectly.
Insert screws with spring washers to secure rack travel

indicator (1) and tighten slightly.
Align rack travel indicator so that pointer displays zero
value on scale plate.
Tighten securing screws.
Remove knurled screw locating control rack on injection
pump.
20042/10 E –08.94–
Page 3
Mount cover (1) on lower section of rack travel indicator

with gasket, nuts and spring washers.
20042/10 E –08.94–
Page 1
3.12 Fuel System

Contents
3.12.1 H.P. fuel lines

3.12.1.2 Removal
3.12.2 Fuel lines

3.12.2.2 Removal
3.12.2.5 Assembly
3.12.3 Fuel duplex filter

3.12.3.2 Removal
3.12.3.5 Assembly
3.12.4 Fuel delivery pump

3.12.4.2 Removal
3.12.4.5 Assembly
3.12.5 Fuel collecting housing with hand pump

3.12.5.2 Removal
3.12.5.5 Assembly
3.12.6 Cold-start system

3.12.6.2 Removal
20046/20 E –07.96–
Page 2

A
S4

Magnifier
Surface sealant Loctite No. 573 40031
Hydrochloric acid
Engine oil SAE 10 Shell Rotella X 10 W 40504

Caution
20046/20 E –07.96–
Page 1
3.12.1 H.P. Fuel Lines
H.P. fuel lines, 8V
1 H.P. line, cylinder A1 11 Pipe clamp

2 H.P. line, cylinder A2 12 Damping strip
4 H.P. line, cylinder A4 14 Spring washer
5 H.P. line, cylinder B1 15 Hex screw
6 H.P. line, cylinder B2 16 Sleeve
7 H.P. line, cylinder B3 17 Clamp bar
8 H.P. line, cylinder B4 18 Spring washer
9 Damping strip 19 Hex screw
10 Damping strip
20046/20 E –07.96–
Page 2
H.P. fuel lines, 12V

8 H.P. line, cylinder B2 22 Plate
10 H.P. line, cylinder B4 24 Plate
11 H.P. line, cylinder B5 25 Sleeve
12 H.P. line, cylinder B6 26 Clamp bar
13 Damping strip 27 Spring washer
14 Damping strip 28 Hex screw
20046/20 E –07.96–
Page 3
H.P. fuel lines, A1 to A4 and B1 to B4
1 H.P. line, cylinder A1 11 Pipe clamp half

2 H.P. line, cylinder A2 12 Pipe clamp half
3 H.P. line, cylinder A3 13 Washer
6 H.P. line, cylinder B2 16 Terminal strip
7 H.P. line, cylinder B3 17 Spring washer
9 Damping strip 19 Sleeve
10 Pipe clamp half
20046/20 E –07.96–
Page 4
H.P. fuel lines, A5 to A8 and B5 to B8
1 H.P. line, cylinder A5 5 H.P. line, cylinder B5

20046/20 E –07.96–
Page 5
Arrangement of H.P. fuel lines, 8V engine
20046/20 E –07.96–
Page 6
T012 045 c0
Arrangement of H.P. fuel lines (double-walled) at injection pump and nozzle holder
1 Profile pipe 5 Nozzle holder

2 Union nut 6 Union nut
3 Injection pump
4 H.P. line K Label ”A” for autofretted H.P. line
20046/20 E –07.96–
Page 7
Arrangement of H.P. lines at injection pump and nozzle holder (shrink-fitted H.P. line)
1 H.P. line 5 Union nut

2 Union nut
3 Injection pump K Label ”A”
4 Nozzle holder R Identification groove
20046/20 E –07.96–
Page 8
Arrangement of emergency injection line at injection pump and nozzle holder
1 H.P. line 5 Union nut

2 Union nut
3 Injection pump A = straight fuel-line element
4 Nozzle holder B = adapted fuel-line element on engine
Attention
Emergency injection is only permissible when the engine is operated for a limited period only and when the engine room
is monitored.
20046/20 E –07.96–
Page 1


- x x Disconnect electric cable Op. Man.
20038/10 E –08.94–
Page 1
3.12.1.2 Removal
Detach H.P. line (1) from nozzle holder (2).
Release H.P. line at fuel injection pump.
Remove pipe clamps (1) from charge air manifold.

Remove H.P. line with damping strips and sleeves.
20038/10 E –08.94–
Page 1

Check H.P. line for damage and chafing. Depending on the type of engine, the H.P. fuel lines are double-walled.
Damaged H.P. lines, or those with indented or rusted cones, must be replaced.
A new, straight H.P. line must be bent to conform precisely to damaged H.P. line.
Attention
Autofretted H.P. lines may only be bent to a minimum degree (± 2°).<F>).

Designation of autofretted H.P. line: ”A” on the union nut on nozzle holder side.
Check union nuts for damage, replace H.P. line if necessary.
20038/10 E –11.92–
Page 1
Connecting H.P. lines
Note
Before carrying out installation work, blow H.P. lines

clear with compressed air.
Ensure that lines are particularly clean!
Do not remove blanking plug until just before installation.
Install H.P. lines with new damping strips, sleeves and
pipe clamps (1) on charge air manifold; lines must be
free from strain.
For H.P. line layout, see 3.12.1.
Using a torque wrench (2), tighten the H.P. line (1) union
nut at the nozzle holder. For torque setting, see Section
1.3.
Install the H.P. line (1) union nut to the injection pump
and, using special wrench (2) and torque wrench,
tighten to tightening specification 1.3.
Install H.P. line between unions and pipe clamps so that
it is free from strain; use bending lever to end line to cor-
rect shape if necessary.
Attention
Autofretted H.P. lines may only be bent to a minimum deĆ
gree (± 2°).<F>).
Designation of autofretted H.P. line: ”A” on the union nut
on nozzle holder side.nut on nozzle holder side.
In event of leaking connections, release union nuts and
retighten to specified torque.
Repeat procedure if connections are still leaking.
20038/10 E –07.96–
Page 1
3.12.2 Fuel Lines
1 Fuel line 8 Flange

3 Banjo bolt 10 Bolt
4 Fuel line 11 Sealing ring
5 O-ring 12 Union
6 Elbow 13 Sealing cone
7 O-ring 14 Nut
20046/20 E –07.96–
Page 2
Fuel supply and return lines to fuel injection pumps 8V, 12V (Injection pump IIB)
1 Fuel line 22 Nut

2 Sealing ring 23 Return line
3 Union 24 Banjo bolt
4 Retainer 25 Sealing ring
5 Spring washer 26 Grommet
6 Hex screw 27 Pipe clamp half
7 Grommet 28 Spring washer
8 Pipe clamp half 29 Hex screw
11 Retainer 32 Hex nut
12 Grommet 33 Retainer
16 Hex nut 37 Hex screw
18 Reduction union 39 Pipe clamp half
19 Return line 40 Spring washer
20 Non-return valve 41 Hex screw
21 Sealing cone
20046/20 E –07.96–
Page 3
Fuel supply lines to fuel injection pumps, 16 V (injection pump IIB)
1 Fuel line 17 Sealing ring

2 T-piece 18 Double union
3 Retainer 19 Fuel line
5 Bolt 21 Double union
6 Grommet 22 Grommet
7 Pipe clamp half 23 Pipe clamp half
10 Retainer 26 Bolt
11 Grommet 27 Bolt
12 Pipe clamp half 28 Grommet
13 Bolt 29 Pipe clamp half
15 Nut 31 Bolt
16 Fuel line
20046/20 E –07.96–
Page 4
Fuel return lines from fuel injection pumps, 16 V (injection pump IIB)
1 Connector 16 Pipe clamp half

3 Bolt 18 Bolt
5 Plug 20 Sealing ring
6 Non-return valve 21 Banjo bolt
8 Double union 23 Pipe clamp half
10 Union 25 Bolt
11 Return line 26 Grommet
12 Sealing ring 27 Pipe clamp half
14 Return line 29 Bolt
15 Grommet
20046/20 E –07.96–
Page 5
Fuel supply and return lines to fuel injection pumps, 8V, 12V (Injection pump IID)
1 Bolt 13 Fuel return line

3 Retainer 15 Banjo bolt
4 Spacer bushing 16 Union
5 Spacer 17 Fuel supply line
6 Pipe clamp half 18 Bolt
8 Bolt 20 Bolt
10 Union 22 Retainer
11 Fuel return line 23 Bolt
12 Non-return valve
20046/20 E –07.96–
Page 6
Fuel supply lines to fuel injection pumps, 16V (injection pump IID)
1 Union 16 Spacer bushing

2 Fuel supply line 17 Spring washer
3 Fuel supply line 18 Bolt
4 Connector 19 Spring washer
5 Union 20 Bolt
7 Union 22 Pipe clamp half
9 Grommet 24 Bolt
10 Grommet 25 Sealing ring
11 Retainer 26 Plug
12 Spacer bushing 27 Fuel supply line
13 Spring washer 28 Fuel supply line
14 Bolt 29 Bolt
15 Retainer
20046/20 E –07.96–
Page 7
Fuel return lines from fuel injection pumps, 16V (injection pump IID)
1 Connector 14 Return line

2 Connector 15 Sealing ring
3 Spring washer 16 Union
4 Bolt 17 Return line
5 Bolt 18 Grommet
7 Plug 20 Bolt
8 Non-return valve 21 Sealing ring
9 Union 22 Reduction union
11 Reduction union 24 Return line
12 Sealing ring 25 Retainer
20046/20 E –07.96–
Page 8
Leak-off fuel lines
1 Leak-off fuel line 14 Pipe clamp half

3 Damping strip 16 Bolt
4 Collecting line 17 Bolt
5 Banjo union 18 Grommet
6 Spacer 19 Pipe clamp half
8 Sealing nut 21 Bolt
9 Non-return valve 22 Leak-off fuel line
10 Leak-off fuel line 23 Grommet
11 Leak-off fuel line 24 Pipe clamp half
12 Bracket 25 Spacer sleeve
13 Grommet
20046/20 E –07.96–
Page 9
Leak-off fuel lines, 6V, 8V, 12V
1 Fuel line 11 Nut

2 Fuel line 12 Retainer
4 Banjo bolt 14 Bolt
5 Mounting bracket 15 Grommet
6 Grommet 16 Pipe clamp half
8 Bolt 18 Bolt
10 Pipe clamp half
20046/20 E –07.96–
Page 10
Leak-off fuel lines, 16 V
1 Fuel line 15 Grommet

2 Fuel line 16 Pipe clamp half
3 Fuel line 17 Bolt
5 Banjo bolt 19 Pipe clamp half
6 Banjo bolt 20 Nut
7 Mounting bracket 21 Retainer
8 Spacer bushing 22 Spring washer
9 Spring washer 23 Bolt
10 Bolt 24 Grommet
13 Bolt 27 Bolt
14 Mounting bracket 28 Nut
20046/20 E –07.96–
Page 11
Leak-off fuel lines
1 Connecting line 11 Hose

2 Connecting line 12 Washer
3 Connecting line 13 Grommet
4 Bracket 14 Pipe clamp half
7 Grommet 17 Hex screw
8 Pipe clamp half 18 Spacer sleeve
10 Elbow
20046/20 E –07.96–
Page 12
Leak-off fuel lines, 12 V
1 Connecting line 10 Bolt

2 Connecting line 11 Grommet
5 Spring washer 14 Washer
7 Connecting line 16 Hose
8 Retainer 17 Elbow
9 Bolt 18 Bolt
20046/20 E –07.96–
Page 13
Leak-off fuel lines
1 Collecting line 6 O-ring

2 Sealing cone 7 Connecting line
3 Sealing nut 8 Connecting line
4 Connecting line 9 Banjo bolt
5 Oil transfer pipe 10 Sealing ring
20046/20 E –07.96–
Page 14
Fuel line to measuring block

9 Hex screw
20046/20 E –07.96–
Page 15
Leak-off fuel tank
1 Mounting bracket 11 Plug

4 Hex screw 14 Spring washer
5 Buffer 15 Cover
6 Spring washer 16 Stud
7 Hex screw 17 Hex nut
8 Housing 18 Spring washer
20046/20 E –07.96–
Page 1


- x x Drain fuel from leak-off fuel tank and fuel duplex filter Op. Man.
20038/10 E –11.92–
Page 1
3.12.2.2 Removal
Before removing fuel lines, it is useful to take photographs of all sides of engine or to identify fuel lines with numbered
markers to avoid confusion during reassembly.
After removing fuel lines, seal all connections immediately with suitable plugs.
Remove non-return valves from fuel lines, fuel duplex filter and connector.
Remove leak-off fuel tank and buffer from carrier, remove carrier from crankcase upper section, see Table 3.12.2
20042/10 E –11.95–
Page 1
Disassembling non-return valve
1 2 3 Unscrew union nut (3) from union (1).

Remove valve cone with spring and guide plate (2).
L59 889 V
Remove circlip (1), valve guide (6) with spring (2), taper
sleeve (3) and valve head (4) from housing (5).
Disassembling leak-off fuel tank

Remove magnetic float switch from cover (see 3.84.5.2)
Remove cover from housing.
Remove plugs, unions and studs from housing as re-
quired.
1 Magnetic float switch

2 Nut
3 Spring washer
4 Sealing ring
5 Cover
6 Stud
7 Plug
8 Sealing ring
9 Housing
10 Spring washer
11 Plug
12 Plug
13 Sealing ring
14 Union
20042/10 E –08.94–
Page 1

Clean fuel lines with cleaner. Check condition of lines and inspect for damage; repair lines if necessary and carry out
pressure test as required.
Replace sealing cones and banjo unions that are damaged, indented or corroded.
Using welding torch, heat lines which do not fit until red-hot.
Tighten all connections and screw fittings.
Do not cool off lines with water.
Remove realigned lines from engine, pickle in a sulphuric acid solution, (9 parts water to 1 part sulphuric acid), then
wash with hot water and blow dry with compressed air.
Then preserve lines in oil bath and allow to dry.
Check condition of hoses and for signs of aging; replace if necessary.
Inspect brackets, grommets and mounting components of fuel lines for damage and wear; replace if necessary.
Check valve cone, valve head, seating surface in housing, spring and guide plate of non-return valves for damage and
wear; replace if necessary.
Check condition of threads of union and union nut.
Clean leak-off fuel tank.
Check condition of sealing and bolt-on surfaces and inspect for damage; rub down with oilstone if necessary.
Check condition of thread in cover; recut if necessary.
Replace plugs, studs and unions as required.
Replace sealing rings.
Replace non-return valves for permanent vent as required.
Check condition of buffer, replace as required.
20042/10 E –08.94–
Page 1
3.12.2.5 Assembly
Assembling non-return valve
1 2 3 Coat components with engine oil.

Install valve cone with spring and guide plate (2) in union
(1).
Screw union nut (3) onto union and tighten.
Note
Pay attention to direction of arrow on non-return valve

during reassembly.
Check opening pressure (0.5 or 2.0 bar).
L59 889 V
Install valve head (4), taper sleeve (3) and spring (2) in
housing (5); secure with circlip (1).
Note
Ensure circlip is properly seated in housing.

Check opening pressure (0.5 bar ±0.1 bar).
Assembling leak-off fuel tank

Mount cover with spring washers and nuts on housing.
Install plugs and union with sealing rings in housing.
Install magnetic float switch with sealing ring in cover,
see 3.84.5.6
1 Float switch
2 Nut
3 Spring washer
4 Sealing ring
5 Cover
6 Stud
7 Plug
8 Sealing ring
9 Housing
10 Spring washer
11 Bolt
12 Plug
13 Sealing ring
14 Union
20042/10 E –08.94–
Page 1
Blow out the fuel lines with compressed air before installation; check that they are particularly clean.
Install fuel lines with gaskets and securing elements ensuring that they are tension-free; see photos or markings.
Install non-return valves.
Note
The arrow on the non-return valve must point in the same direction as the direction of the fuel supply.
Mount carrier with securing screws and spring washers on crankcase upper section.
Mount buffer with screws and spring washers to carrier, see Table 3.12.2, Page 15.
Mount leak-off fuel tank with screws and spring washers on carrier, see Table 3.12.2.
20038/10 E –07.96–
Page 1
3.12.3 Fuel Duplex Filter
ET 12 507 5
1 Intermediate plate 18 Union

2 Fuel duplex filter 19 Sealing cone
8 Stud 25 Drain valve
9 Hex nut 26 Sealing ring
10 Connector 27 Double union
11 O-ring 28 Retainer
16 Hex screw 33 Sealing cone
20042/10 E –08.94–
Page 2
Fuel duplex filter with individual components
1 Housing 17 Sealing ring

2 Heli-Coil thread insert 18 Hex screw
3 Sealing ring 19 Protective shroud
4 Plug 20 Nameplate
5 Diverter valve, complete 21 Grooved pin
6 Washer 22 Thread insert
7 Snap ring 23 Label
8 Heli-Coil thread insert 24 Sealing ring
9 Sealing ring 25 Threaded bush
10 Spring 26 Sealing ring
11 Outlet tube 27 Plug
12 Fuel filter element 28 Plug
14 Valve Z20 30 Threaded bush
15 O-ring 31 Wing nut
16 Cover 32 Lockwasher
20042/10 E –08.94–
Page 3
Fuel duplex filter
1 Protective shroud 13 Filter drain

2 Filter element 14 Shaped seal
3 Cover 15 Diverter valve
4 Centre screw 16 Plug
5 Wing nut 17 Housing
6 Outlet tube 18 Plug
7 Leak-off fuel drain 19 Spring
9 Plug key 21 Vent channel
10 Washer 22 Non-return valve
11 Fuel inlet 23 O-ring
12 Fuel outlet 24 Restrictor
20042/10 E –08.94–
Page 1


- - x Shut off fuel supply line Op. Man.
- x x Drain fuel from duplex filter Op. Man.
- x x Disconnect fuel line 3.12.2.2
20038/10 E –04.95–
Page 1
3.12.3.2 Removal
Removing duplex filter with intermediate plate
Unscrew bolts (1) on intermediate plate.
Remove duplex filter with intermediate plate
Removing intermediate plate

Remove intermediate plate (2) with screws and spring
washers from duplex filter (1).
20038/10 E –08.94–
Page 1
Removing connector
Clamp duplex filter (3) in a vice.
Unscrew bolts (1).
Remove connector (2).
Remove O-rings from connector.
Removing protective shroud

Unscrew wing nut (1).
Take off shroud (7).
Remove bolt (2) with sealing ring (3).
Remove cover (8) with O-ring (4).
Remove valve (6) and O-ring (5) from housing.
20038/10 E –11.92–
Page 2
Removing filter element

Remove filter element (1) from outlet tube (2).
Remove spring (3).
Unscrew plug (4) with sealing ring (5).
Removing diverter valve

Remove snap (3) from filter housing (1) with circlip
pliers.
Remove washer (2).
Withdraw diverter valve (4) from filter housing.
Remove shaped seal (6) and spring (7).
Remove O-rings (5) from diverter valve.
20038/10 E –11.92–
Page 1

Brush off rust spots and water droplets on filter housing, outlet tube and diverter valve.
Check filter housing and cover for cracks using surface crack-testing method with red penetrant dye; replace parts if
necessary.
Pressure-test filter housing with diesel fuel at 9 bar.
Inspect diverter valve bore in filter housing for wear and pitting.
Use emery cloth to polish out slight wear and pitting; replace filter housing if necessary.
Inspect filter cover and shroud for warping and wear and replace if necessary.
Check condition of securing bolt for cover.
Replace filter element.
Replace permanent venting valve as required.
Check condition of springs and replace if necessary.
Check condition and smoothness of intermediate plate and connector, smooth with oilstone if necessary, check thread
for ease of movement, recut if necessary.
Replace shaped seal and O-rings.
20038/10 E –11.92–
Page 1
3.12.3.5 Assembly
Installing diverter valve
Ensure that all components are particularly clean.
Insert new O-rings (5) in grooves in diverter valve (4).
Install spring (7) and shaped seal (6).
Insert diverter valve into filter housing (1).
Insert washer.
Install circlip (3).
Ensure that circlip is correctly seated in groove.
Installing filter element

Slip spring (3) over outlet tube (2).
Install filter element (1).
Screw plug (4) with sealing ring (5) into filter housing and
tighten.
Note
Only remove filter cartridge from its packaging at this

point.
Only use filter cartridges marked ”Fuel Filter” and manu-
facturer’s part code.
20038/10 E –11.95–
Page 2
Installing protective shroud

Install valve (6) with O-ring (5) in filter housing.
Insert O-ring (4) in groove in cover (8).
Fit cover and tighten with bolt (2) and sealing ring (3) as
Install hood (7).
Tighten wing nut (1).
Installing connecting section

Insert O-rings into grooves in connector (1).
Mount connector on housing (3) with bolts and spring
washers and tighten.
20038/10 E –11.95–
Page 1
Installing intermediate plate
Mount the intermediate plate (2) with screws and spring
washers to the duplex filter (1) and tighten.
Installing fuel duplex filter

Mount the duplex filter with intermediate plate, screws
(1) and spring washers to the cylinder head and tighten.
20038/10 E –11.92–
Page 1
3.12.4 Fuel Delivery Pump

Fuel delivery pump (6V, 8V)
1 Bearing housing 10 Drive sleeve

2 Spring pin 11 Socket-head screw
3 Shaft seal 12 Drive shaft
4 O-ring 13 Snap ring
6 Nut 15 Bolt
7 Gear-type pump 16 Sealing ring
8 Seal carrier 17 Union
9 O-ring 18 Union
20042/10 E –08.94–
Page 2
ET 12 409 2
1 Flanged body 12 Radial-lip oil seal

2 Gear carrier plate 13 Bearing bush
3 Cover 14 Bearing bush
4 Valve cone 15 Snap ring
5 Valve spindle 16 Socket-head screw
6 Pipe nut 17 Tapered pin
7 Cap nut 18 USIT ring
8 Spring 19 Name plate
9 Drive shaft 20 Arrow
10 Axle 21 Grooved pin
11 Gear
20042/10 E –08.94–
Page 3
1 Bearing housing 9 Drive sleeve

2 Shaft seal 10 Bolt
3 O-ring 11 Drive shaft
4 Spring washer 12 Snap ring
5 Nut 13 Spring washer
6 Gear-type pump 14 Bolt
7 Seal carrier 15 Sealing ring
8 O-ring 16 Union
20042/10 E –08.94–
Page 4
ET 12 409 6
1 Flanged body 12 Sealing ring

2 Gear carrier plate 13 Radial-lip oil seal
3 Cover 14 Bearing bush
4 Valve piston 15 Bearing bush
5 Valve spindle 16 Snap ring
6 Locknut 17 Bolt
7 Cap nut 18 Tapered pin
8 Spring 19 USIT ring
9 Drive shaft 20 Name plate
10 Axle 21 Arrow
11 Plug 22 Grooved pin
20042/10 E –08.94–
Page 5
Fuel delivery pump
1 Bearing bush 10 Socket-head screw

2 Cover 11 Sealing ring
3 Gear carrier plate 12 Valve spindle
4 Gear 13 Cap nut
5 Flanged body 14 Pipe nut
6 Drive shaft 15 Spring
7 Shaft seal 16 Valve cone
8 Snap ring 17 Shaft
9 Tapered pin
20042/10 E –08.94–
Page 6
Fuel delivery pump with drive
1 Fuel delivery pump 12 Shaft

2 Spring pin 13 Shaft seal
3 Nut 14 Crankcase
4 Spring washer 15 O-ring
5 Bolt 16 Bearing housing
7 Drive sleeve 18 Hex screw
8 Snap ring 19 Socket-head screw
9 Drive shaft
10 Follower 0
11 Seal carrier B Length of drive shaft = 67mm –0.5 mm
20042/10 E –08.94–
Page 1


- - x Shut off fuel supply line -
- x x Remove compressed air lines on compressed air distributor 3.18.3a.2
- x x Disconnect fuel lines 3.12.2.2
- x x Remove fuel manifold with manual pump 3.12.5.2
20054/00 E –04.95–
Page 1
3.12.4.2 Removal
Remove fuel delivery pump
Release securing screws (1) and remove.
Remove delivery pump (2) from bearing housing.
Removing bearing housing

Remove nuts.
Remove bearing housing (2) with O-ring.
20038/10 E –11.92–
Page 1
Removing drive sleeve and drive shaft
Remove snap ring (4) from groove in drive sleeve (3).
Remove drive shaft (5) from drive sleeve.
Release socket head screw (2) on drive sleeve.
Remove drive sleeve with seal carrier from shaft of gear-
type pump (1).

Remove seal carrier (3) with O-ring (4) from drive sleeve
(1).
Remove screw (2) from drive sleeve.
Removing oil seal from bearing housing

Using a manual press (1) and removal mandrel (2),
press shaft seal out of bearing housing (3).
20038/10 E –11.92–
Page 2
Disassembling gear-type pump

Removing cover
Remove socket head screws (4) from cover (1).
Release and detach cover from gear carrier plate (3) by
tapping gently with a plastic mallet.
Note
When removing the cover, be particularly careful with

the fitted taper pin (2).
Disassembling cover
Unscrew cap nut (1) from valve spindle (5).
Remove USIT ring (2).
Release pipe nut (3) from valve spindle.
Carefully unscrew valve spindle from cover (8) and re-
move with USIT ring (4).
Note
Valve spindle is under tension of spring (6).

Withdraw spring (6) and valve cone (7) from cover.
Using suitable extraction tool, remove bearing bushes
(9) from cover only as required.
Removing gear carrier plate

Remove gear carrier plate (1) from flange body (3) over
tapered pin (2) and gears (4).
20038/10 E –11.92–
Page 3
Removing gears
Remove drive shaft with gear (1) and pump gear shaft
with gear (3) from flanged body (2).
Disassembling flanged body

Remove snap ring (4) from groove in flanged body (1)
using snap ring pliers.
Use pry bar to force radial-lip oil seal out of flanged body.
Press bearing bushes (2) and (5) out of flanged body
only as required.
Remove tapered pin (6) as required.
20038/10 E –11.92–
Page 1

Using surface crack-testing procedure with fluorescent penetrant dye, check bearing housing, gear carrier plate and
flanged body for cracks.
Check drive shaft, drive sleeve, gear pump shaft and gears for cracks using magnetic crack-testing method with fluor-
Check drive shaft serrations for evidence of wear and replace if necessary.
Inspect gear pump shaft and drive shaft of gear-type pump for signs of wear.
Rub down with polishing cloth as required; replace components if necessary.
Check gears for indentations and wear; rub down with oilstone if necessary.
Check bearing bushes for signs of wear and replace as required.
Inspect cover, gear carrier plate and flanged body for signs of wear; rub down with polishing cloth as required and re-
place if necessary.
Check running surface for radial-lip oil seal on drive sleeve for signs of wear and damage.
Polish with a fine polishing cloth as required.
Check serrations and pilot of drive sleeve for evidence of wear; replace if necessary.
Replace tapered pin as required.
Inspect sealing surfaces of individual components for evidence of wear; if necessary, recondition sealing surfaces or
replace components.
Check bearing housing and crankcase sealing surfaces for irregularities; rub down if necessary.
Replace radial-lip oil seal, USIT ring and O-ring.
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Page 1
3.12.4.5 Assembly
Assembling gear-type pump
Note
Make sure that components are particularly clean be-

fore assembly.
Installing bearing bushes

Press bearing bushes (2) and (3) into flanged body (1)
so that they are flush.
Drive tapered pin (4) into locating bore in flanged body.
Installing gears
Coat bearing bushes, drive shaft and gear pump shaft
with engine oil.
Insert drive shaft (1) and gear pump shaft (3) into bear-
ing bushes in flanged body (2).
Installing gear carrier plate

Coat running surface in gear carrier plate (1) with engine
oil.
Push gear carrier plate over gears (4) and tapered pin
(2) until seated on flanged body (3).
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Page 2
Assembling cover
Note
Make sure that components are particularly clean be-

fore assembly.
Press new bearing bushes (9) into cover (8) so that they
are flush.
Coat valve cone (7) with engine oil and install in bore in
cover.
Insert spring (6) into valve cone.
Turn valve spindle (5) into cover, paying attention to
position of spring.
Screw-in position of valve spindle is determined during
inspection and adjustment of gear-type pump.
Fit new USIT ring (4) on valve spindle.
Screw pipe nut (3) onto valve spindle (5) so that cham-
fered side of nut faces slot in spindle.
Tighten pipe nut loosely by hand only.
Screw cap nut with a new Usit ring (2) onto valve spindle
and tighten loosely by hand only.
Installing cover
Position cover (1) on preassembled gear carrier plate
(3).
Tapered pin must engage corresponding bore in cover.
Mount cover with socket head screws (4).
Tighten screws diagonally and evenly.
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Page 3
Installing radial-lip oil seal
Note
The sealing lip of the oil seal must face the pump when
installed.
Coat radial-lip oil seal (2) sealing lip with petroleum jelly.
Press radial-lip oil seal with suitable protective sleeve
over drive shaft into preassembled gear-type pump (1).
Insert snap ring (3) into groove in flanged body using
snap ring pliers.
Make sure that snap ring is securely seated.
Adjusting gear-type pump

Unscrew cap nut (1) from valve spindle (3) and remove
with Usit ring (2).
Connect fuel supply line to gear-type pump (5).
Connect suitable pressure gauge to delivery side of
pump (5).
Operate pump at approx. 750 rpm or 1500 rpm (see
nameplate).
Set fuel inlet pressure to 2.5 bar.
Set delivery pressure by adjusting the valve spindle (3)
to 6.5 bar (note nameplate).
Hold valve spindle in position with screwdriver and lock
with pipe nut (4).
Check delivery pressure again.
Fit Usit ring (2) on valve spindle, screw on cap nut (1)
and tighten.
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Page 4
Installing radial-lip oil seal in bearing housing

Clean external surfaces of oil seal and coat with surface
sealant.
Using hand press and mandrel, press oil seal into bear-
ing housing.
Assembling and installing drive sleeve

Install screw (2) in drive sleeve (1).
Insert O-ring (4) into groove in seal carrier (3).
Coat O-ring with petroleum jelly and insert seal carrier
into drive sleeve.
O-ring must face screw.
Installing drive sleeve and drive shaft

Push drive sleeve (3) with seal carrier onto shaft of deliv-
ery pump (1) until seated.
Tighten socket head screw (2) with torque wrench to
Coat drive shaft (5) with engine oil and insert seal carrier
into drive sleeve.
Secure drive shaft with snap ring (4) in the groove of the
drive sleeve.
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Page 1
Installing bearing housing
Rub down sealing surfaces of crankcase and bearing
housing (2) with oilstone.
Insert O-ring into groove on bearing housing and coat
Install bearing housing on crankcase with nuts (1) and
spring washers and tighten.
Installing fuel delivery pump

Coat drive shaft (1) with engine oil.
Install fuel delivery pump (4) with drive shaft and drive
sleeve (3) in bearing housing.
Take care not to damage oil seal.
Ensure correct location with spring pin (2).
Secure delivery pump (2) to bearing housing (1) with

bolts (3) and spring washers.
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Page 1
3.12.5 Fuel Collecting Housing with Hand Pump
Fuel collecting housing with hand pump (8V, 12 V)

3 O-ring 19 Plug
4 Connecting line 20 Support ring
5 Collecting housing 21 O-ring
6 Valve 22 Cartridge valve
8 Plug 24 Plug
9 Plug 25 Cartridge valve
10 Sealing ring 26 O-ring
11 Sealing ring 27 Non-return valve
12 Plug 28 Plug
13 Spring washer 29 Valve housing
14 Bolt 30 Valve interior component
15 Sealing ring 31 Spring
16 Hand pump 32 Snap ring
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Page 2
Fuel collecting housing with hand pump (12V, 16 V)
1 O-ring 16 Hand pump

2 Connecting line 17 Plug
4 Plug 19 Bolt
5 Collecting housing 20 Cartridge valve
6 Valve 21 O-ring
7 O-ring 22 Non-return valve
9 Plug 24 Plug
10 Sealing ring 25 Cartridge valve
12 Plug 27 Spring
13 Spring washer 28 Valve housing
14 Sealing ring 29 Valve interior component
15 Bolt 30 Snap ring
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Page 3
Arrangement of fuel collecting housing with valves
1 Nut 9 Spring washer

2 Union 10 Collecting housing
3 Sealing ring 11 Fuel hand pump
4 Elbow 12 O-ring
5 Fuel line 13 Support ring
6 Fuel delivery pump 14 Cartridge valve
7 Elbow 15 O-ring
8 Bolt 16 Flange
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Page 4
Fuel hand pump (first version)
1 Housing 5 Cover
2 Piston rod 6 Handle
3 Gasket 7 Sleeve
4 O-ring
Fuel hand pump (second version)
20046/20 E –07.96–
Page 5
1 To fuel delivery pump 9 Housing

2 Fuel collecting housing 10 From fuel tank
3 To fuel duplex filter 11 From fuel delivery pump
4 Gasket 12 Delivery valve
5 O-ring 13 Suction valve
6 Plunger
7 Handle A Suction stroke
8 Sleeve B Delivery stroke
20046/20 E –07.96–
Page 1


- - x Shut off fuel supply line Op. Man.
- x x Disconnect fuel lines 3.12.2.2
20038/10 E –11.92–
Page 1
3.12.5.2 Removal
Removing collecting housing
Release and remove screws for securing the fuel col-
lecting housing (1).
Remove fuel collecting housing (1) with fuel hand pump

(2).
Removing collecting line

Remove collecting line (3) from collecting chamber (1).
Remove O-rings (2) from grooves in collecting line.
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Page 1
Disassembling collecting housing
Release and remove hand pump (2) at collecting hous-
ing (1).
Removing elbow
Remove elbow (3) with flange (2) from collecting hous-
ing (1).
Removing union
Release and remove union (2) at collecting housing (1).
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Page 2
Removing valve
Take valve (2) out of collecting housing (1).
Removing plug, cartridge valves and union

Unscrew plug (2) from collecting housing (1).
Remove cartridge valve (2) and non-return valve (order-

specific) from collecting housing (1).
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Page 3
Remove union (2) from collecting housing (1).
Withdraw cartridge valve (2) from collecting housing (1).

Release and remove all plugs at collecting housing.
Disassembling hand pump

Detach handle (6) from sleeve (7).
Unscrew handle from plunger rod (2).
Attention
Handle is secured with high-strength thread-locking liquid.

Before unscrewing, heat the handle to approx. 120°C.
Caution
Use protective gloves to handle the tappet.

Unscrew cover (5) from housing (1).
Remove sleeve from housing.
Withdraw plunger rod from housing.
Remove O-ring (4) and gasket (3).
20038/10 E –11.95–
Page 1

Check fitted bores and valve seats in collection housing for wear, corrosion and damage.
Check threads for ease of movement; if necessary, recut or insert threaded inserts.
Replace parts if necessary
Inspect screw-down surfaces for irregularities; recondition if necessary.
Check condition of valves and unions; replace if necessary.
Replace cartridge valves during repair operations.
Check condition of hand pump components; replace if necessary.
Check condition of non-return valve, if necessary disassemble and replace valve interior component and spring. (non-
return valve – order-specific)
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Page 1
3.12.5.5 Assembly
Assembling hand pump
Fit O-ring (4) and gasket (3) on plunger rod (2).
Install plunger rod (2) in housing (1).
Slip sleeve (7) over housing.
Bolt cover (5) to housing.
Coat thread of plunger rod with high-strength thread-
locking liquid and screw on handle (6).
Connect handle to sleeve.
Check operation of hand pump.
Assembling collecting housing

Install cartridge valve (2) in collecting housing (1).
Note
Ensure that support ring and O-ring are positioned

properly; see arrangement 3.12.5
Screw union (2) with sealing ring into collecting housing

(1) and tighten.
20038/10 E –08.94–
Page 2
Screw all plugs with sealing ring at collecting housing (1)

and tighten.
Insert cartridge valve (2) and non-return valve (order-
specific) in collecting housing (1).
Installing plugs, valves and union

Screw plug (2) with sealing ring into collecting housing
(1) and tighten.
Install valve (2) in collecting housing (1).
20038/10 E –11.95–
Page 3
Screw union (2) with O-ring into collecting housing (1)

and tighten.
Installing elbow
Connect elbow (3) with flange (2) and O-ring to collect-
ing housing (1).
Installing hand pump

Screw hand pump (2) with sealing ring into collecting
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Page 1
Installing connecting line
Install O-rings (2) in grooves in connecting line (3).
Install connecting line in collecting housing (1).
Installing collecting housing

Connect collecting housing (1) with hand pump (2) to
fuel delivery pump.
Secure collecting housing (1) with bolts and spring

washers.
20038/10 E –11.95–
Page 1
3.12.6 Cold-Start System
1 Insulated fuel nipple 26 Sealing ring

2 Flame torch 27 Sealing nut
3 Flange 28 Double taper ring
4 Jacket 29 Union nut
5 Jacket 30 Retainer
6 Flange 31 Spacer
8 Gasket 33 Grommet
10 Solenoid valve 35 Bolt
13 Banjo union 38 Spacer sleeve
14 Spring washer 39 Retainer
17 Retainer 42 Spring washer
18 Bolt 43 Bolt
19 Washer 44 Bolt
20 Pipe clamp half 45 Bolt
21 Grommet 46 Sealing element
22 Spring washer 47 Protective shroud
23 Bolt 48 Protective shroud
24 Fuel line 49 Bolt
25 Fuel line
20046/20 E –07.96–
Page 2
Cold-start system 16V
1 Insulated fuel nipple 26 Hex screw

2 Flame torch 27 Spring washer
3 Flange 28 Retainer
4 Jacket 29 Hex screw
5 Jacket 30 Hex screw
6 Flange 31 Spring washer
10 Fuel line 35 Hex screw
11 Nut 36 Hex screw
12 Fuel line 37 Hex screw
13 Fuel line 38 Spacer
14 Double taper ring 39 Retainer
21 Hex screw 46 Sealing element
22 Spring washer 47 Protective shroud
23 Pipe clamp half 48 Protective shroud
25 Grommet
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Page 3
1 Solenoid valve 20 Grommet

3 Union 22 Fuel line
5 Hex screw 24 Fuel line
6 Fuel line 25 Nut
7 Sealing ring 26 Spacer
9 Solenoid valve/distributor 28 Grommet
11 Union 30 Hex screw
15 Retainer 34 Retainer
19 Pipe clamp half
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Page 4
Cold-start system 8V, 12V
1 Solenoid valve 3 Fuel line 12V

2 Fuel line 8V 4 Fuel return line
Note
Install the solenoid valve so that the arrow at the bottom of the valve body points in the direction of flow; take note of
the integrally cast digits on the valve body (1 = inlet; 2 = outlet).
20046/20 E –07.96–
Page 5
1 Right engine side - middle 4 Solenoid valve/distributor

2 Right engine side - driving end 5 Left engine side - middle
3 Left engine side - driving end 6 Solenoid valve
Note
Install the solenoid valve so that the arrow at the bottom of the valve body points in the direction of flow; take note of
the integrally cast digits on the valve body (1 = inlet; 2 = outlet).
20046/20 E –07.96–
Page 1


- - x Shut off fuel supply line -
20046/20 E –07.96–
Page 1
3.12.6.2 Removal
Remove flame torch
Remove protective shroud (4).
Unscrew fuel line (10) union nut (9).
Mark electrical cables (8), disconnect cable connections
(5), (6) and disconnect from flame torch.
Release locknut and unscrew flame torch.
Remove sealing element (7).
Unscrew bolts from flange (11).
Remove flange and gasket.
Remove flange (2) and jacket (1) from charge air mani-
fold.
Unscrew fuel nipple as required.
20046/20 E –07.96–
Page 1

Check jacket, flange, protective shroud, flame torch, fuel nipple and sealing element and flanges for wear and damage;
replace parts as necessary.
Check flame torch and solenoid valve, see description and operating instructions.
Replace gaskets.
20046/20 E –07.96–
Page 1
Install flame torch
Insert jacket (1) with gasket at charge air manifold.
Coat flame torch (3) thread with sealing paste.
Screw flange (2) onto flame torch.
Insert gasket into jacket.
Set flame torch distance to 34 mm ±1 mm and secure
with a locknut.
Fit flange (11) with gasket on jacket.
Screw fuel nipple onto flame torch.
Press sealing element (7) onto fuel nipple.
Connect electrical cables to flame torch according to
their markings and secure with nuts (5) and (6).
Fit protective shroud (4) and make sure that sealing el-
ement is correctly positioned.
Mount fuel line (10) on fuel nipple and secure with union
nut (9).
Wiring diagram – cold-start system

1 Starter switch
2 Start interlock switch
3 Bimetallic series resistor
4 Flame torch
5 Solenoid valve
6 Indicator lamp
A Switch ”OFF position 0”

B Switch ”Preheat position 1”
C Switch ”Start position 2”
20046/20 E –07.96–
Page 1
3.13 Coolant Pumps

Contents
3.13.1 Engine coolant pump

3.13.1.2 Removal
3.13.1.5 Assembly
3.13.2 Raw water pump

3.13.2.2 Removal
3.13.2.5 Assembly
3.13.3 Bilge Pump

3.13.3.2 Removal
3.13.3.5 Assembly
20038/10 E –11.92–
Page 2

A
S4
S 5.9
S 5.10
S 5.11
S 5.13
S 5.14
S 6.16
S 6.19

Magnifier
Thin-film lubricant Molykote G-N plus 40041
Sealing compound Epple 22 40130
Cleaning agent P3-Solvclean KW 40022
Corrosion inhibitor oil Donax 40419
Engine oil SAE 10 Shell Rotella X10W 40504
Dry compressed air

Caution
20038/10 E –07.96–
Page 1
3.13.1 Engine Coolant Pump
Version 558 200 05 01
1 Pump housing 10 Impeller

2 Rotary seal 11 O-ring
3 Shaftseal 12 Counterring
4 Pump shaft 13 Thrust washer
5 Bearing housing 14 Stress bolt
6 Angular-contact ball bearing 15 Connector
7 Tab washer 16 O-ring
8 Slotted nut 17 Socket-head screw
9 Screw
20046/20 E –07.96–
Page 2
Engine coolant pump
Version 558 200 05 01
1 Slotted nut 10 O-ring

2 Bearing housing 11 Connector
3 Screw 12 O-ring
4 Pump shaft 13 Counterring
5 Angular-contact ball bearing 14 Stress bolt
6 Tab washer 15 Thrust washer
7 Shaft seal 16 Impeller
8 Housing 17 Rotary seal
9 Screw
20046/20 E –07.96–
Page 3
Engine coolant pump
Version 559 200 01 01
1 Housing 10 Impeller
3 Shaft seal 12 Counterring
4 Pump shaft 13 Thrust washer
5 Bearing housing 14 Stress bolt
6 Angular-contact ball bearing 15 Connector
7 Tab washer 16 O-ring
8 Nut 17 Screw
9 Screw
20046/20 E –07.96–
Page 4
Engine coolant pump
Version 559 200 01 01
1 Slotted nut 10 O-ring

3 Screw 12 O-ring
4 Pump shaft 13 Counterring
5 Angular-contact ball bearing 14 Stress bolt
6 Tab washer 15 Thrust washer
7 Shaft seal 16 Impeller
8 Housing 17 Rotary seal
9 Screw
20046/20 E –07.96–
Page 5
Arrangement of coolant pump bearing flange
1 Coolant pump 9 Spring washer

3 Plug 11 Sleeve
4 Bearing flange 12 Cover
5 Cylindrical roller bearing 13 O-ring
6 Snap ring 14 Spring washer
7 Gasket 15 Hex bolt
8 O-ring
20046/20 E –07.96–
Page 6
Engine coolant pump
Version 559 200 02 01 / 03 01
1 Housing 10 Screw
2 Rotary seal 11 Impeller
3 Shaft seal 12 O-ring
4 Counterring 13 Thrust washer
5 Pump shaft 14 Stress bolt
7 Angular-contact ball bearing 16 O-ring
8 Tab washer 17 Socket-head screw
9 Slotted nut
20046/20 E –07.96–
Page 7
Engine coolant pump
Version 559 200 02 01
1 Stress bolt 10 Screw

2 Thrust washer 11 Pump shaft
3 Impeller 12 Angular-contact ball bearing
4 O-ring 13 Tab washer
5 Counterring 14 Housing
7 Shaft seal 16 Connector
9 Bearing housing
20046/20 E –07.96–
Page 8
Engine coolant pump
Version 559 200 03 01
1 Stress bolt 10 Screw

2 Thrust washer 11 Pump shaft
3 Impeller 12 Angular-contact ball bearing
4 O-ring 13 Tab washer
5 Counterring 14 Housing
7 Shaft seal 16 Connector
9 Bearing housing
20046/20 E –07.96–
Page 9
Arrangement of coolant pump bearing flange
1 Coolant pump 6 O-ring

2 Bearing flange 7 Spring washer
3 Cylindrical roller bearing 8 Hex bolt
4 Snap ring 9 O-ring
5 Gasket
20046/20 E –07.96–
Page 1
3.13.1.1 Before-removal Operations


- x x Remove bilge pump (equipment-specific) 3.13.2.2
- x x Remove speed transmitter drive (equipment-specific) 3.17.1.2
- x x Remove air compressor drive (equipment-specific) 3.86.4.2
20038/10 E –07.96–
Page 1
3.13.1.2 Removal
Removing cover
Remove securing screw (1) with spring washer (2).
Remove cover (3).
Removing sleeve from pump shaft
Caution
Danger !
Hydraulic removal must only be carried out by trained personnel.
Use only those tools and equipment stipulated for hydraulic removal.
The equipment must be checked once a year for cracks in draw spindle.
It is not permitted for personnel to remain within the danger area behind the equipment during the removal operations.
The max. expansion pressure (Pmax = 1500 bar) must not be exceeded.
Removing sleeve
Screw draw spindle (1) into coolant pump shaft and
tighten.
Install removal tool so that there is at least 5 mm clear-
ance between catcher plate (5) and sleeve.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Catcher plate
6 Grub screw
20038/10 E –11.92–
Page 2
Connect H.P. line (1) to screw connection on removal

tool (2) and hydraulic hand pump and tighten.
Fill hydraulic hand pump with SAE 10 engine oil and
actuate pump plunger until resistance is clearly felt at
actuating lever.
Wait until the pressurized expansion fluid penetrates
press-fit on sleeve.
In most cases, the press-fit is released after a few min-
utes. If necessary, resume pumping.
Do not exceed max. permissible expansion pressure
Pmax = 1500 bar, as otherwise the bore of the press-fit
is expanded too much.
Relieve pressure on hydraulic hand pump and remove
removal tool with draw spindle and H.P. line.
Removing vent
Remove banjo bolt (3) on vent pipe from engine coolant
pump (4).
Remove vent pipe from bracket (1).
Remove bracket from screw fitting.
Remove screw fitting from crankcase.
Removing bearing flange, free end

Remove screws securing coolant pump to bearing
flange (1).
Using jackscrew, press bearing flange (1) out of crank-
case.
Note
If only coolant pump is to be removed, it is not necessary

to remove free end bearing flange from crankcase.
20038/10 E –11.92–
Page 3
Removing coolant pump

Remove coolant pump (1) from crankcase.
If necessary, separate from crankcase by lightly tapping
pump housing with plastic mallet.
Remove gasket.
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Page 1
Removing connector
Insert coolant pump in retaining device.
Remove screw (2) from connector.
Release connector with jackscrew (1).
Remove connector (1) from pump housing.

Remove O-ring (2).
Removing impeller
Use socket wrench (1) to remove stress bolt from im-
peller.
Remove thrust washer.
20038/10 E –11.92–
Page 2
Install removal tool (1) with 3 screws on impeller (2).

Release impeller with thrust bolt from pump shaft.
Use removal tool to remove impeller (1) from pump

shaft.
Unscrew removal tool from impeller.
Removing pump shaft

Remove coolant pump from retaining device.
Remove screws from bearing housing (1) of pump shaft.
20038/10 E –11.92–
Page 3
Release and remove pump shaft (1) with bearing hous-

ing (2), gently tapping with plastic mallet, from pump
housing.
Removing bearing housing from pump shaft

Insert pump shaft with gear in assembly device (1).
Release slotted nut.
Release slotted nut with socket wrench (1) from pump

shaft and remove with tab washer.
20038/10 E –11.92–
Page 4
Remove bearing housing (2) from pump shaft (1) with

removal tool.
Removing bearing inner race from pump shaft

Remove angular-contact ball bearing inner race (1) from
pump shaft with removal tool.
Remove cylindrical roller bearing inner race on opposite
side of pump shaft with removal tool.
20038/10 E –11.92–
Page 5
Removing angular-contact ball bearing from bear-

ing housing
Press angular-contact ball bearing out of bearing hous-
ing (1) with mandrel.
Removing shaft seal

Remove shaft seal (1) from pump housing with pry bar
or screwdriver.
Removing rotary seal

Remove rotary seal from pump housing (1) with press
sleeve (2).
20038/10 E –11.92–
Page 6
Removing cylindrical roller bearing from bearing

flange
Use circlip pliers to remove circlip (1) from bearing
flange.
Press cylindrical roller bearing out of bearing flange (1)

with mandrel.
20038/10 E –11.92–
Page 1

Using red-penetrant dye, check surface of pump housing, impeller and bearing flange for cracks.
Using the magnetic crack-testing method with fluorescent magnetic powder, check coolant pump shaft with gear, stress
bolt and sleeve for cracks.
Replace relevant components if cracks are found.
Check coolant pump housing and impeller for pitting.
In event of pitting more than 1 mm deep, replace part.
Check relief bore on pump housing for obstruction, clean if necessary.
Check coolant pump shaft for wear and damage.
Smooth minor wear and damage with emery cloth.
Spray-metallize sealing surface as per MTU specifications as required, replace part if necessary.
Check gear of coolant pump shaft for indentations and wear.
If necessary, smooth with oilstone and emery cloth.
Check tapered seat 1:5 and 1:50 with taper gauge, replace parts if necessary.
Check condition of threads and recut if necessary.
Check sealing surfaces and bore on bearing flange for wear, smooth with polishing cloth as necessary.
Adjust bore gauge, measure bore for cylindrical roller bearing in bearing flange and bore for angular-contact ball bearing
in bearing housing.
Measure bearing seat on coolant pump shaft with outside micrometer.
Replace components if specified limits are exceeded (see Tolerances and Wear Limits List).
Always replace cylindrical roller bearings and angular-contact ball bearings during W6 overhaul.
Replace rotary seal, counterring shaft seal and O-ring as part of every overhaul.
20038/10 E –08.94–
Page 1
3.13.1.5 Assembly
Installing rotary seal
Clean and dry seating surface of rotary seal so that it is
free from grease, then coat with surface sealant.
Use drift (1) and manual press or plastic mallet to drive
rotary seal (2) into pump housing until seated.
Turn over pump housing.
Installing shaft seal

Clean and dry shaft seal seating surface so that it is free
from grease.
Use drift (1) to drive shaft seal (2) into pump housing
until seated.
Note
Sealing lip must face angular-contact ball bearing.
Installing angular-contact ball bearings in bearing

housing
Before installing angular-contact ball bearings, make
sure that wide faces (1) are facing each other for installa-
tion.
20038/10 E –11.92–
Page 2
Use mandrel to press both ball bearings (1) into bearing

housing (2).
Insert bearing housing securing screws (2).

Place bearing housing with screws in installation tool (1).
Insert pump shaft (1) in bearing housing (3).
Note
Screws (2) must be inserted in bearing housing before

pump shaft is installed.
20038/10 E –11.92–
Page 3
Press pump shaft (1) into bearing housing.
Install pump shaft in retaining device.

Fit tab washer (1) on pump shaft.
Coat pump shaft thread with engine oil.
Install slotted nut and tighten with socket wrench (1). For
torque settings, see Section 1.3.
20038/10 E –11.92–
Page 4
Secure slotted nut with tab washer.
Installing bearing housing in pump housing

Place pump shaft with bearing housing (1) in pump
housing.
Secure bearing housing (1) to pump housing with

screws.
20038/10 E –11.92–
Page 5
Installing counterring in impeller

Insert O-ring (2) in groove on impeller (1) and coat with
corrosion inhibitor oil.
Press counterring (2) into impeller (1).

Clean running surface on counterring with denaturated
ethanol.
Running surface must be dry and free of grease.
Installing impeller
Clean taper on pump shaft and running surface of rotary
seal (1) with denaturated ethanol.
Taper and running surface must be free of grease and
dry before installation of impeller.
20038/10 E –11.92–
Page 6
Position impeller (1) on shaft taper.
Tightening impeller
Install thrust washer.
Coat contact surface and thread of stress bolt with en-
gine oil.
Install stress bolt (1) and pretighten with torque wrench
(2) according to specifications. For torque settings, see
Section 1.3.
Set stress bolt by tapping bolt head with 1000 g hammer.

Tighten stress bolt with torque wrench according to
specifications. For torque settings, see Section 1.3.
20038/10 E –11.92–
Page 7
Installing connector
Insert O-ring (2) into groove on connector and coat with
petroleum jelly.
Place connector (1) on pump housing so that retaining
bolt aligns with threaded bore.
Align connector with bolt and drive into pump housing
with plastic mallet.
Screw in and secure retaining bolts.
Measuring clearance
Use feeler gauge to measure clearance between im-
peller (1) and connector (2).
Gap clearance: max. 1.5 mm; min. 0.6 mm
Installing inner race

Heat inner race to 200 °C.
Degrease pump shaft seating surface.
Caution
Wearing protective glove, push inner (2) race onto pump

shaft.
Use drift to drive inner race home as far as it will go.
20038/10 E –11.95–
Page 8
Assembling bearing housing

Press cylindrical roller bearing (2) into bearing housing
(3) with mandrel (1).
Use circlip pliers to insert circlip (1) in groove on bearing

housing.
Make sure that circlip is securely seated in groove.
20038/10 E –11.92–
Page 1
Installing bearing housing for engine coolant pump
Insert O-ring (1) into groove on bearing housing and coat
Insert bearing flange into corresponding bore in crank-
case.
Installing engine coolant pump

Smooth sealing surfaces on crankcase and pump hous-
ing (1) with oilstone.
Coat gasket with sealing paste and place on sealing sur-
face of pump housing.
Insert engine coolant pump into bore in crankcase.
Take care not to damage cylindrical roller bearing in
bearing flange.
Securing engine coolant pump

Coat thread of screws with engine oil.
Using screws and spring washers, install and secure
coolant pump and bearing flange (1).
Press coupling sleeve onto coolant pump shaft, see
3.86.4.6
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Page 2
Installing sleeve
Check sleeve and drive shaft tapers for damage.
Check for burrs at transition areas between contact and
lateral surfaces, and oil distribution and discharge
grooves.
Machining scores and transition radii must be polished
smooth if necessary.
Clean press-fit surfaces with denaturated ethanol and
coat with SAE 10 engine oil.
Push sleeve (1) onto drive shaft taper (2) and measure
distance from shaft end to sleeve end.
Installing sleeve
Caution
Danger !
Hydraulic installation may only be carried out by trained personnel.
The equipment must be checked once a year for cracks in draw spindle.
The max. expansion pressure (Pmax = 1500 bar) must not be exceeded.
It is not permitted for personnel to remain within the danger area behind the equipment during the installation oper-
ations.
Fit installation tool with draw spindle (1) to coolant pump

shaft and secure.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Catcher plate/thrust washer
6 Grub screw
20038/10 E –11.92–
Page 3
Connect and secure H.P. line (1) to threaded connection

on installation tool and hydraulic hand pump.
Fill hydraulic hand pump with SAE 10 engine oil and vent
pump.
Pretighten hex nut (2) on installation tool with open-end
wrench.
Operate hydraulic hand pump.
Make sure that when commencing installation, that ex-
pansion pressure is sufficiently high to achieve pre-
scribed travel of 3.8 mm – 1 mm and no more.
The maximum permissible expansion pressure must not
exceed Pmax = 1500 bar.
Release hand pump pressure and disconnect H.P. line.
Do not relieve pressure on thrust washer (3) on draw
spindle until after approx. 60 minutes.
Remove draw spindle and installation tool from drive
shaft.
Check installation travel.
Installing vent
Install threaded adapter with sealing ring in crankcase.
Insert O-ring on screw element and vent pipe (2) and
Introduce elbow (1) into union in crankcase.
Insert ventilation pipe (2) with O-ring into bracket.
Install vent pipe with banjo bolt (3) and sealing rings on
engine coolant pump (4).
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Page 4
Mounting cover
Coat O-ring (4) with petroleum jelly and insert into
groove of bearing flange (5).
Install cover (3) with washer (2) and hex screw (1) on
bearing flange.
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Page 1
3.13.2 Raw Water Pump
1 Bearing housing 17 Spring washer

2 Grooved ball bearing 18 Hex nut
3 Shim 19 Sleeve
4 Snap ring 20 Counterring
5 Drive shaft 21 Rotary seal
6 Cylindrical roller bearing 22 Impeller
7 Shim 23 Stress bolt
9 Shaft seal 25 Thrust ring
10 O-ring 26 Cap nut
11 O-ring 27 Spacer ring
12 Pump housing 28 O-ring
13 Spring washer 29 Inlet elbow
15 Cover 31 Hex nut
16 Gasket
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Page 2
Coolant suction line and bearing flange
1 Raw water pump 13 Snap ring

2 Elbow 14 Sleeve
3 Gasket 15 Cover
4 Flange segment 16 O-ring
6 Screw 18 Screw
10 Plug 22 O-ring
11 Bearing flange 23 Spring washer
12 Back-up ring 24 Screw
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Page 3
Raw water pump
1 Inlet elbow 17 Sleeve

2 Spacer ring 18 Counterring
3 Pump housing 19 Rotary seal
4 Spring washer 20 Hex nut
6 Bearing housing 22 Impeller
7 Grooved ball bearing 23 Cover
8 Snap ring 24 Gasket
9 Drive shaft 25 O-ring
10 Cylindrical roller bearing 26 Spring washer
11 Shim 27 Hex nut
12 Shim 28 O-ring
13 Snap ring 29 Thrust ring
14 Shaft seal 30 Stress bolt
15 O-ring 31 Cap nut
16 O-ring
20046/20 E –07.96–
Page 1


- - x Close raw water supply and return line Op. Man.
- - x Drain raw water Op. Man.
- x x Remove generator 3.86.1.2
- x x Remove generator coupling 3.86.2.2
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Page 1
3.13.2.2 Removal
Removing bearing flange, driving end
Note
If only raw water pump is to be removed, do not remove

bearing flange.
Remove screws (1) from bearing flange (2).
Using jackscrews, press bearing flange out of crank-
case.
Remove O-ring.
Press coupling part off drive shaft, see 3.86.2.2
Remove raw water pump

Remove raw water pump (1) from crankcase (3).
Remove O-ring (2).
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Page 1
Removing cover
Install raw water pump in retaining device.
Secure latch.
Remove cover (1) and seal from pump housing.
Removing inlet elbow

Remove inlet elbow (1) from pump housing.
Remove spacer and O-ring.
Measure and record thickness of spacer.
Removing cap nut and thrust ring

Remove cap nut from impeller (1) and thrust ring.
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Page 2
Removing impeller
Install removal tool (1) on impeller (2).
Remove impeller with thrust bolt from drive shaft.
Remove O-ring.
Removing rotary seal and counterring

Remove rotary seal (1), counterring and cup seal from
pump housing.
Removing stress bolt from pump shaft

Remove stress bolt from pump shaft with extractor tool.
Note
Thrust bolt is secured with high-strength thread-locking

liquid.
If stress bolt cannot be removed, disassemble drive
shaft and heat to 200 °C at level of tapped bore.
Screw stud puller (1) onto stress bolt and remove stress
bolt.
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Page 3
Removing bearing housing

Remove raw water pump from retaining device and
place on workbench.
Inscribe assembly mark (3) on bearing cap (1) and pump
housing (2).
Remove bolts and spring washers from bearing cap.
Remove bearing housing (1) from pump housing (2).

Remove O-rings from grooves on bearing housing.
Marking (3) on bearing and pump housing.
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Page 4
Removing shaft seal

Remove shaft seal from bearing housing.
Use snap ring pliers to remove snap ring from drive
shaft.
Remove shim.
Removing drive shaft

Place bearing housing with drive shaft (2) on a hollow
pipe section (1).
Use manual press to press drive shaft out of bearing
housing.
Use removal tool to remove cylindrical roller bearing
inner race from drive shaft.
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Page 5
Removing grooved ball bearing from bearing hous-

ing
Remove snap ring (1) from grooved ball bearing.
Remove shim from bearing housing (2).
Use removal tool and manual press to remove grooved

ball bearing from bearing housing (1).
Dismantling bearing flange

flange (4).
Remove back-up ring (2).
Remove grooved ball bearing (3) from bearing flange.
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Page 1

Using red-penetrant dye, check pump housing, impeller, bearing flange and bearing housing for cracks.
Using the magnetic crack-testing method with fluorescent magnetic powder, check drive shaft with gear and stress bolt
for cracks.
Replace the relevant components if cracks are found.
Check coolant pump housing, impeller and inlet elbow for pitting.
Check drive shaft for wear and damage.
Smooth minor wear and damage with emery cloth.
Spray-metallize sealing surface as per MTU specifications as required.
Check thread for ease of movement, recut or install thread insert as required.
Check gear of drive shaft for indentations and wear.
If necessary, smooth with oilstone and emery cloth.
Check stress bolt for damage.
Check tapered seats 1:5 and 1:50 with taper gauge, replace parts if necessary.
Check sealing surfaces and bearing bore on bearing flange for wear, smooth with polishing cloth if necessary.
Adjust bore gauge and measure bore for grooved ball bearing in bearing flange and bearing housing.
Measure bearing seat and fit diameter on drive shaft with outside micrometer.
Replace rotary seal, counterring, cup seal, shaft seal and O-rings during each overhaul.
Always replace cylindrical roller bearings and grooved ball bearings during W6 overhaul.
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Page 1
3.13.2.5 Assembly
Installing grooved ball bearing in bearing housing
Press grooved ball bearing with thrust plate (1) into bear-
ing housing (2) bore.
Determine thickness of shim (1) and place on grooved

ball bearing.
Use snap ring pliers to install snap ring (1) in groove in

bearing housing (2).
Make sure that snap ring is correctly seated.
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Page 2

Use manual press to press drive shaft into grooved ball
bearing in bearing housing.
Determine thickness of shim (1), and place on grooved

ball bearing in bearing housing.
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Page 3
Installing snap ring

Use snap ring pliers to install snap ring (1) in groove on
drive shaft.
Check drive shaft axial clearance (max. 0.05 mm).
Use suitable shims to adjust axial clearance.

Degrease and dry bearing housing bore for shaft seal
(2).
Rub down shaft seal seating surface with denaturated
ethanol.
Use drift to press shaft seal into place.
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Page 4
Inserting O-rings
Coat O-ring with petroleum jelly and insert into inner
groove on bearing housing.
Coat O-ring (1) with petroleum jelly and insert into outer
groove on bearing housing.
Installing bearing housing

Install bearing housing (1) with drive shaft in pump hous-
ing (2) in accordance with marks (3).
Make sure that O-rings remain in grooves and do not
shear.
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Page 5
Coat thread of bolts with engine oil.

Install spring washers.
Screw bolts (2) into pump housing.
Tighten bearing housing (1).
Installing cup seal and counterring

To assemble counterring (1), moisten cup seal(2) with
undiluted corrosion inhibitor oil.
Insert counterring in cup seal.
Note
Insert reverse side with groove on counterring facing in-

wards into cup seal.
Install raw water pump in retaining device.

Secure latch.
Spray cup seal with denaturated ethanol
Insert counterring with cup seal (1) in pump housing (2)
bore.
Note
Polished front side faces friction surface area of rotary

seal.
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Page 6

Clean running surfaces on rotary seal (1) and counter-
ring (2) with denaturated ethanol.
Push dry rotary seal onto drive shaft (3).
Degrease and dry stress bolt and blind bore in drive

shaft.
Coat stress bolt thread with high-strength thread-locking
liquid.
Insert stress bolt with stud inserter (1) into the drive shaft
until the stop and tighten.
Make sure that stress bolt is correctly seated in drive
shaft.
Remove stud driver from stress bolt.

Install O-ring between stress bolt (2) and drive shaft (3).
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Page 7
Installing impeller
Degrease and dry drive shaft and impeller tapers.
Push impeller onto drive shaft.
Install thrust ring.
Installing cap nut

Coat stress bolt thread and cap nut mating surface with
engine oil.
Install cap nut and tighten with torque wrench (1). For
Installing inlet elbow

Smooth sealing surfaces for spacer (1) on pump hous-
ing and on inlet elbow with oilstone.
Install spacer on pump housing with same thickness as
spacer removed.
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Page 8
Insert O-ring (1) into groove on pump housing and coat

Ensure that O-ring is not twisted when installed.
Install inlet elbow (1) on pump housing with nuts and

spring washers and tighten.
Measuring clearance between impeller and inlet

elbow
Use feeler gauge (1) to check distance between impeller
and inlet elbow.
For this purpose, press shaft towards inlet elbow to elim-
inate axial clearance.
Specified distance 0.5 mm +0.5 mm.
If specified distance is not achieved, remove inlet elbow
Install suitable spacer of 1.0 / 1.5 / 2.0 or 2.5 mm.
Note
It is possible to install two spacers.
20038/10 E –11.95–
Page 9
Installing cover
Install cover (1) with new gasket on pump housing.
Secure with nuts and spring washers.
Assembling bearing flange

Install grooved ball bearing (3) with appropriate press-in
mandrel up to stop in bearing flange (4).
Note
Press grooved ball bearing only on outer race.

Install back-up ring (2).
Use circlip pliers to install circlip (1) in groove in bearing
flange.
Note
Make sure that snap ring is securely seated.
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Page 1
Install raw water pump
Smooth sealing surfaces on crankcase (3) and raw
water pump with oilstone.
Insert O-ring (2) into groove in bearing housing of raw
water pump (1).
Insert raw water pump into crankcase bore so that relief
bore for leak-off water faces downwards.
Installing bearing flange, driving end

with ”petroleum jelly” .
Insert bearing flange into corresponding bore in crank-
case.
Coat thread of screws (1) with engine oil.
Secure raw water pump and bearing flange with screws
and spring washers on crankcase.
Press coupling element onto drive shaft, see 3.86.2.6
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Page 1
3.13.3 Bilge Pump
1 Housing 14 Cross gasket

2 Grooved ball bearing 15 Screw
3 Back-up ring 16 Spring washer
4 Snap ring 17 Rotary seal
5 Flow-control disc 18 Impeller
6 Shaft seal 19 Taper
7 Thrust ring 20 Stress bolt
8 Cup seal 21 Cover
9 O-ring 22 Seal
10 Drive shaft 23 Nut
11 Back-up ring 24 Spring washer
12 Snap ring 25 Sealing ring
13 Stud 26 Plug
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Page 2
Coolant lines and intermediate flange
1 Intermediate flange 13 Elbow

2 O-ring 14 Gasket
4 Screw 16 Screw
5 Coupling element 17 Screw
6 Coupling sleeve 18 Sealing ring
7 Snap ring 19 Plug
11 Union 23 Bilge Pump
12 Elbow
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Page 3
Bilge pump
1 Seal 12 Spring washer

2 Cover 13 Flow-control disc
3 O-ring 14 Cross gasket
4 Shaft seal 15 Pump housing
5 Stress bolt 16 Locking screw
6 Taper 17 Snap ring
7 Rotary seal 18 Back-up ring
8 Thrust ring 19 Grooved ball bearing
9 Cup seal 20 Back-up ring
10 Impeller 21 Snap ring
11 Hex nut 22 Drive shaft
20038/10 E –11.92–
Page 1


- - x Close raw water supply and return line Op. Man.
20038/10 E –11.92–
Page 1
3.13.3.2 Removal
Removing bilge pump
Disconnect engine oil line (1) from intermediate flange
(2).
Remove securing bolts.
Remove bilge pump with coupling sleeve.
Remove intermediate flange from bilge pump.
Remove O-rings.
Remove coupling (see 3.86.4.2).
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Page 1
Removing cover
Install bilge pump in retaining device (2).
Mark relative positions of cover, flow-control disc and
pump housing.
Remove cover (1) from bilge pump, then remove
gasket.
Removing impeller
Remove stress bolt (1) from impeller (2).
Removing taper and impeller

Install puller bolt (1) with thrust nut (2) in drive shaft
taper.
Holding thrust nut steady, remove taper from drive shaft
with puller bolt.
Remove taper from puller bolt.
Install puller bolt with thrust nut in drive shaft.
Secure thrust nut to impeller (3) with bolts.
Remove impeller from drive shaft with puller bolt and re-
move removal tool.
20038/10 E –11.92–
Page 2
Removing flow-control disc, rotary seal, thrust ring,

cup seal and shaft seal
Remove locating bolt (1) from pump housing.
Remove flow-control disc with rotary seal.
Remove gasket and O-rings from flow-control disc.
Remove thrust ring with cup seal from flow-control disc
bore.
Use suitable mandrel to press shaft seal from flow-con-
trol disc bore.
Removing snap ring and back-up ring

Remove snap ring and back-up ring (2) for grooved ball
bearing from drive shaft (1).
Remove bilge pump from retaining device.
Removing drive shaft

Use plastic mallet to remove drive shaft (1) from pump
housing (2).
20038/10 E –11.92–
Page 3
Removing grooved ball bearing

Use snap ring pliers (1) to remove grooved ball bearing
snap ring from pump housing (2).
Remove back-up ring.
Use drift (1) to drive grooved ball bearing out of pump

housing (2).
20038/10 E –11.92–
Page 1

Using red-penetrant dye, check pump housing, flow-control disc, impeller and cover for cracks.
Using the magnetic crack-testing method with fluorescent magnetic powder, check drive shaft with coupling element,
sleeve and stress bolt for cracks.
Replace the relevant components if cracks are found.
Check pump housing, flow-control disc, impeller and cover for cavitation and pitting.
Check sealing surfaces on pump housing, flow-control disc and cover for damage and evenness, level out if necessary.
Check bearing bore in pump housing and sealing ring seats in flow-control disc for damage and wear, smooth with pol-
ishing cloth if necessary.
Check coupling and sleeve toothing for wear and indentations, replace parts if necessary.
Check drive shaft for wear and damage; smooth with emery cloth as necessary.
Metal-spray sealing surface for shaft seal as per MTU specifications as necessary.
Check thread for ease of movement, install thread insert if necessary.
Check tapered seat 1:5 with taper gauge, check taper for wear, smooth or replace if necessary.
Check stress bolt for wear, replace if necessary.
Adjust bore gauge. Measure bore for grooved ball bearing in pump housing.
Measure bearing seat and fit diameter on drive shaft with outside micrometer.
Replace rotary seal, counterring, cup seal and shaft seal during each overhaul.
Always replace grooved ball bearings during W6 overhaul.
20038/10 E –11.92–
Page 1
3.13.3.5 Assembly
Use manual press (1) and drift to press grooved ball
bearing into pump housing (2).
Installing back-up ring

Place back-up ring (1) on grooved ball bearing in pump
housing (2).
Installing snap ring

Use snap ring pliers to install snap ring (1) in groove in
pump housing (2).
20038/10 E –11.92–
Page 2

Degrease and dry shaft seal bore in flow-control disc.
Use drift (1) to drive shaft seal into flow-control disc (3).
Install O-rings (2) in flow-control disc groove, making
sure that O-rings are not twisted.

Press drive shaft (1) into pre-installed grooved ball bear-
ing and place back-up ring on bearing.
Use snap ring pliers to install snap ring in drive shaft.
Installing flow-control disc

Install pump housing with drive shaft in retaining device.
Coat sealing surfaces on pump housing and flow-control
disc with sealing compound.
Install gasket on flow-control disc, making sure that
openings are correctly positioned.
Fit flow-control disc in accordance with marking on
pump housing and tighten with screw (1) and spring
washer.
Ensure that cross-gasket does not move out of position.
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Page 3
Installing cup seal and thrust ring

To assemble counterring (2), moisten cup seal with
undiluted corrosion inhibitor oil.
Install thrust ring (1) in cup seal.
Spray cup seal with denaturated ethanol.

Insert thrust ring with cup seal (1) in flow-control disc
bore (2).

Clean rotary seal (1) and thrust ring (2) sealing surfaces
with denaturated ethanol.
Sealing surface between thrust ring and rotary seal must
be free of grease and dry.
Install rotary seal in flow-control disc with sealing sur-
face facing thrust ring.
20038/10 E –11.92–
Page 4
Installing impeller
Clean and degrease fits on impeller and drive shaft.
Push impeller onto drive shaft.
Screw installation device (2) with thrust screw (1) into
drive shaft.
Push impeller (3) onto drive shaft with thrust nut.
Measure gap clearance 0.15 mm to 0.25 mm between
impeller and flow-control disc with feeler gauge (4).
Remove installation device.
Tightening taper and impeller

Coat taper with thin-film lubricant and install with
washer.
Insert thrust bolt on impeller (2).
fication 1.3.
Check clearance between impeller and flow-control disc
with feeler gauge.
Checking impeller seating

Secure testing unit (2) on four puller threads M 8 on im-
peller.
Check impeller (3) seating on drive shaft with checking
torque with torque wrench (1).
For checking torque, see Section 1.3.
Do not restrain the impeller directly.
Remove test device.
20038/10 E –07.96–
Page 5
Adjusting impeller
With depth gauge (1), measure distance between flow-
control disc (3) and upper edge of impeller (2).
Example: Distance = 24.0 mm
Install gasket on sealing surface of cover.

With depth gauge (1), measure distance between seal-
ing surface of cover (3) with gasket and base of cover
(2).
Example: Distance = 24.3 mm
Specified gap dimension between

Flow-control disc - impeller 0.2 mm ± 0.05 mm
Impeller - cover base 0.3 mm ± 0.05 mm
Example
Flow-control disc - cover base 24.3 mm
Impeller - flow-control disc 24.0 mm
Gap impeller - cover 0.3 mm
Note
Specified clearance 0.3 mm + 0.20 mm between im-

peller (1) and cover (2) can be altered by the number of
cover gaskets.
Coat sealing surfaces of flow-control disc (3) and cover
with sealing compound.
Install gasket.
Place cover on flow-control disc in accordance with
markings applied at disassembly.
Secure cover with nuts and spring washers.
20038/10 E –07.96–
Page 1
Insert O-ring (4) into groove on bilge pump (5) and coat
Install intermediate flange (3) on bilge pump and secure
with bolts and spring washers.
Installing coupling element (8), see 3.86.4.6
Install snap rings (2) in coupling sleeve (7), making sure
that they are correctly seated.
Lubricate coupling sleeve with engine oil and push onto
coupling.
Insert O-ring (6) on bearing cap (1) into groove and coat
Push bilge pump with drive shaft into coupling sleeve

with leak outlet pointing downwards.
Secure bilge pump with bolts and spring washers.
Install oil line (1) on adapter on intermediate flange (2)
and secure.
20038/10 E –07.96–
Page 1
3.14 Cooling System

Contents
3.14.1 Engine coolant lines

3.14.1.2 Removal
3.14.2 Vent and drain lines

3.14.2.2 Removal
3.14.3 Raw water lines

3.14.3.2 Removal
3.14.5c Coolant expansion tank

3.14.5c.2 Removal
3.14.5c.5 Assembly
3.14.6 Engine Coolant Cooler

3.14.6.2 Removal
3.14.6.5 Assembly
3.14.7b Coolant thermostat

3.14.7b.2 Removal
3.14.7b.5 Assembly
3.14.9 Engine coolant chamber pressure testing
20046/20 E –07.96–
Page 2

A
S4
Ink-check plate
Pressure-testing equipment
Pressure gauge, to 10 bar
Water bath with temperature tester

Amide sulphonic acid (Höchst) Euron 1308
Cold cleaner P3/T280 (Henkel)
Long-term lubricating grease Long-Term 2 Plus 40337
Engine oil – SAE 10 Shell Rotella X10 W 40504
High-strength pipe-thread sealant Loctite No. 586 40033
Dry compressed air
Caution
20046/20 E –07.96–
Page 1
3.14.1 Engine Coolant Lines
Engine coolant pressure and suction lines, 8V
1 Vent line 28 Gasket

2 O-ring 29 Water pump flange
4 Union 31 Socket-head screw
5 O-ring 32 Plug-in pipe
6 Elbow 33 O-ring
7 Sealing ring 34 Inlet elbow
8 Union 35 O-ring
9 Drain valve 36 Washer
10 Elbow 37 Hex bolt
12 Plug 39 Plug
13 O-ring 40 Diffusor
14 O-ring 41 O-ring
15 O-ring 42 Mounting bracket
18 Hex bolt 45 Plug-in pipe
19 Hex bolt 46 O-ring
20 Banjo bolt 47 Elbow
22 Vent pipe 49 Plug
23 O-ring 50 Gasket
24 Union 51 Washer
27 Elbow
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Page 2
1 Vent line 24 O-ring

2 O-ring 25 Flange
5 O-ring 28 Screw
6 Elbow 29 Plug-in pipe
8 Union 31 Elbow
9 Vent pipe 32 Sealing ring
10 Banjo bolt 33 Plug
12 O-ring 35 Screw
13 Union 36 Screw
15 O-ring 38 Drain line
16 Elbow 39 O-ring
17 Inlet elbow 40 Sealing ring
18 O-ring 41 Union
19 Washer 42 Drain valve
20 Screw 43 Mounting bracket
22 Plug 45 Screw
23 Diffusor
20046/20 E –07.96–
Page 3
1 Elbow 24 Mounting bracket

2 Gasket 25 Washer
3 Washer 26 Screw
4 Screw 27 Vent line
5 Screw 28 O-ring
7 Gasket 30 Union
8 Screw 31 O-ring
9 Spring washer 32 Elbow
11 Flange 34 Union
12 Plug-in pipe 35 Drain valve
13 Spring washer 36 Banjo bolt
15 O-ring 38 Vent pipe
16 Inlet elbow 39 O-ring
17 O-ring 40 Union
19 Screw 42 O-ring
20 Sealing ring 43 Elbow
22 Diffusor 45 Plug
23 O-ring
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Page 4
Engine coolant line from intercooler to engine oil heat exchanger, 8V
1 Elbow 21 Spring washer

2 Gasket 22 Hex bolt
3 Washer 23 Plug
5 Hex bolt 25 Mounting bracket
6 Washer 26 Washer
8 Washer 28 Pipe clamp half
9 Hex bolt 29 Pipe clamp half
10 Plug-in socket pipe 30 Washer
12 Coolant line 32 Plug-in pipe
13 O-ring 33 O-ring
14 Socket-head screw 34 Elbow
15 Washer 35 Gasket
16 Mounting bracket 36 Washer
17 Coolant line 37 Hex bolt
19 Plug 39 Hex bolt
20 Gasket
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Page 5
Engine coolant lines from intercooler to engine oil heat exchanger and to coolant pump, 12V
1 Coolant line 15 Elbow

3 Plug 17 Washer
4 Gasket 18 Screw
6 Screw 20 Plug-in pipe
7 Plug 21 O-ring
9 Mounting bracket 23 Sealing ring
10 Pipe clamp half 24 Plug
11 Screw 25 Gasket
13 Plug-in pipe 27 Screw
14 O-ring 28 Screw
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Page 6
Engine coolant line from intercooler to engine oil heat exchanger
1 Elbow 20 Gasket
4 Hex bolt 23 Plug
6 Washer 25 Mounting bracket
9 Hex bolt 28 Pipe clamp half
10 Plug-in socket pipe 29 Pipe clamp half
11 O-ring 30 Washer
13 O-ring 32 O-ring
14 Socket-head screw 33 Plug-in pipe
15 Washer 34 Elbow
16 Mounting bracket 35 Gasket
17 Coolant line 36 Washer
19 Plug 38 Hex bolt
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Page 7
Engine coolant line from heat exchangers to coolant pump
1 Elbow 12 Washer
2 Plug 13 Screw
3 Sealing ring 14 Plug-in pipe
4 Gasket 15 O-ring
5 Washer 16 Elbow
7 Screw 18 Plug
8 Plug-in pipe 19 Gasket
9 O-ring 20 Washer
10 Elbow 21 Screw
11 Gasket
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Page 8
Engine coolant line at crankcase, 16V
1 Coolant line 9 Washer

3 Plug 11 Hex bolt
5 Plug 13 Union
6 Drain valve 14 Pipe elbow
7 Plug-in pipe 15 Sealing cone
8 O-ring 16 Nut
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Page 9
Engine coolant lines, turbocharger cooling jackets
1 Flange 17 Plug
2 Gasket 18 Screw
3 Socket-head screw 19 Screw
5 O-ring 21 Screw
6 Elbow 22 Washer
8 Screw 24 O-ring
9 Washer 25 Coolant line
10 O-ring 26 Connecting pipe
11 Plug-in pipe 27 O-ring
12 O-ring 28 Screw
13 Elbow, left 29 Washer
14 Elbow, right 30 O-ring (order-specific)
15 Restrictor 31 Plug-in pipe (order-specific)
16 Sealing ring 32 O-ring (order-specific)
20046/20 E –07.96–
Page 10
Engine coolant lines from thermostat to engine coolant pump
1 Elbow 16 Washer
5 Plug 20 O-ring
7 O-ring 22 Washer
9 Injector 24 Hex bolt
10 Sealing cone 25 Sealing ring
11 Nut 26 Plug
12 Annular slide thermostat 27 Threaded bush
14 Flow restrictor 29 Plug
15 O-ring
20046/20 E –07.96–
Page 11
Engine coolant lines from thermostat to engine coolant pump
1 Elbow 16 Washer
5 Plug 20 O-ring
7 O-ring 22 Washer
9 Injector 24 Hex bolt
10 Sealing cone 25 Sealing ring
11 Nut 26 Plug
12 Annular slide thermostat 27 Threaded bush
14 O-ring 29 Plug
15 Flow restrictor
20046/20 E –07.96–
Page 12
Coolant lines from coolant manifold and exhaust line to thermostat
1 Connecting line 19 Sealing ring

3 Elbow 21 Plug
4 Elbow 22 Snap ring
5 Gasket 23 Gasket
6 Washer 24 Washer
9 Plug 27 Plug
10 Sealing ring 28 Cover
11 Plug 29 Gasket
13 Plug 31 Hex bolt
14 Elbow 32 Hex bolt
15 Plug 33 Plug-in pipe
17 Elbow 35 Strainer
18 Plug
20046/20 E –07.96–
Page 13
Engine coolant line to intercooler, 8V, 12V
1 Elbow 19 Hex bolt

4 Washer 22 Washer
6 Plug-in pipe 24 Hex bolt
7 O-ring 25 Washer
8 Coolant line 26 Pipe clamp half
10 Plug 28 Washer
11 Coolant line 29 Hex nut
13 Plug 31 O-ring
14 Plug 32 Gasket
16 Mounting bracket 34 Hex bolt
18 Hex bolt
20046/20 E –07.96–
Page 14
Engine coolant lines to intercooler, 16 V
1 Elbow 18 Mounting bracket

3 O-ring 20 Washer
4 Washer 21 Screw
5 Screw 22 Washer
7 O-ring 24 Pipe clamp half
8 Coolant line 25 Screw
10 Plug 27 Nut
11 Coolant line 28 Plug-in pipe
12 Plug 29 O-ring
14 Mounting bracket 31 Washer
16 Screw 33 Screw
17 Mounting bracket
20046/20 E –07.96–
Page 15
Engine coolant lines from coolant expansion tank to intake elbow of engine coolant pump
1 Elbow 13 Union
2 Plug 14 Mounting bracket
4 Washer 16 Grommet
6 Threaded bush 18 Hex bolt
7 Drain line 19 Hex bolt
9 Adapter 21 Grommet
10 Banjo bolt 22 Spring washer
11 Pipe 23 Hex bolt
12 Sealing ring
20046/20 E –07.96–
Page 16
Connecting line from engine coolant pump to measuring block, 8V
1 Adapter 18 Pipe clamp half

2 Connecting line 19 Spring washer
3 Grommet 20 Spacer sleeve
4 Pipe clamp half 21 Hex bolt
5 Spring washer 22 Bracket
7 Pipe 24 Grommet
11 Pipe clamp half 28 Bracket
14 Bracket 31 Grommet
17 Grommet
20046/20 E –07.96–
Page 17
Coolant line from coolant pump to measuring block
1 Adapter 15 Spring washer

2 Connecting line 16 Screw
6 Screw 20 Spacer sleeve
7 Pipe 21 Screw
8 Banjo bolt 22 Bracket
14 Bracket 28 Screw
20046/20 E –07.96–
Page 18
Engine coolant supply and return line to air compressor
1 Mounting bracket 14 Hex nut

2 Pipe clamp half 15 Coolant drain line
4 Hex bolt 17 Adapter
5 Spring washer 18 Adapter
6 Hex nut 19 Spring washer
7 Mounting bracket 20 Hex bolt
10 Pipe clamp half 23 Coolant supply line
11 Spacer bush 24 Adapter
13 Spring washer 26 Adapter
20046/20 E –07.96–
Page 19
Coolant line bilge pump - raw water pump

2 Mounting bracket 7 Hex nut
3 Grommet 8 Adapter
4 Pipe clamp half 9 Sealing ring
5 Spring washer 10 Union
20046/20 E –07.96–
Page 1


20038/10 E –11.92–
Page 1
3.14.1.2 Removal
Before removing coolant lines, it is advisable to take photographs of engine from all sides or to identify lines with
markers so as to avoid confusion during subsequent reassembly.
Remove all monitoring instruments.
After removing coolant lines, seal all connections with suitable plugs.
20038/10 E –11.92–
Page 1

Clean coolant lines with cold cleaner and brushes.
Make visible inspection of plug-in connections and annular grooves on elbows, plug-in pipes, connecting lines and
flanges for wear, pitting and cavitation.
Provide damaged plug-in connections with bushes in accordance with MTU specifications, replace if necessary.
Pressure-test components as required.
Recondition damaged sealing surfaces and inspect for irregularities on an ink-check plate.
Replace damaged, indented or corroded sealing cones and banjo unions.
Realign badly fitting lines. Heat the lines red-hot with welding torch, tighten connections and unions.Allow lines to cool
slowly, do not cool with water.
Remove realigned lines from engine, pickle in a hydrochloric acid solution, (9 parts water to 1 part hydrochloric acid).
Then wash with hot water and blow dry with compressed air.Then preserve lines in oil bath and allow to drip dry.
Check restrictors and strainers for damage, replace as necessary.
Check brackets, grommets and fixtures of lines for damage and wear, replace parts if necessary.
Replace unions as required.
20038/10 E –11.93–
Page 1
Before installation, blow coolant lines, plug-in pipes and connecting lines clear with compressed air.
Ensure that components are particularly clean.
Coat O-rings with petroleum jelly and insert into grooves of plug-in pipes and flanges.
Install coolant lines, plug-in pipes, connecting lines and flanges with new gaskets and O-rings and attaching hardware
so that they are free from strain in accordance with photographs, markers and layout in illustrations in 3.14.1.
Ensure that strainers are installed in correct position, see 3.14.1.
Once coolant distribution has been finally set, mark position of flow restrictor on elbow flange with a notch, see 3.14.1.
20038/10 E –07.96–
Page 1
3.14.2 Vent and Drain Lines
Vent line from intercooler and turbocharger casing connecting line to distributor, 8V
1 Plug 11 Banjo screw

3 Distributor 13 Hex bolt
6 Sealing ring 16 Bracket
7 Banjo screw 17 Pipe clamp half
8 Vent line 18 Pipe clamp half
9 Vent line 19 Hex bolt
10 Sealing ring
20046/20 E –07.96–
Page 2
Vent line from intercooler and turbocharger casing connecting line to distributor, 12V, 16V
1 Plug 11 Banjo screw

3 Distributor 13 Hex bolt
7 Banjo screw 17 Pipe clamp half
10 Sealing ring
20046/20 E –07.96–
Page 3
Vent line from distributor to coolant expansion tank, 8V
1 Vent line 9 Spring washer

3 Union 11 Hex bolt
6 Bracket 14 Washer
7 Grommet 15 Hex bolt
8 Pipe clamp half
20046/20 E –07.96–
Page 4
1 Vent line 9 Washer

2 Sealing ring 10 Spacer bush
3 Union 11 Washer
6 Grommet 14 Hex bolt
7 Pipe clamp half 15 Hex bolt
20046/20 E –07.96–
Page 5
1 Vent line 10 Washer

2 Vent line 11 Screw
4 Union 13 Screw
6 Reduction union 15 Washer
7 Grommet 16 Screw
20046/20 E –07.96–
Page 6
Vent line from distributor to coolant inlet/outlet housing, 8V

2 Sealing cone 9 Hex bolt
3 Nut 10 Grommet
5 Union 12 Hex bolt
6 Bracket 13 Spring washer
7 Bracket 14 Hex bolt
20046/20 E –07.96–
Page 7
Vent line from distributor to coolant inlet/outlet housing, 16V
1 Vent line 11 Screw

2 Sealing cone 12 Screw
3 Nut 13 Screw
6 Bracket 16 Grommet
8 Bracket 18 Screw
9 Retainer (order-specific) 19 Spring washer
10 Screw 20 Nut
20046/20 E –07.96–
Page 8
Vent line from coolant inlet/outlet housing to coolant thermostat

2 Reduction union 9 Spring washer
4 Vent line 11 Sealing ring
5 Reduction union 12 Union
7 Bracket
20046/20 E –07.96–
Page 9
Vent line and drain pipe on coolant expansion tank
1 Drain pipe 11 Union

2 Bracket 12 Vent line
4 Hex bolt 14 Union
5 Rubber sleeve 15 Sealing ring
6 Clamp 16 Reduction union
7 Pipe clamp half 17 Vent line
9 Hex bolt 19 Banjo screw
10 Sealing ring 20 Hex nut
20046/20 E –07.96–
Page 10
Vent line, intercooler
1 Restrictor banjo screw 8 Bracket

3 Drain line 10 Grommet
4 Drain line 11 Pipe clamp half
20046/20 E –07.96–
Page 11
Vent line, intercooler
1 Drain line 8 Grommet

2 Drain line 9 Pipe clamp half
7 Bracket
20046/20 E –07.96–
Page 1


20038/10 E –11.92–
Page 1
3.14.2.2 Removal
Before removing vent and drain lines, it is advisable to take photographs of engine from all sides or to identify lines with
After removing lines, seal all connections with suitable plugs.
20038/10 E –11.92–
Page 1

Clean drain and vent lines with cold cleaner.
Carry out visual check for damage and condition, repair if necessary, pressure-test as required.
Heat badly fitting lines red-hot with welding torch, tighten connections and unions.
Allow pipes to cool slowly, do not cool with water.
Disconnect realigned lines from engine.
Pickle with a hydrochloric acid solution (9 parts water to 1 part hydrochloric acid).
Then wash with hot water and blow dry with compressed air.
Then preserve lines in oil bath and allow to drip dry.
Replace unions as necessary.
Replace O-rings and hose sleeve.
20038/10 E –11.92–
Page 1
Before installation, blow vent and drain lines clear with compressed air.
Ensure that components are particularly clean.
Fit vent and drain lines with new sealing rings and attaching hardware so that they are free from strain in accordance
with photographs, markers and layout in illustrations in 3.14.2.
20038/10 E –07.96–
Page 1
3.14.3 Raw Water Lines
Connecting line from coolant pump to engine coolant cooler
1 Elbow 10 Inlet elbow

2 Converter flange (order-specific) 11 Gasket
5 Hex bolt 14 Cover (order-specific)
6 Sealing ring 15 Hex bolt (order-specific)
7 Union 16 Spring washer (order-specific)
8 Link 17 Gasket (order-specific)
20046/20 E –07.96–
Page 2
Raw water outlet at engine coolant cooler (plate-core cooler)
1 Elbow 12 Plug
2 Gasket 13 Restrictor (order-specific)
3 Spring washer 14 Gasket (order-specific)
4 Screw 15 Screw (order-specific)
5 Screw 16 Spring washer (order-specific)
6 Elbow 17 Nut (order-specific)
7 Gasket 18 Reduction union
8 Flange segment 19 Nut
9 Spring washer 20 Sealing taper
10 Screw 21 End taper
11 Sealing ring
20046/20 E –07.96–
Page 3
Raw water line from elbow to measuring block
1 Connector 10 Pipe clamp half

3 Union 12 Hex bolt
5 Hex bolt 14 Grommet
6 Raw water line 15 Pipe clamp half
7 Raw water line 16 Hex bolt
20046/20 E –07.96–
Page 1


20038/10 E –11.92–
Page 1
3.14.3.2 Removal
Before removing raw water lines, it is advisable to take photographs of engine from all sides or to identify lines with
After removing raw water lines, seal all connections with suitable plugs.
20038/10 E –11.92–
Page 1

Clean raw water lines with cold cleaner and brushes.
Make visible inspection of plug-in connections and annular grooves on elbows, plug-in pipes, connecting lines and
flanges for wear, pitting and cavitation.
Provide damaged plug-in connections with bushes in accordance with MTU specifications, replace if necessary.
Pressure-test components as required.
Pickle with a hydrochloric acid solution (9 parts water to 1 part hydrochloric acid).
Then wash with hot water and blow dry with compressed air.
Replace unions as required.
20038/10 E –11.92–
Page 1
Before installing, blow raw water lines clear with compressed air.
Make sure parts are perfectly clean.
Fit raw water lines with new sealing rings and O-rings and attaching hardware so that they are free from strain in accord-
ance with photographs and layout in illustrations in (3.14.3).
Note
Before fitting, coat O-rings with petroleum jelly.
20038/10 E –07.96–
Page 1
3.14.5c Coolant Expansion Tank
1 Expansion tank 19 Gasket

2 Warning plate 20 Housing
3 Gasket 21 Washer
4 Flange 22 Hex bolt
5 Valve 23 Level switch
8 Sheet-metal eye 26 Gasket
9 Hex bolt 27 Coolant level indicator
10 Washer 28 Socket head-screw
11 Hex bolt 29 Coolant level sight glass
12 Spring washer 30 Pipe elbow
13 Blank flange 31 Nut
14 Gasket 32 Union
16 Sealing ring 34 Threaded pin
18 Plug 36 Warning plate
20046/20 E –07.96–
Page 1


- x x Remove coolant line to expansion tank 3.14.1.2
- x x Disconnect level switch (coolant) and remove 3.84.1.2
20046/20 E –07.96–
Page 1
3.14.5c.2 Removal
Remove screws (2) and washers (3) from expansion
tank (1).
Lift expansion tank from cooler housing (5).
Remove sealing ring (4) from cooler housing.
Remove cooler housing 3.14.6.2
20046/20 E –07.96–
Page 1
Removing blind flanges
Release bolts (2) in both blind flanges (4) and remove
together with spring washers (3).
Remove blind flanges with gaskets (5) from expansion
tank (1).
Removing coolant level indicator

Remove socket head screws (4) from coolant level indi-
cator (3).
Remove coolant level indicator from expansion tank (1).
Remove sight glass (5) and seals (2) from seat in expan-
sion tank.
Removing housing and level switch

Remove level switch (6), see 3.84.1
Release hex bolts (5) in housing flange (3) and remove
together with spring washers (4).
Withdraw housing from expansion tank (1).
Remove gasket (2).
20046/20 E –07.96–
Page 2
Removing breather valve

Open valve cover (4).
Release hex bolts (5) in breather valve flange (3) and re-
move together with spring washers (6).
Remove sheet-metal eye (7) with valve cover.
Lift flange off expansion tank (1).
Remove gasket (2).
20046/20 E –07.96–
Page 1
Caution
When using chemical agents, always follow the manufacturer’s instructions for use.
Clean expansion tank and fitted parts with cold cleaner and brush.
Remove scale with a descaling product that does not attack the metal surface (e.g. P3 T288 from Henkel or Euron 1308
amidosulfonic acid from Hoechst).
Once cleaning is completed, rinse all parts with a powerful jet of water.
Check expansion tank for wear and cavitation, smooth sealing surfaces and mating faces with oilstone if necessary,
replace as required.
Check threaded bores for ease of movement, recut thread if necessary, or install threaded inserts.
Clean coolant level sight glass; replace if necessary.
Check seal on valve cover, replace valve cover if necessary.
Replace gaskets.
Inspect flange, cover, blind flanges and coolant level indicator for surface irregularities.
Rub down screw-down and sealing surfaces with oilstone.
20046/20 E –07.96–
Page 1
3.14.5c.5 Assembly
Installing breather valve
ary.
Correctly position flange (3) with a new gasket (2) on ex-
pansion tank.
Secure flange to expansion tank (1) with hex bolts (5)
and washers (6).
Note
Secure sheet-metal eye (7) of valve cover (4) with one

of the hex screws (5).
Tighten hex bolts diagonally and evenly.
Screw valve cap into flange.
Installing housing and level switch

ary.
Mount housing with a new gasket (2) on expansion tank
(1) with hex bolts (5) and washers (4).
Fit level switch (6), see 3.84.1.6.
Installing coolant level indicator

Install sight glass (5) with new seals (2) in its seat in ex-
pansion tank (1).
Attach coolant level indicator (3) to expansion tank with
socket head screws (4).
Note
Make sure gaskets are correctly positioned.

Tighten socket head screws in diagonally opposite se-
quence.
20046/20 E –07.96–
Page 2
Installing blind flanges

Mount blind flanges (4) with new gaskets (5) on expan-
sion tank (1) with hex bolts (2) and spring washers (3).
20046/20 E –07.96–
Page 1
Install new sealing ring (4) in cooler housing (5).
Place expansion tank (1) in position.
Tighten bolts (2) and washers (3) diagonally and evenly.
Mount cooler housing 3.14.6.6
20046/20 E –07.96–
Page 1
3.14.6 Engine Coolant Cooler
1 Raw water outlet 10 At operating temperature to intercooler

2 Plate pack 11 From raw water pump
3 Stud 12 Guide pin
4 Spacer sleeve 13 First plate
5 Cover 14 Channel plate
6 O-ring 15 End plate
7 Cooler housing 16 Threaded sleeve
8 At operating temperature 17 Pressure plate
9 Bypass to intercooler
20046/20 E –07.96–
Page 2
Engine coolant cooler
1 First plate 6 Pin

2 Channel plate 7 Spacer sleeve
3 Channel plate 8 Threaded sleeve
4 Channel plate 9 Sealing ring
5 Stud
Number of channel plates to be installed:
8V 16V
Item 2 = 23 x Item 2 = 45 x
Item 3 = 4 x Item 3 = 13 x
Item 4 = 18 x Item 4 = 31 x
12V
Item 2 = 33 x
Item 3 = 8 x
Item 4 = 24 x
20046/20 E –07.96–
Page 3
Cooler housing, pressure plate and carrier
1 Carrier 15 Pressure plate

2 Carrier 16 Bush
3 Spring washer 17 Flange
4 Hex screw 18 O-ring
6 Stress bolt 20 Socket head-screw
7 Spring washer 21 Sealing cap
8 Hex screw 22 Sealing cap
9 Cooler housing 23 O-ring
10 Bush 24 Spring washer
11 Flange 25 Hex screw
12 O-ring 26 Drain valve
14 Socket head-screw
20046/20 E –07.96–
Page 1


- - x Close raw water supply and return lines Op. Man.
- - x Drain raw water -
- x x Remove raw water outlet line 3.14.3.2
- x x Remove raw water emergency supply inlet line (order-specific) -
- x x Remove engine coolant line to intercooler 3.14.1.2
- x x Remove drain line to cooler housing 3.14.1.2
20046/20 E –07.96–
Page 1
3.14.6.2 Removal
Identify plate pack with a coloured diagonal stroke
(arrowed) in correct installation sequence for purposes
of subsequent reassembly.
T0140421b0
Removing pressure plate

Insert guide pin (1).
Unscrew threaded sleeves (2).
Remove pressure plate.
Removing channel plates

Beginning at top, remove channel plates (1) in turn.
Remove coolant transfer sealing rings from cooler
housing.
Remove spacer sleeves from stud bolts.
20038/10 E –11.92–
Page 2
Removing cooler housing

Unscrew bolts (2) and washers (3) securing cooler
housing (1).
Remove securing bolts (7) and spring washers (5) from
mounting brackets (4) and (8).
Remove cooler housing from brackets.
Remove securing bolts (6) and spring washers from
brackets.
Detach brackets (4) and (8) from crankcase.
20038/10 E –11.92–
Page 1
Disassembling cooler housing
Use a suitable mandrel and plastic mallet, remove bush
(6) from cooler housing (1) from flange side.
Remove socket head screw (3).
Use suitable mandrel and plastic mallet to drive flange
(4) out of cooler housing (1).
Remove O-rings (5) from flange (4).
Note
Unscrew studs (2) and guide pins (4) on cooler housing

(1) only if required.
Parts are secured by means of high-strength thread-
locking compound.
Unscrew drain valve (3) from cooler housing.
20038/10 E –11.92–
Page 2
Removing pressure plate

Using a suitable mandrel and plastic mallet, remove
bush (4) from pressure plate (3) from flange side.
Remove socket head screw (6).
Using a suitable mandrel and plastic mallet, drive flange
(1) out of pressure plate.
Remove O-rings (2) from flange (1).
20038/10 E –11.92–
Page 1

Cleaning cooler housing and pressure plate
Caution
When using chemical agents, always follow the manufacturer’s instructions for use.
Clean cooler housing and pressure plate with cold cleaner and brush.
To remove scale deposits, use a decalcifying agent which is non-harmful to metal (e.g. P3 T288 manufactured by Hen-
kel or amidosulfonic acid Euron 1308 manufactured by Hoechst).
Cleaning channel plates
Attention
Never use hydrochloric acid for cleaning purposes!

Never use water with more than 300 ppm C1 to prepare a cleaning solution!
Prevent aluminium components from coming into contact with chemicals!
Coarse fouling (algae, wood, barnacles, crabs)
Perform mechanical cleaning with a soft brush and run-
ning water or high-pressure water jet.
Attention
Do not damage seals.
Biological fouling and sludge (bacteria, protozoa)

Attention
Note
To prevent damage to the plates, observe specified ser-

vice pressure and minimum spraying distance of the
high-pressure jet.
Carefully follow the operating instructions of the manu-
facturer.
20038/10 E –11.95–
Page 2
Chemical cleaning, select from

- caustic soda *
- sodium carbonate *
* concentration max. 4 %; temperature max. 80 °C.
Note
The cleaning effect can be considerably improved by

adding small quantities of hypochlorite or agents for
forming complexes and foam generators.
Encrustation, scale deposits and sediments

Attention

Chemical cleaning, select from
- nitrous acid *
- citric acid *
- phosphoric acid *
- sodium polyphosphate acid *
* concentration max. 4 %; temperature max. 60 °C.
Oil residues, grease

Hydrocarbon-base deposits can be removed by using a
soft brush and a paraffin-or naphthalene-base solvent
(e.g. kerosene).
Attention
Solvents cause seals and gaskets to expand

Contact period: max. 30 min
20038/10 E –11.95–
Page 3
Following solvents should not be used:

– Ketone (e.g. acetone, methyl ethyl ketone, methyl isobutyl
ketone)
– Ester (e.g. ethyl acetate, butyl acetate)
– halogenated hydrocarbon (e.g. chlorothene, carbon
tetrachlorides, feron)
– Aromatic compounds (e.g. benzene, toluene)
Clean the plate profile gaskets and check them for damage.
If a damaged gasket is found, replace the affected channel plate.
Repair work can possibly involve the manufacturer replacing the rubber.
Check leak-off grooves (breaks in the rubber profile) in the profile gaskets.
Before the leak-off grooves are compressed, they must be approx. 8 mm wide.
If a leak-off groove is pressed together, it has to be recut with a knife.
Inspect screw-down surfaces, sealing surfaces and bores in cooler housing and pressure plate for damage; rub down
with oilstone if necessary.
Fit thread inserts if required.
Inspect flanges, bushes and mounting brackets for wear; rub down with oilstone or polishing cloth if necessary.
Check stud threads and threaded sleeves for ease of movement.
Replace parts as required.
Check components for cracks using surface crack-testing method with red penetrant dye; replace components if cracks
are found.
Leak-check cooler housing with fluid as required.
Test pressure, select 4.5 bar – 7.0 bar.
Replace O-rings.
20038/10 E –11.95–
Page 1
3.14.6.5 Assembly
Assembling cooler housing
Coat jacket surface of bush (6) with petroleum jelly and,
using a plastic mallet, drive into cooler housing (1) as il-
lustrated in drawing.
Insert O-rings (5) into flange (4).
Press flange (4) into cooler housing (1), taking care not
to damage screw holes. Installation position: see il-
lustration.
Secure flange (4) with socket head screw (3) and spring
washer (2).
Coat threads of pins (4) and studs (2) with high-strength

thread-locking liquid.
Screw pins and studs into cooler housing.
Install drain valve (3) in cooler housing.
20038/10 E –11.95–
Page 2
Installing pressure plate

Coat jacket surface of bush (4) with petroleum jelly and,
using a plastic mallet, drive into pressure plate (3) as il-
lustrated in drawing.
Insert O-rings (2) into flange (1).
Press flange (1) as shown in illustration into pressure
plate (3), taking care not to damage screw holes.
Secure flange (1) with socket head screw (6) and spring
washer (5).
20038/10 E –11.95–
Page 1
Installing cooler housing
Secure mounting brackets (4) and (8) to crankcase with
bolts (6) and spring washers (5).
Use torque wrench to tighten to specified torque. For
Position cooler housing (1) on mounting brackets.
Using screws (2) and (7), secure washers (3) and spring
washers (5) to mounting bracket.
Using torque wrench, tighten bolts to specified torque.
Installing channel plates

Insert coolant transfer sealing rings in cooler housing.
Insert guide pins (1) and coat with petroleum jelly.
Fit channel plates (4) on guide pins in accordance with
layout and colour markings.
Note
See the nameplate on coolant expansion tank for layout.

The direction of arrow of the plate seats must point left
and then right, alternating constantly.
Push spacer sleeves (3) onto stud bolts (2).
20038/10 E –11.92–
Page 2
Installing pressure plate

Coat threads of stud bolts with engine oil.
Slide pressure plate (3) onto guide pins (1).
Coat support surfaces of threaded sleeves with thin-film
lubricant.
Secure plates in position by tightening threaded sleeves
(2) diagonally and evenly.
Tighten threaded sleeves with torque wrench to speci-
fied torque. For torque setting, see Section 1.3.
Note
The degree of pretensioning for the profile seals is deter-

mined by the spacer and threaded sleeves.
Remove guide pins (1).
20038/10 E –11.92–
Page 1
3.14.7b Coolant Thermostat (Annular Slide)
1 Cover 13 Scraper ring

2 Vent connection 14 Guide ring
3 Locking bush 15 Annular slide
4 Threaded bush
5 Spring a From engine
6 O-ring b Bypass to engine coolant pump
7 Stop pin c To coolant cooler
8 Pin d Bypass
9 Washer
10 Snap ring A At operating temperature
11 Thermostat housing B With cold engine
12 Thermal element
20038/10 E –11.95–
Page 2
Coolant thermostat
1 Thermostat housing 11 Sealing ring

2 Spring 12 Threaded bush
3 Stop pin 13 Locking bush
4 O-ring 14 O-ring
5 Spring 15 Warning plate
7 Snap ring 17 Scraper ring
8 Pin 18 Thermal element
9 Spring 19 Annular slide
10 Cover 20 Washer
20038/10 E –11.95–
Page 3
Coolant thermostat
1 Spring 12 Snap ring

2 Annular slide 13 Thermal element
3 Cover 14 Thermal element
4 Stop pin 15 Thermal element
5 Locking bush 16 Washer
6 Threaded bush 17 Spring
7 Sealing ring 18 Spring
8 O-ring 19 Pin
9 Hex bolt 20 Thermostat housing
10 Washer 21 O-ring
11 Scraper ring
20038/10 E –11.92–
Page 4
Coolant thermostat on plate-type cooler housing (annular slide thermostat)
1 Annular slide thermostat 6 Screw

2 Washer 7 Washer
3 Screw 8 O-ring
4 Plug 9 O-ring
5 Sealing ring 10 Cooler housing
20038/10 E –11.95–
Task Description Section 3.14.7b1
Page 1
3.14.7b1 Before-Removal Operations


- x x Disconnect level switch (coolant) -
20038/10 E –11.95–
Page 1
3.14.7b2 Removal
Removing securing screws (1) from annular slide ther-
mostat.
Remove annular slide thermostat from cooler housing.
Remove O-ring from thermostat.
20038/10 E –11.95–
Page 1
3.14.7b3 Disassembly
Removing governor insert
Release and remove securing screws (1) for governor
insert.
Remove governor insert (2) from housing (3).

Remove O-ring (1).
Remove scraper rings from housing.
Disassembling governor insert

Release locking bush (1) and remove from threaded
bush (2).
20038/10 E –11.95–
Page 2
Turn stop pin (1) back to stop.
Use manual press (1) to gently press in thermal element

(2).
Remove circlip (3) from groove in slide valve (4).
Remove thermal element and snap ring.
Caution
Spring tension
Remove washer (1) and spring (2) from slide valve.
20038/10 E –11.95–
Page 3
Screw stop pin into threaded bush (1) completely until

connection with threaded bush is released.
Remove pin (1) and pressure spring (2) from stop pin
(3).
Withdraw stop pin (1) from slide (2).

Remove O-ring from stop pin.
20038/10 E –11.95–
Page 4
Remove pressure spring (1) and slide (2).
Removing threaded bush from cover

Heat threaded bush (1) to approx. 250 °C and remove.
Note
Threaded bush is secured with high-strength pipe

thread sealant.
Remove threaded bush with sealing ring (2) from cover
(3).
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Page 1
3.14.7b4 Inspection and Repair

Clean all components with cold cleaner.
Check annular slide housing for indentations, wear and cavitation.
Smooth mating faces and bores as required with oilstone or polishing cloth, replace as required.
Check annular slide running surface for wear; rub down with emery cloth as required and replace if necessary.
Check slide in guide bands of thermostat housing for ease of movement.
Check condition of tapped bores; recut threads if necessary and install thread inserts as required.
Check cover, threaded bush, locking bush, stop pin, washer and pin for wear.
Rub down bolt-on and sealing surfaces with oilstone as required; replace components if necessary.
Check springs for impact marks, burrs and frictional wear; deburr areas of minor wear and replace springs if necessary.
Replace scraper rings during W6 overhaul.
Replace thermal element as required.
Replace O-rings.
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3.14.7b5 Assembly
Installing threaded bush
Coat thread of threaded bush (1) with high-strength pipe
thread sealant.
Coat friction face with long-life grease.
Insert threaded bush (1) with sealing ring (2) in cover (3)
and secure.
Assembling governor insert
Note
Before installing, check that slide valve (1) moves freely

in guides of annular slide housing.
Rotate cover (2) and insert O-ring (3) in groove on cover.
Install slide valve (1) in cover.
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Page 2
Grease support surfaces of pressure spring (1) and bore

in threaded bush evenly with long-life grease.
Insert pressure spring in slide (2).
Mount O-ring (1) on assembly sleeve (2).
Note
Always use assembly sleeve to when installing, in order

to prevent threads damaging O-rings.
Mount assembly sleeve (1) with O-ring on thread of stop
bolt (2).
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Page 3

groove in stop pin (2).
Remove assembly sleeve.
Coat stop pin (1) with long-life grease and insert in slide
(2).
Insert stop pin into threaded bush (1) until there is a

clearance of R = 5 mm +1 mm in slide valve, see illustra-
tion on page 4.
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Page 4
Clearance R = 5 mm +1 mm
Place preassembled parts in vertical position

(slide valve at top).
Insert pressure spring (2) and pin (1) in stop pin (3).
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Page 5
Insert pressure spring (2) and washer (1) in slide.
Insert thermal element (2).

Place circlip (4) in position with gap offset from groove
(6) in slide.
Mount assembly jigs (1) and (3).
Press thermal element and snap ring against spring
pressure until snap ring clicks into place in groove (5).
Caution
Spring tension
Remove assembly tool.
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Page 6
Check that circlip is seated in groove in slide.
Note
Make sure that gap of circlip is offset from recess.
Adjustment of governor insert outside housing

Screw in stop pin (1) until slide (3) starts to lift from cover
(2).
Turn back stop pin 1/2 to 1 revolution to create a gap S2

= 0.6 mm to 1.2 mm.
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Page 7
Install locking bush (1) in threaded bush (2).
Tighten locking bush.
Note
When tightening locking bush, hold already adjusted

stop pin firmly in position with Allen key (1).
Press lightly on thermal element to check gap S2 be-
tween element and stop pin.
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Page 8
Check position of slide against housing by visual inspec-

tion (see arrow).
Preassembling housing
Insert scraper rings in grooves in housing.
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Page 9
Coat housing between guide bands evenly with long-life

grease.
Installing governor insert

Introduce governor insert (2) into housing (3).
Secure governor insert with screws (1) and washers.
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Page 10
Check trip setting

Immerse annular slide thermostat in heated water bath
with thermometer.
Heat water and check thermometer reading when ther-
mostat starts to open.
Working range of thermal element: 70°C to 85°C
Trip setting: 70°C +3.2°
Ć1.6°
Bypass to intercooler closed: 80°C
Slide valve ease-of-movement check

Heat thermal element (3) to a temperature 10°C to 15°C
above the trip setting stamped on the body.
Slide valve (2) must lift at least 10 mm from stop on
cover (1).
When thermal element then cools down to 3 °C below
startĆofĆopening value, slide must return to cover.
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3.14.7b6 Installation
Insert O-ring into groove on annular slide housing and
Mount annular slide thermostat with O-ring, screws (1)
and washers on the cooler housing and tighten.
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3.14.9 Engine Coolant Chamber Pressure Testing

Install pressure-testing equipment (2) on expansion
tank.
1
Connect connecting hose (1).
Connect vent line to intercooler.
2
Remove plug from oil pan.
Note
Engine completely assembled, with plate-core heat ex-

changer and expansion tank, or raw water cooler.
L91 3218
Install pressure-testing equipment (2) on elbow of en-

gine coolant line.
Connect connecting hose (1).
Fill engine coolant chambers with treated water (cool-
ant).
Open cock on vent line until coolant emerges.
Close pressure-testing equipment on coolant expansion
tank.
Pressure-test engine with coolant at 80°C for at least
20 minutes at max. 7 bar pressure.
Check coolant transfer pipes between cylinder heads
and charge air/coolant manifolds and constant-pressure
manifold housing for leaks.
Remove drain plugs from engine oil filter connection
1 2 L91 3219 housing and oil pan and check for water discharge.
Relieve pressure.
Drain or draw off engine coolant.
Remove pressure-testing equipment.
Screw in drain plugs and tighten.
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3.15 Oil Pump

Contents
3.15.1 Engine oil pump in oil pan 6V, 8V, 12V

3.15.1.2 Removal from removed oil pan
3.15.1.2a Removal from lowered oil pan
3.15.1.5 Assembly
3.15.1.6 Installation in removed oil pan
3.15.1.6a Installation in lowered oil pan
3.15.1b Engine oil pump on intermediate frame, 12V

3.15.1b.2 Removal
3.15.1b.5 Assembly
3.15.2 Engine oil pump in oil pan, 16 V

3.15.2.2 Removal from removed oil pan
3.15.2.2a Removal from lowered oil pan
3.15.2.5 Assembly
3.15.2.6 Installation in removed oil pan
3.15.2.6a Installation in lowered oil pan
3.15.2a Engine oil pump on intermediate frame, 16V

3.15.2a.2 Removal
3.15.2a.5 Assembly
3.15.3a Engine oil suction line and delivery line with suction housing on crankcase intermediate frame, 16V
3.15.3a.2 Removal
3.15.3b Engine oil suction line and delivery line with suction basket on crankcase intermediate frame, 12V
3.15.3b.2 Removal
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3.15.4 Valve seat lubrication

3.15.4.2 Removal
3.15.4.5 Assembly
3.15.5 Pressure relief valve (15 bar)

3.15.5.2 Removal 6V, 8V, 12V
3.15.5.2a Removal, 16V
3.15.5.2b Removal with crankcase intermediate frame
3.15.5.5 Assembly
3.15.5.6 Installation 6V, 8V, 12V
3.15.5.6a Installation, 16V
3.15.5.6b Installation with crankcase intermediate frame
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Page 3

A
S4
S 5.12
S 6.11
S 6.15
S 6.19
Puller for gears

Extractor
Manual press
Assembly tool for pressure relief valve

Oil pressure gauge
Magnifier
Liquid nitrogen
Engine oil
Cleaner P3 Solvclean 40022
Thread-locking paint RAL 4001 red/lilac 40664

Caution
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Page 1
3.15.1 Engine Oil Pump in Oil Pan, 8V, 12V
1 Oil pump 4 Plate (only for 12V)

2 Spring washer 5 Dowel pin
3 Screw 6 Screw
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Page 2
Engine oil pump, 8V, 12V
1 Oil pump housing 8 Drive gear

2 Oil pump cover 9 Thrust washer
3 Pump gear 10 Screw
4 Pump gear 11 Shroud
6 Screw 13 Screw
7 Woodruff key
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Page 3
Engine oil pump, 8V, 12V
1 Bearing bush 8 Spring washer

2 Screw 9 Screw
3 Oil pump housing 10 Shroud
4 Drive shaft 11 Drive gear
5 Bearing bush 12 Woodruff key
6 Secondary shaft 13 Thrust washer
7 Cover
Tooth width, items 4 and 6

8V = 79.9 mm
12V = 99.8 mm
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Page 4
Suction and delivery line, 8V, 12V
1 Suction line 7 Elbow

3 Tab washer 9 Screw
4 Screw 10 Pressure relief valve, 15 bar
Length of item 5
8V = 435 mm
12V = 327 mm
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Arrangement of oil pump in oil pan
1 Oil pump 4 Elbow

2 Suction line 5 Pressure relief valve
3 Delivery line (plug-in pipe) 6 Oil pan
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- x - Disconnect engine from gearbox and alternator -
- x x Remove elbow from free end cover and oil pan 3.4.1.2
- x x Remove oil pressure lines and elbow from oil pan to oil heat exchanger,
carrier housing and exhaust turbocharger 3.16.1.2
- x x Remove engine oil heat exchanger 3.16.2.2
- x x Remove electric starter (equipment-specific) 3.18.5.2
- x x Remove air starter (equipment-specific) 3.18.4.2
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3.15.1.2 Removal from Removed Oil Pan

Removing suction and delivery lines
Remove pressure relief valve, see 3.15.5.2.
Remove screws from elbow (2).
Pull delivery line (1) from engine oil pump.
Pull elbow out of delivery line.
Remove O-ring.
Release and remove screws on suction basket (3).
Pull suction line (4) out of engine oil pump.
Remove O-ring.
Removing oil pump

Remove idler gear, see 3.2.2.2.
Use socket wrench (2) to remove screws.
Remove engine oil pump (1) from oil pan.
Remove plate (only 12 V) from locating pins.
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3.15.1.2a Removal from Lowered Oil Pan

Lowering oil pan
Oil pan must be lowered at least 200 mm.
Install lowering appliances (1) at four corners of oil pan.
Remove all bolts securing oil pan.
Remove cover at free end.
Using four ratchets, evenly lower oil pan at all four
points.
Take care not to damage seal (2).
Removing delivery line

Remove screws from elbow (2).
Remove elbow with delivery line (1) from oil pump.
Remove O-ring.
Removing suction line

Release and remove bolts from suction strainer of suc-
tion line (1).
Withdraw suction line from oil pump.
Remove O-ring.
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Removing oil pump and idler gear

Remove bolts securing oil pump (2) with ratchet wrench
(1).
Remove locknut (1) from idler gear with ratchet wrench

(2).
In so doing, hold stress bolt in position with open-end
wrench (46 mm A/F).
Release idler gear (1) and bearing pin from oil pan using
pry bar or puller.
Release oil pump (2) from both dowel pins and remove
together with idler gear.
Note
The oil pump can only be removed simultaneously with

the idler gear.
Withdraw idler gear and bearing pin from oil pan.
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Before removing oil pump (1) from oil pan, detach

shroud from oil pump.
Remove oil pump from oil pan.
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Removing shroud
Remove screws (2).
Remove shroud (1) from engine oil pump (3).
Removing drive gear

Secure engine oil pump in assembly jig.
Secure drive gear with retaining jig (2).
Remove bolt from drive gear with socket wrench and ex-
tension (1).
Detach drive gear from drive shaft with puller.
Removing cover
Remove engine oil pump from assembly jig.
Unscrew bolts (1) securing cover (2) to oil pump housing
(3).
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Removing drive and secondary shafts

Remove Woodruff key from drive shaft.
Detach cover (1) with dowel pin (3) from oil pump hous-
ing (2).
Remove drive shaft (2) and secondary shaft (1) from

pump housing (3).
4 = Mating faces of oil pump against oil pan.
Note
Insert oil pump gears in transport trestles.

Protect against damage.
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Page 1

Using the magnetic crack-testing method and fluorescent magnetic powder, check the drive and secondary shafts for
Use red penetrant dye to surface crack-test oil pump housing.If cracks are detected, replace parts.
Check drive shaft, secondary shaft and drive gear.
Check tooth flanks for wear, indentations and chipping.
Check bearings for wear, scoring and indentation.
Check taper on drive shaft for wear and scoring.
Check key groove for pitting and thread for ease of movement.
Remove minor wear, indentation and scoring with emery cloth or oilstone, replace components as necessary.
Check oil pump housing for wear; recondition minor wear.
In event of wear marks deeper than 0.3 mm in oil chamber of pump housing, replace oil pump housing.
Check sealing and mating faces for evenness.
Check cover and shroud for evenness on installation surface.
Check plug-in pipe locating bores for evidence of wear and box to MTU specifications as required.
Check bearing bushes in housing and cover for scoring and indentations; replace as part of every W6 overhaul.
Adjust bore gauge and measure bearing bush bore in oil pump housing and cover.
Measure bearings on drive and secondary shafts with outside micrometer.
Check connecting points of plug-in pipe and suction line for wear and rub down as required.
Check locating bore for plug-in pipe and thread for pressure relief valve on elbow.
Rechase thread as necessary, smooth bore and replace components as necessary.
Check whether suction strainers are clean.
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Replacing bearing bushes

Press bearing bush (3) out of oil pump housing and
cover using extractor (2).
Adjust bore gauge.
Measure bearing bush bore in oil pump housing and
cover.
List.
Chill new bearing bush in liquid nitrogen and, using suit-
able installation tool, press into oil pump housing and
cover at right angles.
Note

tions in 1.5.
Installation position of bearing bush and dowel pin

in oil pump cover 6V, 8V and 12V.
The bearing bushes (1) should have a clearance of 5
±
mm 0.5 mm opposite the mating face of the oil pump
cover.
The dowel pin (2) should have a projection of 9 mm -1
mm opposite the mating face of the oil pump cover.
Installation position of bearing bush in oil pump

housing 6V, 8V, 12V
There must be a clearance (measurement A) between
bearing bushes (2) and pump chamber.
Dimension A:
6V = 5 mm ± 0.5 mm
8V = 4 mm ± 0.5 mm
12V = 5 mm ± 0.5 mm
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3.15.1.5 Assembly
Installing drive and secondary shafts
Clean parts.
Spray oil pump gears (1) and (2) with engine oil and in-
stall in pump housing (3).
Note
Insert drive shaft with taper (2) into pump housing oppo-
site supports (4), as shown in illustration.
Installing cover
Ensure that contact surfaces of pump housing (2) and
cover (3) are clean.
Coat bearing bushes in cover (1) with engine oil.
Position cover on pump housing until dowel pins are cor-
rectly engaged.
Using torque wrench, tighten hex bolts with spring
washers to specified torque. For torque setting, see
Section 1.3.
It must be possible to turn the pump by hand without
feeling resistance.
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Page 2

Dry and degrease taper surfaces.
Insert Woodruff key into taper.
Place drive gear (1) on taper of drive shaft.
Using feeler gauge, check that Woodruff key play is
0.1 mm.
Coat bolt thread with engine oil and fit washer.
Secure drive gear with retaining jig.
Install bolt with thrust washer (2) in drive shaft and
tighten with torque wrench to specified torque. For
Remove oil pump from assembly jig.
Installing shroud
Install and secure shroud (1) to pump housing (3) with
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3.15.1.6 Installation in Removed Oil Pan

Installing oil pump
Clean mating surfaces and rub down irregularities with
oilstone.
Install shim plate (12 V version only) on locating pins.
Install oil pump (3) in oil pan (1) and locate on dowel pins.
Secure oil pump with bolts and spring washers and
tighten with torque wrench (2) to specified torque. For
Installing suction and delivery lines

Insert new O-ring (2) into groove of intake line (3) and
H.P. fuel line and coat with petroleum jelly.
Install suction line with O-ring in oil pump (1).
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Page 2
Secure suction line (4) with bolts and tab washers to oil
pan.
Tighten bolts on suction strainer (3) with torque wrench
to specified torque. For torque setting, see Section 1.3.
Insert H.P. fuel line (1) with new O-ring into engine oil
pump.
Tighten elbow (2) with bolts and spring washers with
torque wrench to specified torque. For torque setting,
see Section 1.3.
Installing pressure relief valve in elbow, see 3.15.5.6.
Install oil pump idler gear, see 3.2.2.6.
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Page 1
3.15.1.6a Installation in Lowered Oil Pan

Check dowel pins (2) for locking oil pump for damage
and replace as required.
Coat thread of stress bolt (1) for pump idler gear with en-
gine oil.
Note
Remove shroud from oil pump before installing pump.

Position engine oil pump (1) in oil pan.
Mount shroud on oil pump in oil pan with bolts and spring
washers and tighten.
Fit idler gear (1) with bearing pin and oil pump simulta-
neously in oil pan.
Pay attention to dowel pins.
Do not bend bearing pin in oil pan bore during installa-
tion.
Force bearing pin into inner race of angular-contact ball
bearing using drift.
Seat bearing pin in oil pan by means of locknut.
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Page 2
Tighten locknut (1) with torque wrench (2) to specified

Tighten bolts in oil pump (2) with torque wrench (1) to

Insert suction line (1) with new O-ring into oil pump.
Tighten and secure suction strainer to oil pan with bolts
and tab washers.
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Page 3
Coat O-rings with petroleum jelly and insert into grooves

of H.P. fuel line (1).
Install delivery line and tighten elbow (2) with bolts and
washers as specified in Section 1.3.
Check seal (2) for damage; fit new seal in oil pan if
necessary.
To ensure driving end is sealed correctly in the range of
bore dia. 360 H8 on oil pan and crankcase, coat both
sides of gaskets with sealing paste.
Raise oil pan by means of four lowering appliances (1).
Note

Install all bolts (note markings) with washers in oil pan
and pretighten.
Washers with larger inside diameters must be fitted with
two long bolts provided with collars.
Tighten bolts in oil pan to specified torque. For torque
Note

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Page 1
3.15.1b Engine Oil Pump on Intermediate Frame, 12V
1 Oil pump 4 Screw

2 Dowel pin 5 Screw
3 Washer
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Page 2
Engine oil pump on intermediate frame, 12V
1 Oil pump housing 9 Woodruff key

2 Bearing bush 10 Drive gear
4 Pump gear 12 Thrust washer
5 Cover 13 Screw
6 Bearing bush 14 Shroud
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Page 3
1 Bearing bush 10 Spring washer

2 Oil pump housing 11 Screw
3 Pump gear 12 Shroud
4 Pump gear 13 Woodruff key
5 Dowel pin 14 Screw
6 Spring washer 15 Thrust washer
7 Screw 16 Drive gear
8 Bearing bush
9 Cover K Final digits of component number
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Page 4
1 Oil pump housing 6 Shroud

2 Oil pump gear of drive shaft
3 Oil pump gear of countershaft a Oil inlet
4 Cover b Oil outlet
5 Drive gear
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Page 1


carrier housing and centrifugal oil filter 3.16.1.2
- x x Remove oil pan 3.1.6a.2
- x x Remove engine oil intake and delivery lines 3.15.3a.2
20046/20 E –07.96–
Page 1
3.15.1b.2 Removal
Removing oil pump
Unscrew securing screws (3), (4) on engine oil pump (1)
with socket from crankcase intermediate frame and re-
move together with washers (2).
Press engine oil pump (1) with pry bar off dowel pins (5)
on crankcase intermediate frame and remove.
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Removing shroud
Remove screws (2) on cover.
Remove shroud (1) from engine oil pump (3).
Removing drive gear

Secure drive gear against turning with retaining unit (2).
Unscrew screw (1) on drive gear and remove with thrust
washer.
Remove drive gear from drive shaft with puller.
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Page 2
Removing cover
Unscrew bolts (1) securing cover (2) to oil pump housing
(3).

Lift cover (1) with dowel pin (3) from oil pump housing
(2).
Removing drive and secondary shafts

Withdraw drive shaft (1) and secondary shaft (3) from
pump housing (2).
Note

20046/20 E –07.96–
Page 1

Using the magnetic crack-testing method and fluorescent magnetic powder, check the drive and secondray shafts for
Use red penetrant dye to surface crack–test oil pump housing.If cracks are detected, replace parts.
Check oil pump gears and drive gear.
Inspect sealing and contact surfaces for irregularities; rub down as required.
Inspect contact surface of cover for irregularities and rub down as required.
Recut threads as required and install thread inserts if necessary.
Replace components as required.
20046/20 E –07.96–
Page 2

Press bearing bush (3) out of oil pump housing and
cover using hand press (1) and extractor (2).
Adjust bore gauge and measure bearing bush bore in oil
pump housing and cover.
List.
Chill new bearing bush in liquid nitrogen and, using suit-
Caution

tions in 1.5.

in oil pump cover
The bearing bushes (2) and (3) should have a clearance
±
”A” of 5 mm 0.5 mm opposite the mating face of the oil
pump cover.
The dowel pins (1) should have a projection ”B” of 9
mm -1 mm opposite the mating face of the oil pump
cover.

housing
The bearing bushes (2) should have a clearance (di-
±
mension A) of 4 mm 0.5 mm opposite the pump
chamber.
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Page 1
3.15.1b.5 Assembly
Clean parts.
Spray pump gears (1) and (3) with engine oil and install
in pump housing (2).
Ensure that drive shaft is installed correctly (see illustra-
tion).
Installing cover
Ensure that contact surface of pump housing (2) and
Coat bearing bushes in cover with engine oil.
Fit cover on oil pump housing so that dowel pins (3) en-
gage in bore.
Mount screws (1) and spring washers on cover (2) and

insert in oil pump housing (3).
Tighten with torque wrench to specified torque. For
Insert Woodruff key (3) in groove in drive shaft.
Check ease of movement of oil pump.
Note

feeling resistance.
20046/20 E –07.96–
Page 2

Dry and degrease taper surfaces.
0.1 mm.
Coat thread of screw with engine oil and fit thrust washer
(2).
Install screw (3) and thrust washer in drive shaft.
Secure drive gear against turning with retaining unit (2).

Tighten screw on drive gear with torque wrench (1) to
Installing shroud
Install and secure shroud (1) to pump housing (3) with
20046/20 E –07.96–
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Installing oil pump
Rub down contact surfaces of intermediate frame and
oil pump with oilstone and clean.
Insert dowel pins (2) into bores in oil pump housing.
Position engine oil pump (1) on intermediate frame in
such a way that the dowel pins engage the bores.
Coat screws (3) and (4) with engine oil and insert with
washers (5) in crankcase intermediate frame.
Tighten securing screws with torque wrench to tighten-
Measuring backlash
Mount dial gauge holder with dial gauge (1) on inter-
mediate frame.
Use screwdriver to lock oil pump idler gear (3).
Position dial gauge with preload on tooth profile of oil
pump drive gear (2).
Measure backlash.
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3.15.2 Engine Oil Pump in Oil Pan, 16 V
1 Oil pump
2 Spring washer
3 Screw
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Engine oil pump in oil pan, 16V
ET 15 285 2
1 Oil pump housing 9 Woodruff key

2 Cover 10 Drive gear
5 Pump gear 13 Connecting housing
7 Screw 15 Screw
8 Screw
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Page 3
Engine oil pump, 16 V
1 Drive gear 9 Cover

2 Pump gear 10 Bearing bush
3 Pump gear 11 Bearing bush
4 Oil pump housing, 16V 12 Screw
5 Screw 13 Woodruff key
6 Spring washer 14 Thrust washer
7 Connecting housing 15 Screw
8 Pump gear
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Page 4
Suction and delivery line, 16V
ET 15 286
1 Suction line 10 O-ring

2 Connecting line 11 Spring washer
3 O-ring 12 Screw
4 Tab washer 13 Sealing ring
5 Screw 14 Plug
6 Spring washer 15 Pressure relief valve, 15 bar
7 Screw 16 O-ring
8 Oil line (delivery line) 17 Sealing ring
9 Connecting line
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Page 5
Arrangement of oil pump in oil pan
1 Oil pump 3 Oil pan

2 Delivery line 4 Suction line
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carrier housing and exhaust turbocharger 3.16.1.2
- x x Remove engine oil filter 3.16.3.2
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3.15.2.2 Removal from Removed Oil Pan

Unscrew bolts from delivery line (2) in oil pan with socket
wrench (1).
Remove delivery with connecting line from connecting
housing of engine oil pump.
Remove O-rings from connecting line.

Release and remove bolts (3) from suction strainer.
Remove bolts (2) from bracket of suction line (1).
20038/10 E –11.92–
Page 2
Remove suction line (3) with connecting line (2) from

connecting housing (1) of engine oil pump.
Remove O-ring from connecting line.
Removing oil pump

Removing idler gear for oil pump drive, see 3.2.2.2.
Remove bolts securing engine oil pump (2) with socket
wrench (1).
Force oil pump off dowel pins with pry bars and remove
from oil pan.
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3.15.2.2a Removal from Lowered Oil Pan

Lowering oil pan
Oil pan must be lowered at least 240 mm.
Install lowering appliances (1) at four corners of oil pan.
Remove all bolts securing oil pan.
Remove cover at free end.
Using four ratchets, evenly lower oil pan at all four
points.
Take care not to damage seal (2).
Removing idler gear

Unscrew stress bolt (5) from bearing pin.
In so doing, hold locknut (10) in position with open-end
wrench.
To force bearing pin (4) out of oil pan (8), install an as-
sembly screw in centre of locknut.
Force idler gear (1) off oil pan using puller.
Remove assembly screw and puller.
1 Idler gear
2 Snap ring
4 Bearing pin
5 Stress bolt
6 Washer
7 Washer
8 Oil pan
9 O-ring
10 Clamping nut
20038/10 E –11.92–
Page 2

Unscrew bolts from delivery line (3) in oil pan with socket
wrench (2).
Remove delivery line with connecting line (1) from con-
necting housing of engine oil pump.
Remove O-rings from connecting line.

Release and remove bolts (3) from suction strainer.
Remove bolts (2) from bracket of suction line (1).
20038/10 E –11.92–
Page 3
Remove suction line (3) with connecting line (2) from

connecting housing (1) of engine oil pump.
Remove O-ring from connecting line.
Removing oil pump

Remove connecting housing (3) from oil pump (2).
Unscrew bolts securing oil pump with socket wrench (4).
Force engine oil pump off dowel pins with pry bars.
Remove idler gear (1) and oil pump simultaneously from
oil pan.
Note
Rotate the crankshaft with the barring tool so that the en-
gine oil pump can be removed from between the inter-
mediate frame and the oil pan.
20038/10 E –11.92–
Page 1
Remove connecting housing (1) from oil pump housing.
Remove bolt (1) from drive gear (3).

Remove washer (2).
Unscrew bolts securing cover (1) to pump housing (2).
20038/10 E –11.92–
Page 2
Remove cover (1) from pump housing (2).
Withdraw pump gears (1), (2) and (3) from pump hous-
ing (4).
Note

20038/10 E –11.92–
Page 1

Use red penetrant dye to surface crack-test oil pump housing.
Check drive shaft, secondary shaft and drive gear.
Check contact surface of cover for irregularities and rub down if necessary.

Press bearing bush out of oil pump housing and cover using extractor.
Chill new bearing bush in liquid nitrogen and, using suitable installation tool, press into oil pump housing and cover at
right angles.
Caution
When using liquid nitrogen, observe the Safety Instructions in 1.5.
20038/10 E –11.95–
Page 2

in oil pump cover 16V
The bearing bushes (3) should have a clearance of ”A”
±
= 5 0.5 mm opposite the mating face of the oil pump
cover (1).
The dowel pin (2) should have a projection of ”B” = 9 -1
mm opposite the mating face of the oil pump cover.

housing 16 V
The bearing bushes (2) should have a clearance of 5 ±
0.5 mm opposite the pump chamber in the housing (1).
20038/10 E –11.92–
Page 3
Pump curve - lube oil pump

Operating conditions:
Overpressure after pump 10 bar
Oil viscosity SAE 30
Oil temperature 80 °C
Delivery volume flow
(rpm)
Pump speed
20038/10 E –11.95–
Page 1
3.15.2.5 Assembly
Spray pump gears (1), (2) and (3) with engine oil.
Install in oil pump housing (4) as shown in adjoining il-
lustration.
Ensure that drive shaft (1) is correctly installed.
Installing cover
Check whether contact surfaces of oil pump housing
and cover are clean.
Position cover (1) on pump housing (2) so that dowel
pins are correctly engaged.
Tighten bolts and spring washers with torque wrench to
feeling resistance.
20038/10 E –11.92–
Page 2

Dry and degrease taper surface on drive shaft (2).
Insert Woodruff key (1) into taper.
Dry and degrease taper in drive gear (3).

Position drive gear on drive shaft taper.
Check key clearance with feeler gauge (specified clear-
ance: 0.1 mm).
Coat thread of bolt (1) with engine oil.
Screw bolt with thrust washer (2) into drive shaft.
Tighten bolt to secure drive gear (1) with torque wrench

to specified torque. For torque setting, see Section 1.3.
20038/10 E –11.92–
Page 3
Install stop housing (1) with screws and spring washers

on oil pump housing.
Tighten with torque wrench to specified torque. For
20038/10 E –11.92–
Page 1
3.15.2.6 Installation in Removed Oil Pan

Installing oil pump
Rub down mating surfaces of oil pan and engine oil
pump with oilstone and clean.
Install engine oil pump (2) in oil pan so that dowel pins
engage bores.
Coat securing bolts with engine oil and install with spring
washers in oil pan.
fication 1.3.
Installing suction line

Insert O-rings into grooves of connecting line (2) and
Insert connecting line into engine oil pump (1).
Insert intake line (3) into connecting line.
20038/10 E –11.95–
Page 2
Screw bolts (2) and tab washers into suction strainer.

Screw bolts into bracket of suction line (1).
Tighten all bolts with torque wrench to specified torque.
Secure bolts with tab washers.
Installing delivery line

Insert O-rings into grooves of connecting line for delivery
line (2) and coat with ”petroleum jelly”.
Insert connecting line into oil pump.
Connect delivery line to connecting line.
Using torque wrench (1), secure delivery line by tighten-
ing oiled bolts and spring washers to specified torque.
20038/10 E –11.95–
Page 1
3.15.2.6a Installation in Lowered Oil Pan

Coat thread of stress bolt (5) with engine oil.
Install bearing pin with new O-ring (9).
Installing idler gear with bearing pin (4), see 3.2.2.6
Tighten stress bolt (5) with torque wrench to specified
1 Idler gear
2 Snap ring
4 Bearing pin
5 Stress bolt
6 Washer
7 Washer
8 Oil pan
9 O-ring
10 Clamping nut
Note
Remove connecting housing (1) before installing oil

pump.
Check dowel pin for locating oil pump for damage.
Install engine oil pump (2) in oil pan so that dowel pins
engage bores.
Coat securing bolts with engine oil and install with spring
washers in oil pan.
Tighten with torque wrench to specified torque.
Mount and secure connecting housing (1) to oil pump
with bolts and spring washers.
20038/10 E –11.92–
Page 2

Insert connecting line into engine oil pump (1).
Insert intake line (3) into connecting line.
Screw bolts (3) and tab washers into suction strainer of

suction line.
Install bolts (2) to secure suction line (1).
Secure bolts on suction strainer.
20038/10 E –11.95–
Page 3

Insert connecting line into oil pump.
Insert delivery line (3) in connecting line.
Using torque wrench (2), secure delivery line by tighten-
ing oiled bolts and spring washers to specified torque.
Installing oil pan

Check seal (2) for damage; fit new seal on oil pan if
necessary.
To ensure driving end is sealed correctly, in the range of
bore dia. 360 H8 on oil pan and crankcase, coat both
sides of gaskets with sealing paste.
Operate ratchet wrenches (1) on left and right sides of
engine to position oil pan on crankcase.
Screw bolts with washers into oil pan.
Note
Pay special attention to markings and differing bolt

lengths.
Note

20038/10 E –11.95–
Page 1
3.15.2a Engine Oil Pump on Intermediate Frame, 16V
1 Secondary shaft 7 Thrust washer

2 Bearing bush 8 Drive gear
4 Oil pump housing a Oil inlet
5 Drive shaft b Oil outlet
6 Cover
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Page 2
1 Oil pump housing 9 Drive gear

4 Pump gear 12 Connecting housing
7 Screw 15 Screw
8 Woodruff key
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Page 3
1 Bearing bushes 7 Thrust washer

2 Oil pump housing 8 Screw
3 Pump gear 9 Pump gear
4 Oil pump cover 10 Pump gear
5 Drive gear 11 Screw
6 Screw
20054/00 E –10.93–
Page 1


- x x Remove elbow and end cover, free end 3.4.1.2
from carrier housing and centrifugal oil filter to oil pan 3.16.1.2
- x x Remove engine oil intake and delivery lines 3.15.3.2
20046/20 E –07.96–
Page 1
3.15.2a.2 Removal
Use socket and ratchet (1) to remove securing screws
from engine oil pump (2) on crankcase intermediate
frame.
Using pry bars, ease engine oil pump off dowel pins in
intermediate frame.
20054/00 E –10.93–
Page 1
Clamp engine oil pump in assembly jig.
Secure drive gear (1) against turning with retaining jig.
Remove bolt from drive gear.

Unscrew bolts from cover (1).
Remove with spring washers.
Remove cover (1) from dowel pin in oil pump housing.
20038/10 E –11.92–
Page 2
Withdraw pump gears (1) from pump housing.
Note

Unscrew connecting housing (1) from engine oil pump

and remove.
20038/10 E –02.95–
Page 1

Use red penetrant dye to surface crack-test oil pump housing.If cracks are detected, replace parts.
Check oil pump gears and drive gear.
Inspect contact surface of cover for irregularities and rub down if necessary.
Press bearing bush out of oil pump housing and cover
using mandrel (1).
Adjust bore gauge and measure bearing bush bore in oil
pump housing and cover.
1 Chill new bearing bush in liquid nitorgen and, using suit-
Caution

L87 8870.a
tions in 1.5.
20038/10 E –02.95–
Page 2

in oil pump cover 16V
The bearing bushes (1) should have a clearance of ”A”
±
= 5 0.5 mm opposite the mating face of the oil pump
cover (2).
The dowel pin (3) should have a projection of ”B” = 9 mm
–1 mm opposite the mating face of the oil pump cover.
Installation position of bearing bushes in oil pump

housing 16 V
The bearing bushes (2) should have a clearance ”A” =
±
5 mm 0.5 mm opposite the pump chamber in housing
(1).
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Page 1
3.15.2a.5 Assembly
Clean parts.
Spray oil pump gear (1) with engine oil and insert into oil
pump housing.
Spray drive shaft with gear (1) with engine oil and insert
in oil pump housing (2).
Make sure drive shaft is installed properly as shown in
illustration.
Coat oil pump shaft (1) with engine oil and insert into oil
pump housing.
20038/10 E –11.92–
Page 2
Check that support surfaces on oil pump housing and

Place cover on oil pump housing so that dowel pins en-
gage.
Install screws with spring washers in oil pump housing.

feeling resistance.

Clean and degrease taper faces.
Install Woodruff key in keyway in drive shaft.
0.1 mm.
Coat thread of screws with engine oil and fit thrust
washer.
Install screw with thrust washer in drive shaft.
Using torque wrench (1) tighten as per Tightening Spec-
ification 1.3.
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Page 3
Install stop housing (1) with screws and spring washers

on oil pump housing.
20038/10 E –11.92–
Page 1
Smooth and clean mating faces on crankcase inter-
mediate frame and engine oil pump with oilstone.
Insert dowel pins into bores in oil pump housing.
Position engine oil pump (2) on intermediate frame in
such a way that the dowel pins engage the bores.
Coat screws with engine oil and install in intermediate
frame.
Using torque wrench (1) and socket, tighten as per
Tightening Specification 1.3.
Mount dial gauge holder with dial gauge (1) on inter-

mediate frame.
Use screwdriver to lock oil pump idler gear (3).
Set dial gauge with preload and bring stylus into contact
with edge of tooth of oil pump drive gear (2).
Measure backlash.
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3.15.3a Engine Oil Suction Line and Delivery Line with Suction Housing on
Crankcase Intermediate Frame, 16 V
1 Oil pump 12 Suction housing

2 Washer 13 Strainer
3 Hex screw 14 Tab washer
4 Dowel pin 15 Hex screw
5 Suction line 16 Tab washer
6 Connecting line (L=105 mm) 17 Hex screw
7 O-ring 18 Connecting line (L=105 mm)
8 Washer 19 O-ring
9 Hex screw 20 Washer
10 Connecting line (L=105 mm) 21 Hex screw
11 O-ring 22 Delivery line
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20046/20 E –07.96–
Page 1
3.15.3a.2 Removal
Removing suction housing
Release and remove bolts securing suction housing (1).
Remove suction housing from oil pan.
Remove strainer.

Release screws securing suction line (1) and remove.
Remove suction line (1) with connecting line (2) from in-
termediate frame and oil pump.
Detach connecting line (3) from suction line.
20054/00 E –02.95–
Page 2

Release screws securing delivery line (1) and remove.
1
1
L879348/1
Remove delivery line (1) with connecting line (2) from in-
termediate frame and oil pump.
20054/00 E –02.95–
Page 1

Using the surface crack-testing method and red penetrant dye, check delivery lines and suction lines for cracks.
Replace component if cracks are found.
Check bores in delivery line and suction line and suction housing for wear.
Check connecting lines in area of grooves for O-rings for wear.
Replace components if wear marks are severe.
Check locating bore for connecting line and thread on suction housing.
Rechase thread as necessary, smooth bore and replace component as necessary.
Clean suction housing and strainer; replace as required.
Replace O-rings.
20038/10 E –11.92–
Page 1
Installing suction housing
Install strainer on suction housing with bolts and tab
washers.
Tighten and secure bolts.
Insert suction housing (1) with screws and tab washers
in oil pan.
Tighten and secure bolts.

Insert O-rings (1) in grooves in connecting line (2).
Note
Ensure that connecting line is of correct length

(105 mm).
Insert delivery line (1) with connecting line (2) into oil
pump.
20054/00 E –07.96–
Page 2
Mount delivery line (1) with screws and washers on inter-

mediate frame.
Using torque wrench, tighten and secure bolts to speci-
1
1
L879348/1

Insert suction line (1) with connecting line (2) into oil
pump.
Note
Ensure that connecting line is of correct length

(105 mm).
Connect connecting line (3) to suction line.
A new-style connecting line can only be installed in con-
junction with a new-style suction housing.
Mount intake line (1) with screws and washers on inter-

mediate frame.
Oil pan installation, see 3.1.5.6
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Page 1
3.15.3b Engine Oil Suction Line and Delivery Line with Suction Basket on
Crankcase Intermediate Frame, 12V
1 Oil pump 10 Connecting line

2 Washer 11 O-ring
3 Screw 12 Plug-in pipe (L = 308 mm)
4 Screw 13 O-ring
5 Dowel pin 14 Elbow
6 Suction line with suction basket 15 Washer
7 Tab washer 16 Screw
8 Screw 17 Elbow
9 Screw
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20046/20 E –07.96–
Page 1
3.15.3b.2 Removal
Release tab washers (4) on screws (2).
Remove bolts securing suction line (1).
Remove suction line and connecting line (3) from inter-
mediate frame and oil pump.
Remove O-rings (5).
Unscrew screws (3) on elbow (1) and remove together

with washers (2).
Remove elbow.
Remove plug-in pipe (5) from elbow (6).
Remove O-rings (4).
Unscrew screws (3) on elbow (6) and remove together
with washers (2).
Remove elbow.
Remove plug-in pipe (5) from engine oil pump (7).
Remove O-rings (4).
20046/20 E –07.96–
Page 1

Using the surface crack-testing method and red penetrant dye, check delivery lines and suction lines for cracks.
Replace component if cracks are found.
Check bores in delivery and suction lines and elbows for wear and indentations; rub down as required.
Inspect connecting lines in area of O-ring grooves for wear; rub down as required.
Replace components if wear marks are severe.
Check condition and cleanliness of suction baskets and, replace as necessary.
Replace O-rings.
20046/20 E –07.96–
Page 1
Insert O-rings (4) into grooves of plug-in pipe (5) and
Insert plug-in pipe with O-ring into engine oil pump (7);
when doing so, do not twist or damage O-ring.
Fit elbow (6) on plug-in pipe; in doing so, do not twist or
damage O-ring.
Mount elbow (6) with screws (3) and washers on inter-
mediate frame.
Insert O-ring (4) into grooves of plug-in pipe (5) and coat
Fit elbow (1) on plug-in pipe; in doing so, do not twist or
damage O-ring.
Mount elbow with screws (3) and washers (2) on inter-
mediate frame.
Insert O-rings (5) into groove of link (3) and coat with pe-
troleum jelly.
Connect connecting line to suction line (1).
Insert link with O-ring into engine oil pump.
Do not twist or damage O-ring.
Mount suction line on intermediate frame with bolts (2)
and tab washers.
Secure bolts with tab washers.
20046/20 E –07.96–
Page 1
3.15.4 Valve Seat Lubrication
1 Cover with emergency air shut-off flaps 4 Lube oil pump

2 Oil spray nozzle 5 Camshaft
3 Air outlet to manifold 6 Drive flange
20042/10 E –10.94–
Page 2
Valve seat lube oil pump
1 Drive flange 5 Lube oil pump

4 Housing 8 Hex screw
20042/10 E –10.94–
Page 3
Lube oil pump
1 Housing 15 Adjusting screw

2 Plunger 16 Stop pin
3 Cam plate 17 Helical compression spring
4 Driver 18 Sealing ring
5 Spring pin 19 Plug
6 Adjusting shim 20 Bearing bush
7 O-ring 21 Pump shaft
8 Cover 22 Washer
9 Circlip 23 Needle bush
10 Plug 24 Socket-head screw
12 Helical compression spring 26 Screw
13 Pin 27 Tab washer
14 O-ring
20042/10 E –10.94–
Page 4
Lube oil pump
1 Coil spring 15 Screw

2 Notched bolt 16 Tab washer
3 Adjusting screw 17 Washer
4 O-ring 18 Needle bushing
X= clearance 0,003 mm to 0,007 mm of the
5 Plug 19 Bearing bushing
power piston and the pump body
6 Sealing ring 20 Lube oil pump shaft
7 Stop bolt 21 Coil spring
Y= axial clearance 0,05 mm to 0,20 mm of the
8 Housing 22 Power piston
lube oil pump
9 O-ring 23 Adjusting shim
10 Cap 24 Eccentric disc
11 Plug 25 Spring pin
12 Sealing ring 26 Driver
13 Sealing ring 27 Snap ring
14 Plug
20042/10 E –10.94–
Page 1


- x x Remove oil supply lines from charge air manifold to lube oil pump 3.16.1.2
20038/10 E –11.92–
Page 1
3.15.4.2 Removal
Remove lube oil pump (1) with intermediate housing (2)
from camshaft end, right side.
Detach lube oil pump from intermediate housing and re-
move O-ring.
Remove drive flange (1) from camshaft.
20038/10 E –11.92–
Page 1
Release tab washers (12).
Remove screws (14).
Remove cover (13).
Remove O-ring (3) from housing (5).
Remove adjusting screw (23), plug (21) with compres-
sion spring (22) and locking bolt (20).
Remove O-ring (1) from adjusting screw.
Remove snap ring (2) from cover.
Pull plunger (18) with cam plate (19) and driver (4) out
of housing.
Remove screw (15), compression spring (16) and stop
pin (17) from lower section of housing.
Remove screw (8).
Remove lube oil pump shaft (6) with bearing bush (7),
taking care not to damage washers (9) and (10).
Remove needle bush (11).
A = axial play of lube oil pump shaft

X = clearance of plunger
20042/10 E –10.94–
Page 1

Using the magnetic crack-testing procedure and fluorescent magnetic powder check plunger with cam plate and driver,
as well as lube oil pump shaft for cracks ; if necessary replace parts.
Inspect oil pump housing for wear; rub down with oilstone as required and replace if necessary.
Check clearance between housing bore and plunger shaft.
Clearance must be between 0.003 mm and 0.007 mm.
Note
Oil pump housing and plunger must not be replaced individually, as both parts must be matched.
Inspect drive flange and journal of lube oil pump shaft for wear and indentations; rub down as required and replace if
necessary.
Check drive shaft and plunger for signs of wear; if necessary, polish with emery cloth, or replace.
Check bearing bush and coil springs for wear; replace as required.
Check stop pin, adjusting screw and pin for wear; replace as required.
Replace sealing rings and needle bush.
Inspect sealing surfaces of cover for wear; rub down as required and replace cover if necessary.
Replace O-rings and sealing rings.
Checking operation of lube oil pump
Mount lube oil pump on test stand. Check flow rate and inspect for leaks.
Delivery quantity per outlet 0.7 cm3/min ±0.1 cm3/min at:
- Pump speed 1300 rpm
- Supply pressure 6 bar
- Back pressure 1.3 bar
- Temperature 100 °C
- Test oil SAE 30
If specified flow rate is not achieved, turn adjusting screw one notch clockwise or counterclockwise; replace lube oil
pump if necessary.
- Turn adjusting screw counterclockwise to increase the delivery rate
- Turn adjusting screw clockwise to decrease the delivery rate
Secure adjusting screw with locking paint.
20042/10 E –10.94–
Page 1
3.15.4.5 Assembly
Coat outer surface of needle bush with surface sealant.
Insert the needle bush (11) flush with inner edge of hous-
ing.
Push washers (9) and (10) onto lube oil pump shaft (6)
and install with bearing bush (7) in housing (5).
Compensate axial clearance ”A” of lube oil pump shaft
from 0.05 mm to 0.20 mm with washers.
Install bearing bush (7) in such a way that locating pin
of screw (8) engages in bore of bearing bush.
Install stop pin (17) and compression spring (16) with
plug (15) and sealing ring in housing (5); tighten screw.
Coat plunger (18) with cam plate (19) and driver (4) with
engine oil, insert into cover (13) and secure with snap
ring (2).
Coat O-ring (3) with petroleum jelly and mount with
cover on housing.
Secure cover with screw (14) and tab washer (12), using
torque wrench to tighten in accordance with Tightening
Specification 1.3.
Secure screw with tab washer.
Fit blocking pin (20) and compression spring (22) with
plug (21) and sealing ring in housing; tighten plug.
Tighten adjusting screw (23) in cover, and secure with
locking paint after function check.
Function check, see 3.15.4.4.
X = clearance of plunger 0.003 mm to 0.007 mm
20042/10 E –07.96–
Page 1
Mount driver (1) on camshaft (right side) and secure with
bolts and spring washers.
Insert new O-ring in groove in intermediate housing.

Secure intermediate housing (2) to crankcase with bolts
and spring washers.
Fit O-ring on lube oil pump and coat with petroleum jelly.
Mount lube oil pump (1) on intermediate housing and se-
cure with bolts and spring washers.
20038/10 E –07.96–
Page 1
3.15.5 Pressure Relief Valve (15 bar)
1 Pressure relief valve 4 Valve plunger

2 Valve housing 5 Valve seat insert
3 Pressure spring 6 Snap ring
1 Oil pan
2 Pressure relief valve
3 Sealing ring
4 O-ring
20038/10 E –11.95–
Page 1


- x x Disconnect oil supply and return lines to oil pan 3.16.1.2
- x x Remove engine oil filter 3.16.4.2
20042/10 E –07.96–
Page 1
3.15.5.2 Removal, 6V, 8V, 12V

Removing pressure relief valve from elbow in oil
pan
1 Elbow
2 O-ring
3 Sealing ring
Remove valve (1) from elbow of delivery line with socket

wrench and extension.
Remove O-ring and sealing ring.
20038/10 E –11.92–
Page 1
3.15.5.2a Removal, 16V

Removing pressure relief valve from oil pan

2 Sealing ring
3 O-ring
4 Oil pan
Remove valve from oil pan (3) with socket wrench (1)
and extension (2).
Remove O-ring and sealing ring.
20038/10 E –11.92–
Page 1
3.15.5.2b Removal with Crankcase Intermediate Frame

Remove pressure relief valve from elbow on oil pan
(for intermediate frame)
1 Elbow
2 O-ring
3 Sealing ring
Unscrew valve (1) from elbow (2).

Remove sealing ring and O-ring.
20038/10 E –11.95–
Page 1
Press valve plunger downwards using hand press and
suitable drift (2).
Remove snap ring (3) with snap ring pliers.
Release pressure from hand press and remove valve
seat insert (4), plunger and spring (5) from valve housing
(1).
A = Start of opening 15 bar +2.5 bar
–1.5 bar
Caution
Spring tension
20038/10 E –02.95–
Page 1

Inspect valve housing, plunger, valve seat insert and spring for signs of wear.
Check valve housing for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace hous-
ing if cracks are found.
Replace spring if valve does not open at specified pressure.
20038/10 E –11.92–
Page 1
3.15.5.5 Assembly
Insert plunger (2) and spring (5) in valve housing (1).
Fit valve seat insert (4) and snap ring (3).
A = Start of opening 15 bar +2.5 bar
–1.5 bar
Slide assembly tool (2) over valve housing (3).

Using suitable mandrel (1) and plastic mallet, drive in
valve seat insert with snap ring.
Caution
Spring tension
Inspect valve for leaks and check operation on test
pump.
20038/10 E –02.95–
Page 1
3.15.5.6 Installation 6V, 8V, 12V

Installing pressure relief valve in elbow in oil pan
Fit sealing ring on valve.
Insert new O-ring into groove and coat with petroleum
jelly.
1 Elbow
2 O-ring
3 Sealing ring
Screw valve (2) into elbow and tighten with socket

wrench and extension (1).
Note
Make sure that O-ring is not shorn off when valve is in-
serted.
20038/10 E –11.95–
Page 1
3.15.5.6a Installation, 16V

Installing pressure relief valve in oil pan
Fit sealing ring (2) on valve (1).
Insert new O-ring (3) into groove and coat with petro-
leum jelly.
Coat valve thread with engine oil.
Screw valve into oil pan (3) with socket wrench (1) and
extension (2).
Note
Make sure that O-ring is not shorn off when valve is in-
serted.
20038/10 E –11.95–
Page 1
3.15.5.6b Installation with Crankcase Intermediate Frame

Installing pressure relief valve into elbow on oil pan
(for intermediate frame)
Fit sealing ring on valve.
Insert O-ring into groove on pressure relief valve and
1 Elbow
2 O-ring
3 Sealing ring
Screw valve into elbow (1) and tighten.
20038/10 E –11.95–
Page 1
3.16 Oil System

Contents
3.16.1 Engine oil lines

3.16.1.2 Removal
3.16.2a Engine oil heat exchanger with edge-type filter, 12V

3.16.2a.2 Removal
3.16.2a.5 Assembly
3.16.2b Engine oil heat exchanger with edge-type filter, 8V

3.16.2b.2 Removal
3.16.2b.5 Assembly
3.16.3a Engine oil heat exchanger with edge-type filter, 16V

3.16.3a.2 Removal
3.16.3a.5 Assembly
3.16.4a Engine oil filter with filter guide

3.16.4a.2 Removal
3.16.4a.5 Assembly
3.16.4b Engine oil filter suspended with intermediate housing

3.16.4b.2 Removal
3.16.4b.5 Assembly
20046/20 E –08.96–
Page 2
3.16.5a Pressure limiting valve, pressure relief valves and bypass valves
3.16.5a.2 Removal
3.16.5a.5 Assembly
3.16.6 Centrifugal oil filter

3.16.6.2 Removal
3.16.6.5 Assembly
20046/20 E –08.96–
Page 3

A
S4
S 5.12
S 6.19

Magnifier
Pressure-testing equipment
”Nexus” interior puller for centrifugal oil filter
Support for interior puller
Pipe-thread sealant Loctite No. 586 40033

Engine oil
Corrosion inhibitor oil Donnax CC 40419
Hydrochloric acid
Dry compressed air

Caution
20046/20 E –08.96–
Page 1
3.16.1 Engine Oil Lines
Oil supply lines to turbocharger
1 Connector 17 Bracket
2 Gasket 18 Nut
4 Screw 20 Spacer sleeve
5 Sealing ring 21 Oil line, left
6 Plug 22 Oil line, right
10 Union 26 Bracket
11 Oil line 27 Grommet
12 Oil line, right 28 Pipe clamp half
14 Pipe clamp half 30 Spacer tube
16 Screw 32 Screw
20046/20 E –07.96–
Page 2
Oil return lines from carrier housing
1 Oil line 7 Union

2 Reduction union 8 Sealing ring
4 Oil line 10 Pipe clamp half
6 Union 12 Screw
20046/20 E –07.96–
Page 3
Measuring block
1 Measuring block 6 Reduction union

2 Spacer bush 7 Sealing ring
4 Screw 9 Drain valve
5 Sealing ring
20046/20 E –07.96–
Page 4
Oil feed and oil return from injection pump II
1 Oil supply line 9 Hex screw

5 Banjo bolt 13 O-ring
6 Pipe clamp half 14 Sealing ring
8 Pipe clamp half
20046/20 E –07.96–
Page 5
Oil return from fuel injection pump

2 O-ring 4 Union
20046/20 E –07.96–
Page 6
Oil supply line from connector to connection block
1 Connection block 8 Double union

2 Sealing ring 9 Oil supply line
3 Reduction union 10 Oil supply line
20046/20 E –07.96–
Page 7
Oil supply line from connector to connection block
1 Connection block 8 Double union

2 Sealing ring 9 Oil supply line
3 Reduction union 10 Oil supply line
7 Plug 14 Screw
20046/20 E –07.96–
Page 8
Oil supply line to measuring block and injection pump I and II

2 Double union 13 Sealing ring
3 Oil line 14 Banjo bolt
4 Oil line 15 Grommet
6 Double union 17 Screw
7 Intermediate block 18 Spacer bush
9 Plug 20 Oil supply line
11 Spring washer 22 Banjo bolt
20046/20 E –07.96–
Page 9
Oil supply from intermediate element / injection pump II to cut-out control housing
1 Oil supply line 3 Sealing ring

2 Banjo bolt 4 Double union
20046/20 E –07.96–
Page 10
Oil return from injection pumps
1 Sealing ring 7 Oil return line

2 Union 8 Sealing ring
4 Banjo union 10 Oil return line
5 Banjo bolt 11 Sealing ring
6 O-ring 12 Union
20046/20 E –07.96–
Page 11
Oil supply line to centrifugal oil filter, 8V
1 Pipe 13 Sleeve
2 Union 14 Pipe clamp half
4 Oil line 16 Hex screw
5 Straightway valve 17 Hex screw
6 Oil line 18 Spring washer
7 Reduction union 19 Bracket
9 Reduction union 21 Grommet
20046/20 E –07.96–
Page 12

3 Union 14 Screw
4 Oil line 15 Washer
5 Straightway valve 16 Spring washer
6 Reduction union 17 Screw
7 Oil line 18 Sleeve
9 Reduction union 20 Grommet
10 Plug 21 Screw
11 Bracket
20046/20 E –07.96–
Page 13
Oil return line from siphon on crankcase, 8V, 12V
1 Siphon 4 Sealing ring

2 Sealing ring 5 Oil line
3 Union
20046/20 E –07.96–
Page 14

2 Straightway valve 17 Grommet
3 Oil line 18 Spring washer
4 Reduction union 19 Screw
7 Double union 22 Grommet
9 Sleeve 24 Screw
10 Pipe clamp half 25 Spacer bush
12 Screw 27 Pipe clamp half
13 Screw 28 Screw
15 Bracket
20046/20 E –07.96–
Page 15
Oil supply lines for valve seat lubrication, 8V, 12V
1 Pipe 7 Oil supply line, right

2 Non-return valve 8 Sealing ring
3 Sealing ring 9 Banjo bolt
4 Banjo bolt 10 Grommet
5 Spray nozzle 11 Pipe clamp half
6 Oil supply line, left 12 Hex screw
20046/20 E –07.96–
Page 16
Oil supply lines to valve seat lubrication system, 16V
1 Pipe 8 Sealing ring

2 Non-return valve 9 Banjo bolt
5 Oil supply line, left side 12 Screw
6 Oil supply line, right side 13 Spring washer
7 Spray nozzle
20046/20 E –07.96–
Page 17
Oil supply and return lines to air compressor
1 Oil supply line 17 Bracket

4 T-piece 20 Grommet
5 Oil supply line 21 Pipe clamp half
6 Oil supply line 22 Screw
7 Union 23 Grommet
9 Restrictor union 25 Screw
11 Spring washer 27 Return line
13 Screw 29 Reduction union
15 Pipe clamp half 31 Union
16 Screw
20046/20 E –07.96–
Page 18
Oil supply lines from connection block to air compressor
1 Double union 20 Bracket

2 Oil supply line 21 Grommet
3 Distributor element 22 Pipe clamp half
7 Union 26 Grommet
12 Union 31 Bracket
13 Union 32 Grommet
15 Oil line 34 Spacer bush
19 Plug
20046/20 E –07.96–
Page 19
Oil supply line from connection block to bilge pump
1 Oil line 14 Screw

2 Restrictor union 15 Bracket
3 Bracket 16 Screw
7 Screw 20 Screw
8 Spring washer 21 Spacer sleeve
10 Screw 23 Grommet
12 Grommet 25 Screw
13 Pipe clamp half
20046/20 E –07.96–
Page 20
Oil feed to heat exchanger
1 Connecting line 7 Sealing ring

2 O-ring 8 Plug
3 Elbow 9 Pressure relief valve, 15 bar
4 Gasket 10 O-ring
6 Hex screw
20046/20 E –07.96–
Page 21
Oil supply and return lines from control unit to hydraulic coupling for fan drive
1 Oil line 11 Hose

2 Hose 12 Retainer
5 Spacer sleeve 15 Hex screw
7 Pipe clamp half 17 Pipe elbow
8 Grommet 18 Hose
9 Hex screw 19 Reduction union
10 Oil line
20046/20 E –07.96–
Page 22
Oil supply and return lines from control unit to hydraulic coupling for fan drive
1 Control unit 22 Reduction union

3 Stud 24 Banjo bolt
5 Hex nut 26 Washer
6 Sealing wire 27 Bracket
7 Two-hole seal 28 Grommet
8 Oil pressure line 29 Pipe clamp half
9 Reduction union 30 Washer
12 Pipe clamp half 33 Hex nut
13 Hex screw 34 Hose
14 Spring washer 35 Oil pressure line
15 Oil line 36 Hex screw
21 Oil pressure line
20046/20 E –07.96–
Page 23
Oil return line (drainage) from fan wheel flange to housing ventilation
1 Oil line 8 Screw

4 Screw 11 Grommet
5 Retainer 12 Pipe clamp half
6 Grommet 13 Screw
20046/20 E –07.96–
Page 24
Oil supply line from connector to intermediate bell

2 Reduction union 5 Banjo bolt
3 Pipe
20046/20 E –07.96–
Page 25
Oil supply line from connector to intermediate bell

3 Pipe 8 Screw
5 Sealing ring
20046/20 E –07.96–
Page 1


20038/10 E –11.92–
Page 1
3.16.1.2 Removal
Prior to removing engine oil lines, it is advisable either to take photographs from all sides of the engine
or to mark the engine oil lines with metal tabs.
Disconnect oil lines with seals and pipe clamp halves from engine.
After removing oil lines, seal all connections with suitable plugs.
Protect thin-walled oil lines against damage.
20038/10 E –11.92–
Page 1

Clean engine oil lines with cold cleaner.
Check condition and inspect for damage; repair if necessary and perform pressure test as required.
Check plug-in connections for wear; smooth wear or replace components as necessary.
Match rewelded lines to engine.
After repairing the lines, pickle lines in a hydrochloric acid solution (9 parts water, 1 part hydrochloric acid).
After pickling, wash the lines in hot water and blow dry the lines with compressed air.
Then immerse lines in an oil bath and allow to drip dry.
Check hose lines, grommets and attachments of lines for damage and wear; repair components as necessary.
Replace all O-rings.
20038/10 E –11.92–
Page 1
Before installation, blow engine oil lines clear with compressed air and make sure that they are completely clean.
Install oil lines and secure with new seals, attaching hardware, plug-in pipes and O-rings.
Install oil lines so that they are free of strain in accordance with photographs, markers and layout (3.16.1).
20038/10 E –08.96–
Page 1
3.16.2a Engine Oil Heat Exchanger with Edge-Type Filter, 12V
1 Housing upper section 8 Plug (measuring point)

2 Filtered oil duct 9 Pressure relief valve, 6 bar
3 Plate-type oil cooler 10 Pressure limiting valve, 5.5 bar
4 Ratchet lever 11 Bypass valve, 1.8 to 2.6 bar
5 Housing base 12 Engine oil edge-type filter
6 Plug (measuring point) 13 Drain valve
7 Plug (oil drain) 14 Drain valve
20046/20 E –08.96–
Page 2
Engine oil heat exchanger with edge-type filter
1 Housing upper section 29 Screw

2 Housing 30 Washer
3 Plug 31 Gasket
4 Stud 32 O-ring
5 Stud 33 Screw
6 Housing base 34 Screw
7 Threaded bush 35 Hex nut
8 Sleeve 36 Screw
9 Plate-type oil cooler 37 Washer
10 O-ring 38 Plug
11 Gasket 39 Plug
13 Washer 41 Flange
14 Screw 42 Screw
15 Pressure relief valve, 6.0 bar 43 Flange
16 O-ring 44 O-ring
18 Pressure relief valve 46 Flange
19 O-ring 47 Walk-on guard plate
20 Bracket 48 Flange
21 Screw 49 Gasket
22 Spring washer 50 Flange
23 Valve seat 51 O-ring
24 Valve cone 52 Screw
25 Pressure spring 53 Drain valve
26 O-ring 54 Plug
28 Edge-type filter element 56 Snap ring
20046/20 E –08.96–
Page 3
Engine oil heat exchanger, 12V
1 Oil heat exchanger 29 Sealing ring

2 O-ring 30 Plug
4 Screw 32 Plug
6 Screw 34 Plug
7 Walk-on guard plate 35 Sealing ring
10 Cover 38 Elbow
11 Gasket 39 O-ring
12 Screw 40 Screw
14 Clip 42 Plug
16 Spring washer 44 Plug-in pipe
17 Flange 45 O-ring
18 O-ring 46 Bracket
19 Drain valve 47 Screw
21 Gasket 49 Elbow
23 Screw 51 Screw
25 Threaded bush 53 Plug-in pipe
26 Threaded bush 54 O-ring
28 Plug
20046/20 E –08.96–
Page 4
Engine oil heat exchanger 12V with oil return to crankcase intermediate frame and oil supply to oil heat ex-
changer
1 Elbow 7 O-ring
2 Gasket 8 O-ring
3 Washer 9 Elbow
4 Screw 10 Plug-in pipe
5 Screw 11 Oil heat exchanger
6 Plug-in pipe
20046/20 E –08.96–
Page 5
Engine oil edge-type filter (with elastoril casting compound)
1 O-ring 9 O-ring
2 Retaining pin 10 Winding element
3 Clamp 11 Stud
4 Hex nut 12 Screw
5 Ratchet, right 13 O-ring
6 Scraper 14 Spring washer
7 Spring 15 Stud
8 Spring washer
20046/20 E –08.96–
Page 6
Engine oil edge-type filter - metallic seal (without casting compound)
1 Nut 8 Screw
3 Ratchet, right 10 Sealing ring
4 Scraper 11 Stud
5 Spring 12 O-ring
6 Winding element
7 O-ring A – Wire inserted and peaned
20046/20 E –08.96–
Page 7
Engine oil edge-type filter arrangement, 12V
1 Sleeve 5 Edge-type filter element

2 O-ring 6 Housing base
3 Gasket 7 O-ring
4 Ratchet lever
20046/20 E –08.96–
Page 8
Engine oil heat exchanger arrangement, 12V
1 Housing upper section 5 Edge-type filter element

2 Plate-type oil cooler 6 Bypass valve (before paper filter element)
3 Engine oil filter 7 Pressure limiting valve (before engine oil filter)
4 Bypass valve (before oil cooler core) 8 Housing base
20046/20 E –08.96–
Page 1


- x x Remove engine coolant lines and vent line on engine oil heat exchanger 3.14.1.2
- x x Remove elbow for oil pan oil supply to engine oil heat exchanger
(for engines with crankcase intermediate frame) 3.16.1.2
20038/10 E –08.96–
Page 1
3.16.2a.2 Removal
Removing oil feed plug-in pipe from oil heat ex-
changer
Unscrew securing screw (3) with bracket (4) from oil pan
(6).
Using pry bar, press plug-in pipe (2) out of elbow (5) on
heat exchanger (1) downwards into bore in oil pan.
After removing heat exchanger, withdraw plug-in pipe
from oil pan.
Removing oil return plug-in pipe from oil heat ex-

changer
Unscrew securing screw (3) with bracket (2) from oil pan
(5).
Using pry bar, press plug-in pipe out of bore in oil pan up-
wards into bore in elbow (6) on heat exchanger (1).
Removing engine oil heat exchanger

Unscrew securing bolts (1) from heat exchanger (2).
Remove heat exchanger from crankcase with lifting
gear.
Withdraw plug-in pipe from elbow on heat exchanger.
Remove O-rings.
20038/10 E –11.92–
Page 1
Removing elbow
Remove securing bolts (5) and (6) with washers (4) from
elbow (3).
Remove elbow from heat exchanger (1).
Remove gasket (2) and oil transfer pipe (7) from heat ex-
changer.
Removing housing base

Mount oil heat exchanger on assembly jig.
Remove securing bolts (2), (3) and (4) from housing
base (1).
Secure lifting appliance (1) to housing base (2).

Lift housing base and plate-type oil cooler out of housing
upper section (3) with lifting gear.
Remove housing upper section from assembly jig.
20038/10 E –11.92–
Page 2
Opening oil duct, 12 V

Remove snap ring (2) for blanking plug (1) from clean oil
duct of housing upper section using snap ring pliers (3).
Insert screw (4) in blanking plug (3).

Remove blanking plug from bore (1).
Remove screw and O-ring (2) from blanking plug.
Removing flanges and plugs

Remove flange with drain valve (3) and flanges (4) and
(5).
Unscrew plug (2) from housing base (1).
Removing bypass, pressure limiting and pressure relief
valves, see 3.16.5.2.
20038/10 E –11.92–
Page 3
Removing edge-type filter element

Remove ratchet lever (1) from edge-type filter element
(2).
Detach clamp securing ratchet lever from flange.
Remove screws and washers (2) for edge-type filter el-

ement from housing base (1).
Release edge-type filter element (2) from housing base

using jackscrews (1).
Withdraw edge-type filter element from housing base.
Remove O-rings from edge-type filter element.
Note
Protect edge-type filter element against damage.
20038/10 E –11.92–
Page 4
Removing plate-type oil cooler

Unscrew securing bolts (1) and (2) from housing base
(3).
Note
Before removing oil cooler (2), mark direction of oil flow

with arrows (1).
Screw two guide pins (1) into oil cooler core (3) at each
end.
Lift housing base (2) off oil cooler.
Remove guide pins from oil cooler.
Remove O-rings and sleeves.
20038/10 E –11.92–
Page 1

Cleaning water side of plate-type oil cooler
Immerse plate-type oil cooler in a cleaning bath containing a cleansing agent solution.
It is essential to examine extent of contamination of water side prior to cleaning.
If greasy scale deposits are found, water side must first be degreased.
Suitable cleaning chemicals are buffered alkaline agents such as a 3 to 5% solution of Henkel P3 FD.
Period of immersion depends on condition of bath and temperature of cleaning agent and on type and degree of conta-
mination.
Prepare cleaning bath in accordance with manufacturer’s instructions.
For stubborn deposits, it may be necessary to use a 10% solution of hydrochloric acid.
However, an appropriately inhibited acid must be used in such cases (e.g. Euron 1144 manufactured by Hoechst).
Cleaning process is completed when loosened contaminants can be flushed away with a powerful water jet.
After cleaning, system must be flushed with water until pH values of fresh water and flushing water are roughly equal
(permissible difference 1 pH).
Cleaning/flushing oil side of plate-type oil cooler

Connect oil side to sealed, forced-circulation flushing system.
Forced-circulation flushing system must be equipped with a filter (0.05 mm mesh).
Note
Cleaning solution must be pumped through oil cooler in direction opposite to normal oil flow, i.e. opposite to direction
of arrow on cooler.
Cleaning can be improved by ultrasonic means.
In event of severe contamination, e.g. in case of piston seizure or bearing damage, replace the disc-type oil cooler.
After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are roughly equal
This releases contaminants, particularly particles from wear parts, from swirl plates of cooling core, so that they are
flushed out with water.
Continue cleaning process until flushing medium leaving cooler is same as that entering.
Flushing pressure 3 to 4 bar at 150 to 300 litres/minute.
After this cleaning procedure, dry oil side with hot air to remove remaining flushing water from swirl plates and oil ducts.
After drying, oil cooler must be rinsed with engine oil or Haku rinsing oil in order to preserve swirl plates.
This preservation is not necessary if plate-type oil cooler is reinstalled on engine and put into operation immediately
after cleaning.
Insert protective caps in inlet and outlet bore and protect disc-type oil cooler against damage.
20038/10 E –08.96–
Page 2
Cleaning edge-type filter element

Soak filter element in diesel fuel, rinse and then blow clear with compressed air.
If the filter element cannot be turned after being washed out, it must be replaced or sent to the Manufacturer for repair.
Note
Edge-type filter element with metallic and plastic sealing must not be disassembled.
The plastic connection on the front cover must not be damaged; in addition the components must not be subjected to
hard impacts during assembly.
Replace damaged edge-type filter element.
With engines with high load profile, only use edge-type filter with metallic seal.
Check ratchet lever for filter element for freedom of movement; replace if necessary.
Checking housing, elbow and plug-in pipe

Check housing upper section and base, connecting housing and elbow for cracks using surface crack-testing method
with red penetrant dye; replace components if cracks are found.
Pressure-test housing as required.
Check screw-down surfaces for irregularities and damage; rub down as required.
Check condition of threads; recut if necessary or install Helicoil inserts or threaded bushes.
Check plug-in pipe locating bores for indentation and wear; rub down if necessary and box to MTU specifications as
required.
Ensure that oil ducts are perfectly clean.
Inspect connecting points and sealing ring grooves of plug-in pipes for wear; rub down as required.
20038/10 E –08.96–
Page 1
3.16.2a.5 Assembly
Preassembling plate-type oil cooler
Remove protective caps on disc-type oil cooler.
Check screw-down surfaces for irregularities with
straightedge.
Insert sleeves (2) into flanges and position gaskets (1)
on flange surfaces.
Coat O-ring (3) with petroleum jelly and fit over sleeves.
Installing plate-type oil cooler

Check that filtered oil ducts in housing base (1) are per-
fectly clean.
Screw two guide pins (3) into oil cooler (2) at each end.
Position housing base on oil cooler core.
Remove guide pins.
Arrows (2) on oil cooler (1) must correspond to direction

of oil flow.
20038/10 E –08.96–
Page 2
Mount housing base (3) on plate-type oil cooler with se-

curing bolts and washers (1) and (2).
Note
Only pretighten securing screws to tightening specifica-

tion 1.3, do not tighten.
Installing flanges and plugs

Secure flange with drain valve (3) and flanges (4) and (5)
to housing base (1) with gaskets, bolts and washers.
Seal connecting points with plugs (2) and sealing rings.
Completing edge-type filter element

Ensure that edge-type filter element (1) is perfectly
clean before reassembly.
Insert O-ring (2) and (3) into grooves on edge-type filter
element and coat with petroleum jelly.
20038/10 E –08.96–
Page 3
Installing edge-type filter element

Coat bores for edge-type filter element (2) in housing
lower section (1) with petroleum jelly.
Note
Prior to assembling edge-type oil filter, insert two secur-

ing screws of housing upper section through centre
bores in flange of housing lower section. The bores are
no longer accessible once the edge-type filter has been
installed.
Carefully insert filter element into housing base and
press home by hand.
Make sure that O-rings do not shear.
Secure edge-type filter element to housing base (1) with

bolts and washers (2).
Installing bypass, pressure limiting and pressure relief
Pressure-testing housing lower section with disc-

type oil cooler for leaks
Secure cover plates and connection pieces to housing
base and insert seals.
Install housing base with plate-type oil cooler (1) on
pressure-testing device (2) and connect pressure hose
(3).
Pressure-test housing base and oil cooler at 15 bar and
inspect for leaks.
Relieve pressure.
Remove housing base with oil cooler from pressure-
testing device.
Allow oil to drain from housing base.
Remove cover plates, connection pieces and seals.
20038/10 E –08.96–
Page 4
Sealing oil channel

Ensure that clean oil duct is particularly clean.
Insert screw (4) into blanking plug (3).
Insert O-ring (2) in groove on blanking plug and coat with
Insert plug into bore (1) in housing base.
Using snap ring pliers (3), install snap ring (2) to secure
blanking plug (1).
Installing housing upper section

Install housing upper section (3) on assembly jig (1).
Position gasket (2) on sealing surface of housing upper
section.
Screw in two guide pins at each end.
20038/10 E –08.96–
Page 5
Insert O-ring (2) in oil transfer bore on housing lower

section (1) and coat with petroleum jelly.
Installing housing base

Attach lifting appliance (4) to housing base (1).
Install preassembled housing base with oil cooler in
housing upper section (3) with lifting gear.
Screw coolant drain valve (2) into housing upper sec-
tion.
Remove guide pins.
Secure housing base (1) to upper section with washers,

nuts and bolts (2), (3) and (4).
20038/10 E –08.96–
Page 6
Tightening plate-type oil cooler

Using torque wrench (1), tighten bolts (2) to secure oil
cooler to housing base (3) to specified torque. For
Installing ratchet lever on edge-type filter

Install ratchet lever (1) on edge-type filter element (2).
Tighten with hex nut.
Note
Only tighten the hex nut firmly enough to turn the edge-
type filter.
Installing clamp on flange and connecting housing

Mount retaining clamp (2) for ratchet lever on housing
base flange (1) with washers and socket head screws.
20038/10 E –11.92–
Page 7
Installing elbow
Rub down sealing surfaces of elbow.
Connect oil transfer pipe (7) to heat exchanger (1).
Install and tighten elbow (3) on heat exchanger with
gasket (2), washers (4) and securing bolts (5) and (6).
Do not damage oil transfer pipe during installation.
Installing elbow for oil supply to oil heat exchanger

Coat O-ring (2) with petroleum jelly and insert in groove
on elbow (3).
Mount elbow with washers (4) and screws (5) and (6) on
lower section of heat exchanger housing (1) and tighten.
Note
Install only on engines with crankcase intermediate

frame.
20038/10 E –08.96–
Page 1
Installing engine oil heat exchanger, 12V
Coat O-rings (4) and (10) with petroleum jelly.
Insert O-rings in grooves of oil transfer bores on elbows
(3) and (7) and heat exchanger (13).
Fit O-rings (5) and (8) on plug-in pipes (6) and (9) and
Secure elbow to heat exchanger with washers (2) and
screws (1).
Insert plug-in pipe (9) into bore in oil pan.
Insert plug-in pipe (6) into bore in elbow.
Install two eyebolts in upper section of heat exchanger.
Raise heat exchanger with lifting gear and mount with se-
curing screws (12), (14) and (15) and washers (11) on
crankcase.
Mount heat exchanger (2) on crankcase with securing

Tighten with torque wrench.
Unscrew eyebolts.
Installing oil return elbow in intermediate frame

Mount elbow (1) with new gasket (2) on intermediate
frame with hex bolts (4) and (5) and spring washers (3).
Insert plug-in pipe into elbow.
Coat O-rings (8) with petroleum jelly and insert into
grooves of oil transfer bores on heat exchanger (9).
Install heat exchanger as described above.
20038/10 E –08.96–
Page 2
Installing oil supply plug-in pipe in heat exchanger

Using pry bar, press plug-in pipe into bore in elbow (5).
Do not shear O-rings.
To secure plug-in pipe, install bracket (4) with securing
screw (3) on oil pan (6).
Installing oil return plug-in pipe in heat exchanger

Using pry bar, press plug-in pipe (4) into bore in oil pan
(5).
Do not shear off O-ring.
To secure plug-in pipe, install bracket (2) with securing
screw (3).
20038/10 E –11.92–
Page 1
3.16.2b Engine Oil Heat Exchanger with Edge-Type Filter, 8V
1 Filtered oil to main oil gallery 15 To engine oil filters

2 HTC coolant to right engine side 16 Oil measuring point (temperature transmitter)
3 Housing upper section 17 From engine oil filters
4 Oil cooler core 18 Engine oil edge-type filter
5 LTC coolant to mixing point 19 Housing base
6 Inlet elbow 20 HTC coolant to left engine side
7 HTC coolant from engine coolant pump 21 HTC coolant to exhaust cooling jackets
8 Coolant sample extraction cock 22 Oil measuring point (temperature monitor)
9 LTC coolant from intercooler 23 Drain valve
10 Ratchet lever 24 Drain valve, oil sludge from edge-type filter
11 Bypass valve before filter element 25 Drain valve, oil sludge from engine oil filters
13 Bypass valve before oil cooler core HTC = high-temperature circuit
14 Pressure limiting valve before engine oil filter LTC = low-temperature circuit
20058/0 E –03.93–
Page 2
Engine oil heat exchanger
1 Oil heat exchanger 18 Sealing ring

2 Clip 19 Plug
6 Washer 23 Elbow
9 Hex screw 26 Washer
11 Threaded bush 28 Sealing ring
12 Threaded bush 29 Plug
15 Plug 32 O-ring
16 Sealing ring 33 Plug–in pipe
17 Plug 34 O-ring
20058/0 E –03.93–
Page 3
Engine oil heat exchanger, driving end, with edge-type filter
1 Housing upper section 24 O-ring 46 Hex screw

2 Stud 25 Sealing ring 47 Spring washer
3 Stud 26 Edge-type filter element 48 Flange
4 Drain valve 27 Hex screw 49 O-ring
5 Housing base 28 Washer 50 Hex screw
6 Sleeve 29 Gasket 51 Spring washer
7 Plate-type oil cooler 30 O-ring 52 Drain valve
8 O-ring 31 Hex screw 53 Walk-on guard plate
9 Gasket 32 Hex screw 54 Flange
10 Gasket 33 Hex nut 55 Gasket
11 Washer
12 Hex screw
13 Pressure relief valve, 6.0 bar
14 O-ring 36 Plug 58 Spring washer
15 Sealing ring 37 Sealing ring 59 Connecting housing
16 Pressure relief valve 38 Plug 60 O-ring
17 O-ring 39 Sealing ring 61 Hex screw
18 Bracket 40 O-ring 62 Hex screw
19 Hex screw 41 Flange 63 Washer
20 Spring washer 42 Hex screw 64 Sealing ring
21 Valve seat 43 Spring washer 65 Threaded bush
22 Valve cone 44 Flange 66 Sealing ring
23 Pressure spring 45 O-ring 67 Threaded bush
20058/0 E –08.96–
Page 4
Engine oil edge-type filter, 8V

3 Gasket 7 O-ring
4 Ratchet lever
20058/0 E –08.96–
Page 5
Engine oil edge-type filter (with elastoril casting compound)
1 O-ring 9 O-ring
3 Clamp 11 Stud
5 Ratchet 13 O-ring
7 Spring 15 Stud
8 Spring washer
20058/0 E –08.96–
Page 6
Edge-type filter element – metallic seal (without casting compound)

3 Ratchet, right 11 Stud
4 Scraper 12 Sealing ring
5 Spring 13 O-ring
6 Winding element
8 Spring washer
20058/0 E –08.96–
Page 7
1 Housing upper section 5 Edge-type filter Eelement

20058/0 E –08.96–
Page 1


- x x Disconnect engine coolant lines from engine oil heat exchanger 3.14.1.2
20058/0 E –03.93–
Page 1
3.16.2b.2 Removal
Removing engine oil heat exchanger
Remove one securing bolt (1) from both left and right
sides of heat exchanger (2).
Insert assembly pins.
Remove remaining securing bolts.
gear.
Remove assembly pins, plug-in pipes, elbows and O-
rings.
20058/0 E –03.93–
Page 1
Removing engine oil filter, see 3.16.4.2
Removing elbow
Remove securing bolts (6) and (7) with washers (5) from
elbow (4).
Remove elbow from driving-end heat exchanger (1).
Remove O-rings (2), (3) and (9) and sealing ring (8) from
elbow.

Remove securing bolts (2), (3) and (4) from housing
base (1).

20058/0 E –08.96–
Page 2

(5).
Removing bypass, pressure limiting and pressure relief
Removing connecting housing

Unscrew securing bolts (5) and (6) with washers (4) from
connecting housing (3).
Remove connecting housing and O-rings (2) from hous-
ing base (1).
ET16/832B

(2).
Unscrew retaining clamp for ratchet lever from connect-
ing housing.
20058/0 E –08.96–
Page 3


Note

(3).
20058/0 E –08.96–
Page 4
Note

with arrows (1).
end.
20058/0 E –08.96–
Page 1

Cleaning and flushing oil side of plate-type oil cooler
mination.
Cleaning and flushing cooling side of plate-type oil cooler
Note
of arrow on cooler.
In event of severe contamination, e.g. in case of piston seizure or bearing damage, replace the disc-type oil cooler.
after cleaning.
20058/0 E –08.96–
Page 2

Note
Edge-type filter element with metallic sealing and plastic sealing must not be disassembled.
The plastic connection on the front cover must not be damaged; in addition the components must not be subjected to
hard impacts during assembly.
Pressure-test housing and elbow as required.
required.
Inspect connecting points and sealing ring grooves for wear; rub down as required.
20058/0 E –08.96–
Page 1
3.16.2b.5 Assembly
straightedge.
on flange surfaces.
Coat O-ring (3) with petroleum jelly and fit over sleeves.

fectly clean.
Remove guide pins.

of oil flow.
20058/0 E –08.96–
Page 2

Note


Install plugs (2) complete with sealing rings.
Installing connecting housing

Secure connecting housing (3) to housing base (1) with
screws (5) and (6) and washers (4).
ET16/832B
20058/0 E –08.96–
Page 3


Coat bore (1) for edge-type filter element in housing
Note

ing screws (3) of housing upper section through centre
bores in flange of housing lower section.
The bores are no longer accessible once the edge-type
filter has been installed.
Carefully insert filter element (2) into housing base (1)

and press home by hand.
20058/0 E –08.96–
Page 4


(3).
inspect for leaks.
Relieve pressure.
testing device.
Installing housing base with plate-type oil cooler

on housing upper section
20058/0 E –08.96–
Page 5
Install housing upper section (5) on assembly jig.

Apply a thin coat of sealing paste to sealing surface.
section.
tion.
Remove guide pins.


20058/0 E –08.96–
Page 6

Note
type filter.

Mount retaining clamp (4) for ratchet lever on connect-
ing housing (5) with spring washers (3) and socket head
screws (2).
Installing elbow
Insert O-rings (2), (3), (9) and sealing ring (8) into annu-
lar grooves of elbow (4) and coat with petroleum jelly.
Using washers (5) and securing screws (6) and (7),
secure elbow to heat exchanger (1).
Note
20058/0 E –08.96–
Page 1
Installing engine oil heat exchanger, driving end
Coat O-rings (4) and (5) with petroleum jelly and insert
into grooves of oil transfer bores on elbow (3) and heat
exchanger (8).
Secure elbow to heat exchanger with washers (11) and
screws (12).
Insert O-rings (1) and (4) into grooves of plug-in pipes
(2) and (13) and coat with petroleum jelly.
Insert plug-in pipes into oil pan bores.
Insert two assembly pins into crankcase securing bores.

Using lifting gear, lower heat exchanger into position on
assembly pins and introduce plug-in pipe into bore, tak-
ing care not to damage plug-in pipe.
Using screws (2,3) and washers, secure heat ex-
changer (1) to crankcase.
Unscrew assembly pins.
Install remaining securing screws with washers in crank-
case.
Use torque wrench (3) to tighten securing screws (1) on

heat exchanger (2).
For engine oil filter installation, see 3.16.4a.6
20058/0 E –08.96–
Page 1
3.16.3a Engine Oil Heat Exchanger with Edge-Type Filter, 16V

Engine oil heat exchanger driving end, 16V

2 Filtered oil duct 10 Pressure limiting valve 5.5 bar before engine oil filter
3 Plate-type oil cooler 11 Engine oil edge-type filter
4 Coolant inlet elbow 12 Housing base
5 Ratchet lever 13 Plug (measuring point)
6 Connecting housing 14 Drain valve
7 Bypass valve 1.8 to 2.6 bar before filter element 15 Drain valve
8 Pressure relief valve 6.0 bar before oil cooler insert 16 Plug (oil drain)
20038/10 E –08.96–
Page 2
Engine oil heat exchanger, free end, with edge-type filter, 16V

2 Plate-type oil cooler 11 Engine oil edge-type filter
3 Coolant inlet elbow 12 Housing base
4 Cover 13 Filtered oil duct
5 Ratchet lever 14 Coolant channel
6 Connecting housing 15 Plug (measuring point)
7 Bypass valve 1.8 to 2.6 bar before filter element 16 Drain valve
8 Pressure relief valve 6.0 bar before oil cooler insert 17 Plug (oil drain)
9 Pressure limiting valve 5.5 bar before engine oil filter
20038/10 E –08.96–
Page 3
Engine oil heat exchanger driving end, 16V
1 Oil heat exchanger 26 O-ring

2 Clip 27 O-ring
6 Washer 31 Washer
7 Hex screw 32 Bracket
10 Plug 35 Elbow
17 Plug 42 O-ring
18 Plug 43 Plug-in pipe
21 Cover 46 Plug
23 Hex screw 48 Threaded bush
24 Spring washer 49 Threaded bush
25 O-ring
20038/10 E –11.92–
Page 4
Engine oil heat exchanger, driving end, 16V with oil return to crankcase intermediate frame and oil supply to
oil heat exchanger
1 Oil heat exchanger, driving end 8 O-ring

2 O-ring 9 Oil pipe
3 Plug-in pipe 10 Elbow
4 Screw 11 Gasket
6 Elbow 13 Screw
7 O-ring
20038/10 E –08.96–
Page 5
Engine oil heat exchanger, driving end, with edge-type filter

4 Drain valve 27 Hex screw 49 O-ring
5 Housing base 28 Washer 50 Hex screw
6 Sleeve 29 Gasket 51 Spring washer
7 Plate-type oil cooler 30 O-ring 52 Drain valve
8 O-ring 31 Hex screw 53 Walk-on guard plate
10 Gasket 33 Hex nut 55 Gasket
11 Washer
12 Hex screw
13 Pressure relief valve, 6.0 bar
19 Hex screw 41 Flange 63 Washer
20038/10 E –08.96–
Page 6
Engine oil heat exchanger, free end, with edge-type filter

4 Housing base 26 Hex screw 48 O-ring
5 Sleeve 27 Washer 49 Hex screw
6 Plate-type oil cooler 28 Gasket 50 Spring washer
7 O-ring 29 O-ring 51 Drain valve
8 Gasket 30 Hex screw 52 Walk-on guard plate
10 Washer 32 Hex nut 54 Gasket
11 Hex screw 33 Hex screw 55 Hex screw
12 Pressure relief valve, 6.0 bar 34 Washer 56 Hex screw
18 Hex screw 40 Flange 62 Spring washer
20038/10 E –08.96–
Page 7
Engine oil heat exchanger free end, 16V
1 Plug-in pipe 10 Oil transfer pipe

2 O-ring 11 O-ring
3 Plug-in pipe 12 Gasket
4 O-ring 13 Elbow
5 Plug-in pipe 14 Hex screw
7 Oil heat exchanger 16 Washer
8 Plug-in pipe 17 Drain valve
9 O-ring
20038/10 E –08.96–
Page 8
Engine oil edge-type filter with elastoril casting compound
1 O-ring 9 O-ring
3 Clamp 11 Stud
5 Ratchet 13 O-ring
7 Spring 15 Stud
8 Spring washer
20038/10 E –08.96–
Page 9
Edge-type filter element - metallic seal (without casting compound)

3 Ratchet, right 11 Stud
4 Scraper 12 Sealing ring
5 Spring 13 O-ring
6 Winding element
8 Spring washer
20038/10 E –08.96–
Page 10
Engine oil edge-type filter, 8V

3 Gasket 7 O-ring
4 Ratchet lever
20038/10 E –08.96–
Page 11
1 Housing upper section 5 Edge-type filter element

20038/10 E –08.96–
Page 1


- x x Remove engine coolant lines and vent lines on oil heat exchanger 3.14.1.2
- x x Drain or draw off engine oil Op. Man.
- x x Remove elbow for oil pan oil supply to oil heat exchanger
(for engines with crankcase intermediate frame) 3.16.1.2
20038/10 E –08.96–
Page 1
3.16.3a.2 Removal
Removing plug-in pipes from driving-end heat ex-
changer, 16V
Release bolts on brackets (1).
Withdraw brackets from grooves in plug-in pipes.
Using pry bars, press plug-in pipes (2), (3) and (4) into
driving or free-end heat exchanger bores.
Note
Plug-in pipes can be removed only after a heat ex-

changer has been removed.
Removing driving-end heat exchanger, 16V

gear.
Remove assembly pins, plug-in pipes, elbows and O-
rings.
Removing free-end heat exchanger, 16V

gear.
Remove assembly pins, plug-in pipes and O-rings.
20038/10 E –11.92–
Page 1
Removing elbow, driving end
Unscrew securing bolts (6) and (7) and washers (5) from
elbow (4).
Remove elbow from driving-end heat exchanger (1).
Remove O-rings (2), (3) and (9) and sealing ring (8) from
elbow.
Removing elbow, free end

Unscrew securing bolts (5) and (6) and washers (4) from
elbow (3).
Remove elbow from free-end heat exchanger (1).
Remove gasket (2) and oil transfer pipe (7) from heat ex-
changer.

Unscrew bolts (2), (3) and (4) securing oil pan (1).
20038/10 E –11.92–
Page 2


(5).
For bypass valve, pressure limiting valve and pressure
relief valve removal, see 3.16.5.2.
Removing connecting housing

Unscrew securing bolts (5) and (6) with washers (4) from
connecting housing (3).
Remove connecting housing and O-rings (2) from hous-
ing base (1).
ET16/832B
20038/10 E –11.92–
Page 3

(2).
Unscrew retaining clamp for ratchet lever from connect-
ing housing.


Note
20038/10 E –11.92–
Page 4

(3).
Note

with arrows ().
end.
20038/10 E –11.92–
Page 1

Cleaning water side of plate-type oil cooler
mination.
Cleaning/flushing oil side of plate-type oil cooler

Note
of arrow on cooler.
In event of severe contamination, e.g. piston seizure or bearing damage, replace the disc-type oil cooler.
after cleaning.
20038/10 E –02.95–
Page 2

Note
Edge-type filter element with metallic and plastic sealing must not be disassembled.
The plastic bonded joint on the front cover must not be damaged; in addition the components must not be subjected
to hard impacts during assembly.

Pressure-test housing and elbow as required.
required.
Inspect connecting points and sealing ring grooves for wear; rub down as required.
20038/10 E –08.96–
Page 1
3.16.3a.5 Assembly
straightedge.
on flange surfaces.
Coat O-rings (3) with petroleum jelly and fit over sleeves.

fectly clean.
Remove guide pins.

of oil flow.
20038/10 E –08.96–
Page 2

Note


Seal connecting points with plugs (2) and sealing rings.
Installing connecting housing

Secure connecting housing (3) to housing base (1) with
O-rings (2), bolts (5) and (6) and washers (4).
ET16/832B
20038/10 E –02.95–
Page 3


Coat bore (1) for edge-type filter element in housing
Note

ing screws (3) of housing upper section through centre
bores in flange of housing lower section.
The bores are no longer accessible once the edge-type
filter has been installed.
Carefully insert filter element (2) into housing base (1)

and press home by hand.
20038/10 E –08.96–
Page 4


(3).
inspect for leaks.
Relieve pressure.
testing device.
Installing housing base with plate-type oil cooler

on housing upper section
20038/10 E –08.96–
Page 5
Install housing upper section (5) on assembly jig.

Apply a thin coat of sealing paste to sealing surface.
section.
tion.
Remove guide pins.


20038/10 E –08.96–
Page 6

Note
type filter.

Mount retaining clamp (4) for ratchet lever on connect-
ing housing (5) with spring washers (3) and socket head
screws (2).
20038/10 E –11.92–
Page 7
Installing elbow, driving end

Insert O-rings (2), (3) and (9) and sealing ring (8) into
annular grooves of elbow (4) and coat with petroleum
jelly.
Mount and secure elbow to heat exchanger (1) with
washers (5) and bolts (6) and (7).
Note
Installing elbow, free end

Rub down sealing surfaces of elbow.
Insert oil transfer pipe (7) into transfer bore in heat ex-
changer.
Mount and secure elbow (3) to heat exchanger with
gasket (2), washers (4) and bolts (5) and (6).
Feed oil transfer pipe into transfer bore in elbow during
installation.
Installing engine oil filter, see 3.16.4.6.
into grooves of oil transfer bores on elbow (4) and heat
exchanger (2).
Secure elbow (4) to driving-end heat exchanger with
washers (5) and bolts (6).
20038/10 E –08.96–
Page 1
Installing engine oil heat exchanger, driving end
Insert O-rings (1) and (5) into grooves of plug-in pipes
(2) and (6) and coat with petroleum jelly.
Insert plug-in pipes into oil pan bores.
Coat O-rings (3) with petroleum jelly and insert into
grooves on housing of heat exchanger, driving end (4).
Installing oil return elbow in intermediate frame

Mount elbow (1) with new gasket (2) on intermediate
frame with hex bolts (4) and (5) and spring washers (3).
Insert plug-in pipe into elbow.
20038/10 E –08.96–
Page 2

Using lifting gear, lower heat exchanger into position on
assembly pins and introduce plug-in pipe into bore, tak-
ing care not to damage plug-in pipe.
Mount heat exchanger (1) on crankcase with securing
bolts (2) and (3) and washers.
Install remaining securing screws with washers in crank-
case.
Use torque wrench (3) to tighten securing screws (1) on

heat exchanger (2).
For engine oil filter installation, see 3.16.4a.6
Installing engine oil heat exchanger, free end

Insert O-rings (6), (7), (9) and (12) into grooves of plug-in
pipes (5), (8), (10) and (11) and coat with petroleum jelly.
Introduce plug-in pipe (11) into bore in heat exchanger
(1), free end.
Introduce remaining plug-in pipes into bores in driving
end heat exchanger.
20038/10 E –08.96–
Page 3

Using lifting gear, lower free end heat exchanger (1) into
position on assembly pins.
Introduce plug-in pipe into crankcase.
Do not damage plug-in pipe.
Secure heat exchanger to crankcase with screws (1)
and washers.
Install remaining securing screws.
Tighten securing screws with torque wrench.
Secure plug-in pipes to oil heat exchanger, driving

end
Using pry bars, press plug-in pipes (2), (3), (4) into bores
in heat exchanger, free end.
Do not shear O-rings.
Snap brackets (1) into grooves in plug-in pipes and
tighten with bolts.
20038/10 E –11.92–
Page 1
3.16.4a Engine Oil Filter with Filter Guide
1 O-ring 8 Central securing bolt

2 Filter guide 9 Filter bowl
3 Filter element 10 Plug
4 Viton sealing ring 11 Housing base
5 Gasket
6 Spring retainer a From engine oil heat exchanger
7 Vent plug b To engine oil edge-type filter
20046/20 E –08.96–
Page 2
Engine oil filter, 8V, 16V
1 Filter guide element 6 Filter bowl

2 O-ring 7 Gasket
3 O-ring 8 Micronic oil filter element
5 Washer 10 Plate
20046/20 E –08.96–
Page 3
Engine oil filter, 12V
1 Filter guide 6 Filter bowl

2 O-ring 7 Gasket
3 O-ring 8 Micronic oil filter element
5 Washer
20046/20 E –08.96–
Page 1


- - x Drain engine oil from oil heat exchanger Op. Man.
20038/10 E –11.92–
Page 1
3.16.4a.2 Removal
Removing filter bowl
Release central securing bolt (1) in filter bowl.
Do not remove bolt completely from filter bowl unless
necessary.
Remove filter bowl (1) by hand from filter guide (2).
Remove Micronic filter elements (2) from filter guides (1)

and discard.
20038/10 E –11.92–
Page 2
Removing filter guide

Remove O-ring (3) and seal (4) from filter guide.
Unscrew bolts (1) securing filter guide (2).
Remove filter guide from housing base.
Remove O-rings (1) and (2) from filter guide (3).
20038/10 E –11.92–
Page 1
Disassembling filter bowl
Press central securing bolt (1) out of spring retainer (4)
and filter bowl (3).
Remove spring retainer from filter bowl and remove seal
(5) from spring retainer.
Remove sealing ring (2) from securing bolt.
Unscrew plug (7) on filter bowl and remove with sealing
ring (6).
Note
Extracting force of spring retainer (4) min. 150 Nm.
Disassembling spring washer

Remove gasket (2) from spring retainer (1).
Remove sealing ring (3) from bore on spring retainer.
20038/10 E –02.95–
Page 1

Check filter guide and bowl for cracks using surface crack-testing method with red penetrant dye; replace components
if cracks are found.
Inspect sealing and screw-down surfaces of filter guide for damage; rub down with oilstone as required.
Check condition of thread of threaded bush and recut as required.
Inspect filter bowl for warping and damage; replace if necessary.
Check central securing bolt for damage and condition of thread; repair damage and recut thread as required.
Check spring retainer for damage and replace sealing ring in housing.
Replace O-rings, seals, sealing ring and Micronic filter element when oil filter is overhauled.
20038/10 E –11.92–
Page 1
3.16.4a.5 Assembly
Completing spring washer
Fit seal (2) on spring retainer (1).
Insert sealing ring (3) in spring retainer bore.
Mounting filter bowl

Fit sealing ring (2) on central securing bolt (1).
Insert securing bolt in bore in filter bowl (3).
Place assembly sleeve (1) over securing bolt (2) in filter

bowl (3).
20038/10 E –11.93–
Page 2
Fit preassembled spring retainer (5) via assembly

sleeve onto centre screw (1) with sealing ring (2).
Note
Do not damage sealing ring (4).

Spring lug (3) must snap into place in securing bolt
groove.
Attention
It must not be possible to remove spring retainer by hand

from central securing bolt.
Insert plug (8) and sealing ring (7) in filter bowl (6) and
tighten.
Preassembling filter guide

Insert O-ring (1) and (2) in annular grooves on filter guide
(3) and coat with ”petroleum jelly”.
20038/10 E –12.95–
Page 1
Installing filter guide
Mount filter guide (2) on housing base and secure with
Insert O-ring (3) in annular groove on filter guide and
Fit gasket (4) via journal of filter guide and coat with pe-
troleum jelly.
Installing filter element and bowl
Note
Only remove filter from its packaging at this point.

Fit Micronic oil filter element (2) on filter guide (1).
Place filter bowl (3) over filter element onto filter guide.
Secure bowl with central bolt (2) and tighten with torque
wrench (1) to specified torque. For torque setting, see
Section 1.3.
20038/10 E –12.95–
Page 1
3.16.4b Engine Oil Filter Suspended with Intermediate Housing
1 O-ring 12 O-ring
3 Cover 14 Screw
4 Spring washer 15 Connector
5 Screw 16 O-ring
6 Intermediate housing 17 O-ring
8 Blanking plug 19 Screw
9 Snap ring 20 Throwaway oil filter
10 Sealing ring 21 Oil heat exchanger, driving end
11 Plug 22 Oil heat exchanger, free end
20046/20 E –08.96–
Page 2
Engine oil filter suspended with intermediate housing
1 Oil heat exchanger, driving end 8 O-ring

2 Oil heat exchanger, free end 9 O-ring
3 Housing base 10 Throwaway oil filter
4 O-ring 11 O-ring
5 O-ring 12 Intermediate housing
6 Cover 13 Connector
7 O-ring
20046/20 E –08.96–
Page 1


- x x Remove oil heat exchanger 3.16.3a.2
20046/20 E –08.96–
Page 1
3.16.4b.2 Removal
Removing throwaway oil filter
Release throwaway oil filter (1) with strap wrench from
connector (2).
Unscrew throwaway oil filter (2) from connector (1).
Removing connector
Unscrew securing screws (1) on connector (2), (3) and
(4).
Remove screws and washers.
Remove connector from intermediate housing.
20046/20 E –08.96–
Page 2
Removing intermediate housing

Remove O-ring (3) and (4) from intermediate housing
(1).
Remove securing screws (2) on intermediate housing.
Remove intermediate housing from housing lower sec-
tion.
Removing cover
Unscrew securing screws (2) on cover (3).
Remove cover from housing lower section and O-rings
from cover.
20046/20 E –08.96–
Page 1
Disassembling intermediate housing
Remove snap ring (4) with snap ring pliers.
Remove blanking plug (3) and O-ring (2) from bore on
intermediate housing (1).
Remove O-ring from blanking plug.
Unscrew plug (6) and sealing ring (5) if necessary.
20046/20 E –08.96–
Page 1

Clean all components and ensure oil channels are perfectly clean.
Check intermediate housing and connector for cracks using surface crack-testing method with red penetrant dye;
replace components if cracks are found.
Check sealing and mating faces on intermediate housing, connector and cover for damage and smooth with oilstone.
Check thread on connector for ease of movement and rechase as necessary.
Replace throwaway oil filter and O-rings.
20046/20 E –08.96–
Page 1
3.16.4b.5 Assembly
Assembling intermediate housing
groove of blanking plug (3) without twisting.
Insert blanking plug into bore on intermediate housing
(1).
Insert snap ring (4) with snap ring pliers into groove of
bore.
Insert plug (6) and sealing ring (5) on intermediate hous-
ing and tighten.
20046/20 E –08.96–
Page 1
Installing cover
into grooves in cover (1).
Mount cover (3) with screws (2) and spring washers on

housing lower section (1).
Tighten screws.
Installing intermediate housing

Coat O-rings (1), (2) and (3) with petroleum jelly and in-
sert into grooves in intermediate housing (4).
20046/20 E –08.96–
Page 2
Mount intermediate housing (1) with screws (2) and

spring washers on housing lower section.
Tighten screws.
into grooves in intermediate housing.
Installing connecting section

Mount connector (2), (3) and (4) with screws (1) and
spring washers on intermediate housing.
Tighten screws.
Installing throwaway oil filter

Mount throwaway oil filter (2) on connector (1) by hand.
20046/20 E –08.96–
Page 3
Tighten throwaway oil filter (1) with strap wrench on con-

nector (2).
Note
When tightening throwaway oil filter, do not dent filter

casing.
20046/20 E –08.96–
Page 1
3.16.5a Pressure Limiting Valve, Pressure Relief Valves and Bypass Valves
1 Pressure limiting valve, 5.5 bar 8 Plug

2 Valve housing 9 Pressure relief valve, 6.0 bar
3 Valve plunger 10 Valve housing
4 Spring 11 Pressure spring
5 Guide sleeve 12 Valve plunger
6 Snap ring 13 Valve seat insert
Bypass valve 1.8 bar to 2.6 bar

1 Pressure spring
2 Valve cone
3 O-ring
4 Sealing ring
5 Valve seat
20054/00 E –10.93–
Page 2
Pressure relief valve
1 Outlet to oil pan 7 Oil pressure before engine oil filters

2 Housing base 8 Rerouted oil
3 Snap ring 9 Control oil (clean oil after engine oil edge-type filter)
4 Guide sleeve 10 Valve plunger
5 Pressure spring 11 Plug
6 Valve housing
20054/00 E –10.93–
Page 3
Bypass valves
1 Housing base
2 Pressure spring
3 Valve cone
4 Initial pressure after filter element
5 Supply pressure before filter element
6 Valve seat
Pressure relief valve, 6.0 bar (bypass valve)

1 Inlet pressure before oil cooler insert
2 Snap ring
3 Valve seat insert
4 Initial pressure after oil cooler insert
5 Housing base
6 Valve plunger
7 Valve housing
8 Pressure spring
20054/00 E –10.93–
Page 1


20038/10 E –11.92–
Page 1
3.16.5a.2 Removal
Removing bypass valve
Remove valve seats (1) from housing base (2) and con-
necting housing (3).
Withdraw valve seat (2) from bore in housing base (1).

Remove O-ring (3) and sealing ring (4).
Remove valve cone (1) and spring (2) from bore in hous-
ing base (3).
20038/10 E –11.92–
Page 2
Removing pressure limiting valve

Remove retainer (2) securing pressure limiting valve (3)
with bolt and washer from housing base (1).
Press pressure limiting valve out of bore in housing base

(1) with plastic mandrel.
Withdraw pressure limiting valve (2) from bore in hous-

ing base (3).
Remove O-ring (1).
20038/10 E –11.92–
Page 3
Remove pressure relief valve

Remove pressure relief valve (2) from housing base (1).
Withdraw pressure relief valve (3) from bore in housing

base (2).
Remove O-ring (1).
20038/10 E –11.92–
Page 1
Disassembling pressure limiting and relief valves
Note
Fit a locating ring (3) onto the valve housing so as not

to upset the fit diameter on the valve housing.
Press guide sleeve downwards using a hand press (1)
and suitable mandrel (2).
Remove snap ring from valve housing (4) with snap ring
pliers.
Caution
Spring tension
Disassemble pressure relief valve in same way.
Remove snap ring (2) from opposite end of valve hous-

ing (3) with snap ring pliers (1).
Press plug (1) out of valve housing (2) using a suitable

mandrel (3).
Remove O-ring from plug.
20038/10 E –02.95–
Page 1

Check valve housing for cracks using magnetic crack-testing method with fluorescent magnetic powder.
Inspect valve housing, plunger, valve seat insert and springs for signs of wear.
Rub down with polishing cloth as required; replace components if necessary.
Lap valve seats as required.
Replace springs if valves do not open at specified pressure.
Adjust bore gauge and measure register bores.
20038/10 E –11.92–
Page 1
3.16.5a.5 Assembly
Pressure relief valve

2 Guide sleeve 7 Plug
3 Spring 8 Snap ring
4 Valve housing
5 Valve plunger a Start of opening (stamped)
Assembling pressure limiting valve

Insert valve plunger, spring, guide sleeve and snap ring
into valve housing (4).
Fit locating ring (3) on valve housing.
Using suitable mandrel (2) and hand press (1), press in-
serted components downwards against spring pres-
sure.
Install snap ring in groove in valve housing with snap ring
pliers.
Caution
Spring tension
Relieve pressure in hand press and remove locating
ring.
20038/10 E –02.95–
Page 2
Equip plug with O-ring and coat with petroleum jelly.

Press plug (2) into valve housing (3) using a suitable drift
(1).
Install snap ring in groove in valve housing with snap ring
pliers.
Caution
Spring tension
Check start of opening: 5.5 bar +
1.5 bar at an oil tem-
°
perature of 90 C with SAE30 oil.
Assembling pressure relief valve

Insert valve plunger (2) and spring (5) into valve housing
(1).
Spring (5) for 6.0 bar opening pressure (A).
Fit valve seat insert (4) and snap ring (3).
Slide assembly tool (2) over valve housing (3).

Using suitable drift (1) and plastic mallet, drive home
valve seat insert with snap ring.
Caution
Spring tension
Inspect pressure relief valves for leaks on test pump and
check operation.
Start of opening: 6 bar ±0.8 bar
Note
The opening pressure is stamped on the end face of the

valve housing.
20038/10 E –12.95–
Page 1
Note
Ensure that components and bores are particularly

clean.
Installing bypass valve
Insert spring (2) in bore in housing base (3) and connect-
ing housing with valve cone (1).
Insert O-ring (3) into groove on valve seat (2) and coat
Position O-ring (4) on sealing surface of housing base
(1) and connecting housing.
Install valve seat over valve cone and spring in bore in
housing base and connecting housing.
Secure valve seats (1) in housing base (2) and connect-

ing housing (3).
20038/10 E –12.95–
Page 2
Installing pressure limiting valve

Insert O-ring (1) into groove on pressure limiting valve
(2) and coat with petroleum jelly.
Coat bore for pressure limiting valve in housing lower
section (3) with petroleum jelly.
Carefully slide pressure limiting valve into bore in hous-
ing base.
Align pressure limiting valve so that chamfer points to-

wards retainer seat (see picture below).
Press valve into bore in housing base (2) using plastic
mandrel (1).
Secure valve (3) to housing base (1) with retainer and

bolt (2).
20038/10 E –12.95–
Page 3
Installing pressure relief valve

Insert O-ring (1) into groove on pressure relief valve (3)
and coat with petroleum jelly.
Fit sealing ring on pressure relief valve.
Coat thread with engine oil.
Coat bore for pressure relief valve in housing lower sec-
tion (2) with petroleum jelly.
Install pressure relief valve with sealing ring into bore in
housing base.
Secure pressure relief valve (2) in housing base (1).

Make sure that O-ring is not shorn off during installation.
20038/10 E –12.95–
Page 1
3.16.6 Centrifugal Oil Filter

Version 11.31005-0014
1 Housing cover 7 Valve plunger

2 Rotor 8 Housing
3 Nozzle 9 Oil inlet
4 O-ring 10 Clean-oil outlet
5 Plug 11 Nut
6 Pressure spring
20058/0 E –10.94–
Page 2
Centrifugal oil filter
ET 16/297–2
1 Housing 9 Nozzle
2 Eyebolt 10 Housing cover
3 Grooved pin 11 Seal
4 Rotor 12 Nut
5 Seeger V-ring 13 Plug
7 Sleeve 15 Valve
8 O-ring 16 Spring
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Page 1


20058/0 E –03.93–
Page 1
3.16.6.2 Removal
Removing centrifugal oil filter, 8V, 12V
Unscrew nut (2) securing centrifugal oil filter (1) from
vent housing (5) and remove with washer (3).
Remove centrifugal oil filter and gasket (4).
For vent housing removal, see Section 3.1.7c.2
Removing centrifugal oil filter, 12V, 16V

Unscrew nut (2) securing centrifugal oil filter (1) from
vent housing (5) and remove with washer (3).
Remove centrifugal oil filter and gasket (4).
For vent housing removal, see Section 3.1.7b.2
20046/20 E –08.96–
Page 1
Removing cover
Slacken nuts (1) until eyebolts (2) can be disengaged
and swung out.
Removing rotor
Raise cover (1).
Carefully remove rotor assembly (3) from housing (4).
Allow oil to drain.
Take care not to damage bearings and journals.
Remove gasket (2).
20058/0 E –03.93–
Page 2
Disassembling rotor
Clamp rotor (2) in bench vice. Do not overtighten vice (3)
and make sure jaws engage flats on rotor base.
Remove nut (1) of rotor cap with socket wrench.
Carefully remove rotor (1).

Take care not to damage bearing journal (2).
20058/0 E –03.93–
Page 3
Remove contaminated filter element (3) from rotor cap

(2) and discard.
Remove O-ring (6) from base of rotor (5).
Remove base from bench vice.
1 Guides on rotor cap
4 Recesses for guides on cap
Removing nozzle
Unscrew nozzle (2) from base of rotor (1).
20058/0 E –03.93–
Page 4
Removing minimum pressure valve and eyebolts

Remove plug (7) from housing (1).
Remove sealing ring (6).
Remove spring (5) and plunger (4).
Drive grooved pins (3) out of housing with punch.
Remove eyebolts (2).
20058/0 E –03.93–
Page 1

Clean components of centrifugal oil filter.
Remove deposits from inside of rotor cap by scraping with a spatula if necessary.
Using surface crack-testing procedure and red penetrant dye, check housing cover and housing lower section for
cracks.
Remove irregularities from sealing faces and screw-down surfaces by rubbing down with oilstone or polishing cloth.
Replace damaged eyebolts and nuts.
If bearing bushes in housing cover are damaged or loose, replace components.
Check that nozzle bore, dia.1.8, is clean and unobstructed; replace as necessary.
Check plunger and spring of minimum pressure safeguard for wear, replace if necessary.
Check rotor bearing journal for wear, smooth with emery cloth as required, replace rotor if necessary.
Replace sleeve. – It is recommended to replace the sleeve after approx. 100 operating hours.
20058/0 E –08.96–
Page 1
3.16.6.5 Assembly
Note
Ensure that all components are perfectly clean.
Installing minimum pressure safeguard and eye-

bolt
Coat piston (4) and compression spring (5) with engine
oil and insert into bore on housing (1).
Screw in plug (7) with sealing ring (6) and tighten.
Opening pressure 1.2 bar + 0.8/-0.2 bar.
Place eyebolts (2) in position and drive grooved pins into
locating bores.
Installing nozzle
Install nozzle (2) in base of rotor (1) and tighten.
Check that nozzle is free of obstruction.
20058/0 E –03.93–
Page 2
Assembling rotor
Clamp base of rotor (5) in bench vice. Do not overtighten
and make sure jaws engage flats of base.
Insert new filter element (3) in rotor cap (2).
Carefully place cap in position on base of rotor and turn
cap on shaft until guides (1) of cap engage recesses (4)
in base of rotor.
Fit O-ring (6) on rotor lower section and coat with petro-
leum jelly.
Tightening rotor
Mount nut (1) on rotor spindle and tighten to correct
torque with torque wrench.
For torque settings, see Section 1.3.
Note
When tightening nut on rotor cap (2) ensure that cap and
base of rotor are in metal-to-metal contact.
The O-ring forms a seal inside the rotor cap and does not
provide a seating face.
Remove rotor from bench vice (3).
20058/0 E –08.96–
Page 3
Installing cover
Place gasket (2) in position on housing base (4).
Install preassembled rotor (3) in housing base.
Check that rotor rotates freely.
Carefully place cover (1) in position.
Securing cover
Swing eyebolts (2) into position.
Tighten nuts (1) diagonally and evenly.
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Page 1
Installing centrifugal oil filter, 8V, 12V
For vent housing installation, see Section 3.1.7c.6
Mount centrifugal oil filter (1) with gasket (4), nuts (2)
and washers (3) on vent housing (5) and tighten.
Installing centrifugal oil filter, 12V, 16V

For vent housing installation, see Section 3.1.7b.6
Mount centrifugal oil filter (1) with gasket (4), nuts (2)
and washers (3) on vent housing (5) and tighten.
20046/20 E –08.96–
Page 1
3.17 Speed Transmitter Drive

Contents
3.17.1 Speed transmitter drive on camshaft drive gear

3.17.1.2 Removal
3.17.3 Speed transmitter drive (left engine side)

3.17.3.2 Removal
20046/20 E –12.95–
Page 2

A
S4

Engine oil SAE10 Shell Rotella X10 W 40504
Cleaning agent P3-Solvclean 40022
Dry compressed air
Caution
20046/20 E –12.95–
Page 1
3.17.1 Speed Transmitter Drive on Camshaft Drive Gear
1 Flange 5 Drive shaft

3 Electric transmitter 7 O-ring
4 O-ring
20042/10 E –10.94–
Page 2
Arrangement of speed transmitter drive on camshaft drive gear
1 Speed transmitter 6 O-ring

2 Flange 7 Shaft seal
3 Nut 8 Snap ring
4 Spring washer 9 Drive shaft
5 Screw 10 Crankcase
20042/10 E –10.94–
Page 1


- x x Disconnect cable at speed transmitter -
- x x Remove speed transmitter 3.84.2.2
20038/10 E –10.94–
Page 1
3.17.1.2 Removal
Remove nuts from flange (1).
Remove flange from crankcase.
Remove O-ring from groove on flange.
Remove carrier from camshaft drive gear (see 3.6.1.2).
20038/10 E –11.92–
Page 1

Using the surface crack-testing method and red penetrant dye, check flange for cracks.If cracks are detected, replace
part.
Check mating face and locating bore on flange for wear, damage and deformation. Smooth with oilstone as required.
Replace O-rings.
20038/10 E –11.92–
Page 1
Installing flange
Install driver on camshaft drive gear, see 3.6.1.6.
Insert O-rings (2) and (4) into grooves of flange (3) and
Mount flange with O-ring on crankcase (1), tighten with
nuts (5) and spring washers (6).
Install speed transmitter (see 3.84.2.6).
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Page 1
3.17.3 Speed Transmitter Drive (Left Engine Side)
1 Flange 9 Drive shaft

2 Driver 10 O-ring
4 Spring washer 12 Housing
6 Intermediate flange 14 Hex bolt
7 O-ring 15 Washer
8 Socket-head screw 16 Hex bolt
20038/10 E –11.93–
Page 2
Speed transmitter drive arrangement (left engine side)

2 Bearing flange 11 Bolt
3 Intermediate flange 12 Electric speed transmitter
4 O-ring 13 O-ring
5 Washer 14 Snap ring
6 Bolt 15 Housing
8 Bolt 17 O-ring
9 Drive shaft
20038/10 E –11.93–
Page 1


- x x Disconnect cable at speed transmitter, left side -
- x x Remove cable at speed transmitter, left side 3.84.2.2
20038/10 E –11.92–
Page 1
3.17.3.2 Removal
Removing drive
Remove bolts (1) from housing (2).
Remove housing from bearing flange.
1
2
L87 10368.a
Remove bolts from carrier.

Remove carrier from flange.
Removing flange from pump shaft
Caution
Danger!
The flange shall be hydraulically removed from the pump shaft by specially trained personnel only.
Max. permissible expansion pressure must not be exceeded.
20038/10 E –11.92–
Page 2
Removing flange
Screw draw spindle (1) into pump shaft and tighten.
Install hydraulic puller so that catcher plate (5) has at
least 5 mm clearance.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Washer
6 Grub screw
Connect H.P. line (2) to screw connection on hydraulic

puller and hydraulic hand pump and tighten.
Fill hydraulic hand pump with SAE 10 engine oil and op-
erate pump plunger until clear resistance is felt at oper-
ating lever.
Allow time for pressurized expansion fluid to penetrate
interference fit.
Relieve pressure in hand pump.
Remove hydraulic puller with draw spindle, H.P. line (2)
and catcher plate (1).
Unscrew bolts from intermediate flange.

Remove intermediate flange with O-ring.
20038/10 E –11.92–
Page 1

Using the surface crack-testing method with red penetrant dye, check the housing and intermediate flange for cracks.
Using magnetic crack-testing method with fluorescent magnetic powder, check drive shaft, flange and driver for cracks.
Replace respective parts if cracks are found.
Check mating faces of intermediate flange, carrier, flange and housing for evenness, smooth with oilstone as required.
Check carrier and drive shaft splines for wear, replace part if necessary.
Check taper seat 1:50 on flange for wear.
Smooth out slight wear with polishing cloth as required, or replace if necessary.
Check taper seat 1:50 in flange with taper gauge, replace if necessary.
Check housing sealing surfaces for wear. Smooth with polishing cloth as required, or replace if necessary.
Check condition of threads in tapped bores and recut as required.
Replace O-rings.
20038/10 E –11.92–
Page 1
Insert O-ring into groove on intermediate flange and
Install intermediate flange with socket-head screws on

bearing flange and secure.
Installing flange
Clean press-fit surface on drive shaft (2) and in flange
(1) with denaturated ethanol.
Coat surfaces with expansion fluid (SAE 10 engine oil).
Push flange onto drive shaft taper.
Measure and make note of clearance between end of
shaft and end of flange (for calculating installation
travel).
20038/10 E –08.96–
Page 2
Caution
Danger!
The flange shall be hydraulically mounted on the pump shaft by specially trained personnel only.
Installing installation device
Install and secure installation device with draw spindle
(1) on coolant pump shaft.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Washer
6 Grub screw

on installation device and hydraulic hand pump.
pump.
Pretighten thrust nut (2) on installation device with open-
end wrench, and operate hydraulic hand pump at the
same time.
At the beginning of the installation process it is very im-
portant that an expansion pressure is selected which is
just high enough to allow the specified push-on distance
of 3.8 mm - 1.3 to be reached.
Max. permissible expansion pressure Pmax = 1500 bar
must not be exceeded.
Wait approx. 60 minutes before relieving pressure on in-
stallation device thrust plate (3).
Remove draw spindle with installation device from drive
shaft.
Check flange installation travel.
20038/10 E –11.92–
Page 3
Check flange and carrier mating faces for evenness,

smooth with oilstone if necessary.
Check carrier and drive shaft splines for wear, replace
if necessary.
Install snap ring in carrier.
Secure carrier to flange with bolts and spring washers
and tighten diagonally and evenly.
Check housing mating surface face for evenness,

Insert O-ring into groove on housing and coat with petro-
leum jelly.
1 Install and secure housing (2) with bolts (1) and spring
2 washers.
For installation of speed transmitter, see 3.84.3.6.
L87 10368.a
20038/10 E –08.96–
Page 1
3.18 Starting System

Contents
3.18.1 Compressed air distributor

3.18.1.2 Removal
3.18.1.5 Assembly
3.18.1.7 After-installation operations (12V)
3.18.1.7a After-installation operations (16V)
3.18.1.7b After-installation operations (8V)
3.18.2 Starting valve

3.18.2.2 Removal
3.18.3 Starting air lines

3.18.3.2 Removal
3.18.4 Compressed air starter

3.18.4.2 Removal
3.18.4a Compressed air starter

3.18.4a.2 Removal
3.18.5 Electric starter

3.18.5.2 Removal
20046/20 E –08.96–
Page 2

A
S4
S 4.1
S 6.5
S 6.19

Magnifier
Liquid nitrogen
Liquid nitrogen
Hot lubricating paste Ultratherm 50494
Cleaning agent P3-Solvclean KW 40022
Multi-purpose grease
Engine oil
Emery paste
Hydrochloric acid
Dry compressed air

Caution
20046/20 E –08.96–
Page 1
3.18.1 Compressed Air Distributor

Compressed air distributor, 8V, 16V
ET18/244A
1 Reduction union 10 Driver

2 Sealing ring 11 Spacer
3 Compressed air distributor 12 Spring washer
4 Gasket 13 Hex nut
5 Snap ring 14 Sealing ring
6 Flange 15 Reduction union
8 Drive shaft 17 Spring washer
9 Stress bolt
20046/20 E –08.96–
Page 2
Compressed air distributor, 8V, 16V
1 Distributor disc 9 Plate

2 Housing 10 Plate
3 Drive shaft 11 Round-head grooved pin
4 Nut 12 Round-head grooved pin
5 Distributor shaft 13 Spring washer
7 Gasket 15 Dry bush
8 Cover gasket 16 Dry bush
20046/20 E –08.96–
Page 3
Compressed air distributor, 12V
1 Spacer 9 Sealing ring

2 Flange 10 Reduction union
3 Spring washer 11 Drive shaft
4 Compressed air distributor 12 Snap ring
7 Sealing ring 15 Socket-head screw
8 Reduction union
20046/20 E –08.96–
Page 4
1 Distributor disc 9 Plate

2 Housing 10 Plate
3 Drive shaft 11 Round-head grooved pin
4 Nut 12 Round-head grooved pin
5 Distributor shaft 13 Spring washer
7 Gasket 15 Dry bush
8 Cover gasket 16 Dry bush
20046/20 E –08.96–
Page 5
Arrangement compressed air distributor
1 Drive gear 11 Cover

2 Stress bolt 12 Nut
3 Drive shaft 13 Distributor disc
4 Crankcase 14 Distributor shaft
5 Nut 15 Intermediate shaft
6 Coupling 16 Screw
7 Housing 17 O-ring
8 Sealing plate 18 Snap ring
9 Spring washer 19 Driver
10 Screw 20 Camshaft
20046/20 E –08.96–
Page 1


- - x Switch off compressed air Op. Man.
- x x Remove compressed air lines on compressed air distributor 3.18.3.2
20046/20 E –08.96–
Page 1
3.18.1.2 Removal
Remove compressed air distributor
Remove securing bolts (1).
Remove compressed air distributor (2) and drive shaft
from flange.
Withdraw drive shaft from driver on camshaft gear.
Removing flange
Remove nuts (2) from flange (1).
Remove flange from crankcase with jackscrews.
Remove O-ring from groove on flange.
20038/10 E –11.92–
Page 1
Disassembling compressed air distributor
Remove cover (1) from compressed air distributor (2).
Remove cover gasket.
Remove distributor shaft with distributor disc (7) from
compressed air distributor.
Remove drive shaft (5) and snap ring (6) from coupling
(4).
Heat coupling on drive shaft (3) to approx. 200 °C and
remove.
Note
Remove coupling only if necessary.
Secure distributor shaft in vice.

Remove nut on distributor disc with box wrench.
Use mandrel to release distributor disc from distributor
shaft.
L 63 015V
20038/10 E –11.92–
Page 1

Check coupling on intermediate shaft for wear and damage. If necessary, remove coupling from intermediate shaft and
replace.
Check follower of camshaft drive gear for wear and damage; replace if necessary.
Check that surfaces of sealing faces on distributor washer and housing are in perfect condition, replace if necessary.
Check dry bushes in compressed air distributor housing for wear, replace if necessary.
Check taper faces of distributor disc and distributor shaft for wear; if necessary apply fine-grade grinding paste and
turn distributor disc on shaft to grind seat.
Check driver nose of distributor shaft, groove in drive shaft and friction face for wear; replace parts as necessary.
Check all sealing surfaces on flange, compressed air distributor housing and cover for evenness, smooth with oilstone
if necessary.
Make sure air channels and bores are perfectly clean.
Replace gaskets.
20038/10 E –11.92–
Page 1
3.18.1.5 Assembly
Assembling distributor disc
Clean taper surface in the distributor disc and on the dis-
tributor shaft with denaturated ethanol and blow clear
with compressed air.
Mount distributor disc on distributor shaft.
Coat thread of nut with engine oil.
Screw nut manually onto distributor shaft, place in posi-
tion with box wrench but do not tighten.
L 63 015V
Assembling compressed air distributor

Clean coupling (4) and drive shaft (3) with denaturated
ethanol and degrease.
Cool drive shaft (3) with liquid nitrogen to -160 °C .
Caution

tions in 1.5.
Heat coupling (4) on hot plate to 200 °C, with protective
glove or suitable tool install on drive shaft as far as stop.
Coat drive shaft with engine oil and insert in compressed
air distributor housing (2).
Coat distributor shaft (7) with the engine oil and insert in
compressed air distributor housing (2) with distributor
disc.
Make sure that driver journal is properly engaged.
Install air distributor housing and loosely tighten with
bolts and washers.
Install drive shaft (5) in coupling (4) and secure with snap
ring (6).
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Page 1
Installing flange
Insert O-ring into groove on flange and coat with ”petro-
leum jelly”.
Install flange (1) in crankcase and secure with nuts (2)
and spring washers.
Install compressed air distributor

Install gasket on compressed air distributor.
Install compressed air distributor (2) in flange.
At the same time, make sure that drive shaft engages
in driver on camshaft drive gear.
Install compressed air distributor on flange with bolts (1)
and spring washers.
20038/10 E –08.96–
Page 1
3.18.1.7 After-Installation Operations, 12V

Setting compressed air distributor, 12V
Install TDC pointer (1) and graduated disc (2).
Adjustment of degree disc at TDC, see 3.5.1.4.
The vibration damper is also provided with graduations
(order-specific).
For determining the crank angle, see 3.11.4.7.

Set crankshaft journal of cylinder B1 in direction of en-
gine rotation to 4° after firing TDC.
Note
Crank angle after TDC to mm piston stroke after TDC:

4° crank angle corresponds to 0.286 mm piston stroke.
1 Piston at firing TDC (inlet and exhaust valves closed).
2 Piston 4 degrees after TDC
A Piston stroke
20046/20 E –08.96–
Page 2
Compressed air distributor, 12V – long firing order

Remove cover from compressed air distributor.
Release nut on distributor shaft.
Coat distributor shaft with engine oil and insert in com-
pressed air distributor.
Make sure driver engages.
Fit the distributor disc onto taper and turn it so that the
bore (b) is flush with the bore (a) for cylinder B1.
Hold distributor disc firmly and slightly tighten nut.
Note
Tighten nut on distributor disc only after it has been re-

moved.
Direction of rotation of camshaft

Direction of rotation of distributor disc, for
setting
Viewed from driving end:
Cylinders A1 to A6 left side
Cylinders B1 to B6 right side
a Connection cylinder B1
b Setting of distributor disc
Clamp distributor shaft firmly in vice (use soft jaws).

Use torque wrench (2) to tighten nut on distributor shaft
Reinstall distributor shaft with distributor disc and check
the distributor disc setting.
Check radial coupling clearance with dial gauge on bore
of distributor disc, hole radius R = 17.5 mm.
Permissible radial clearance ± 0.5 mm.
20046/20 E –08.96–
Page 3
1 Cover 4 Disc running face

2 Nut 5 Drive shaft
3 Distributor disc 6 Distributor housing
x = Layout – marking of cylinder connections – compressed air distributor-long firing order
20046/20 E –08.96–
Page 4
Fitting cover
Place gasket on cover (1).
Install and secure cover (1) with bolts (2) and spring
washers.
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Page 1
3.18.1.7a After-Installation Operations, 16V

Setting compressed air distributor, 16V
Install TDC timer (1) and timing disc (2).
For setting timing disc in TDC, see 3.5.1.4.
The vibration damper is also provided with graduations
(order-specific).

Note

4° crank angle corresponds to 0.286 mm piston stroke.
1 Piston at firing TDC

A Piston stroke
20046/20 E –08.96–
Page 2
Compressed air distributor, 16V – long firing order

Release nut on distributor shaft.
pressed air distributor.
Note

moved.

Direction of rotation of distributor disc,
for setting
b Setting of distributor disc

Permissible radial clearance ± 0.5 mm.
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Page 3

2 Nut 5 Drive shaft
20046/20 E –08.96–
Page 4
Fitting cover
Install and secure cover with bolts (2) and spring
washers.
20046/20 E –08.96–
Page 1
3.18.1.7b After-Installation Operations, 8V

Adjusting starting air distributor, 8V
Note

4° crank angle corresponds to piston stroke of 0.286
mm.
1 Piston at firing TDC

A Piston stroke
Starting air distributor 8V – long firing order
pressed air distributor, making sure driver engages.
Note

moved.
Direction of rotation of distributor disc,
for setting

b Position of distributor disc
20046/20 E –08.96–
Page 2

2 Nut 5 Drive shaft
20046/20 E –08.96–
Page 3

Permissible radial play ±0.5 mm.
Fitting cover
Install and secure cover (1) with bolts (2) and spring
washers.
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Page 1
3.18.2 Starting Valve
1 Sealing ring
2 Non-return valve
3 Union
20058/0 E –03.93–
Page 2
Starting valve layout

1 Banjo bolt
2 Sealing ring
3 Union
4 Sealing ring
5 Non-return valve
6 Starting air line
20058/0 E –03.93–
Page 1


- x x Remove starting air lines from cylinder head 3.18.3.2
20058/0 E –03.93–
Page 1
3.18.2.2 Removal
Removing starting valve
For removal of banjo screw and compressed air line, see
3.18.3.2.
1 Union
2 Cylinder head
Using socket (1) and ratchet wrench, remove union from

cylinder head.
20046/20 E –08.96–
Page 2
Use curved removal tool (2) to remove starting valve in-

sert (1) from cylinder head.
Take sealing ring out of cylinder head bore and remove
from starting valve insert.
20038/10 E –11.92–
Page 1

Clean all parts.
Check thread in cylinder head and thread on valve body for ease of movement, replace starting valve if necessary.
Check threads on banjo screw for ease of movement, recut thread or replace if necessary.
Check pressurized support surface of valve body for wear, replace valve body if necessary.
Check union for damage, check thread ease of movement; replace union if necessary.
Screw starting valve insert into device and check for leaks in fuel bath (diesel).
Test pressure: 0.5 bar
If leaks are detected, replace starting valve insert.
Note
The starting valve insert must not be dismantled.
1 Union
2 Starting valve insert
3 Sealing ring
4 Spring
5 Test device
6 Compressed air supply
20046/20 E –08.96–
Page 1
Installing starting valve
Coat sealing rings with assembly paste.
Place sealing rings on both sides of starting valve insert
collar.
Use curved removal tool (2) to install starting valve insert
(1) in cylinder head bore.
Coat thread of union (1) evenly with assembly paste.

Install union in cylinder head.
Note
Make sure union is perfectly clean.
Using torque wrench, tighten union as per Tightening

Specification 1.3.
For installation of banjo screw and pipeline, see
3.18.3.6.
20046/20 E –08.96–
Page 1
3.18.3 Starting Air Lines

Starting air liner, 8V
1 Holder, left 18 Compressed air line A3 35 Grommet

2 Holder, right 19 Compressed air line A4 36 Pipe clamp half
3 Hex bolt 20 Compressed air line B1 37 Pipe clamp half
4 Spring washer 21 Compressed air line B2 38 Spring washer
5 Intermediate element 22 Compressed air line B3 39 Hex bolt
6 Hex bolt 23 Compressed air line B4 40 Grommet
7 Spring washer 24 Sealing ring 41 Pipe clamp half
8 Compressed air line A1 25 Banjo bolt 42 Pipe clamp half
9 Compressed air line A2 26 Sealing ring 43 Hex bolt
10 Compressed air line A3 27 Banjo bolt 44 Spring washer
11 Compressed air line A4 28 Grommet 45 Grommet
12 Compressed air line B1 29 Pipe clamp half 46 Pipe clamp half
13 Compressed air line B2 30 Spring washer 47 Spring washer
14 Compressed air line B3 31 Hex nut 48 Hex bolt
15 Compressed air line B4 32 Washer 49 Hex bolt
16 Compressed air line A1 33 Hex bolt 50 Bracket
17 Compressed air line A2 34 Hex bolt 51 Washer
20046/20 E –08.96–
Page 2
Starting air lines, 12V
1 Holder, left 22 Compressed air line A3 42 Washer

2 Holder, right 23 Compressed air line A4 43 Hex bolt
3 Hex bolt 24 Compressed air line A5 44 Hex bolt
4 Spring washer 24 Compressed air line A6 45 Grommet
5 Intermediate element 26 Compressed air line B1 46 Pipe clamp half
8 Compressed air line A1 29 Compressed air line B4 49 Hex bolt
9 Compressed air line A2 30 Compressed air line B5 50 Grommet
10 Compressed air line A3
31 Compressed air line B6 51 Spring washer
13 Compressed air line A6 33 Banjo bolt 53 Hex bolt
14 Compressed air line B1 34 Sealing ring 54 Bracket
15 Compressed air line B2 35 Banjo bolt 55 Washer
16 Compressed air line B3 36 Sealing ring 56 Pipe clamp half
17 Compressed air line B4 37 Banjo bolt 57 Pipe clamp half
18 Compressed air line B5 38 Grommet 58 Pipe clamp half
19 Compressed air line B6 39 Pipe clamp half 59 Grommet
20 Compressed air line A1 40 Spring washer 60 Spring washer
21 Compressed air line A2 41 Hex nut 61 Hex bolt
20046/20 E –08.96–
Page 3
Starting air lines, 16V
1 Holder, left 18 Compressed air line A7 35 Grommet

2 Holder, right 19 Compressed air line A8 36 Pipe clamp half
5 Intermediate element 22 Compressed air line B7 39 Hex bolt
6 Hex bolt 23 Compressed air line B8 40 Grommet
7 Spring washer 24 Sealing ring 41 Pipe clamp half
8 Compressed air line A5 25 Banjo bolt 42 Pipe clamp half
9 Compressed air line A6 26 Sealing ring 43 Hex bolt
10 Compressed air line A7 27 Banjo bolt 44 Spring washer
11 Compressed air line A8 28 Grommet 45 Grommet
12 Compressed air line B5 29 Pipe clamp half 46 Pipe clamp half
13 Compressed air line B6 30 Spring washer 47 Spring washer
14 Compressed air line B7 31 Hex nut 48 Hex bolt
15 Compressed air line B8 32 Washer 49 Hex bolt
16 Compressed air line A5 33 Hex bolt 50 Bracket
17 Compressed air line A6 34 Hex bolt 51 Washer
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Page 4
Air supply line to compressed air distributor
1 Air supply line 4 Spring washer

2 Grommet 5 Screw
3 Pipe clamp half
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Page 1


20038/10 E –11.92–
Page 1
3.18.3.2 Removal
Removing compressed air lines
Before disconnecting compressed air lines, mark them
with cylinder numbers in order to prevent confusion
when reconnecting.
Remove banjo screw (3) from union on cylinder head
while holding the union firmly in position.
Remove compressed air line (2) and sealing rings (1).
After removing air lines, seal all connections immedi-
ately with blanking plugs.
Release screw connections of compressed air lines (1)

and of air supply line (2).
Remove fixtures (2).

Remove compressed air lines (1) with grommets.
Disconnect air supply line.
After removing air lines, seal all connections immedi-
ately with blanking plugs.
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Page 1

Clean compressed air lines with cold cleaner.
Carry out sight check for scuffing or damage, repair or replace if necessary.
Pickle with a hydrochloric acid solution (9 parts water to 1 part hydrochloric acid), then wash with hot water and blow
dry with compressed air.
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Page 1
Installing compressed air lines
Note
Before installing, blow compressed air lines clear with

compressed air.
Do not remove blanking plugs until just before installa-
tion.
Insert compressed air lines (2) with sealing rings (1) and
banjo screw (3) in union on cylinder head and tighten
while holding union firmly in position.
Install compressed air lines (1) as previously marked ac-

cording to cylinder numbers on compressed air distribu-
tor.
Connect air supply line (2).
Install brackets (2) with grommets and secure.

Make sure that lines (1) are installed so that they are free
of strain.
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Page 1
3.18.4 Compressed Air Starter
Air starter, 8V, 12V – Version 000 174 41 02
1 Compressed air starter 5 Bracket

2 Spacer 6 Bracket
3 O-ring 7 Washer
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Page 2
Compressed air starter 000 174 41 02
1 Compressed air to starter control solenoid valve 8 Intermediate housing

2 Control valve housing 9 Gear housing with drive housing
3 Control air from starter control solenoid valve 10 Vibration damper
4 End plate with bearing housing 11 Pneumatic motor housing
5 Spacer 12 End cover with bearing housing
6 Bearing housing for roller bearing 13 Compressed air
7 Starter pinion
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Page 3
Air lines on compressed air starter, 8V, 12V
1 Holder 10 Pipe clamp half

2 Solenoid valve 11 Grommet
3 Screw 12 Screw
5 Air line 14 Nut
6 Air line 15 Plug
7 Union 16 Union
8 Sealing ring 17 Hose
9 Union 18 Union
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Page 1


- - x Disconnect electric cable from solenoid valve -
- - x Close compressed air line -
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Page 1
3.18.4.2 Removal
Remove compressed air starter
Remove air lines (1) and (5) at solenoid valve (4), air
starter (6) and retainer (3), release pipe clamp halves.
Remove compressed air hose (2) and (7) from com-
pressed air starter.
Remove solenoid valve from retainer.
Remove screws and washers (1) from clamping bracket

(6).
Withdraw compressed air starter (2) from spacer ring (4)
in flywheel housing (3) and lift off with lifting gear.
Remove O-ring (5) from starter.
Remove retainer (7) from starter.
Remove spacer (1) from flywheel housing.

Remove O-ring (2).
20046/20 E –08.96–
Page 1

Inspect and repair compressed air starter in accordance with Special Publication.
Use the surface crack-testing method with red penetrant dye to check clamping bracket, spacer ring and retainer for
cracks.Replace components exhibiting cracks.
Check mating faces of mounting brackets for wear, recondition as required.
Check mating faces of starter, spacer and brackets for evenness and wear, recondition or replace as necessary.
Check starter pinion and ring gear on flywheel for damage, wear and broken teeth, recondition if necessary and replace
parts as required.
Check retainer for damage, replace if necessary.
Replace O-rings and hose.
Check air lines for damage, replace as necessary.
Check solenoid valve, see description.
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Page 1
Install compressed air starter
Push the O-ring (5) onto the air starter (2) as far as it will
go and ensure that it is twist-free.
Fit O-ring (6) in groove on spacer ring (4).
Push spacer ring onto air starter as far as it will go.
Using lifting gear, insert air starter in flywheel housing
bore until it reaches the spacer ring stopper.
Secure air starter with clamping bracket (7), screws and
washers (1) to oil pan and/or crankcase intermediate
frame.
The spacer ring guarantees that the distance between
pinion and ring gear remains constant.
It is important that the installation position of the air
starter is correct.
Mount retainer (3) to air starter (6).

Fit solenoid valve to retainer.
Install air lines (1) and (5) at solenoid valve and air
starter and secure to the retainer with pipe clamp halves.
Screw compressed air hose (2) and (7) onto the air
starter and tighten.
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Page 1
3.18.4a Compressed Air Starter
Air starter – Version 000 174 48 02
1 Pneumatic starter 9 Clamp

2 O-ring 10 Union
3 Spacer 11 Sealing ring
4 O-ring 12 Union
5 Washer 13 Nut
6 Socket-head screw 14 Vent line
7 Clamp element 15 Guard plate
8 Spring pin
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Page 2
Compressed air starter 000 174 48 02
1 Starter pinion 15 Connecting flange

2 Shaft seal 16 Compressed air
3 Engagement spindle 17 Main valve piston
4 Shift drive housing 18 Outlet cover
5 Intermediate plate 19 Diaphragm
6 Gear motor housing 20 Rotor body
7 Control air channel 21 Ventilation
8 Compressed air channel 22 Shift gear piston
9 Main valve housing 23 Hollow shaft with internal gear teeth
10 Starting valve housing 24 Spacer ring
11 Starting valve piston 25 Grooved ball bearing
12 Manual actuation 26 Needle bearing
13 Flat-type connector 27 Freewheel
14 Magnetic coil
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Page 1


- - x Disconnect electric cable from solenoid valve 3.84.9b.2
- - x Close compressed air line -
- x x Remove compressed air line on pneumatic starter -
- x x Remove vent line -
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Page 1
3.18.4a.2 Removal
Remove bolts (2) from clamps (1).
Withdraw pneumatic starter (4) from the fit on the fly-
wheel housing (3) and lift off with lifting gear.
Remove O-ring (5) from pneumatic starter.
Remove gaskets (2) from oil pan and crankcase inter-

mediate frame (1).
Do not damage the spring pin (3) when removing the
gaskets.
Remove spacer (1) from flywheel housing.

Remove O-ring (2).
20046/20 E –08.96–
Page 1

Inspect and repair pneumatic starter in accordance with Special Publication.
Use the surface crack-testing method with red penetrant dye to check clamping bracket, spacer ring and gaskets for
cracks.Replace components exhibiting cracks.
Check mating faces of clamp elements and brackets for wear, recondition as required.
Check mating faces of starter, spacer and brackets for evenness and wear, recondition or replace as necessary.
parts as required.
Check spring pin for damage, replace if necessary.
Replace O-rings.
20062/00 E –03.95–
Page 1
Check whether mating surfaces of oil pan and crank-
case intermediate section are clean.
Fit gaskets (2) to oil pan and crankcase intermediate
frame (1).
It is important that the installation position of the spring
pin (3) is correct.
Push the O-ring (1) onto the pneumatic starter as far as

it will go and ensure that it is twist-free.
Install O-ring (2) in groove on spacer.
Coat both O-rings with petroleum jelly.
20046/20 E –08.96–
Page 2
Check whether mating surfaces of the pneumatic starter

(5), brackets, oil pan and crankcase intermediate frame
(6) are clean.
Push spacer (4) onto pneumatic starter as far as it will
go.
Push pneumatic starter with spacer ring into flywheel
housing bore as far as it will go.
Make sure there is a distance ”A” = 3 mm between pinion
(3) and ring gear (2).
This distance is guaranteed by the spacer ring.
Secure pneumatic starter with screws (4), washers (2)

and clamping bracket (1) to oil pan and crankcase inter-
mediate frame.
Make sure that the starter is positioned correctly at the
gaskets and that it sits properly in the flywheel fit.
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Page 1
3.18.5 Electric Starter

Electric starter – Version I 002 151 18 01
1 Starter 5 Bracket
2 Spacer 6 Washer
4 O-ring
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Page 2
Electric starter – Version II 003 151 55 01
1 Starter 6 Socket-head screw

2 Spacer 7 Clamp element
3 O-ring 8 Spring pin
4 O-ring 9 Clamp
5 Washer
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- - x Disconnect electric cable from starter -
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Page 1
3.18.5.2 Removal
Unscrew ground lead.
Disconnect positive lead 30 and both control cables 48
and 50.
Remove bolts from brackets (2).
Withdraw starter (1) from flywheel housing and remove
with lifting gear.
Use plastic mallet to remove spacer from flywheel hous-
ing.
Remove O-rings.
20038/10 E –11.92–
Page 1

Inspect and repair starter in accordance with Special Publication.
Use the surface crack-testing method with red penetrant dye to check clamping and mounting bracket, spacer ring and
gaskets for cracks.
Check clamps and brackets, spacer and clamp elements for wear and evenness, recondition as required and replace
as necessary.
parts as required.
Check mating faces of starter, clamps, brackets and clamp elements for evenness and wear, recondition if necessary.
Replace spring pin if damaged.
Replace O-rings.
20038/10 E –11.92–
Page 1
Install O-ring in grooves of spacer (1).
Use installation tool (2) to insert spacer in bore on fly-
wheel housing.
Use thrust bolt (1) to install spacer in flywheel housing.

Do not damage the O-ring.
Insert starter into bore on flywheel housing as far as it

will go.
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Page 2
Rotate starter (1) until connection terminals face up at

an angle of 45°.
Install and secure brackets (2) with bolts and washers
on oil pan.
Pinion clearance is ensured by spacer.
Connect earth cable, positive lead 30 and both control
cables 48 and 50.
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Page 1
3.19 Engine Mounting

Contents
3.19.1 Engine Mount – Crankcase

3.19.1.2 Removal
3.19.1.5 Assembly
3.19.1.7a After-installation operations
20046/20 E –08.96–
Page 2

A
S4
S 6.1
S 6.16

Compressed air
Cleaner P3 - Solvclean KW 40022
Engine oil SAE10 Shell Rotela 10 XW 40504
Casting resin
Protective paint Pliobond
Caution
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Page 1
3.19.1 Engine Mount - Crankcase
Engine mount driving end, 12V, 16V

1 Engine carrier upper section – driving end
2 Flange
3 Spring washer
4 Nut
5 Engine carrier lower section – driving end
6 Spacer
7 Stop plate
8 Cover plate
9 Bolt
10 Washer
11 Castle nut
12 Split pin
13 Spring washer
14 Bolt
15 Bolt
16 Bolt
17 Dowel pin
18 Bolt
19 Nut
20 Bolt
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Page 2
Arrangement engine mount driving end, lockable
Right engine side illustrated

Left engine side, assembled in mirror-image fashion
20046/20 E –08.96–
Page 3
Engine mount free end, 8V, 12V, 16V

1 Engine carrier – free end
2 Spring washer
3 Bolt
4 Bracket
5 Engine carrier
6 Spring washer
7 Bolt
8 Carrier
9 Bolt
10 Spring washer
11 Nut
12 Cover plate
13 Rubber ring
14 Flange
15 Bolt
16 Bolt
17 Washer
18 Nut
19 Jackscrew
20 Nut
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Page 4
Arrangement engine mount free end, lockable

20046/20 E –08.96–
Page 5
Engine mount driving end, 8V, 12V, 16V
1 Engine carrier upper section 10 Bolt

2 Flange 11 Bolt
3 Bolt 12 Bolt
5 Engine carrier lower section 14 Dowel pin
6 Stop plate 15 Bolt
7 Cover plate 16 Nut
8 Bolt 17 Washer
9 Washer
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Page 6
Arrangement engine mount driving end, lockable

20046/20 E –08.96–
Page 7
Engine mount free end, 8V
1 Engine carrier free end 11 Hex nut

2 Spring washer 12 Cover plate
3 Hex bolt 13 Flange
4 Bracket 14 Rubber ring
5 Engine carrier lower section 15 Bolt
6 Spring washer 16 Jackscrew
8 Carrier 18 Washer
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Page 8
Arrangement engine mount free end, lockable

20046/20 E –08.96–
Page 9
Arrangement engine mount free end (at fan drive)
1 Carrier 5 Carrier
2 Hex bolt 6 Cover
3 Resilient bush 7 Hex bolt
4 Stud 8 Housing
20046/20 E –08.96–
Page 10
Engine mount, free end
1 Coupling housing – fan drive 6 Stud

2 Bolt 7 Carrier
3 Carrier 8 Resilient bush
4 Bolt 9 Cover
5 Frame 10 Bolt
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Page 1


- - x Removal of engine mount not scheduled -
20038/10 E –11.92–
Page 1
3.19.1.2 Removal
Removing engine mount, driving end
Detach engine mount (2) from flywheel housing (1).
Removing engine mount, free end

Detach engine mount (2) from engine carrier (1).
Remove engine carrier (1) from crankcase.
20046/20 E –08.96–
Page 2
Removing engine mount, free end

Unscrew screws (2) from carrier (5).
Unscrew screws (3) from frame (4).
Remove carrier from coupling housing (1).
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Page 1
Disassembling engine mount, driving end
Remove split pins for castle nuts (1).
Unscrew castle nuts and nuts (2).
Remove cover plates (2) and stop plates (1).
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Page 2
Remove engine carrier (1), spacer bushing (3), tapered

mount (4) and flange (5) from engine carrier lower sec-
tion (6).
Remove bolts (2) from engine carrier lower section
Remove securing bolt (1) and locking bolt (13) with nuts
(11) and washers (12) from engine carrier lower section
(10).
Remove washer (2), cover plate (3), stop plate (4) and
engine carrier lower section.
Remove bolts (9) and spring washers (8) securing tap-
ered mount (6) and flange (7) from engine carrier upper
section (5).
Remove tapered mount and flange.
20046/20 E –08.96–
Page 3
Disassembling engine mount, free end

Unscrew bracket (1) with carrier and tapered mount
from engine carrier (2) and remove.
Remove bolts securing tapered mount (3) to bracket (2).

Remove tapered mount and carrier (1).
Remove screws (5) from cover (4).

Remove cover from pin (3).
Using a suitable mandrel, press the pin out of the carrier
(6).
Remove carrier (1) from carrier (6).
Using suitable extraction tool, remove resilient bush (2)
from carrier (1) only as required.
20046/20 E –08.96–
Page 1

Clean components and remove paint as required.
Note
Do not use petrol, benzene or other substances harmful to rubber to clean the rubber surfaces on the rubber mount.
Using the surface crack-testing method and red penetrant dye, check engine carrier and carrier for cracks.
Replace relevant components if cracks are found.
Check the condition of the tapered mount, rubber ring and resilient bush and make a visual inspection for cracks and
deformation; if necessary, check the rubber quality with the testing device.
Replace parts that are cracked, deformed or badly contaminated (oily).
Check protective coating of rubber mounts, renew if necessary.
Check contact surfaces on engine carrier and rubber mount for evenness, smooth with an oilstone if necessary.
Release locknut on jackscrew, check condition of threads and recut if necessary.
Replace spring pins as required.
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Page 1
3.19.1.5 Assembly
Assembling engine mount, driving end
Insert bolts (2) in engine carrier lower section (6).
Position flange (5), tapered mounts (4), spacers (3) and
engine carrier (1) on engine carrier lower section (6).
Install stop plates (1) and cover plates (2).
20046/20 E –08.96–
Page 2
Fit nuts (2) and tighten in accordance with Section 1.3.

Coat threads of castle nuts (1) with engine oil.
Install castle nuts with washers on bolts and hand-
tighten.
Tighten castle nuts with torque wrench and socket (1) to

Secure castle nuts (1) with split pins (2).
20046/20 E –08.96–
Page 3
Install tapered mount (6) and flange (7) with bolts (9) and
spring washers (8) on engine carrier upper section (5).
Install engine carrier lower section (10) with bolt (1),
washer (2), cover plate (3) and stop plate (4) on tapered
mount.
Using torque wrench, tighten bolt to specified torque.
Screw in locking bolt (13) with washers (12) and nuts
(11) only to secure during transportation.
Assembling engine mount, free end

Position carrier (1) and tapered mounts (3) on bracket
(2) and tighten with bolts and spring washers as speci-
fied in Section 1.3.
Mount bracket (1) with carrier and tapered mounts on

engine carrier (2) and secure with bolts and spring
washers.
20046/20 E –08.96–
Page 4
Coat the resilient bush (2) with thin-film lubricant and,

using a suitable installation tool, press into carrier (1).
Insert carrier (1) into carrier (6) and connect together by
pressing the pin (3).
Note
Prior to installation, coat the pin with engine oil.

Mount the cover (4) with screws (6) to the pin.
Using a torque wrench, tighten bolts to specified torque.
20046/20 E –08.96–
Page 1
Installing engine mount, driving end
Install engine mount (1) on flywheel housing with bolts
and spring washers and tighten with torque wrench to
Installing engine mount, free end

Install engine carrier (1) on crankcase with bolts and
spring washers and tighten with torque wrench to speci-

Install engine mount (3) with cover plates (2), flange (5),
rubber ring and bolts on engine carrier (1).
20046/20 E –08.96–
Page 2
Installing engine mount, free end

Mount carrier (5) with screws (2) to the coupling housing
(1).
Coat thread of screws (3) with engine oil, screw into the
carrier (5) on the frame (4) and, using a torque wrench,
tighten to specified torque.
20046/20 E –08.96–
Page 1
Locking engine mounts after engine test run

Engine mount, driving end
Note
Lock engine mount for transportation, remove jackscrew (5).

Insert locking bolts (1) through the engine carrier upper section (3) into the engine carrier lower section (4) and lock
with nuts (2).
Attention
The locking device must not be removed before the engine is aligned on the engine foundation.
Refer also to the instructions regarding engine mount transportation.
20046/20 E –08.96–
Page 2
Note
Lock engine mount for transportation, unscrew jackscrews (5) to dimension ”A” = 54 mm and lock with nut (6).
Bolt together flange (2) and engine carrier lower section (1) manually with the locking screws (3) and lock with nut (4).
Attention
20046/20 E –08.96–
Page 1
3.19.1.7a After-Installation Operations

Locking engine mounts after engine test run
Engine mount, driving end
Install locking bolts (5) and washers (4) in engine carrier
upper section (1), fit nuts (3) on bolts.
Screw bolts by hand into engine carrier lower section (2).
Lock with nuts.

Install locking bolts (1) with washers (2) in flange (5), fit
nuts (3) on bolts (1).
Screw bolts by hand into plate (4).
Lock with nuts.
Attention
The locking device must not be removed before the en-

gine is aligned on the base skid.
Before starting engine, remove transportation locking
bolts.
20046/20 E –08.96–
Page 2
Note
Lock engine mount for transportation, unscrew jackscrews (2) to dimension ”A” = 54 mm and lock with nut (3).
Bolt together flange (4) and engine carrier lower section (1) manually with the locking screws (5) and lock with nut (6).
Attention
20046/20 E –08.96–
Page 1
3.20 Fan Drive

Contents
3.20.1a Hydraulic fan drive – centre distance 218 mm

3.20.1a.2 Removal
3.20.1a.5 Assembly
3.20.1b Hydraulic fan drive – centre distance 400 mm

3.20.1b.2 Removal
3.20.1b.5 Assembly
3.20.3 Control unit for hydraulic fan drive

3.20.3.2 Removal
3.20.3.5 Assembly
3.20.3a Control unit for hydraulic fan drive with supplementary piston
3.20.3a.2 Removal
3.20.3a.5 Assembly
3.20.4 Fan wheel

3.20.4.2 Removal
20046/20 E –10.96–
Page 2

A
S4
S 6.1
S 6.9.2
S 6.12
S 6.15
S 6.16
S 6.17
S 6.18
S 6.19

Lifting device for intermediate housing
Installation and removal tool MTU F0 098 475
Hydraulic press
Nexus internal puller
Inspection lamp
Magnifier
Sealing paste Elastosil N 189 50545
Long-lasting lubricant grease Longterm 2 Plus 40337
Solvent Acetone 40590
Engine oil SAE 10 Shell Rotella X10W 40504
Pipe-thread sealant Loctite No. 586 40033
Locking paint RAL 4001 40664
Dry compressed air

Attention
20046/20 E –10.96–
Page 1
3.20.1a Hydraulic Fan Drive – Centre Distance 218 mm
1 Coolant line 13 Dowel pin

2 Housing 14 Socket-head screw
3 Screw 15 Secondary shell
4 Screw 16 Ring
6 O-ring 18 Washer
7 Gasket 19 Driver disc
8 Cover 20 Washer
10 Screw 22 O-ring
11 Primary shell 23 O-ring
12 Disc
20046/20 E –10.96–
Page 2
Intermediate housing with idler gears – centre distance 218 mm
1 Flange 21 Disc
2 Shaft 22 Spring washer
3 Intermediate housing 23 Hex screw
4 Spacer sleeve (optional) 24 Shaft seal
5 Angular-contact ball bearing 25 Fan flange
6 Disc 26 Spring pin
10 Cover 30 Hex screw
11 O-ring 31 Cylindrical roller bearing
13 Hex screw 33 Plug
14 Shaft 34 Gasket
15 Plug 35 Dowel pin
17 Ring 37 Hex screw
18 Snap ring 38 Gear
19 Angular-contact ball bearing 39 Gear
20 Spacer sleeve (optional)
20046/20 E –10.96–
Page 3
Hydraulic fan drive arrangement – centre distance 218 mm
1 Angular-contact ball bearing 10 Angular-contact ball bearing

2 Housing 11 Cover
3 Flange – vibration damper 12 Cover with oil supply
4 Crankshaft 13 Gears
5 Flange 14 Shaft seal
6 Primary shell 15 Fan flange
7 Secondary shell
8 Driver disc A Oil return
9 Intermediate housing B Oil supply
20046/20 E –10.96–
Page 4
Assembly/disassembly section hydraulic fan drive – centre distance 218 mm
1 Assembled cover with fan flange 3 Assembled intermediate housing

2 Gear 4 Housing, primary and secondary shells
20046/20 E –10.96–
Page 1


- - x Removal not planned -
- x - Remove cooler -
- x - Remove fan wheel -
20046/20 E –10.96–
Page 1
3.20.1a.2 Removal
Disconnecting oil line
Disconnect oil line (1) for oil supply on cover of fan drive.
Remove pipe clamp halves, grommets and oil line.
Seal oil line connection.
Removing cover with fan flange

Release hex screws (2) from cover (1) and remove with
spring washers.
Screw in two guide pins for removal of cover on inter-
mediate housing.
Gently tap cover (1) with fan flange with a plastic mallet
to release and remove via guide pins.
Attention
The cover is located with two dowel pins.

Remove gasket.
Unscrew guide pins.
Note
The gear with fan flange is still mounted on the cover.
20046/20 E –10.96–
Page 2
Removing bearing inner race from coupling shaft

Use removal tool to remove inner race (1) of cylindrical
roller bearing from coupling shaft (2).
Mark position of gear (3) on coupling shaft to facilitate
reassembly.
Press gear from coupling shaft
Caution
Danger
Use only specified tools.
The installation pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
Screw draw spindle (5) of removal tool (3) into coupling
shaft (1) as far as it will go.
Note
Draw spindle M16 has left-hand thread.

Fit pressure plate (2) and hydraulic removal tool on draw
spindle.
Screw hex nut (4) onto draw spindle as far as it will go,
then unscrew by approx. 6 mm.
Note
When the hex nut is being screwed on, the removal tool
must be at its initial position (0 stroke).
Screw reducer (9) into gear (10) and union (6) of installa-
tion tool and tighten.
Connect H.P. lines for expansion pressure (8) and in-
stallation pressure (7).
20046/20 E –10.96–
Page 3
Fill oil pressure hand pumps with engine oil SAE 10.
Vent pumps and pipework until bubble-free oil emerges.
Close valves.
Actuate oil pressure hand pump for removal tool (3) until
pressure plate of removal tool is in contact with gear (1).
The tool is intended to catch the gear sliding off the tap-
ered seat smoothly and to ensure safety as the gear is
released.
Note:
Actuate oil pressure hand pump for expansion of gear until half max. expansion pressure is reached. Maintain this pres-
sure for approx. 5 minutes.
Increase expansion pressure in stages, holding for approx. 2 minutes between each stage, until hex nut (4) takes up
removal force.
If expansion pressure drops, continue pumping to maintain pressure at a constant level until gear is released or further
pressure increase is required.
Max. expansion pressure = 1600 bar
The max. expansion pressure is stamped on gear and must not be exceeded.
Release of gear is signalled by increasing pressure in removal tool.
Back off hex nut with wrench.
Gradually drain oil from removal tool.
Relieve pressure at oil pressure hand pumps.
Press piston of removal tool with hex nut to final position.
Remove H.P. lines and removal tool.
Remove gear from coupling shaft.
20046/20 E –10.96–
Page 4
Removing securing screws from secondary shell

Use a socket wrench (3) to remove stress bolts securing
secondary shell (2).
Rotate secondary shell on coupling shaft until socket
wrench can be fitted through opening on intermediate
housing (1) onto next bolt.
Make sure that all 12 bolts are unscrewed.

Remove securing screws from intermediate housing (1).
Gently tap intermediate housing with a plastic mallet to
release from housing.
Remove complete intermediate housing (2) from hous-

ing.
Remove O-ring (1) from intermediate housing.
20046/20 E –10.96–
Page 5
Removing driver disc

Remove socket-head screws (1) from driver disc (2).
Removing driver disc and secondary shell

Remove driver disc (2) and secondary shell (1) from pri-
mary shell.
If necessary, press ring out of secondary shell.
For this purpose, remove socket-head screws from sec-
ondary shell.
Removing primary shell

Remove securing screws (3) and disc (2).
Remove primary shell (1) from drive flange.
20046/20 E –10.96–
Page 6
Removing housing
Unscrew securing screws (1) and (3) on housing (4)
from bearing retaining plate (5) and remove with spring
washers (2).
Attach housing to lifting gear with rope and tension.
Using two assembly levers, press housing off bearing
retaining plate of crankcase and remove with lifting gear.
Remove coolant line (6) from housing (7) and remove O-

rings (5).
Remove O-rings (8) and (9) from housing (7).
from cover (3).
Remove cover and gasket (4) from housing.
20046/20 E –10.96–
Page 1
Disassembling cover with fan flange
1 Hex screw 10 Snap ring

2 Spring washer 11 Ring
3 Cover 12 Angular-contact ball bearing
4 O-ring 13 Gear
5 Fan flange 14 Inner race
6 Shaft seal 15 Spacer sleeve
7 Fan shaft 16 Disc
8 Plug 17 Cover for intermediate housing
9 Sealing ring 18 Cylindrical roller bearing
Removing cover
Remove securing screws and remove cover (1) for oil
supply.
20046/20 E –10.96–
Page 2
Remove bearing inner race from fan shaft

Remove inner race (1) of cylindrical roller bearing with
removal tool from fan shaft (2).
Mark position of gear (3) on fan shaft to facilitate reas-
sembly.
Press gear off fan shaft
Caution
Danger
Hydraulic removal must be carried out only by trained personnel. Use only specified tools for hydraulic removal. The
installation pressure stamped on the tool and the expansion pressure stamped on the gear must not be exceeded.
Screw draw spindle (6) of removal tool (4) into fan shaft
(1) on gear (10) as far as it will go.
Note

spindle.
Note
Before the hex nut is screwed on, the removal tool must
be at its initial position (0 stroke).
Screw reducer (2) for H.P. connection into gear and
tighten.
20046/20 E –10.96–
Page 3
Fit H.P. lines for expansion pressure (3) and installation pressure (8).
Close valves.
Actuate oil pressure hand pump for removal tool until pressure plate of removal tool is in contact with gear.
The tool is intended to catch the gear sliding off the tapered seat smoothly and to ensure safety as the gear is released.
Expand gear with oil pressure hand pump until gear is released from fan shaft.
The max. expansion pressure = 1600 bar is stamped on gear and must not be exceeded.
For further information, see Section 3.20.1a.2, Page 3.
Use wrench to unscrew hex nut and relieve pressure on oil pressure hand pumps.
Remove H.P. lines and reducers (3), (4).
Remove removal tool (1) from fan shaft.
Remove gear (2) from fan shaft.
Removing outer race from cover

Use mandrel to remove outer race (1) of cylindrical roller
bearing from cover (2).
Make sure cover is positioned evenly when outer race
is removed.
20046/20 E –10.96–
Page 4
Removing fan shaft

Place cover (2) on a hollow steel cylinder.
Use hydraulic press to remove fan shaft (1) out of angu-
lar-contact ball bearings.
Make sure fan shaft and fan flange move freely in hollow
cylinder.
Remove securing screws from disc (2) on fan shaft bear-

ing.
Remove disc.
Remove spacer sleeve (1).
Remove shaft seal from cover.
Now use Seeger assembly pliers to remove accessible
snap ring from groove on cover.
Remove ring from bore.
Removing angular-contact ball bearing from cover

Use mandrel (1) and manual press to remove angular-
contact ball bearing (3) from cover (2).
20046/20 E –10.96–
Page 5
Removing fan flange
Caution
Danger
The installation pressure stamped on the tool and the expansion pressure stamped on the fan flange must not be ex-
ceeded.
Screw draw spindle (6) M22x1.5 of removal tool (4) as
far as it will go into fan shaft (1) on fan flange (10).
spindle.
Note
Before the hex nut is removed, the removal tool must be

at its initial position (0 stroke).
Screw reducer (2) into flange.
Connect H.P. lines for expansion pressure (2) and in-

Close valves.
pressure plate (6) is in contact with fan flange (1).
The tool is intended to catch the fan flange sliding off the
tapered seat smoothly and to ensure safety as the fan
flange is released.
Expand fan flange with oil pressure hand pump until max. expansion pressure is reached and flange is released from
fan shaft.
Max. expansion pressure = 1600 bar is stamped on fan flange and must not be exceeded.
For further information, see Section 3.20.1a.2, Page 3.
Disconnect H.P. lines, remove reducer and removal tool, remove fan flange.
20046/20 E –10.96–
Page 6
Disassembling intermediate housing with coupling flange
1 Coupling shaft
2 Coupling flange
3 Intermediate housing
20046/20 E –10.96–
Page 7
Caution
Danger
The installation pressure stamped on the tool and the expansion pressure stamped on the coupling flange must not
be exceeded.
Screw draw spindle (6) M22x1.5 of hydraulic removal

tool (4) as far as it will go into coupling shaft (1).
spindle.
Note
Before the hex nut is screwed on, the hydraulic removal

tool must be at its initial position (0 stroke).
Screw reducer (2) into flange and tighten.
Connect H.P. lines (3) for expansion pressure (2) and in-
Close valves.
Actuate oil pressure hand pump for removal tool until
pressure plate of removal tool (2) is in contact with
flange (1).
The tool is intended to catch the flange sliding off the tap-
ered seat smoothly and to ensure safety as the flange
is released.
Expand flange (3) with oil pressure hand pump until
flange is released from coupling shaft.
Max. expansion pressure = 1600 bar is stamped on
coupling flange.
For further information, see Section 3.20.1a.2, Page 3. Unscrew hex nut (1) with wrench.
Relieve pressure on oil pressure hand pump. Disconnect H.P. lines and remove reducer and removal tool.
Remove flange from coupling shaft.
20046/20 E –10.96–
Page 8
Removing washer and spacer sleeve

Release and remove securing screws (2) from coupling
shaft bearing on intermediate housing (4).
Remove washer (1).
Mark spacer sleeve (3) to facilitate and remove from in-
termediate housing.
Removing coupling shaft with bearing

Place intermediate housing (2) on a hollow steel cylin-
der.
Use a mandrel (1) and hydraulic press to remove coupl-
ing shaft and angular-contact ball bearing from inter-
mediate housing.
Pressing angular-contact ball bearing from coupl-

ing shaft
Press angular-contact ball bearing (2) from coupling
shaft (1).
20046/20 E –10.96–
Page 9
Removing bearing outer race from intermediate

housing
Use Nexus internal puller to remove outer race (1) of cy-
lindrical roller bearing for fan shaft from intermediate
housing (2).
Note
Note that bearing inner races are assigned to their re-

spective antifriction bearings. This must not be altered.
20046/20 E –10.96–
Page 1

Unscrew plugs from housing, clean oil galleries and check that they are perfectly clean.
Clean oil galleries of coupling and fan gear shafts and check that they are perfectly clean.
Using the surface crack-testing method and red penetrant dye, check coupling housing, intermediate housing and
cover, and primary shell, secondary shell and cover for cracks.
Replace parts if cracked.
Using the magnetic crack-testing method and fluorescent magnetic powder, check coupling shaft, shaft for fan wheel,
gears, fan flange, coupling flange, disc and ring for cracks.
Check sealing surfaces, mating and bolt-on faces on housings and covers, and primary shell, secondary shell, ring,
disc and flanges for evenness, wear and damage; smooth with oilstone or emery cloth as required, replace parts if
necessary.
Check bearing bores for wear, smooth if necessary, fit bush or metal-spray in accordance with MTU instructions if re-
quired.
Check threaded bores, recut thread if necessary, fit Helicoil inserts or threaded bushes as required.
Check bearings, running surface, taper seats and threaded bores of coupling shaft, fan gear shaft for wear and damage.
Smooth slight wear and damage with oilstone or emery cloth, metal-spray sealing surface on fan gear flange in accord-
ance with MTU instructions as required.
Check taper seats 1:50 with taper gauge.
Check tooth flanks and bores of gears for wear and indentations; smooth with oilstone or emery cloth as required, re-
place parts if necessary.
Check locating bore for coolant line on coupling housing for wear; if necessary, smooth with an oilstone and provide
with a bush to MTU Specifications.
Check coolant line at connecting points for wear and pitting; smooth with an oilstone if necessary.
Adjust bore gauge and measure bearing bores on housings and cover.
Measure bearing seats, running surface and fit on shafts with outside micrometer.
If limit values as per Tolerance and Wear Limits List are exceeded, replace or recondition parts.
Always replace cylindrical roller bearings and angular-contact ball bearings during a W6 overhaul.
Replace shaft seal, O-rings, gasket and sealing rings during all overhaul work.
20046/20 E –10.96–
Page 1
3.20.1a.5 Assembly
Check that bore for angular-contact ball bearing in inter-
mediate housing is clean.
Using mandrel (1), press angular-contact ball bearing
for coupling shaft, with contact surfaces on outer race
facing outwards, into intermediate housing.
Note
For installation position of angular-contact ball bearing,

see also technical drawing, Section 3.20.1a, Page 3.
Measuring installation dimension for spacer sleeve

Measure distance between surface of intermediate
housing and angular-contact ball bearing (2) with dial
gauge (1) and bridge meter.
Example: Distance 11.95 mm
Insert 12.00 mm spacer sleeve.
Specified protrusion 0.02 mm to 0.07 mm
Spacer sleeves of 11.80 mm to 12.55 mm are available.
Installing spacer sleeve and disc

Insert spacer sleeve (2) with appropriate thickness in
bore.
Install disc (3) with screws (4) and spring washers and
tighten with torque wrench (1). For torque settings, see
Section 1.3.
20046/20 E –10.96–
Page 2
Caution
Danger
be exceeded.
Clean taper surfaces on coupling shaft (1) and coupling

flange (10) with denaturated ethanol and coat with en-
gine oil SAE 10.
Install flange on shaft and measure distance between
surface of shaft and flange.
Screw draw spindle (6) M22 as far as it will go into shaft.
Fit pressure plate (9) and hydraulic installation tool (4)
on draw spindle.
Screw hex nut (5) as far as it will go onto draw spindle.
Install reducer (2) on flange and tighten.
Connect H.P. line (3) for expansion and H.P. line (8) for
installation and tighten.
Vent oil pressure hand pumps and pipework until
bubble-free oil emerges.
Close shut-off valves.
20046/20 E –10.96–
Page 3
Installing coupling shaft with flange in intermediate

housing
Actuate oil pressure hand pumps to increase installation
pressure and expansion pressure alternately, starting
with installation pressure, until flange (4) is in contact
with shoulder of shaft (3).
The max. expansion pressure = 1600 bar is stamped on
flange and must not be exceeded.
After completion of installation procedure, relieve ex-
pansion pressure and maintain installation pressure on
flange for a further approx. 60 minutes.
Relieve expansion pressure, remove H.P. lines (1) and
(2) and nut (6).
Remove installation tool (5).
Again measure distance between surfaces of shaft and
flange.
Compare measured push-on distance with specified
push-on distance 6.8 mm -1.3 mm.
Use hydraulic press to install preassembled coupling

shaft (1) in angular-contact ball bearings (2) in inter-
mediate housing.
Use a suitable support sleeve (3) to support angular-
contact ball bearings.
Make sure that coupling shaft with flange remains verti-
cal at all times with regard to angular-contact ball bear-
ings.
20046/20 E –10.96–
Page 4
Installing bearing outer race in intermediate hous-

ing
Use mandrel to install bearing outer race of cylindrical
roller bearing (1) for fan shaft in bore in intermediate
housing (2).
Note
Note the fixed assignment of bearing inner race to bear-

ing outer race. This must be adhered to.
Assembling cover
Check that bore for fan gear bearing in cover (4) is clean.
Insert snap ring (3) with Seeger assembly pliers.
Fit ring (2) in bore.
Use mandrel to install angular-contact ball bearing (1),
with one contact surface facing down and one facing up
as shown in illustration.

Use bridge meter and dial gauge (1) to measure dis-
tance between surface of cover and upper angular-con-
tact ball bearing (2).
Fit spacer sleeve of appropriate thickness in bore.
Insert 12.00 mm spacer sleeve.
Specified projection 0.02 mm to 0.07 mm.
Spacer sleeves 11.80 to 12.55 mm thick are available.
20046/20 E –10.96–
Page 5
Installing spacer sleeve and ring

Install disc (1) with screws and spring washers on cover
(fan shaft) and tighten with torque wrench. For torque
settings, see Section 1.3.

Carefully fit shaft seal on installation tool.
Clean press-on surfaces on shaft seal and housing
cover with denaturated ethanol and blow with com-
pressed air.
Thinly coat fit with surface sealant.
Use installation tool (1) to drive shaft seal into bore (2).
20046/20 E –10.96–
Page 6
Installing fan flange
Caution
Danger
The installation pressure stamped on the tool and the expansion pressure stamped on the fan flange must not be ex-
ceeded.
Drive spring pin into fan flange.

Clean taper surfaces on fan shaft (1) and fan flange (10)
with denaturated ethanol and coat with engine oil
SAE10.
Fit fan flange on shaft and measure distance between
surface of shaft and fan flange.
Screw draw spindle (6) M22 as far as it will go into fan
shaft.
on draw spindle.
Screw reducer (2) on fan flange and union (7) on installa-
tion tool and tighten.
Connect H.P. line (3) for expansion and H.P. hose (8) for
20046/20 E –10.96–
Page 7

with shoulder of shaft.
(5) and installation tools (3), (4) and (6).
Again measure distance between surface of shaft and
fan flange.
push-on distance 6.3 mm - 1.3 mm.
Note
Before sealing the expansion bore on the fan flange,

after the holding period, remove remaining oil from the
bore.
Installing fan flange with shaft in cover
Use hydraulic press to install preassembled fan shaft
with fan flange (1) into angular-contact ball bearings (3)
in cover (4).
Use a suitable support sleeve to support angular-con-
tact ball bearings (5).
Take care not to damage shaft seal (2) when installing
fan flange.
Make sure that during installation shaft remains vertical
at all times with regard to angular-contact ball bearings.
20046/20 E –10.96–
Page 8
Installing gear on fan shaft

Clean taper surfaces on fan shaft (2) and gear (1) with
denaturated ethanol and blow with compressed air.
Coat taper surfaces with engine oil SAE 10.
Fit gear on fan shaft taper in accordance with markings
and speed table.
Measure distance between shaft end and gear.
Caution
Danger
ceeded.
Screw draw spindle (6) as far as it will go into fan shaft

(1).
Note

on draw spindle.
Screw reducer (2) on gear and union (7) on installation
tool and tighten.
Vent oil pressure hand pump and pipework until bubble-
free oil emerges.
20046/20 E –10.96–
Page 9

with installation pressure, until gear (2) is in fully seated
in bearing.
gear and must not be exceeded.
gear for a further approx. 60 minutes.
Relieve installation pressure, remove oil pressure hand
pumps, H.P. lines (3), (4) and installation tool (1).
gear.
push-on distance 5.6 +0.3 mm
–1.3
Installing bearing inner race on fan shaft
Note

Heat bearing inner race (2) of cylindrical roller bearing
to 80 °C and install up to gear (1) on fan shaft.
Caution
Always use protective gloves to hold bearing ring.
20046/20 E –10.96–
Page 10
Installing cover
Insert O-ring (2) in groove of cover (1) and coat with pe-
troleum jelly.
Fit cover with oil supply connection for coupling shaft in
housing cover.
Coat thread and screw head faces with engine oil.

Install cover (2) with screws and spring washers and
Section 1.3.
Installing bearing outer race in cover

Use installation tool (2) to install bearing outer race (1)
of cylindrical roller bearing for coupling shaft in cover
bore.
Note

20046/20 E –10.96–
Page 11
Assembling secondary shell

Check that mating faces on secondary shell and ring are
even and clean, smooth with oilstone if necessary.
Screw two guide pins (1) for assembly of secondary
shell into ring (2).
Place secondary shell (2) on ring.

Use lever press (1) to press ring into secondary shell.
Unscrew guide pin (3).
Screw ring (2) with two socket-head screws (3) and

washers to secondary shell (1).
20046/20 E –10.96–
Page 1
Installing housing
Insert O-rings (5) into grooves on coolant line (6).
Insert coolant line into bore on housing (7).
Install housing with rope and lifting gear on bearing re-
taining plate of crankcase; in doing so, install coolant line
(6) on crankcase.
Mount cover (3) and gasket (4) with screws (1) and
spring washers (2) on housing (7).
Insert O-rings (8) and (9) into grooves on housing and
Securing housing
Mount housing (4) with screw (1), (3) and spring
washers (2) on bearing retaining plate (5) of crankcase
and tighten.
20046/20 E –10.96–
Page 2
Installing primary shell

Check that mating faces on drive flange and primary
shell (1) are even and clean, smooth with oilstone if
necessary.
Drive dowel pin into primary shell.
Coat thread and head surface of stress bolts with engine
oil.
Screw two guide pins, offset by 180°, into drive flange.
Screw in stress bolts and tighten with socket wrench (3)
and torque wrench (2). For torque settings, see Section
1.3.
Fit primary shell and washer on guide pins.
Remove guide pins, screw in remaining stress bolts and
tighten.
Installing secondary shell and driver disc

Place secondary shell (1) in driver disc (2) and insert in
housing.
20046/20 E –10.96–
Page 3
Tightening driver disc and secondary shell

Coat thread and head surface of socket-head screws
with engine oil.
Screw socket-head screws (2) with washers into driver
disc (1) and tighten diagonally and evenly on secondary
shell with torque wrench. For torque settings, see Sec-
tion 1.3.

Check that mating faces on housing and intermediate
housing are even and clean, smooth with oilstone if
necessary.
Insert O-ring (1) into groove on intermediate housing
and coat with petroleum jelly.
Make sure that O-ring is fitted free from torsion.
Install intermediate housing (2) with screws and spring

washers on coupling housing.
Take care not to damage dowel pins and O-ring (1).
20046/20 E –10.96–
Page 4
Tighten intermediate housing (1) with screws and spring

washers with torque wrench diagonally and evenly. For
Securing secondary shell

Coat thread and head surfaces of stress bolts with en-
gine oil.
Screw all 12 stress bolts into thread of secondary shell.
For this purpose, rotate secondary shell on coupling
shaft until socket wrench can be fitted to next bolt.
Tighten stress bolts with torque wrench (1) diagonally
and evenly. For torque settings, see Section 1.3.
20046/20 E –10.96–
Page 5
Installation of gears in accordance with speed table

Before installing gears, check which gear is to be press-fitted to lower coupling shaft and which gear to fan shaft.
Gears are marked at disassembly.
When using new gears, proceed in accordance with the speed table.
The part number is stamped on the gear.
Example
Fit lower gear with 50 teeth to coupling shaft.
Fit upper gear with 55 teeth to fan shaft.
Speed table for hydraulic fan drive
Number of teeth Gear part no. Engine speed
Top, fan Bottom Top, Bottom

shaft fan sh. fan shaft fan shaft
Fan speed
Hydraulic coupling slip
20046/20 E –10.96–
Page 6
Installing gear on coupling shaft
Caution
Danger
ceeded.
Clean taper surfaces on coupling shaft (1) and gear (10)

with denaturated ethanol and coat with engine oil SAE
10.
Install gear on shaft and measure distance between sur-
face of shaft and gear hub.
Screw draw spindle (5) as far as it will go into shaft.
Note

Measure reference dimension ”K” = 185.
on draw spindle.
Screw reducer (9) to gear and union (6) of installation
tool and tighten.
installation.
Fill oil pressure hand pump with engine oil SAE 10.
20046/20 E –10.96–
Page 7

with installation pressure, until gear (4) is in contact with
shaft bearing.
Relieve installation pressure, remove oil pressure hand
pump, H.P. lines (1) and (3) with installation tool (2).
Again measure distance between front surfaces of shaft
and flange.
)
push-on distance 5.6 0.3 mm.
–1.3
819827/31
Installing bearing inner race on coupling shaft
Note

ing outer race.
This must be adhered to.
to 80 °C and install up to gear (1) on coupling shaft.
Caution
Always use protective gloves to hold bearing ring.
Installing cover with fan flange

Check dowel pins (2) for damage, replace if necessary.
Thinly apply spots of sealing paste as bonding agent to
gasket.
Fit gasket on sealing surface on intermediate housing
(1).
Note
Fit gasket with sealing paste within 20 minutes.
20046/20 E –10.96–
Page 8
Screw two guide pins for assembling cover (1) on inter-

mediate housing.
Install assembled cover via guide pins and insert in
dowel pins on intermediate housing.
Gently tap cover with a plastic mallet to fit cover on hous-
ing.
Make sure the gears engage properly.
Unscrew guide pins.
Install screws (2) with spring washers on cover (1) and

tighten diagonally and evenly with torque wrench. For
Installing oil line

Screw union with sealing ring in cover.
Install oil line (1) for oil supply with pipe clamp halves and
grommets on cover and tighten.
20046/20 E –10.96–
Page 1

To check operation of the coupling, when no fan wheel is mounted, a mechanical tachometer can be used to check
the fan speed resulting from the gear transmission by briefly running up the engine to rated speed.
20046/20 E –10.96–
Page 1
3.20.1b Hydraulic Fan Drive – Centre Distance 400 mm
1 Coolant line 15 Primary shell

2 Housing 16 Disc
3 Hex screw 17 Dowel pin
4 Hex screw 18 Socket-head screw
5 Spring washer 19 Secondary shell
6 O-ring 20 Ring
7 Dead-centre indicator 21 Socket-head screw
9 Hex screw 23 Driver disc
10 Stud 24 Washer
11 Gasket 25 Socket-head screw
12 Cover 26 O-ring
14 Hex nut
20046/20 E –10.96–
Page 2
Intermediate housing with idler gears – centre distance 400 mm
1 Flange 24 Shaft
2 Shaft 25 Cylindrical roller bearing
3 Intermediate housing 26 Ring
4 Spacer sleeve 27 Cover
5 Angular-contact ball bearing 28 O-ring
6 Disc 29 Spring washer
8 Hex screw 31 Stress bolt
9 Cover 32 O-ring
10 Cover 33 Gear T = 56
13 Hex screw 36 Cylindrical roller bearing
14 Fan gear shaft 37 Gasket
15 Spacer sleeve 38 Spring washer
16 Cylindrical roller bearing 39 Hex screw
17 Angular-contact ball bearing 40 Dowel pin
18 Retaining pin 41 Gear T = 35
19 Spacer screw 42 Gear T = 51
20 Disc 43 Flange
22 Hex screw 45 Socket-head screw
23 Shaft seal
20046/20 E –10.96–
Page 3
Hydraulic fan drive arrangement – centre distance 400 mm
1 Flange 15 Secondary shell

2 Cover with bearing 16 Driver disc
3 Spacer sleeve 17 Flange
4 Gear T = 56 18 Angular-contact ball bearing
5 Intermediate housing 19 Gear T = 35
6 Cylindrical roller bearing 20 Cover
7 Oil supply for lubrication 21 Gear T = 51
8 O-ring 22 Cover
9 Housing 23 Shaft
10 Disc 24 Angular-contact ball bearing
11 Driver/vibration damper 25 Cylindrical roller bearing
12 Shaft 26 Shaft seal
13 Crankshaft 27 Fan gear shaft
14 Primary shell 28 Flange
20046/20 E –10.96–
Page 4
Assembly/disassembly section hydraulic fan drive – centre distance 400 mm
1 Assembled cover with fan flange 3 Assembled intermediate housing

2 Gear 4 Housing, primary and secondary shells
20046/20 E –10.96–
Page 1


- - x Removal not planned -
- x - Remove cooler -
- x - Remove fan wheel -
20046/20 E –10.96–
Page 1
3.20.1b.2 Removal
Disconnecting oil line
Remove oil line (4) for oil supply from cover of fan drive,
oil line from intermediate housing and oil line (2) for
drainage from flange.
Remove pipe clamp halves, grommets and oil lines and
unscrew union (1).
1 Seal oil line connections.
2
4
3
1
SG200001a0
Removing cover with fan flange

Release hex screws (1) from cover (2) and remove with
spring washers.
Screw in two guide pins for removal of cover on inter-
mediate housing.
Gently tap cover (1) with fan flange with a plastic mallet
to release and remove via guide pins.
Note
The cover is located with two dowel pins.The gear with

fan flange is still mounted on the cover.
Remove gasket.
Unscrew guide pins.
20046/20 E –10.96–
Page 2
Removing intermediate shaft and gear

Remove intermediate shaft and gear (1) from cylindrical
roller bearing in intermediate housing (4).
Use removal tool to remove inner races (2) and (3) of cy-
lindrical roller bearing from intermediate shaft.
Removing bearing inner race from coupling shaft.

Use removal tool to remove inner race (1) of cylindrical
roller bearing from coupling shaft (2).
Mark position of gear (3) on coupling shaft to facilitate
reassembly.
20046/20 E –10.96–
Page 3
Press gear from coupling shaft
Caution
Danger
The removal pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
Screw draw spindle (5) of removal tool (3) into coupling
shaft (1) as far as it will go.
Note

spindle.
Note
When the hex nut is being screwed on, the removal tool
must be at its initial position (0 stroke).
Screw reducer (9) into gear (10) and union (6) of removal
tool and tighten.
Connect H.P. lines for expansion pressure (8) and re-
moval pressure (7).
Close valves.
pressure plate of removal tool is in contact with gear
(10).
released.
20046/20 E –10.96–
Page 4
Note
Actuate oil pressure hand pump for expansion of gear

until half max. expansion pressure is reached.
Maintain this pressure for approx. 5 minutes.
Increase expansion pressure in stages, holding for ap-
prox. 2 minutes between each stage, until hex nut (3)
takes up removal force.
If expansion pressure drops, continue pumping to main-
tain pressure at a constant level until gear (5) is released
or further pressure increase is required.
Release of gear is signalled by increasing pressure in removal tool.

Back off hex nut with wrench.
Gradually drain oil from removal tool.
Relieve pressure at oil pressure hand pumps.
Press piston of removal tool with hex nut to final position.
Disconnect H.P. lines (1) and (4) and removal tool (2).
Remove gear from coupling shaft.
Removing securing screws from secondary shell
Use a socket wrench (2) to remove stress bolts securing
secondary shell.
Rotate secondary shell on coupling shaft until socket
wrench can be fitted through opening on intermediate
housing (1) onto next bolt.
Make sure that all 12 bolts are unscrewed.
20046/20 E –10.96–
Page 5

Unscrew securing screws (1) and (3) from intermediate
housing (2).
Mount lifting device (1) on intermediate housing (2).

Insert two guide pins (3) into housing.
Gently tap intermediate housing with a plastic mallet to
release from housing.
Remove complete intermediate housing (1) from hous-

ing.
Remove O-ring (2) from intermediate housing.
20046/20 E –10.96–
Page 6
Removing driver disc

Remove socket-head screws (2) from driver disc (1).
Removing driver disc and secondary shell

Remove driver disc (2) and secondary shell (1) from pri-
mary shell.
If necessary, press ring out of secondary shell.
For this purpose, remove socket-head screws from sec-
ondary shell.
Removing primary shell

Remove securing screws (2) and disc (3).
Remove primary shell (1) from drive flange.
20046/20 E –10.96–
Page 7
Removing housing
Unscrew securing screws (1) and (3) on housing (4)
from bearing retaining plate (5) and remove with spring
washers (2).
Attach housing to lifting gear with rope and tension.
Using two assembly levers, press housing (4) off bear-
ing retaining plate on crankcase.
Remove coolant line (9) from housing (10) and remove

O-rings (8).
Remove O-rings (11) and (12) from housing (10).
Remove nuts (1) and spring washers (2) from cover (3).
Remove cover and gasket (4) from housing.
from housing (10).
Remove dead-center indicator (7) from housing.
20046/20 E –10.96–
Page 1
Disassembling cover with fan flange
1 Cover 13 Screw
2 Gear 14 O-ring
3 Screw 15 Cover, coupling shaft
4 Disc 16 Screw
5 Spacer disc 17 O-ring
6 Bearing inner race 18 Cover, intermediate shaft
7 Spacer sleeve 19 Flange
8 Four-point bearing 20 Fan gear shaft
9 Cylindrical roller bearing 21 Shaft seal
10 Ring 22 Spring pin
11 Cylindrical roller bearing – intermediate shaft 23 Socket-head screw
12 Cylindrical roller bearing – coupling shaft 24 O-ring
20046/20 E –10.96–
Page 2
Remove bearing inner race from fan shaft

Remove inner race (2) of cylindrical roller bearing with
removal tool from fan shaft (3).
Mark position of gear (1) on fan shaft to facilitate reas-
sembly.
Press gear off fan shaft
Caution
Danger
Use only specified tools. The installation pressure stamped on the tool and the expansion pressure stamped on the
gear must not be exceeded.
Screw draw spindle (6) of removal tool (4) into fan shaft
(1) on gear (10) as far as it will go.
Note

spindle.
Note
Screw reducer (2) for H.P. connection into gear and tighten.
Fit H.P. lines for expansion pressure (3) and installation pressure (8).
20046/20 E –10.96–
Page 3
Close valves.
Actuate oil pressure hand pump for removal tool until pressure plate of removal tool is in contact with gear.
The tool is intended to catch the gear sliding off the tapered seat smoothly and to ensure safety as the gear is released.
Expand gear with oil pressure hand pump until gear is released from fan shaft.
The max. expansion pressure = 1600 bar is stamped on gear and must not be exceeded.
For further information, see Section 3.20.1b.2, Page 4.
Use wrench to unscrew hex nut and relieve pressure on oil pressure hand pumps.
Remove H.P. lines and reducer (2), (3) and unscrew nut
(5).
Remove removal tool (1) from fan shaft.
Remove gear (4) from fan shaft.
Removing fan gear shaft

Place cover (2) on a hollow steel cylinder.
Using hydraulic press, force fan gear shaft (1) out of
four-point bearing and cylindrical roller bearing (4) and
spacer sleeve (5).
Make sure the fan flange moves freely in hollow cylinder.
Remove spacer sleeve.
Press retaining pin out of washer.
Drive spring pin (3) out of fan flange.
20046/20 E –10.96–
Page 4
Removing flange from cover

Remove flange from cover (5).
1 2 Remove O-ring from flange.
Remove shaft seal (2) from flange (1).
SG200005a0
Removing disc and bearing from cover

Remove securing screws (1) and spring washers from
cover.
Remove disc (2).
Remove spacer disc (3) from four-point bearing.
Press retaining pin (4) out of disc (2).
Using extractor mandrel, force four-point bearing (6)
and cylindrical roller bearing (5) out of cover (7).
Note

is removed.
Removing cover for intermediate shaft bearing

Unscrew securing screws (6) with spring washers (7).
Remove cover (5) of intermediate bearing from (hous-
ing) cover (1).
Remove O-ring (2).
Remove ring (4) from cylindrical roller bearing.
bearing from cover.
Note

is removed.
20046/20 E –10.96–
Page 5
Removing cover for coupling shaft bearing

Remove securing screws (2) with spring washer (3).
Remove cover (1) of coupling shaft bearing from (hous-
ing) cover (6).
Remove O-ring (4).
bearing from cover.
Note

is removed.
Removing intermediate shaft

Remove intermediate shaft (1) from cylindrical roller
bearing in intermediate housing (4).
Use removal tool to remove inner races (2) and (3) of cy-
lindrical roller bearing from intermediate shaft.
Press gear off intermediate shaft
Caution
Danger
Use only specified tools. The installation pressure stamped on the tool and the expansion pressure stamped on the
gear must not be exceeded.
20046/20 E –10.96–
Page 6
Screw draw spindle (6) M22x1.5 into intermediate shaft

(1) until it contacts the stop.
Fit pressure plate (9) and hydraulic removal tool (4) on
draw spindle (6).
Note
Screw reducer (2) into gear (10) and tighten.
Fit H.P. lines for expansion pressure (3) and installation
pressure (8).
Vent oil pressure hand pumps until bubble-free oil
emerges.
Close valves.
pressure plate (6) of removal tool is in contact with gear
(7).
released.
During removal, pay special attention to instructions
3.20.1b.2, Page 4.
Max. expansion pressure = 1900 bar.
Max. expansion pressure is stamped on gear; do not ex-
ceed this pressure.
Use wrench to unscrew hex nut (4) and relieve pressure
on oil pressure hand pumps.
Remove H.P. lines (2) and (5) with reducer and removal
tool from intermediate shaft.
Remove gear from intermediate shaft.
20046/20 E –10.96–
Page 7
Disassembling intermediate housing with coupling flange
1 Intermediate housing 6 Coupling shaft

2 Cylindrical roller bearing, fan shaft 7 Angular-contact ball bearing
3 Cylindrical roller bearing, idler gear 8 Hex screw
4 O-ring 9 Washer
5 Coupling flange 10 Spacer sleeve
20046/20 E –10.96–
Page 8
Caution
Danger
be exceeded.
Screw draw spindle (6) M22x1.5 of hydraulic removal
tool (4) as far as it will go into coupling shaft (1).
spindle.
Note
Before the hex nut is screwed on, the hydraulic removal

tool must be at its initial position (0 stroke).
Screw reducer (2) into flange and tighten.
Connect H.P. lines (3) for expansion pressure (2) and in-
Close valves.
Actuate oil pressure hand pump for removal tool until
pressure plate of removal tool (2) is in contact with
flange (1).
The tool is intended to catch the flange sliding off the tap-
ered seat smoothly and to ensure safety as the flange
is released.
Expand flange (3) with oil pressure hand pump until
flange is released from coupling shaft.
Max. expansion pressure = 2600 bar is stamped on
coupling flange.
For further information, see Section 3.20.1b.2, Page 4. Unscrew hex nut (1) with wrench.
Relieve pressure on oil pressure hand pump. Disconnect H.P. lines and remove reducer and removal tool.
Remove flange from coupling shaft.
20046/20 E –10.96–
Page 9
Removing washer and spacer sleeve

Release and remove securing screws (2) from coupling
shaft bearing on intermediate housing (4).
Remove disc (1).
Mark spacer sleeve (3) to facilitate and remove from in-
termediate housing.
Removing coupling shaft with bearing

Place intermediate housing (2) on a hollow steel cylin-
der.
Use a mandrel (1) and hydraulic press to remove coupl-
ing shaft and angular-contact ball bearing from inter-
mediate housing.
Pressing angular-contact ball bearing off coupling

shaft
Press angular-contact ball bearing (2) off coupling shaft
(1).
20046/20 E –10.96–
Page 10
Removing bearing outer races from intermediate

housing
Remove outer races of cylindrical roller bearing (1) and
(2) for intermediate shaft and fan gear shaft with Nexus
interior puller from intermediate housing (3).
Note
Note that bearing inner races are assigned to their re-

spective antifriction bearings. This must not be altered.
20046/20 E –10.96–
Page 1

Unscrew plugs from housing, clean oil galleries and check that they are perfectly clean.
Clean oil galleries of coupling, intermediate and fan gear shafts and check that they are perfectly clean.
Using the surface crack-testing method and red penetrant dye, check coupling housing, intermediate housing and
cover, and primary shell, secondary shell and flange for cracks.
Using the magnetic crack-testing method with fluorescent magnetic powder, check coupling shaft, intermediate gear
shaft and fan gear shaft, gears, coupling flange, spacer sleeve, spacer disc, spacer sleeve and disc for cracks.
Check sealing surfaces, mating faces on housings and covers, drive torus and driven torus, spacer sleeve, spacer disc,
disc and flange on the fan gear shaft for evenness, wear and damage; smooth with an oil stone or emery cloth or replace
components as necessary.
Check bearing bores for wear, smooth if necessary, fit bush or metal-spray in accordance with MTU instructions if re-
quired.
Check threaded bores, recut thread if necessary, fit Helicoil inserts or threaded bushes as required.
Check locating bore for coolant line on coupling housing for wear and pitting; if necessary, smooth with an oilstone and
provide with a bush to MTU Specifications.
Check coolant line at connecting points for wear; smooth with an oilstone if necessary.
Check bearings, running surfaces, taper seats and threaded bores of coupling shaft, idler gear shaft and fan gear shaft
for wear and damage.
Smooth slight wear and damage with oilstone or emery cloth, metal-spray sealing surface on fan gear shaft in accord-
ance with MTU instructions as required.
Check taper seats 1:50 with taper gauge.
Check tooth flanks and bores of gears for wear and indentations; smooth with oilstone or emery cloth as required, re-
place parts if necessary.
Adjust bore gauge and measure bearing bores on housings and cover.
Measure bearing seats, running surface and fit on shafts and flange with outside micrometer.
If limit values as per Tolerance and Wear Limits List are exceeded, replace or recondition parts.
Replace cylindrical roller bearings, angular-contact ball bearings and four-point bearings as part of every W6 overhaul.
Replace shaft seal, O-rings and gaskets a part of every overhaul.
20046/20 E –10.96–
Page 1
3.20.1b.5 Assembly
Check that bore for angular-contact ball bearing in inter-
mediate housing is clean.
Using mandrel (2), press angular-contact ball bearing
for coupling shaft, with contact surfaces on outer race
facing outwards, into intermediate housing (2).
Note
For installation position of angular-contact ball bearing,

see also technical drawing, Section 3.20.1b, Page 3.

Measure the distance between the surface of the bore
in the intermediate housing (2) and the bearing outer
race (1) on the angular-contact ball bearing with depth
gauge (3).
Insert 8,00 mm spacer sleeve.
Specified projection 0.02 mm to 0.07 mm.
Spacer sleeves of 7,80 mm to 8,55 mm are available.
Installing spacer sleeve and disc

Insert spacer sleeve (2) with appropriate thickness in
bore.
Install disc (3) with screws (4) and spring washers and
Section 1.3.
20046/20 E –10.96–
Page 2
Caution
Danger
be exceeded.
Clean taper surfaces on coupling shaft (1) and coupling
flange (10) with denaturated ethanol and coat with en-
gine oil SAE 10.
Install flange on shaft and measure distance between
surface of shaft and flange.
Screw draw spindle (6) M22 as far as it will go into shaft.
on draw spindle.
Install reducer (2) on flange and tighten.
Connect H.P. line (3) for expansion and H.P. line (8) for
with shoulder of shaft (3).
(2) and nut (6).
Again measure distance between surfaces of shaft and
flange.
push-on distance 6.8 mm -1.3 mm.
20046/20 E –10.96–
Page 3
Installing coupling shaft with flange in intermediate

housing
Use hydraulic press to install preassembled coupling
shaft (1) in angular-contact ball bearings (2) in inter-
mediate housing.
Use a suitable support sleeve (3) to support angular-
contact ball bearings.
Make sure that coupling shaft with flange remains verti-
cal at all times with regard to angular-contact ball bear-
ings.
Installing bearing outer races in intermediate hous-

ing
Check that bearing bores in intermediate housing (2) are
clean.
Using press-in mandrel (1), press bearing outer race (4)
of cylindrical roller bearing into bores for intermediate
shaft and fan gear shaft (3) in intermediate housing (2).
Note


Carefully fit shaft seal on installation tool.
Clean press-on surfaces on shaft seal and flange with
1 denaturated ethanol and blow with compressed air.
Use installation tool (1) to drive shaft seal (2) into flange
4 (3) until it contacts the stop.
2 Coat sealing lip with ”petroleum jelly”.
Insert O-ring into flange groove (4) and coat with petro-
leum jelly.
SG200003a0
20046/20 E –10.96–
Page 4
Assembling cover
Positioning correctly, install cover (1) with oil return (2)
on cover (3).
Tighten securing screws with torque wrench to tighten-
1
SG200004a0
installing bearing in cover

Check that bore for fan gear bearing in cover (4) is clean.
Using press-in mandrel (1), press cylindrical roller bear-
ing and four-point bearing into cover.
For installation position of bearing, see also technical
drawing, Page 3.
Measuring installation dimension for spacer disc

Using depth gauge (2), measure distance between sur-
face of bore in cover (1) and of bearing outer race (3) on
four-point bearing.
Example:
Distance 6.05 mm
Fit spacer disc of thickness 6.00 mm.
Specified clearance 0.02 mm to 0.07 mm
Spacer discs of thickness 5.80 mm to 6.50 mm are avail-
able.
Fit spacer disc of appropriate thickness in bore.
20046/20 E –10.96–
Page 5
Installing spacer disc and ring

Positioning correctly, drive retaining pin into disc (3).
Positioning correctly, align spacer disc in relation to re-
taining pin (2) in disc.
Mount disc (3) with securing screws and spring washers
and tighten with torque wrench (1) to Tightening Specifi-
cation 1.3.
Installing fan gear shaft in cover

1
Press fan gear shaft (2) with manual press (1) into bear-
ing in cover (3).
2 Note
Support inner race of four-point bearing with suitable

seating sleeve.
3 Take care not to damage shaft seal when installing fan
gear shaft.
Ensure that fan gear shaft remains vertical at all times
with regard to bearings during installation.
If necessary, drive spring pin into fan flange.
SG200002a0
Fit spacer sleeve (2) on fan gear shaft (1).
20046/20 E –10.96–
Page 6
Installing gear on fan shaft

Clean taper surfaces on fan shaft (2) and gear (1) with
denaturated ethanol and blow with compressed air.
Fit gear on fan shaft taper in accordance with markings
and speed table.
Measure distance between shaft end and gear.
Caution
Danger
ceeded.
(1).
Note

on draw spindle.
tool and tighten.
20046/20 E –10.96–
Page 7

with installation pressure, until gear (4) is in fully seated
in bearing.
Release installation pressure, remove oil pressure hand
pumps, H.P. lines (2), (3) and unscrew nut (5).
Remove installation tool (1) from fan shaft.
gear.
push-on distance 5,7 mm - 2,4 mm.
Installing bearing inner race on fan shaft

to 80 °C and install up to gear (1) on fan shaft.
Caution
Always use protective gloves to hold bearing inner race.
Note

Installing cover
Insert O-ring (2) in groove of cover (1) and coat with pe-
troleum jelly.
Fit cover with oil supply connection for coupling shaft in
housing cover.
20046/20 E –10.96–
Page 8
Coat thread and screw head faces with engine oil.
Install cover (2) with screws and spring washers and

Section 1.3.
Installing bearing outer race in cover

Use installation tool (2) to install bearing outer race (1)
of cylindrical roller bearing for coupling shaft in cover
bore.
Note

20046/20 E –10.96–
Page 9
Fitting gear on intermediate shaft
Caution
Danger
ceeded.
Clean taper surfaces on intermediate shaft (1) and idler
gear (10) with denaturated ethanol and blow with com-
pressed air.
Fit idler gear on shaft and measure distance between
surface of shaft and idler gear.
(1).
on draw spindle.
tool and tighten.
bubble-free oil emerges. Close shut-off valves.
lip (1) shaft.
Release installation pressure and remove oil pressure
hand pumps and H.P. lines (2) and (5).
Unscrew hex nut (4) and remove installation tool (3) and
thrust pad (6).
Again measure distance between surface of shaft and gear.
Compare measured push-on distance with specified push-on distance 5.0 mm - 1.3 mm.
20046/20 E –10.96–
Page 10
Fitting bearing inner race on intermediate shaft, in-

termediate housing side
Heat bearing inner race of cylindrical roller bearing to
80 °C and, using installation sleeve (1), fit on intermediate
shaft (intermediate shaft side) until it contacts stop on
gear (2).
Note

Fitting bearing inner race on intermediate shaft,

cover side
Heat bearing inner race of cylindrical roller bearing to
80 °C and, using installation sleeve (1), fit on intermediate
shaft (cover side) until it contacts stop on gear (2).
Note

Inserting intermediate gear shaft in intermediate

housing and provisionally assembling cover with
intermediate housing
Insert preassembled intermediate gear shaft (1) into cy-
lindrical roller bearing (2) in intermediate housing (3).
Fit gasket on intermediate housing.
20046/20 E –10.96–
Page 11
Fit preassembled cover (3) on intermediate housing and

assemble with 4 screws.
Using depth gauge (1), measure distance between sur-
face of bore on cover and of bearing inner race (2) on
intermediate shaft.
Determine thickness of ring.
Overall clearance S = 0.5 mm to 1.5 mm
Note
The provisional assembly only serves to determine the

thickness of the ring. For this reason, remove housing
cover from intermediate housing for further assembly.
Fit O-ring on cover (1) on intermediate gear shaft bear-

ing and coat with petroleum jelly.
Insert O-ring into groove without twisting.
Coat thread and seating of screws with engine oil.
Mount cover with screws and spring washers.
Insert ring of determined thickness into cover (1).
20046/20 E –10.96–
Page 12
Using installation tool (1), insert cylindrical roller bearing

(3) into bore for intermediate shaft on cover (2).
Assembling secondary shell

Check that mating faces on secondary shell and ring are
even and clean, smooth with oilstone if necessary.
Screw two guide pins (1) for assembly of secondary
shell into ring (2).
Place secondary shell (2) on ring.

Use lever press (1) to press ring into secondary shell.
Unscrew guide pin (3).
20046/20 E –10.96–
Page 13
Screw ring (2) with two socket-head screws (3) and

washers to secondary shell (1).
20046/20 E –10.96–
Page 1
Installing housing
Insert O-rings (8) into grooves on coolant line (9) and
Insert coolant line into bore on housing (10).
Mount housing with rope and lifting gear on bearing re-
taining plate of crankcase.
Insert coolant line into bore on elbow of oil pan.
Mount dead-center indicator (7) with hex bolts (5) and
spring washers (6) on housing (10).
Insert studs (13) in housing.
Mount cover (3) and gasket (4) with nuts (1) and spring
washers (2) on housing.
Coat O-rings (11) and (12) with ”petroleum jelly” and in-
sert into grooves on housing (10).
Securing housing
Mount housing (4) with screws (1), (3) and spring
washers (2) on bearing retaining plate (5) of crankcase
and tighten with torque wrench to tightening specifica-
tion 1.3.
20046/20 E –10.96–
Page 2
Installing primary shell

Check that mating faces on drive flange and primary
shell (1) are even and clean, smooth with oilstone if
necessary.
Drive dowel pin into primary shell.
Coat thread and head surface of stress bolts with engine
oil.
Screw two guide pins, offset by 180°, into drive flange.
Screw in stress bolts and tighten with socket wrench (3)
and torque wrench (2). For torque settings, see Section
1.3.
Fit primary shell and disc on guide pins.
Remove guide pins, screw in remaining stress bolts and
tighten.
Installing secondary shell and driver disc

Place secondary shell (1) in driver disc (2) and insert in
housing.
Tightening driver disc and secondary shell

Coat thread and head surface of socket-head screws
with engine oil.
Screw socket-head screws with washers (2) into driver
disc (1) and tighten diagonally and evenly on secondary
shell with torque wrench. For torque settings, see Sec-
tion 1.3.
20046/20 E –10.96–
Page 3

Insert O-ring (1) into groove on intermediate housing (1)
Make sure that O-ring is fitted free from torsion.
Check that mating faces on housing and intermediate

housing are even and clean, smooth with oilstone if
necessary.
Insert two guide pins (3) into housing.
Mount lifting device (1) on intermediate housing (2).
Insert intermediate housing over guide pin.
Install intermediate housing (2) with screws and spring
washers on coupling housing.
Ensure that dowel pins and O-ring are not damaged.
Unscrew guide pins.
Tighten screws (1) and (3) on intermediate housing (2)

diagonally and evenly with torque wrench to Tightening
Specification 1.3.
20046/20 E –10.96–
Page 4
Securing secondary shell

Coat thread and head surfaces of stress bolts with en-
gine oil.
Screw all 12 stress bolts into thread of secondary shell.
For this purpose, rotate secondary shell on coupling
shaft until socket wrench can be fitted to next bolt.
Tighten stress bolts with torque wrench (1) diagonally
and evenly. For torque settings, see Section 1.3.
Installing gear on coupling shaft
Caution
Danger
ceeded.
Clean taper surfaces on coupling shaft (1) and gear (10)
with denaturated ethanol and coat with engine oil SAE
10.
Install gear on shaft and measure distance between sur-
face of shaft and gear hub.
Screw draw spindle (5) as far as it will go into shaft.
Note

Measure reference dimension ”K” = 185.
on draw spindle.
Screw reducer (9) to gear and union (6) of installation
tool and tighten.
installation.
20046/20 E –10.96–
Page 5
Fill oil pressure hand pump with engine oil SAE 10.
shaft bearing.
Release installation pressure, disconnect oil pressure
hand pump, H.P. lines (1) and (4) and unscrew hex nut
(3).
Again measure distance between front surfaces of shaft
and flange.
push-on distance 5.0 mm - 1.6 mm.
Installing bearing inner race on coupling shaft
to 80 °C and install up to gear (1) on coupling shaft.
Note

20046/20 E –10.96–
Page 6
Installing cover with fan flange

Check dowel pins (5) for damage, replace if necessary.
Apply a thin, dotted coat of sealing paste to gasket as an
adhesive. Securely attach gasket to sealing surface on
intermediate housing (1).
Note
Fit gasket with sealing paste within 20 minutes.

Insert idler gear (3) into intermediate housing.
Screw two guide pins for assembling cover (2) into inter-
mediate housing.
Install assembled cover (1) via guide pins and insert in

dowel pins on intermediate housing.
Gently tap cover with a plastic mallet to fit cover on hous-
ing.
Make sure the gears engage properly.
Unscrew guide pins.
Install screws (1) with spring washers on cover (2) and

tighten diagonally and evenly with torque wrench. For
20046/20 E –10.96–
Page 7
Installing oil line

Screw union with sealing ring (1) in cover (3).
Mount oil line (2) for drainage and oil line (4) for oil supply
with grommets and pipe clamp halves on cover and se-
cure.
2
4
3
1
SG200001a0
20046/20 E –10.96–
Page 1
3.20.3 Control Unit for Hydraulic Fan Drive
1 Housing 14 Pressure spring

2 Sleeve 15 Nozzle needle
3 O-ring 16 Seal
4 Thermal element 17 Cover
6 Snap ring 19 Hex screw
7 Control piston 20 Sealing ring
8 Hex nut 21 Plug
9 Threaded pin 22 Sealing ring
10 Pressure spring 23 Reduction union
13 Control piston
20046/20 E –10.96–
Page 2
Arrangement for control unit for hydraulic fan drive
1 Housing 15 Cover
2 Sleeve 16 Spring washer
3 O-ring 17 Screw
4 Thermal element 18 Sealing ring
6 Snap ring 20 Plug
7 Control piston 21 Plug
9 Threaded pin 23 Plug for access port to secure control piston when locking
10 Pressure spring
11 Pressure spring (1) Oil supply from engine
12 Control piston (2) Oil supply to hydraulic fan drive
13 Nozzle needle (3) Leak-off oil
14 Seal
20046/20 E –10.96–
Page 1


20046/20 E –10.96–
Page 1
3.20.3.2 Removal
Remove nuts (1).
Remove spring washers (2), control unit (3) and gasket
(4).
Remove studs (5) from elbow if necessary.
20046/20 E –10.96–
Page 1
Removing cover from housing
(10).
Remove cover and gasket (11) from housing (1).
Unscrew plugs (5) and (8) on cover and remove with
sealing rings (4) and (9).
Only if necessary, unscrew plug (7) and sealing ring (6)
from plug (5).
Removing nozzle needle

Release nut (3) on nozzle needle (2).
Remove nozzle needle from housing (1).
Removing compression spring and control piston

Remove control piston (3) and compression spring (2)
from housing (1).
20046/20 E –10.96–
Page 2
Disassembling control piston

Release nut (3) on threaded pin (2).
Remove threaded pin from control piston (1).
A = Dimension of projection
Removing plug-in sleeve, thermal element and con-

trol piston
Remove compression spring (8), control piston (7) and
thermal element (4) from housing (1).
Remove snap ring (6) from plug-in sleeve (2).
Remove plug-in sleeve from housing and remove
O-rings (5) and (3) from plug-in sleeve (2).

20046/20 E –10.96–
Page 1

Using surface crack-testing procedure and red penetrant dye, check housing and cover cracks.
Check housing bores, running surfaces and control lips of control piston for wear; smooth with emery cloth if necessary.
Adjust bore gauge and measure fitted bores in housing.
Using outside micrometer, measure fit diameter of control piston.
Check compression springs for wear.
Check housing and cover sealing surfaces and screw interfaces for evenness and damage, smooth with oilstone if
necessary.
Check threaded bores and rechase as necessary; insert threaded inserts as necessary.
Check nozzle needle and seat for wear; smooth as necessary.
Replace gasket, O-ring and sealing rings.
20046/20 E –10.96–
Page 1
3.20.3.5 Assembly
Preassembling control piston
Insert threaded pin (2) into control piston (1).
Preset threaded pin projection to dimension ”A” =
±
3.5 mm 0.2 mm; final setting takes place on engine.
Lock threaded pin (2) with nut (3).
Installing plug-in sleeve, thermal element and con-

trol piston
Blow out all bores in housing (1) with compressed air
and ensure bores are clean.
Insert new sealing rings (3) and (5) into grooves of
plug-in sleeve (2) and coat with ”petroleum jelly”.
Press thermal element (4) into plug-in sleeve.
Insert plug-in sleeve and thermal element into housing
and secure with snap ring (6).
Insert control piston (7) and compression spring (8) into
housing and check for ease of movement.

Set threaded pin to dimension ”A” = 18 mm ±0.5 mm
and lock with nut (3).
20046/20 E –10.96–
Page 2
Insert compression spring (2) and control piston (3) into

housing (1) and check for ease of movement.
Insert nozzle needle (2) into housing (1) until it contacts

stop, release approx. 1.5 rotations and secure with lock-
nut (3).
Assembling and installing cover

Insert plugs (5), (8) with sealing rings (4), (9) into cover
(10).
Insert plug (7) with sealing ring (6) into plug (5).
Screw cover (10) with screws (3), spring washers (2)
and gasket (11) onto housing (1) and tighten.
Tighten plugs.
20046/20 E –10.96–
Page 3
Check projection ”A” = 21.5 mm ±0.5 mm of thermal el-

ement with depth gauge.
Setting idling oil supply

Connect control unit to test unit and check idling oil sup-
ply.
When testing on control test stand, use engine oil SAE
10.
Oil temperature: 50 °C to 55 °C.
Oil pressure between connection 1 and 2 = 4 bar
Set flow rate between connection 1 and 2 at approx. 1.5
l/min to 1.8 l/min at nozzle needle (corresponds approx.
1.5 rotations at nozzle needle (3) from closing position).
Lock nozzle needle (3) with nut (4).
Insert plug (6) with sealing ring (5) into cover (7) and
tighten.
Remove control unit from test stand.
When installing on engine, use engine oil SAE 30.
20046/20 E –10.96–
Page 1
Clean and smooth sealing surfaces on control unit (3)
and elbow.
Insert studs (5) into elbow.
Fit gasket (4) and mount control unit with spring washers
(2) and nuts (1) on elbow and tighten.
20046/20 E –10.96–
Page 1

Setting control piston on engine
Oil is supplied from engine, connection ”B”, to hy-
draulic fan drive, connection ”A” at an engine coolant
outlet temperature of 82 °C +1 °C.
If necessary, adjust control unit using threaded pin (3) in
control piston (4) in such a way that when coolant circu-
lates thermal element at am engine coolant temperature
of 82 °C +1 °C oil flows from connection ”B” to ”A”.
For this purpose unscrew plugs (1).
Control piston (4) can be held in position by locking the
nut (6) by means of access port (2) on housing (5).
Switching off fan drive:
Fan drive can be switched off by interrupting oil flow from
connection ”B” to connection ”A” at an engine coolant
temperature of 80 °C -1 °C.
Closing gear case and providing with lead seal

Insert plugs (1) with new sealing rings and mark with
locking paint.
Secure securing screws with sealing wire and lead seal
(2).
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3.20.3a Control Unit for Hydraulic Fan Drive with Supplementary Piston
1 Housing 20 Control piston (supplementary piston)

2 O-ring 21 Gasket
3 Sleeve 22 Cover
4 Thermal element 23 Spring washer
6 Snap ring 25 Plug
8 Hex nut 27 Reduction union
9 Threaded pin 28 Sealing ring
10 Pressure spring 29 Solenoid valve
11 Sealing ring 30 Socket-head screw
12 Plug 31 Union
14 Pressure spring 33 Banjo union
15 Nozzle needle 34 Sealing nut
16 Gasket 35 Return line
17 Cover 36 O-ring
19 Hex screw 38 Reduction union
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Page 2
Arrangement of control unit for hydraulic fan drive with supplementary piston
1 Return line 23 Sealing ring

2 Seal carrier 24 Hex nut
3 O-ring 25 Nozzle needle
4 Sealing nut 26 Pressure spring
5 Sealing ring 27 Sleeve
6 Banjo union 28 O-ring
7 Union 29 Thermal element
8 Solenoid valve 30 Snap ring
9 Cover 31 O-ring
10 Hex screw 32 Control piston
11 Spring washer 33 Threaded pin
12 Gasket 34 Pressure spring
14 Gasket 36 Reduction union
15 Control piston (supplementary piston) 37 Sealing taper
16 Threaded pin 38 Nut
17 Control piston 39 Wrapped tube
18 Housing 40 Hex screw
19 Socket-head screw
20 Plug a Oil return from engine
21 Sealing ring b Oil supply to hydraulic fan drive
22 Plug c Leak-off oil
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20046/20 E –10.96–
Page 1
3.20.3a.2 Removal
Remove nut (6).
Remove spring washers (5), control unit (2) with sole-
noid valve (1) and gasket (3).
Remove stud (4) from elbow if necessary.
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Page 1
Removing solenoid valve and return line
Unscrew locknut (10) from union (7).
Remove return line (2) from cover and remove with seal-
ing rings (8).
Remove banjo union (9) from return line and remove O-
ring (1) from return line.
Remove union (7) from solenoid valve (4).
Remove socket-head screws (6) from solenoid valve.
Remove solenoid valve from cover of control unit (5).
Note
To remove or turn solenoid valve (4), release or unscrew

nut (3).
Removing cover from gear case and removing supp-

lementary piston
Release screws (17) and spring washers (16) from
cover (15).
Remove cover and gasket (14) from cover (12).
Remove supplementary piston (13) from cover.
(12).
Remove cover and gasket (9) from housing (8).
Unscrew plug (11) and union (1) from cover (12) and re-
move with sealing rings (2) and (10).
Unscrew plug (5) and union (7) from housing (8) and re-
move with sealing rings (6).
20046/20 E –10.96–
Page 2
Removing nozzle needle

Release nut (3) on nozzle needle (2).
Remove nozzle needle from housing (1).
Removing compression spring and control piston

Remove control piston (3) and compression spring (2)
from housing (1).

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Page 3
Removing plug-in sleeve, thermal element and con-

trol piston
Remove compression spring (8), control piston (7) and
thermal element (4) from housing (1).
Remove snap ring (6) from plug-in sleeve (2).
Remove plug-in sleeve from housing and remove O-
rings (5) and (3) from plug-in sleeve (2).

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Page 1

Using surface crack-testing procedure and red penetrant dye, check housing and cover cracks.
Check housing bores, running surfaces and control lips of control piston for wear; smooth with emery cloth if necessary.
Adjust bore gauge and measure register bores in housing.
Using outside micrometer, measure fit diameter of control piston.
Check compression springs for wear.
Check housing and cover sealing surfaces and screw interfaces for evenness and damage, smooth with oilstone if
necessary.
Check threaded bores and rechase as necessary; insert threaded inserts as necessary.
Check nozzle needle and seat for wear; smooth as necessary.
Check return line and banjo union for damage and evenness on bolted-on components and replace as necessary.
Replace gasket, O-ring and sealing rings.
Check solenoid valve, see 3.86.
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Page 1
3.20.3a.5 Assembly
Preset threaded pin projection to dimension ”A” =
±
3.5 mm 0.2 mm; final setting takes place on engine.
Lock threaded pin (2) with nut (3).
Installing plug-in sleeve, thermal element and con-

trol piston
Blow out all bores in housing (1) with compressed air
and ensure bores are clean.
Insert new sealing rings (3) and (5) into grooves of
plug-in sleeve (2) and coat with petroleum jelly.
Press thermal element (4) into plug-in sleeve.
Insert plug-in sleeve and thermal element into housing
and secure with snap ring (6).
Insert control piston (7) and compression spring (8) into
housing and check for ease of movement.

Set threaded pin to dimension ”A” 18 = mm ±0.5 mm
and lock with nut (3).
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Page 2
Insert compression spring (2) and control piston (3) into

housing (1) and check for ease of movement.
Insert nozzle needle (2) into housing (1) until it contacts

stop, release approx. 1.5 rotations and secure with lock-
nut (3).
Installing cover on gear case and installing supple-

mentary piston
Mount cover (12) with gasket (9) on gear case (8) and
install with screws (3) and spring washers (4).
Insert supplementary piston (13) in gear case.
Installation position as in figure 3.20.3a, page 2.
Check supplementary piston for ease of movement.
Mount cover (15) with gasket (14) with screws (17) and
spring washers (16) on cover (12).
Insert plugs (5), (11) with sealing rings (6), (10), reduc-
tion unions (1), (7) with sealing rings (2), (6) on cover
(12) or housing (8) and tighten.
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Page 3
Check installation position of thermal element

Check projection of thermal element (1) dimension ”K”
±
= 21.5 mm 0.5 mm with depth gauge.
Setting idling oil supply

Connect control unit to test unit and check idling oil sup-
ply.
When testing on control test stand, use engine oil SAE
10.
Oil pressure between connection 1 and 7 = 4 bar
Set flow rate between connection 1 and 7 at approx. 1.5
l/min to 1.8 l/min at nozzle needle (2) (corresponds ap-
prox. 1.5 rotations at nozzle needle from closing posi-
tion).
Lock nozzle needle (2) with nut (3).
Insert plug (6) with sealing ring (5) into cover (4) and
tighten.
Remove control unit from test stand.
When installing on engine, use engine oil SAE 30 at an
oil temperature of 75 °C -85 °C.
Note
Pressure difference
Engine/control unit approx. 2.5 bar.
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Page 4
Installing solenoid valve and return line

Unscrew nut (3) and remove coil housing from solenoid
valve (4).
Mount solenoid valve with socket-head screws (6) on
cover (5) of control unit.
Mount coil housing with nut.
Fit union (7) on solenoid valve and secure.
Coat O-ring (1) with petroleum jelly and fit on cover (2).
Fit banjo union (9) over return line; when doing so, take
care not to damage O-ring.
Mount return line with sealing rings (8) and locknut (10)
on union (7) and cover (5) and tighten.
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Page 1
Clean and smooth sealing surfaces on housing and
elbow.
Insert studs (4) on housing.
Mount gasket (3).
Mount control unit (2) and solenoid valve (1) with nuts (6)
and spring washer (5) on housing and tighten.
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Page 1

Setting control piston on engine
Oil is supplied from engine, connection ”B”, to hydraulic
fan drive, connection ”A” at an engine coolant outlet tem-
perature of 82 ° C +1 ° C.
If necessary, adjust control unit using threaded pin (4) in
control piston (5) in such a way that when coolant circu-
lates thermal element at am engine coolant temperature
° °
of 82 C +1 C oil flows from connection ”B” to ”A”.
For this purpose, remove reduction union (1) and plug
(2).
Control piston (5) can be held in position by locking the
nut (7) by means of access port (3) on housing (6).
Switching off fan drive:
Fan drive can be switched off by interrupting oil flow from
connection ”B” to connection ”A” at an engine coolant
°
temperature of 80 C -1 C. °
Closing gear case and providing with lead seal

After engine test run, mark plug (2) with screw locking
paint.
Secure securing screws (1) with sealing wire and lead
seal (2).
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3.20.4 Fan Wheel
1 Fan wheel 5 Nut

2 Screw 6 Cover plate
3 Spring pin 7 Washer
4 Flange 8 Screw
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Page 2
Arrangement of fan wheel/hydraulic fan drive
1 Spring pin 6 Cover plate

2 Cover with bearing 7 Screw
3 Fan wheel 8 Nut
4 Washer 9 Fan gear shaft
5 Screw 10 Flange
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Page 3


3.20.4.2 Removal
Perform removal as shown in illustration, page 1 and 2.

Using surface crack-testing procedure and red penetrant dye, check fan wheel and flange for cracks.
If cracks are found on fan wheel, eliminate crack and weld to MTU Specifications; repeat crack test.
Replace flange if cracks are found.
Check fan wheel for damage, round as necessary or weld to MTU Specifications.
Check fit diameter, mating faces and thread; recondition as necessary or replace.
After reconditioning, fan wheel must be balanced.
Permitted residual imbalance max. 60 gmm/kg.
Check condition of cover plate, replace as necessary.
Prior to installation, check mating faces on fan wheel shaft and fan wheel for flatness; smooth with oilstone if necessary.
Perform installation as shown in illustration, page 1 and 2.
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3.27 Additional Control Devices

Contents
3.27.1a Sequential turbocharging system

3.27.1a.2 Removal
3.27.1b Sequential turbocharging system

3.27.1b.2 Removal
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Page 2

A
S4

Engine oil
Hydrochloric acid
Dry compressed air
Caution
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Page 1
3.27.1a Sequential Turbocharging System
1 Distributor element 12 Union

4 Solenoid valve 15 Screw
5 Union 16 Compressed air line
6 Vent line 17 Compressed air line
7 Nut 18 Union
10 Union 21 Sealing cone
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Page 2
Sequential turbocharging system
1 Exhaust turbocharger B-side 5 Actuating cylinder

2 Solenoid valve/distributor 6 Accumulator link
3 Air line 7 Intake housing
4 Air line
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Page 3


- - x Cut out compressed air supply Op. Man.
- x x Disconnect cable from solenoid valve Op. Man.
3.27.1a.2 Removal
Prior to removing compressed air lines, it is advisable to take photographs of all sides of the engine or to identify lines
with metal tags.
Remove solenoid valve and distributor as shown in illustration, Page 1 and 2.
For actuating cylinder removal, see 3.10.8a.2

Remove realigned lines from engine, pickle in a hydrochloric acid solution, (9 parts water to 1 part hydrochloric acid),
then wash with hot water and blow dry with compressed air.
Check actuating cylinder and solenoid valves, see 3.86
Mount distributor and solenoid valve as shown in illustration, Page 1 and 2.
Prior to installation, blow out all compressed air lines with dry compressed air.
Mount free of tension with attachments as shown in illustration 3.27.1 and photographs or markings.
For actuating cylinder installation, see 3.10.8a.6.
Note
Before mounting air lines on distributor and actuating cylinder, check function of exhaust flow control flap and air flow
control flap – see Description and Operating Instructions.
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3.27.1b Sequential Turbocharging System
1 Air line 6 O-ring

2 Air line 7 Solenoid valve
3 Drain valve 8 Valve
4 Pipe clamp half 9 Connector
5 Bracket 10 Air line
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Page 2
Sequential turbocharging system
1 Solenoid valve/distributor 5 Accumulator link

2 Air line 6 Intake housing
3 Air line 7 Exhaust turbocharger B-side
4 Actuating cylinder 8 Air line
20046/20 E –11.96–
Page 3


- x x Disconnect cable from solenoid valve Op. Man.
3.27.1b.2 Removal
Prior to removing compressed air lines, it is advisable to take photographs of all sides of the engine or to identify lines
with metal tags.
Remove solenoids and valve as shown in illustration, Page 1 and 2.
For actuating cylinder removal, see 3.10.8a.2.

Remove realigned lines from engine, pickle in a hydrochloric acid solution, (9 parts water to 1 part hydrochloric acid),
then wash with hot water and blow dry with compressed air.
Replace O-rings.
Check actuating cylinder and solenoid valves, see 3.86
3.27.1b6 Installation
Remove valve and solenoid valves as shown in illustration, Page 1 and 2.
Prior to installation, blow out all compressed air lines with dry compressed air.
Mount free of tension with attachments as shown in illustration 3.27.1 and photographs or markings.
For actuating cylinder installation, see 3.10.8a.6.
Note
Before mounting air lines on distributor and actuating cylinder, check function of exhaust flow control flap and air flow
control flap – see Description and Operating Instructions.
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Page 1
3.84 Monitoring System

Contents
3.84.1a Level switch (coolant level monitoring)

3.84.1a1 Before-removal operations
3.84.1a2 Removal
3.84.1a4 Inspection and repair
3.84.1a6 Installation
3.84.2 Speed transmitter (camshaft drive)

3.84.2.2 Removal
3.84.2.5 Assembly
3.84.3 Speed transmitter (left engine side)

3.84.3.2 Removal
3.84.3.5 Assembly
3.84.4 Engine speed sensor

3.84.4.2 Removal
3.84.4a Engine speed sensor

3.84.4a1 Before-removal operations
3.84.4a2 Removal
3.84.4a4 Inspection and repair
3.84.4a6 Installation
3.84.5 Solenoid float switch (leak-off fuel)

3.84.5.2 Removal
3.84.6 Miltac microswitch (limit switch)

3.84.6.2 Removal see (3.84.6)
3.84.6a Proximity switch

3.84.6a1 Before-removal operations (see 3.84.6a)
3.84.6a2 Removal (see 3.84.6a)
3.84.6a4 Inspection and repair (see 3.84.6a)
3.84.6a6 Installation (see 3.84.6a)
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A
S4

Installation paste Ultratherm 50547
Engine oil SAE30 Shell Rotella 30XW
Dry compressed air
Ammeter and voltmeter

Caution
20046/20 E –11.96–
Page 1
3.84.1a Level Switch (Coolant Level Monitoring)
1 Float
2 Flange
3 Housing with switch
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Page 2
Level switch arrangement
1 Housing 4 Level switch

2 Washer 5 Nut
3 Screw
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Task Description Section 3.84.1a1
Page 1
3.84.1a1 Before-Removal Operations


- x x Disconnect cable at level switch Op. Man.
20046/20 E –10.96–
Page 1
3.84.1a2 Removal
Release securing screws (1) at level switch (2) and re-
move together with washers.
Remove level switch (2) with gasket from cooler housing

(1).
Note
When removing the level switch, make sure that the float
is not damaged.
20062/00 E –10.96–
Page 1
3.84.1a4 Inspection and Repair

Remove dirt and metallic sediment from the float and
rocker switch with fitted magnet.
Check float for corrosion and for ease of movement.
Check bolt-on surfaces for irregularities and smooth
with oilstone if necessary.
Functional check:
Connect ohmmeter to trip points, see illustration.
Hold float switch in a horizontal position.
Move float upwards and check the switching function of
the switch.
Replace float switch if necessary.
20062/00 E –03.95–
Page 1
Install level switch (2) with gasket in cooler housing (1).
Note
Take care not to damage float when installing.
Mount level switch (2) with screws (1) and washers to

housing.
Using a torque wrench, tighten bolts diagonally and
evenly to specified torque (see 1.3).
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Page 1
3.84.2 Speed Transmitter (Camshaft Drive)
1 Speed transmitter
2 O-ring
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20038/10 E –11.92–
Page 1
3.84.2.2 Removal
Release tightening bolt (2) at flange (1).
Withdraw speed transmitter (3) from flange.
20038/10 E –11.92–
Page 1
Withdraw snap ring (1) with scriber (3) from groove at
speed transmitter.
Withdraw drive shaft (2) from gear teeth at speed trans-
mitter.
Remove O-rings (4) from groove at speed transmitter.
20038/10 E –11.92–
Page 1

Check drive shaft for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace compo-
nent if cracks are detected.
Check drive shaft gear teeth and speed transmitter for wear, replace parts if necessary.
Replace O-ring.
Check operation of speed transmitter (see Operation Manual).
20038/10 E –11.92–
Page 1
3.84.2.5 Assembly
Insert O-ring (4) into speed transmitter groove and coat
Coat gear teeth of drive shaft (2) with engine oil.
Insert drive shaft in gear teeth at speed transmitter.
Secure drive shaft with snap ring (1).
Using a scriber (3), press snap ring into retaining groove
at speed transmitter.
20038/10 E –11.96–
Page 1
Coat speed transmitter at the fit with assembly paste.
Insert speed transmitter (3) in the flange (1) at crank-
case upper section.
Insert the shaft in the driver gear teeth at the camshaft
drive gear.
Secure tightening bolt (2) in flange.
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Page 1
3.84.3 Speed Transmitter (Left Engine Side)
1 Electric speed transmitter

2 O-ring
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20038/10 E –11.92–
Page 1
3.84.3.2 Removal
Removing speed transmitter (left engine side)
Release screw (1) on speed transmitter drive housing.
Withdraw speed transmitter from housing.
20054/00 E –10.93–
Page 1
Withdraw snap ring (1) with scriber (3) from groove at
speed transmitter.
Withdraw drive shaft (2) from gear teeth.
Remove O-ring (4) from groove at speed transmitter.
20038/10 E –11.92–
Page 1

Check drive shaft for cracks using magnetic crack-testing method with fluorescent magnetic powder.
If cracks are detected, replace part.
Check drive shaft gear teeth and speed transmitter for wear, replace parts if necessary.
Replace O-ring.
Check operation of speed transmitter (see Operation Manual).
1 Connection, coil I
2 Connection, coil I
3 Connection, coil II
4 Connection, coil II
20054/00 E –10.93–
Page 1
3.84.3.5 Assembly
Insert O-ring (4) into speed transmitter groove and coat
Coat gear teeth of drive shaft (2) with engine oil.
Insert drive shaft in gear teeth at speed transmitter.
Secure drive shaft with snap ring (1).
Using a scriber (3), press snap ring into retaining groove
at speed transmitter.
20038/10 E –11.96–
Page 1
Installing speed transmitter (left engine side)
Insert speed transmitter in speed transmitter drive hous-
ing.
Insert shaft in driver gear teeth.
Tighten tightening screw (1) on speed transmitter drive

housing.
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Page 1
3.84.4 Engine Speed Sensor
1 Plug-in connection 3 Crankcase

2 Engine speed sensor 4 Idler gear
20038/10 E –11.92–
Page 1


- x x Unscrew connector at engine speed sensor -
20038/10 E –11.92–
Page 1
3.84.4.2 Removal
Removing speed sensor
Unscrew speed sensor (1) from crankcase.
Remove O-ring (2).
20038/10 E –11.96–
Page 1

Speed sensor DM 12/A
Carry out functional check (see Operation Manual).
Check speed sensor for damage, replace as necessary.
Recondition wrench surfaces with oilstone as required.
Replace O-ring.
1 Voltage input system 1

2 Voltage output system 1
5 Voltage output system 2
7 Jacket
a Voltage stabilisation
b Voltage protection
20038/10 E –11.96–
Page 1
Installing speed sensor
Insert new O-ring (2) in groove in speed sensor (1).
Screw speed sensor into crankcase.
Check distance X of the speed sensor lower edge to

gear.
X = 0.50 mm to 1.20 mm
Tighten speed sensor to specified torque.
20038/10 E –11.96–
Page 1
3.84.4a Engine Speed Sensor
1 Threaded connector 6 Idler gear

2 Gasket 7 Connector
3 Speed transmitter 8 Toothed washer
4 O-ring 9 Screw
5 Crankcase
20062/00 E –03.95–
Page 2
Speed transmitter
1 Engine speed sensor

2 O-ring
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Page 1
3.84.4a1 Before-Removal Operations


- x x Unscrew connector at engine speed sensor -
20062/00 E –03.95–
Page 1
3.84.4a.2 Removal
Removing speed sensor
Unscrew speed sensor (1) from crankcase.
Remove O-ring (2).
20062/00 E –11.96–
Page 1

Speed sensor DM 11/A
Check speed sensor condition and check for damage,
Recondition wrench surfaces with oilstone as required.
Replace O-ring.
Block diagram
A Winding 1
approx. 700 Ohm
B Winding 1
C (NC) jacket
D Winding 2
approx. 1000 Ohm
E Winding 2
20062/00 E –11.96–
Page 1
Installing speed sensor
Insert new O-ring (2) in groove in speed sensor (1).
Screw speed sensor into crankcase.
Check distance X of the speed sensor lower edge to

gear.
X = 0.50 mm to 1.20 mm
Tighten speed sensor to specified torque.
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Page 1
3.84.5 Solenoid Float Switch (Leak-off Fuel)
1 Magnetic float switch
20038/10 E –11.92–
Page 1


- x x Disconnect cable from float solenoid switch -
20038/10 E –11.92–
Page 1
3.84.5.2 Removal
Removing float solenoid switch
Release single-ended union (2) on cover of leak-off fuel
tank.
Remove float solenoid switch (1) with sealing ring (3).
20038/10 E –11.92–
Page 1

Clean float element (3) and Teflon pipe (2) of dirt and
contamination.
Check float element for ease of movement.
Connect ohmmeter to brown and blue conductors.
Hold float switch (1) in a vertical position.
Move float element upwards and check switching func-
tion of switch on ohmmeter.
Replace sealing ring.
Switch setting:
1 Float element, bottom
2 Float element, top
20038/10 E –11.92–
Page 1
Installing float solenoid switch
Install float solenoid switch (1) with new sealing ring (3)
into housing of leak-off fuel tank.
Tighten screw fitting (2).
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3.84.6 Miltac Microswitch (Limit Switch)
1 Miltac microswitch
2 Cable entry
3 Sealing ring


- x x Disconnect cable from Miltac miniature switch -
3.84.6.2 Removal
For removal of Miltac miniature switch – see 3.10.4a.2
20046/20 E –11.96–
Page 2

Check rubber sleeve between tappet and housing.
Replace limit switch if rubber sleeve is cracked.
Connect ohmmeter to terminal 0 and 2.

Press button until ohmmeter displays flow.
Connect ohmmeter to terminal 0 to 1.
Press button until ohmmeter displays interruption.
Contact switchover must be sudden in both instances
(snap-action contact).
Replace limit switch if necessary.
For installation of Miltac miniature switch – see 3.10.4a.6
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Page 1
3.84.6a Proximity Switch
1 Proximity switch
2 Housing
3 Cable entry


- x x Disconnect cable from Miltac miniature switch -
3.84.6a.2 Removal
For removal of proximity switch – see 3.10.4a.2
20046/20 E –11.96–
Page 2

Check condition of proximity switch.
For functional check, see operating instructions.
Connection pattern for NPN changeover switch
PIN 1: Brown + battery voltage
PIN 2: White break contact
PIN 3: Blue - battery voltage
PIN 4: Black make contact
Connection diagram
NPN (identifying colour of active surface: red)
Load (L) is supplied to minus (-)
Connection pattern for PNP changeover switch

PIN 1: Brown + battery voltage
PIN 2: White break contact
PIN 3: Blue - battery voltage
PIN 4: Black make contact
Connection diagram
PNP (identifying colour of active surface: green)
Load (L) is supplied to plus (+)
For installation of proximity switch – see 3.10.4a.6
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Page 1
3.86 Accessories (Electric, Pneumatic)

Contents
3.86.1 Generator
3.86.1.2 Removal
3.86.2 Generator coupling

3.86.2.2 Removal
3.86.3 Auxiliary PTO, free end

3.86.3.2 Removal
3.86.3.5 Assembly
3.86.3a Three-phase alternator with V-belt drive

3.86.3a.2 Removal
3.86.4 Air compressor drive

3.86.4.2 Removal
3.86.4a Air compressor drive

3.86.4a.2 Removal
3.86.6a 4/2-way directional control valve (cylinder cutout)

3.86.6a.2 Removal (see 3.11.8b.2)
3.86.6a.6 Installation (see 3.11.8b.6)
3.86.7 Solenoid
3.86.7.2 Removal (see 3.10.4.2)
3.86.7.4 Inspection and repair (3.86.7)
3.86.7.6 Installation (see 3.10.4.6)
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Page 2
3.86.9 Actuating cylinder

3.86.9.2 Removal (see 3.86.9)
3.86.9.5 Assembly
3.86.9.6 Installation (see 3.86.9.5)
3.86.9b Actuating cylinder

3.86.9b.1 Before-removal operations (see 3.86.9b)
3.86.9b.2 Removal (see 3.10.8a.2)
3.86.9b.5 Assembly
3.86.9b.4 Inspection and repair (see 3.86.9b)
3.86.9b.6 Installation (see 3.10.8a.6)
3.86.10 Solenoid valve

3.86.10.2 Removal (see 3.86.10)
3.86.10a 4/2-way solenoid valve (air and exhaust flow control flap control)
3.86.10a.2 Before-removal operations (see 3.86.10a.1)
3.86.10a.4 Inspection and repair (see 3.86.10a.1)
3.86.10a.6 Installation (see 3.86.10a.1)
20046/20 E –11.96–
Page 3

A
S4
S 5.12
S 5.13
S 5.14
S 6.19

Inspection lamp
Magnifier
Ammeter and voltmeter

Part-joiner Loctite No. 675 40093
Long-life lubricating grease Longterm 2 Plus 40336
Solvent Aceton 40590
Engine oil SAE30 Shell Rotella 30XW
Assembly grease Festo S620ML – silicon-free
Dry compressed air

Caution
20046/20 E –11.96–
Page 1
3.86.1 Generator
ET 86 69 1
1 A/C generator
20038/10 E –11.92–
Page 2
Generator mounting
ET 86 72 1
1 Mounting bracket 3 Screw

2 Washer 4 Screw
20038/10 E –11.92–
Page 1


- x x Disconnect electric cable from generator -
20038/10 E –11.92–
Page 1
3.86.1.2 Removal
Remove protective guard (2) and flange (1) from gener-
ator.
Remove nuts from coupling (1).
Remove right mounting bracket (2) from generator.

Release left mounting bracket (1).
Move generator in direction of driving end and remove.
Remove left mounting bracket from crankcase.
20038/10 E –11.92–
Page 1

Check and repair generator (three-phase alternator) in accordance with Special Publication.
Check mounting bracket for cracks using surface crack-testing method with red penetrant dye.
Check mounting brackets and bolts for damage; recondition or replace as required.
20038/10 E –11.92–
Page 1
Mount left mounting bracket (1) with screws and
washers to retain generator on crankcase.
Drive generator with coupling element into left mounting
bracket and then mount right mounting bracket with
screws and washers.
Move generator in direction of free end.
Turn resilient coupling and insert screws (2) into coupl-
ing element, drive side.
Coat thread of bolts with engine oil.
Fit spring washers and tighten nuts with torque wrench
in accordance with tightening specification 1.3.
Remove band clamp (3) from resilient coupling.
Turn generator in mounting brackets so that all connec-

tion cables can be mounted without strain.
Press generator slightly to left and evenly tighten mount-
ing brackets (1) and (2).
For generator connection, see Description.
Note
Prior to generator operation, remove protective guard

from air intake opening.
Mount flange (1) to secure protective cover with screws

and spring washers on bearing housing and tighten.
Mount protective cover (2) with screws and spring
washers on flange and tighten.
20038/10 E –11.92–
Page 1
3.86.2 Generator Coupling
1 Shaft seal 8 Protective cover

2 Coupling element 9 Flange
3 Resilient coupling 10 Screw
4 Coupling element 11 Spring washer
5 Screw 12 Screw
7 Nut
20038/10 E –11.92–
Page 2
Generator coupling
1 Drive side, coupling element 7 Coupling element, generator side

2 Resilient coupling 8 Screw
3 Band clamp 9 Screw
4 Protective cover 10 Spring washer
5 Nut 11 Flange
6 Spring washer 12 Bearing housing
20038/10 E –11.92–
Page 1


- - x Disconnect cable from generator -
- x x Remove protective shroud 3.86.1.2
20038/10 E –11.92–
Page 1
3.86.2.2 Removal
Removing resilient coupling
Remove screws (1) from resilient coupling.
Remove coupling from coupling element (2).
Removing coupling element

Clamp securing device (2) in clamp.
Using coupling element, fit generator (1) on securing de-
vice.
Remove nut on coupling element with socket and exten-
sion (3).
Remove generator from retaining device.
Heat coupling element with welding torch to approx.

250 °C.
Note
Coupling element is secured with part joiner.

Use removal tool (1) to remove coupling element from
armature shaft of generator (2).
20038/10 E –11.92–
Page 2
Hydraulically removing coupling element from drive shaft of generator
Caution
Danger

Insert draw spindle (1) of removal tool (2) into threaded
bore of drive shaft and tighten.
Install hydraulic puller so that catcher plate has at least
5 mm clearance.

pump.
Actuate pump plunger until definite resistance is re-
ached at operating lever.
press-fit on coupling element (1).
Remove removal tool with draw spindle and H.P. line.
Remove coupling element from drive shaft.
20038/10 E –11.92–
Page 1

Replace resilient coupling as part of every W6 overhaul.
Using the magnetic crack-testing method and fluorescent magnetic powder, check both coupling elements for cracks.
Check multi-groove connection of armature shaft and coupling element for wear and pitting: replace components if
necessary.
Check tapered seat 1:50 on coupling element for wear.
Check tapered seat with taper gauge 1:50; replace component as necessary.
Check running surface for shaft seal on coupling element for wear and damage.
Smooth minor wear and damage with emery cloth, metal-spray running surface in accordance with MTU instructions
as required; replace component if necessary.
Check condition of protective shroud and replace if necessary.
20038/10 E –11.92–
Page 1
Installing coupling element
Clean press-fit surface of coupling element (1) and drive
shaft with acetone and coat with engine oil SAE 10.
Push coupling element onto drive shaft taper.
Measure distance of drive shaft end to coupling element
end with depth gauge.
Hydraulically installing coupling element onto drive shaft of generator
Caution
Danger
Use only those tools and equipment stipulated for hydraulic installation.
The maximum permissible expansion pressure of Pmax = 2000 bar must not be exceeded.
It is not permitted for personnel to remain within the danger area behind the equipment during the installation operations.
Insert draw spindle (1) of installation device (2) into
threaded bore of drive shaft and tighten.
20038/10 E –11.92–
Page 2

on installation tool (2) and hydraulic hand pump.
pump.
Tighten thrust nut on installation device with open-end
wrench, and operate hydraulic hand pump at the same
time.
scribed travel of 3.8 mm – 1.3 mm at the coupling el-
ement (1) and no more.
The maximum permissible expansion pressure must not
exceed Pmax = 2000 bar.
stallation device catcher plate.
Remove installation tool from drive shaft.
Check push-on dimension.
Installing coupling element on generator
Clean multi-groove connection of armature shaft and
coupling element with activator and blow dry with com-
pressed air.
Evenly coat multi-groove connection of armature with
part joiner.
Fit coupling element on armature shaft.
Coat thread of nut with engine oil.
20038/10 E –11.92–
Page 3
Clamp securing device (2) in clamp.

Using coupling element, fit generator (1) on securing de-
vice.
Fit washer on armature shaft.
Tighten nut with torque wrench (3) in accordance with
Note
Screws for coupling element on drive shaft must be in-

serted prior to installation of resilient coupling.
Mount resilient coupling with inserted screws (2) on
coupling element of generator with screws (1), spring
washers and nuts, taking care not to tighten screws.
20038/10 E –11.92–
Page 1
3.86.3 Auxiliary PTO, Free End
1 Bearing flange 10 Cover*

2 Grooved ball bearing 11 O-ring*
3 Back-up ring 12 Spring washer *
4 Snap ring 13 Screw *
5 Drive shaft 14 Cover*
6 Bearing flange, free end 15 O-ring*
7 Cylindrical roller bearing 16 Spring washer *
8 Snap ring 17 Screw *
9 Sleeve *
* Components not applicable when installing auxiliary PTOs
20046/20 E –11.96–
Page 2
Auxiliary PTO, free end
1 O-ring 9 Back-up ring

2 Snap ring 10 Gear case
3 Nut 11 Drive shaft
4 Washer 12 Cylindrical roller bearing
5 Sleeve or coupling part for generator 13 Screw (order-specific)
(order-specific) 14 Washer (order-specific)
6 Cover (order-specific) 15 Screw
7 Bearing flange 16 Bearing flange
8 Grooved ball bearing
20046/20 E –11.96–
Page 3
Auxiliary PTO, free end with V-belt PTO for generator
1 O-ring 10 Back-up ring

2 Snap ring 11 Gear case
3 Screw 12 Drive shaft
4 Cover * 13 Grooved ball bearing
5 Sleeve * 14 Screw *
6 Flange 15 Washer *
7 Belt pulley 16 Cover*
8 Bearing flange 17 Nut
9 Cylindrical roller bearing 18 Bearing flange
* Components not applicable when installing auxiliary PTOs
20046/20 E –11.96–
Page 1


- x x Disconnect cable from generator -
- x x Remove protective shroud 3.86.1.2
- x x Remove generator coupling 3.86.1.2
20038/10 E –11.92–
Page 1
3.86.3.2 Removal
Removing cover
Removing securing screw (1) with spring washer (2).
Remove cover (3).
Hydraulically removing sleeve from pump shaft
Caution
Danger

The maximum permitted expansion pressure stamped on sleeve must not be exceeded.
Insert draw spindle (1) of removal tool (2) into threaded
bore of drive shaft and tighten.
Install hydraulic puller so that catcher plate has at least
5 mm clearance.
20038/10 E –11.92–
Page 2

pump.
press-fit on sleeve (1).
Remove sleeve.
Removing bearing flanges

Remove securing nuts (4).
Remove washers.
Remove securing screws (1).
Using jackscrews, press bearing flange (8) out of crank-
case (6).
Remove O-ring (2).
Using jackscrews, press bearing flange (5) and drive
shaft (7) out of crankcase (6).
Remove O-ring (3).
20038/10 E –11.92–
Page 1
Removing cylindrical roller bearing
flange.
Press cylindrical roller bearing out of bearing flange (1)

with mandrel.
Removing inner race

Use removal tool to remove inner race from drive shaft.
20038/10 E –11.92–
Page 2
Disassembling bearing flange

Press drive shaft out of bearing flange (1).
Press shaft seal (6) out of bearing flange (5).

Remove snap ring (1) with circlip pliers.
Remove back-up ring (2).
Using suitable mandrel, press grooved ball bearing (3)
out of bearing flange (5).
20038/10 E –11.92–
Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check drive shaft, and bearing flanges for
cracks.If cracks are detected, replace parts.
Check bearing seats for localized galling; smooth if necessary.
Check gear of drive shaft for wear and indentations; if necessary, smooth with oilstone and emery cloth.
Check tapered seats 1:50 with taper gauge; replace drive shaft if necessary.
Check sleeve for wear in internal diameter; replace as necessary.
Adjust bore gauge and measure bore in bearing flange.
Using outside micrometer, measure bearing seats on drive shaft.
Replace cylindrical roller bearings and grooved ball bearings as part of every W6 overhaul.
Replace O-ring and shaft seal.
20038/10 E –11.92–
Page 1
3.86.3.5 Assembly
Installing cylindrical roller bearing
Using press-in mandrel (1), insert cylindrical roller bear-
ing (2) (without inner race) into bearing flange (3).
Note
Bearing inner races must not be interchanged. Note the

fixed assignment of bearing inner race to bearing outer
race. This must be adhered to.
Use circlip pliers to install circlip (1) in bearing flange.

Insert O-ring into groove on bearing flange and coat with
Installing inner race

Heat inner race (2) to approx. 60 °C.
Caution
Always use protective gloves to hold inner race.

Clean and degrease drive shaft (1) seating surface.
Press drive shaft (1) into inner race (2) of cylindrical
roller bearing.
20038/10 E –11.96–
Page 2
Installing bearing flange

Degrease and dry bore for shaft seal (5) in bearing hous-
ing (4).
Wipe seating surface on shaft seal with ”denaturated
ethanol” and, using press-in mandrel, press into bearing
flange until it contacts the stop.
Install grooved ball bearing (2) with press-in mandrel up
to stop in bearing flange (4).
Fit back-up ring (1).
Use circlip pliers to install circlip (3) in bearing flange (4).
Fit O-ring (6) onto bearing flange.
Coat O-ring and shaft seal with ”petroleum jelly”.
Press drive shaft (1) into preassembled bearing flange

(2).
Note
Support inner race of ball bearing with a suitable pipe.
20038/10 E –11.96–
Page 1
Insert drive shaft with bearing flange on generator side
into crankcase.
Insert second bearing flange, free end (2) into crank-

case.
Secure both bearing flanges with screws (1), washers
and nuts (3).
Installing sleeve
Check taper in sleeve (1) and taper on drive shaft (2) for
damage.
Check for burrs at transition areas between contact and
lateral surfaces, and oil distribution and discharge
grooves.
Machining scores and transition radii must be polished
Degrease press-fit surface with acetone, blow dry with
compressed air and coat with engine oil SAE 10.
Fit sleeve onto drive shaft taper.
Measure distance from shaft end to sleeve end.
20038/10 E –11.92–
Page 2
Hydraulically installing sleeve
Caution
Danger

The expansion pressure stamped on sleeve must not be exceeded.
ations.
Insert draw spindle (1) of installation tool (2) into
threaded bore of drive shaft and tighten.

on installation tool (2) and hydraulic hand pump (3).
pump.
Tighten thrust nut on installation tool with open-end
wrench, and operate hydraulic hand pump at the same
time.
of 3.8 mm - 1.3 to be reached.
The max. permitted expansion pressure of Pmax = 1500
bar is stamped on the sleeve and must not be exceeded.
stallation tool catcher plate.
Remove installation tool from drive shaft.
20038/10 E –11.92–
Page 3
Installing cover
Insert sealing ring (4) into groove on bearing flange (5)
Mount end cover (3) on free end with screw (1) and
spring washer (2) on bearing flange and tighten.
20038/10 E –11.96–
Page 1
3.86.3a Three-phase Alternator with V-belt Drive
1 Shaft seal 21 Threaded rod

2 Flange 22 Nut
3 V-belt 23 Bracket
4 Belt pulley 24 Guard plate
5 Belt pulley 25 Bracket
6 Screw 26 Screw
7 Centring element 27 Spring washer
8 Carrier 28 Compression spring
9 Dowel pin 29 Spring retainer
10 Screw 30 Nut
11 Screw 31 Threaded pin
12 Screw 32 Nut
13 Washer 33 Sleeve
14 Threaded pin 34 Bracket
15 Bush 35 Washerevice
16 Nut 36 Screw
17 Setting bush 37 Washer
18 Spacer sleeve 38 Screw
19 Bracket 39 Nut
20 Threaded pin
20046/20 E –11.96–
Page 2
Three-phase alternator with V-belt drive
1 Crankcase 9 Carrier
2 Output shaft 10 Centring element
3 Bearing flange 11 Bracket with clamp
4 Drive flange 12 Generator
5 V-belt 13 Shaft seal
6 Belt pulley 14 Grooved ball bearing
7 Threaded pin 15 Snap ring
8 Setting bush
20046/20 E –11.96–
Page 1


- x x Disconnect cable on three-phase alternator -
20046/20 E –11.96–
Page 1
3.86.3a.2 Removal
Removing accidental-contact protection
Remove screws (4) on bracket (2).
Remove guard plate (3) and bracket (5).
Remove screws (1).
Remove bracket (2).
Removing three-phase alternator

Release nuts (5) on threaded rod (4).
Caution
Spring tension
Remove nuts on threaded pin (1).
Remove nuts (5) from threaded rod and remove spring
retainer (3), spring (2) and threaded rod (4).
20046/20 E –11.96–
Page 2
Release nuts (8) on threaded pin (5)

Press three-phase alternator (9) in initial position.
Remove V-belt.
Remove nuts (3) and (8) on threaded pin.
Remove spacer sleeves (7) and bushes (4).
Remove setting bushes (6).
Lift three-phase alternator and simultaneously remove
threaded pin and remove three-phase alternator.
Remove nut (12); for this purpose, hold V-belt pulley (11)
securely in position.
Remove V-belt pulley with removal tool.
Remove Woodruff key (10).
Remove screws on V-belt pulley (2) and remove V-belt
pulley from flange (1).
Press-off flange – see 3.86.2.2
Removing carrier
Remove screws (3).
Remove carrier (4).
Remove screws (1).
Remove centring elements (2).
Remove centering pins (5) if necessary.
20046/20 E –11.96–
Page 1

Check and repair three-phase alternator; see Special Publication.
Check V-belt pulleys and flange for cracks using magnetic crack-testing method with fluorescent magnetic powder;
replace if cracks are found.
Check V-belt pulley for wear; replace as necessary.
Visually inspect condition of V-belt; replace as necessary.
Check threaded pin, setting bushes and spacer sleeves for wear; replace as necessary.
Check taper seat on flange for wear; check taper seat with taper gauge 1:50 and replace as necessary.
Check running surface on flange for shaft seal for wear and damage; smooth minor wear and damage with emery cloth
and metal-spray, if necessary, in accordance with MTU instructions.
Check condition of carrier, centring elements, bracket, threaded rod, threaded pin, spring, guard plate and dowel pins
and check for wear; replace components as necessary.
20046/20 E –11.96–
Page 1
Installing carrier
Fit centring elements (2) on dowel pins (5) on carrier (4).
Tighten screws (1) with torque wrench to tightening
specification 1.3.
Install carrier with screws (3) on crankcase and tighten
with torque wrench to tightening specification 1.3.
Installing three-phase alternator

Press on flange (1) – see 3.86 2.6
Coat screws securing V-belt pulley (2) with engine oil.
Mount V-belt pulley on flange.
Tighten screws with torque wrench to tightening specifi-
cation 1.3.
Insert Woodruff key (4) into armature shaft of generator
(3).
Heat V-belt pulley (5) to 80 °C and fit on armature shaft.
Caution
Use protective gloves to hold V-belt pulley in position.

Coat thread of armature shaft with engine oil and tighten
nut (6) with torque wrench to tightening specification 1.3.
20046/20 E –11.96–
Page 2
Coat threaded pin (4) and setting bushes (5) with en-
gine oil.
Insert three-phase alternator (8) into carrier; in doing so,
insert threaded pins at same time.
Insert setting bushes into carrier (6).
Fit bushes (3) on threaded pin and tighten nuts (2) to
Using straightedge, check that both V-belt pulleys (1)
and (9) are aligned.
Axially adjust V-belt by means of threaded pins and set-
ting bushes.
Install spacer sleeves and fit nuts (7).
Push three-phase alternator in initial position and fit V-
belt on V-belt pulleys.
Note
Replace V-belts in pairs only.

Coat threaded pin (3) with thread-locking agent and in-
sert into three-phase alternator housing and tighten.
Mount bracket (2) and tighten nut (1).
Mount threaded rod (5) on threaded pin (3) and tighten
with nuts.
Mount compression springs and spring retainers with
nuts (4) on threaded rod (5).
Tension compression spring with nut (4).
Caution
Spring tension
For initial assembly dimension X = 26 mm
Tighten nut on threaded pin with torque wrench to
tightening specification 1.3 and lock locknuts on
threaded pin (3) and threaded rod (5).
Tighten nuts of spacer sleeves on carrier with torque
wrench to tightening specification 1.3.
20046/20 E –11.96–
Page 3
Installing accidental-contact protection

Install bracket (2) with screws (1) and washers and
tighten.
Install guard plate (3) and bracket (5) with screws (4)
and spring washers on bracket (2) and tighten.
20046/20 E –11.96–
Page 1

Checking pretension of V-belt
Pretension of V-belts (6) must be checked 2 to 4 hours
after assembly.
Remove guard plate.
Release nuts (1), (2) and (3).
Compression springs’ own tension retensions V-belts.
Pretension is correct if
dimension x = 30 mm.
If necessary, use nut (2) to adjust
dimension x = 30 mm; lock adjusting nut.
Tighten nuts (1), (2) and (3) to tightening specification
1.3.
Install guard plate.
1 Adjusting nut
2 Locknut
3 Threaded rod
x Setting dimension
20046/20 E –11.96–
Page 1
3.86.4 Air Compressor Drive
1 Suction filter 6 Snap ring

2 Sealing ring 7 Coupling sleeve
3 Air compressor 8 Coupling element
4 Coupling element 9 Spring washer
5 Collar nut 10 Screw
20038/10 E –11.92–
Page 2
Air compressor arrangement
1 Connection for air inlet 11 Connection for engine oil outlet

2 Connection for compressed air outlet 12 Crankcase
3 O-ring 13 Crankshaft bearing
4 Woodruff key 14 Conrod bearing
5 Connection for engine oil inlet 15 Cover
6 Connection for coolant outlet 16 Conrod
7 Connection for coolant inlet 17 Piston
8 Intermediate flange 18 Cylinder with cooling fins
9 Grooved ball bearing 19 Valve plate
10 Crankshaft 20 Cylinder head cover
20038/10 E –11.96–
Page 3
Air compressor drive arrangement
1 Air compressor 3 Intermediate flange

2 Coupling element 4 Bearing flange
20038/10 E –11.96–
Page 1


- x x Remove compressed air lines -
20038/10 E –11.92–
Page 1
3.86.4.2 Removal
Removing air compressor
from air compressor (1).
Pull air compressor from fit on bearing flange (4) and re-
move.

Remove collar nut (3) from crankshaft of air compressor
(1).
Remove coupling element (2) with removal tool from
crankshaft of air compressor.
Removing coupling sleeve

Remove coupling sleeve (2) from coupling element (3)
on coolant pump shaft.
Remove snap rings (1) from coupling sleeve.
20038/10 E –11.92–
Page 2
Hydraulically removing coupling element
Caution
Danger

The maximum permissible expansion pressure (Pmax = 1500) bar must not be exceeded.
Insert draw spindle (1) of removal tool into threaded bore
of pump shaft and tighten.
ance between locating plate (5) and coupling element.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Locating plate
6 Grub screw

pump.
press-fit on coupling element.
Release catcher plate (3).
20038/10 E –11.92–
Page 3
Remove coupling element (1) from coolant pump shaft

(2).
20038/10 E –11.92–
Page 1

Check taper on coupling element and coolant pump shaft for wear.
Check taper on coupling element and air compressor crankshaft for wear.
Replace damaged components as necessary.
Check toothing in coupling sleeve and on coupling elements for wear; replace components as necessary.
Using the magnetic crack-testing method and fluorescent magnetic powder, check coupling elements and coupling
sleeve for cracks.
Check collar nut for damage and check thread for ease of movement; replace as necessary.
Check mating faces of intermediate flange for evenness; smooth with oilstone if necessary.
Replace snap rings as necessary.
Inspect and repair air compressor in accordance with manufacturer’s specifications.
20038/10 E –11.92–
Page 1
Hydraulically installing coupling element
Clean press-fit surfaces with acetone.
Coat press-fit surfaces with engine oil SAE 10.
Fit coupling element (1) onto taper of coolant pump shaft
(2).
Caution
Danger

ations.
Fit installation tool with draw spindle (1) to pump shaft
and secure.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Thrust washer
6 Grub screw
20038/10 E –11.92–
Page 2

pump.
wrench.
scribed travel of 3.8 mm –1.3 mm is achieved.
The maximum permissible expansion pressure of Pmax
= 1500 bar must not be exceeded.
stallation device thrust washer (3).
shaft.
Insert snap rings (3) into coupling sleeve (4).
Ensure snap rings are correctly seated in groove.
Coat coupling sleeve (4) with engine oil and fit onto
coupling element (5).
20038/10 E –11.92–
Page 3

Clean and degrease taper on coupling element and air
compressor crankshaft with acetone.
Fit coupling element (2) onto taper of air compressor
crankshaft.
Coat thread of collar nut with engine oil and fit onto
crankshaft of air compressor. Tighten nut with torque
wrench in accordance with tightening specification 1.3.
Installing air compressor

Mount air compressor (1) on bearing flange (4).
Ensure that coupling elements engage correctly.
Secure air compressor with screws (2) and spring
washers (3) to bearing flange (4).
20038/10 E –11.96–
Page 1
3.86.4a Air Compressor Drive
1 Single – cylinder air compressor 8 Spring washer

2 Hex bolt 9 Intermediate flange
4 Coupling element 11 Snap ring
5 O-ring 12 Coupling sleeve
6 Collar nut 13 Bearing flange
7 Hex bolt 14 Coupling element
20046/20 E –11.96–
Page 2
Air compressor arrangement
1 Cylinder head cover 7 Nameplate

2 Plug 8 Front flange
3 Opening for engine oil return 9 Crankshaft
4 Cover 10 Collar nut
5 Connection for engine oil supply 11 Cylinder with cooling fins
6 Crankcase 12 Valve plate
20046/20 E –11.96–
Page 3
Air compressor drive arrangement
1 Air compressor 5 Coupling element

2 Coupling element 6 Bearing flange
3 Coupling sleeve 7 Intermediate flange
4 Collar nut
20046/20 E –11.96–
Page 1


- x x Remove compressed air lines -
20046/20 E –11.96–
Page 1
3.86.4a.2 Removal
Removing air compressor
Remove securing screws (1) and spring washers from
air compressor (3).
Remove air compressor from fit on intermediate flange.
Remove O-ring from air compressor flange.

Remove collar nut (3) from crankshaft of air compressor
(1).
Remove coupling element (2) with removal tool from

Remove securing screws (4) from intermediate flange
(1).
Withdraw intermediate flange (1) from fit on bearing
flange and remove.
Remove O-ring (2) from bearing flange.
20046/20 E –11.96–
Page 2
Removing coupling sleeve

Remove coupling sleeve (2) from coupling element (3)
on coolant pump shaft.
Remove snap rings (1) from coupling sleeve.
Hydraulically removing coupling element
Caution

Insert draw spindle (1) of removal tool into threaded bore
of pump shaft and tighten.
ance between locating plate (5) and coupling element.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Locating plate
6 Grub screw
20046/20 E –11.96–
Page 3

pump.
press-fit on coupling element.
Release catcher plate (3).
Remove coupling element (1) from coolant pump shaft

(2).
20046/20 E –11.96–
Page 1

Check taper on coupling element and coolant pump shaft for wear.
Check taper on coupling element and air compressor crankshaft for wear.
Replace damaged components as necessary.
Check toothing in coupling sleeve and on coupling elements for wear; replace components as necessary.
Using the magnetic crack-testing method and fluorescent magnetic powder, check coupling elements and coupling
sleeve for cracks.If cracks are detected, replace parts.
Check collar nut for damage and check thread for ease of movement; replace as necessary.
Check mating faces of intermediate flange for evenness; smooth with oilstone if necessary.
Replace snap rings as necessary.
Inspect and repair air compressor in accordance with manufacturer’s specifications.
20046/20 E –11.96–
Page 1
Hydraulically installing coupling element
Clean and degrease press-fit surfaces with acetone.
Coat press-fit surfaces with engine oil SAE 10.
Fit coupling element (1) onto taper of coolant pump shaft
(2).
Caution
Danger
ations.
Fit installation tool with draw spindle (1) to pump shaft
and secure.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Thrust washer
6 Grub screw
20046/20 E –11.96–
Page 2

pump.
wrench.
of 3.8 mm – 1.3 to be reached.
The maximum permissible expansion pressure of Pmax
= 1500 bar must not be exceeded.
stallation device thrust washer (3).
shaft.
Insert snap rings (3) into coupling sleeve (4).
Ensure snap rings are correctly seated in groove.
Coat coupling sleeve (4) with engine oil and fit onto
coupling element (5).
20046/20 E –11.96–
Page 3

Insert O-ring (2) into groove on bearing flange and coat
Fit intermediate flange (1) on fit on bearing flange and
secure with screws (4) and spring washers (3).

Clean and degrease taper on coupling element and air
compressor crankshaft with acetone.
Fit coupling element (2) onto taper of air compressor
crankshaft.
Coat thread of collar nut with engine oil and fit onto
Tighten nut with torque wrench in accordance with
Installing air compressor

Insert O-ring into groove on bearing flange and coat with
petroleum jelly.
Mount air compressor (3) on intermediate flange (2).
Ensure that coupling elements engage correctly.
Secure air compressor with screws (1) and spring
washers to intermediate flange.
20046/20 E –11.96–
Page 1
3.86.6a 4/2-Way Solenoid Valve (Cylinder Cutout)

4/2-way solenoid valve – S6 VH67 G020 1924 AV
A Service line
B Service line
P Delivery line
T Ventilation
20047/10 E –12.95–
Page 2
4/2-way solenoid valve arrangement
1 4/2-way directional control valve 5 Nut

2 End element 6 Solenoid
3 Plate 7 Equipment socket
4 Grooved pin
20047/10 E –12.95–
Page 3


- x x Disconnect electric cable from 4/2-way solenoid valve -
3.86.6a.2 Removal
For removal of 4/2-way solenoid valve – see 3.11.8b.2
Check condition of 4/2-way solenoid valve, replace O-rings.
For installation of 4/2-way solenoid valve – see 3.11.8b.6
20047/10 E –12.95–
Page 1
3.86.7 Solenoid
1 Solenoid
2 Pull rod
3 Nut
20038/10 E –03.95–
Page 2
Solenoid arrangement
1 Solenoid
2 Guide rod
3 Terminal box
Solenoid diagram
Voltage: 24 VDC
Rated current: 1.42 A
Protection: IP 65
Pulling force: 59 N
20038/10 E –11.92–
Page 3


- x x Disconnect electric cable from D/C solenoid -
3.86.7.2 Removal
For solenoid removal, see 3.10.4.2.

Check guide rod for ease of movement.
Installing solenoid, see 3.10.4.6.
20038/10 E –11.92–
Page 1
3.86.9 Actuating Cylinder

Version 559 090 0709/1209
1 Actuating cylinder
2 Connector
20038/10 E –11.96–
Page 2
Actuating cylinder – arrangement
1 Cylinder pipe 12 O-ring

2 Piston 13 Sleeve
3 Bush 14 Pot sleeve
4 Cylinder head cover 15 Boot
5 Restrictor screw 16 Designation diagram
6 Collar nut 17 Piston rod
7 Clamp 18 Crown
8 Washer 19 Tie bolt
9 Washer 20 Grooved ring
10 Snap ring 21 Nut
20038/10 E –12.95–
Page 3


3.86.9.2 Removal
Removing actuating cylinder, see 3.10.8.2.
20038/10 E –12.95–
Page 1
Prior to disassembly, remove boot from actuating cylin-
der – see 3.10.8.3
Remove nut (1) from piston rod (19).
Remove collar nuts (3) and washers (4) from tie bolts
(12).
Remove cylinder head cover (5) and cylinder crown (13)
from cylinder pipe (7) and/or from piston rod.
Withdraw piston rod from cylinder pipe.
In order to be able to disassemble piston rod, the nut
(14) secured with high-strength thread-locking agent
must be removed.
Then individual components (15, 16, 17, 18) can be re-
moved from piston rod.
Remove gasket (11) from cylinder head cover and cylin-
der crown.
Remove snap ring (2) from cylinder head cover.
Press scraper (8), bush (9) and grooved ring (10) out of
cylinder head cover.
20038/10 E –11.92–
Page 1

Check sliding surfaces and sealing surfaces on cylinder pipe, piston rod and piston, cylinder head cover and cylinder
crown for wear, damage and pitting.
In event of minor wear, smooth with emery cloth and replace components as necessary.
Check thread on piston rod and tie bolts; rechase as necessary.
Replace seals, O-ring and packings during disassembly operations.
20038/10 E –11.92–
Page 1
3.86.9.5 Assembly
Prior to assembly, coat all sliding-contact surfaces and
rubber components with ”petroleum jelly”.
Insert grooved ring (10), bush (9), scraper (8) and snap
ring (2) in specified sequence into cylinder head cover
(5).
Apply a few drops of high-strength thread-locking agent
to mating face on retaining ring (15) and to lip of piston
rod (19).
Fit individual components (15, 16, 17, 18) on piston rod
in correct sequence in accordance with illustration.
Coat thread of nut (14) with high-strength thread-locking
agent and tighten to Tightening Specification 1.3.
Insert gasket (11) into annular groove of cylinder head
cover (5) and cylinder crown (13).
Fit cylinder (7) on cylinder crown.
Insert readily-assembled piston rod into cylinder pipe.
Ensure that sealing lips of pot sleeve are not damaged.
Fit cylinder head cover on piston rod.
Four tie bolts (12) hold cylinder together.
Tighten collar nuts (3) of tie bolt diagonally and evenly
with torque wrench.
After assembly, check actuating cylinder for leaks and
check function.
For boot and connector installation – see 3.10.8.5
Installing actuating cylinder, see 3.10.8.6.
20038/10 E –12.95–
Page 1
3.86.9b Actuating Cylinder
Version 000 098 18 18
1 End cover 8 Complete piston

2 Connection Y 9 Bearing cap
3 Bore for condensation drain 10 Connection X
4 O-ring 11 Bearing bush
5 Cylinder pipe 12 Scraper rod gasket
6 Compression spring 13 Piston rod
7 Stop 14 Tie bolt
20046/20 E –11.96–
Page 2


3.86.9b.2 Removal
For actuating cylinder removal, see 3.10.8a.2
20046/20 E –11.96–
Page 1
Remove scalloped rings (1) of adjustable end-position
dampings.
Remove adjusting screws (2).
Remove O-ring from adjusting screw.
Caution
Spring tension
Remove collar screws (1), (4) for bearing cap (5) and
end cover (3).
Note
Collar screws are secured with thread-locking agent

and, before removal, must be heated to approx. 200 °C.
Remove bearing cap and end cover from cylinder pipe
(3), (2).
Remove tie bolt (6).
Remove O-ring from end cover.
Remove compression spring (6) from stop (1).

Remove piston rod (4) and stop from bearing cap (3).
Remove O-ring (5) from bearing cap.
Remove stop from piston rod.
Note
Threaded fitting is secured with thread-locking agent

and, prior to removal, must be heated to approx. 200 °C.
Remove pot sleeve (2).
20046/20 E –11.96–
Page 2
Remove snap ring (1) from bearing cap (3).

Remove rod gasket (2).
20046/20 E –11.96–
Page 1

Using magnetic crack-testing method with fluorescent magnetic powder, check stop and piston rod for cracks.
Replace respective part if cracks are found.
Check sliding surfaces and sealing surfaces on cylinder pipe, on piston rod, bearing cap and end cover for wear, dam-
age and pitting.
In event of minor wear, smooth with emery cloth and replace components as necessary.
Check parts for wear and warping; recondition or replace as necessary.
Check all thread for ease of movement; recut or replace part as necessary.
Check compression spring for wear, pitting and spring pressure; replace as necessary.
Spring forces:
S 60 mm = 232 N
S 160 mm = 143 N
When disassembling the actuating cylinder, replace O–rings and pot sleeve.
20046/20 E –11.96–
Page 1
3.86.9b.5 Assembly
Note

When assembling actuating cylinder, use assembly
grease from repair kit.
Clean and degrease thread of piston rod (2) and stop (3)
and coat with thread-locking agent.
Fit pot sleeve (1) onto piston rod.
Fit stop onto piston rod and tighten to specified tightening
torque – see 1.3.
Insert rod gasket (2) into bearing cap (3) as far as it will
go and secure with snap ring (1).
Coat sliding surfaces of gaskets with assembly grease.
Coat O-ring (5) with assembly grease and insert into

groove on bearing cap (3).
Coat sliding surface of piston rod (4) and pot sleeve (2)
with assembly grease.
Fit bearing cap on piston rod.
Fit on compression spring (6) until the stop (1).
20046/20 E –11.96–
Page 2
Clean, degrease and dry thread of collar screws and tie

bolt and coat with thread-locking agent.
Coat sliding surfaces in cylinder pipe and sealing rings
with assembly grease.
Insert sealing ring into groove of end cover (2).
Fit cylinder pipe (3) on bearing cap (5).
Positioning correctly, mount end cover onto cylinder
pipe.
Caution
Spring tension
Insert tie bolt (6).
Mount collar screws (1), (4) on tie bolt and tighten diag-
onally and evenly to specified tightening torque – see
1.3.
Coat O-ring with assembly grease and install on adjust-
ing screws (2) twist-free.
Insert adjusting screws into bearing cap and end cover
as far as it will go.
Back-off adjusting screw in bearing cap by one rotation
and adjusting screw in end cover by three rotations.
Secure adjusting screws with thread locking varnish.
Insert scalloped rings (1).
Check function of actuating cylinder and check for leaks.
For actuating cylinder installation, see 3.10.8a.6
20046/20 E –11.96–
Page 1
3.86.10 Solenoid Valve
1 Block diagram 5 Armature guide pipe

2 Valve body 6 Connection 0
3 Armature 7 Connection 1
4 Solenoid 8 Connection 2
20046/20 E –11.96–
Page 2


- x x Disconnect electric cable from solenoid valve -
3.86.10.2 Removal
For solenoid valve removal – see 3.20.3a.2

For solenoid valve installation – see 3.20.3a.5
20046/20 E –11.96–
Page 1
3.86.10a 4/2-Way Solenoid Valve (Air and Exhaust Flow Control Flap Control)
10
7 6 5
1 Pressure port 6 Manual emergency control

2 Control air line 7 Restrictor screw, connection 4
3 Ventilation 8 Valve body
4 Control air line 9 Pilot valve
5 Restrictor screw, connection 2 10 Solenoid coil
20058/0 E –03.93–
Page 2


- x x Disconnect electric cable from solenoid valve -
3.86.10a.2 Removal
For solenoid valve removal – see 3.10.8a.

For solenoid valve installation – see 3.10.8a.
20058/0 E –03.93–
Page 1
3.87 Engine/Gearbox Controls

See MTU Elektronik Documentation and/or Operating Instructions.
20046/20 E –11.96–
Page 1
3.88 Accessories (Mechanical)

Engine coupling – see Special Publication.
For details of engine transportation locking device, see Operation Manual and Special Description.
20038/10 E –11.92–

MTU 12 V 4000M Main Engine Workshop Manual

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MTU 12 V 4000M Main Engine Workshop Manual

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Service Publication

MTU Friedrichshafen GmbH

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1.1 Important Information

1.2 Designation of engine sides and cylinders

1.3 Tightening specifications for bolts and nuts

1.5 Dangers at working area

1.6 Data sheets

1.8 Publication summary

1.1 Important Information

Quickly finding the sought-after information

Basic requirements for maintenance and service work

General assembly instructions

Information on installing the Flexmaster pipe connection

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

Clamp halves are fitted over seal carrier and sleeve,

Threaded connections without tightening specifications

Threaded connections with tightening specifications

Threaded bores for threaded inserts (heli-coil)

Thread Blind hole dia. (max./min.) Twist drill dia.

Removing and installing threaded inserts (heli-

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

Use spindle to turn thread insert through mouth

Mount installation tool on threaded hole and install

1.2 Designation of Engine Sides and Cylinders

Applicable designations and abbreviations

1.3 Tightening Specifications for Bolts and Nuts

Designation Torque specifications Lubricant See

Designation Torque specifications Lubricant See

Conrod cap bolt

Designation Torque specifications Lubricant See

M12 bolt for vibration damper 70 Nm + 7 Nm Engine oil 3.3.8.5

Bolts for intermediate flange, auxiliary PTO

Air intake system/exhaust system

Designation Torque specifications Lubricant See

M12 bolt for disc assembly 100 Nm + 10 Nm Engine oil 3.11.4.6

Designation Torque specifications Lubricant See

Self-locking nut for disc assembly 29 Nm + 2 Nm - 3.11.4.6

Securing bolts for fuel injection pump

Designation Torque specifications Lubricant See

Bolt for oil cooler in oil pan 74 Nm + 7 Nm Engine oil 3.16.2a.5

Centre bolt for filter bowl 25 Nm Engine oil 3.16.4a.6

Designation Torque specifications Lubricant See

Engine mount, free end (with flange-mounted

Tightening torques for stress bolts as per standard MTN 5007

Thread Not torsion-protected Torsion-protected*

*Protect shank against torsion when tightening.

Thread Hand-tightened Machine-tightened

Tightening torques for plugs as per standard MTN 5183–1

DIN 908 DIN 910 DIN 7604A/C

Tightening torques for banjo screws as per standard MTN 5183–2

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

Tightening torques for male connectors as per standard MTN 5183–3

DIN 2353, model C

Firing order for 8 V 396, long firing order A1 – B4 – A4-A2 – B3 – A3 – B2-B1

Direction of rotation, viewed towards driving end

Opening pressure of fuel injector nozzles, model 5550102051

Setting pressure with new spring 250 bar to 258 bar

Opening pressure of fuel injection nozzles, version 555100751 / 2151 / 2551

Setting pressure with new spring 280 bar to 288 bar

Opening pressure of fuel injector nozzles, model 5550102651

Setting pressure with new spring 310 bar to 318 bar