MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD
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MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD
Language : English
Pages :820
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD
toc................................................................................. 0 1.1 Important Information....................................................... 0 1.1.1 Reman assemblies – Prerequisites for maintenance tasks a.............. 0 REMAN assemblies........................................................ 0 Requirements for maintenance tasks...................................... 0 General assembly instructions........................................... 0 Information on installation of Flexmaster pipe connection............... 0 1.2 General Conditions...................................................... 0 1.2.1 General conditions.................................................... 0 General................................................................. 0 Correct use............................................................. 0 Modifications or Conversions............................................ 0 Spare parts............................................................. 0 Reworking components.................................................... 0 1.2.2 Personnel and organizational requirements ............................ 0 Personnel requirements.................................................. 0 Organizational measures................................................. 0 Working clothes and protective equipment................................ 0 1.2.3 Safety precautions when working on the engine......................... 0 Engine operation........................................................ 0 Maintenance and repair.................................................. 0 Welding work............................................................ 0 Hydraulic installation and removal...................................... 0 Working on electrical/electronic assemblies............................. 0 Working with laser equipment............................................ 0 Operation of electrical equipment....................................... 0 1.2.4 Auxiliary materials, fire prevention and environmental pro............ 0 Fire prevention......................................................... 0 Noise................................................................... 0 Environmental protection................................................ 0 Auxiliary materials..................................................... 0 Lead.................................................................... 0 Acids and alkaline solutions............................................ 0 Paints.................................................................. 0 Liquid nitrogen......................................................... 0 Compressed air.......................................................... 0 Used oil................................................................ 0 1.2.5 Standards for warning notices in the publication...................... 0 1.2.6 General information regarding the Tolerances and Wear Limi............ 0 1.2.7 Engine side and cylinder designations................................. 0 1.2.8 Torque specifications for screws, nuts and bolts...................... 0 Crankcase............................................................... 0 Running gear............................................................ 0 Cylinder head........................................................... 0 Valve gear.............................................................. 0 Fuel system - high-pressure............................................. 0 Exhaust turbocharger 20 V ZR 205........................................ 0 Exhaust system.......................................................... 0 Charge-air cooler....................................................... 0 Staring equipment 12/16 V engines, Bosch starter........................ 0 Staring equipment 12/16 V engines, Nikko starter........................ 0 Lube oil system......................................................... 0 Generator............................................................... 0 Mounting/support........................................................ 0 Tightening specification for setscrew and stud connections as pe........ 0 Tightening torques for stress bolt connections as per standard M........ 0 Tightening torques for plug screws as per standard MTN€5183-1 .......... 0 Tightening torques for DIN€7604C plug screws (with long screwed ........ 0 Tightening torques for banjo screws as per standard MTN 5183-2 ......... 0 Tightening torques for banjo screws made of steel....................... 0 Tightening torques for banjo screws made of copper/aluminum allo........ 0 Tightening torques for male connectors as per standard MTN€5183-........ 0 Tightening torques for union nuts on screwed plugs ISO 6149-3........... 0 1.2.9 Settings.............................................................. 0 Firing order for Series 4000 engines.................................... 0 Direction of rotation, viewed towards driving end....................... 0 Valve clearance, engine cold (20 °C).................................... 0 Valve timing with valve clearance adjusted.............................. 0 Cam and valve lift for camshaft adjustment.............................. 0 1.2.10 Conversion tables.................................................... 0 Length.................................................................. 0 Area.................................................................... 0 Volume.................................................................. 0 Speed................................................................... 0 Mass.................................................................... 0 Force................................................................... 0 Density................................................................. 0 Torque.................................................................. 0 Pressure................................................................ 0 Mass moment, 2nd grade.................................................. 0 Energy.................................................................. 0 Power................................................................... 0 Temperature............................................................. 0 Fuel consumption........................................................ 0 1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil............ 0 1.2.12 Transport............................................................ 0 Transport............................................................... 0 Setting the engine down after transport................................. 0 2.1 Engine – Checking condition before a major overhaul......................... 0 2.2 Preface..................................................................... 0 General..................................................................... 0 MTU maintenance concept..................................................... 0 Note........................................................................ 0 Out-of-service periods...................................................... 0 Application group........................................................... 0 Load profile................................................................ 0 2.3 Maintenance tasks........................................................... 0 2.4 Maintenance schedule matrix................................................. 0 Maintenance schedule matrix (10,000-30,000 operating hours) for ............ 0 Maintenance schedule matrix (9,000 operating hours) for applicat............ 0 Maintenance schedule matrix (6,000 operating hours) for applicat............ 0 Maintenance schedule matrix (6,000 operating hours) for applicat............ 0 2.5 Engine – Removal............................................................ 0 2.6 Engine – Disassembly........................................................ 0 2.7 Engine – Assembly........................................................... 0 2.8 Engine – Installation....................................................... 0 2.9 Engine – Run-in procedure................................................... 0 Running in engine after component replacement............................... 0 Setting engine operational values........................................... 0 2.10 Initial engine operation................................................... 0 3.1 Crankcase and Attachments................................................... 0 3.1.1 Engine layout......................................................... 0 Also applies to 8/12/16 V 4000 G and R.................................. 0 3.1.2 Crankcase and attachments – Overview.................................. 0 Crankcase and attachments – Overview.................................... 0 3.1.3 Crankcase – Overview ................................................. 0 Crankcase with cover.................................................... 0 Crankcase............................................................... 0 Oil filler neck with oil dipstick....................................... 0 3.1.4 Crankcase – Disassembly............................................... 0 3.1.5 Crankcase – Cleaning.................................................. 0 3.1.6 Crankcase – Check..................................................... 0 3.1.7 Crankcase – Tolerances................................................815 Crankcase bore for crankshaft...........................................815 Crankcase bore for camshaft............................................. 6 Crankcase bore for cylinder liner....................................... 0 Main bearing cap........................................................ 0 Main bearing bore....................................................... 0 Crankcase crankshaft bore coaxiality.................................... 0 Crankcase camshaft bore coaxiality...................................... 0 3.1.8 Crankcase – Assembly.................................................. 0 3.1.9 Cylinder liner – Overview............................................. 0 Overview of cylinder liner with scraper ring............................ 0 Cylinder liner with scraper ring in crankcase........................... 0 3.1.10 Cylinder liner – Removal............................................. 0 3.1.11 Cylinder liner – Cleaning............................................ 0 3.1.12 Cylinder liner – Check............................................... 0 3.1.13 Cylinder liners – Tolerances......................................... 0 Reconditioning instructions:............................................ 0 3.1.14 Cylinder liner – Installation........................................ 0 3.1.15 Oil pan – Overview................................................... 0 View from free end...................................................... 0 3.1.16 Oil pan – Removal.................................................... 0 3.1.17 Oil pan – Cleaning................................................... 0 3.1.18 Oil pan – Check...................................................... 0 3.1.19 Oil pan – Installation............................................... 0 3.1.20 Oil pan – Tightening sequence for oil pans made of GGG .............. 0 3.1.21 Engine lifting equipment - Overview.................................. 0 Overview................................................................ 0 Engine lifting equipment................................................ 0 3.1.22 Engine lifting equipment – Removal................................... 0 3.1.23 Engine lifting equipment – Cleaning.................................. 0 3.1.24 Engine lifting equipment – Check..................................... 0 3.1.25 Engine lifting equipment - Installation.............................. 0 3.1.26 End housing overview, driving end.................................... 0 End housing with fittings............................................... 0 Guide bush location for end housing removal/installation................ 0 3.1.27 End housing, driving end – Removal................................... 0 3.1.28 End housing, driving end – Disassembly............................... 0 3.1.29 End housing, driving end – Cleaning.................................. 0 3.1.30 End housing, driving end – Check..................................... 0 3.1.31 End housing , driving end – Tolerances............................... 0 3.1.32 End housing, driving end – Assembly.................................. 0 3.1.33 End housing, driving end – Installation.............................. 0 3.1.34 Crankcase ventilation – Overview..................................... 0 Crankcase ventilation, driving end...................................... 0 Crankcase ventilation, free end......................................... 0 3.1.35 Crankcase ventilation – Removal...................................... 0 3.1.36 Crankcase ventilation – Cleaning..................................... 0 3.1.37 Crankcase ventilation – Check........................................ 0 3.1.38 Crankcase ventilation – Installation................................. 0 3.2 Gear Train.............................................................. 0 3.2.1 Gearcase, free end – Overview......................................... 0 Arrangement of alignment tool for equipment carrier and equipmen........ 0 3.2.2 Gearcase, free end – Removal.......................................... 0 3.2.3 Gearcase, free end – Disassembly...................................... 0 3.2.4 Gearcase, free end – Cleaning......................................... 0 3.2.5 Gearcase, free end – Check............................................ 0 3.2.6 Gearcase, free end – Tolerances....................................... 0 Crankshaft bearing, free end, 8/12/16V.................................. 0 Crankshaft bearing, free end, 20V....................................... 0 3.2.7 Gearcase, free end – Assembly......................................... 0 3.2.8 Gearcase, free end – Installation..................................... 0 3.2.9 Gear train, free end – Overview....................................... 0 3.2.10 Gear train, free end – Removal....................................... 0 3.2.11 Gear train, free end – Cleaning...................................... 0 3.2.12 Gear train, free end – Check......................................... 0 3.2.13 Gear train, free end – Tolerances.................................... 0 3.2.14 Bearing bush – Removal and installation.............................. 0 3.2.15 Gear train, free end – Installation.................................. 0 3.3 Running Gear............................................................ 0 3.3.1 Running gear – Overview .............................................. 0 Running gear............................................................ 0 3.3.2 Crankshaft overview................................................... 0 Crankshaft, detail...................................................... 0 Crankshaft.............................................................. 0 Crankshaft with bearing................................................. 0 3.3.3 Crankshaft – Removal.................................................. 0 3.3.4 Crankshaft – Disassembly.............................................. 0 3.3.5 Crankshaft – Cleaning................................................. 0 3.3.6 Crankshaft – Check.................................................... 0 3.3.7 Crankshaft – Tolerances............................................... 0 Crankshaft bearings..................................................... 0 Conrod bearings......................................................... 0 Crankshaft bearings, guide bearing expanding dimension.................. 0 Crankshaft bearing expansion dimension.................................. 0 Crankshaft axial play................................................... 0 Crankshaft bearing shells............................................... 0 Crankshaft gear, free end............................................... 0 Main bearing journal concentricity...................................... 0 3.3.8 Crankshaft – Assembly................................................. 0 3.3.9 Crankshaft – Balancing................................................ 0 3.3.10 Main bearing shells – Check.......................................... 0 Checking main bearing shells............................................ 0 Main bearing shells (grooved bearing), upper half....................... 0 Assessment.............................................................. 0 Main bearing shell (sputtered bearing), lower half...................... 0 Assessment.............................................................. 0 Damage to bearing....................................................... 0 3.3.11 Main bearing bore – Check............................................ 0 3.3.12 Crankshaft – Installation............................................ 0 3.3.13 PTO flange, driving end, flywheel – Overview......................... 0 Installation/removal device assembly, long.............................. 0 Installation/removal device assembly, short............................. 0 3.3.14 PTO flange, driving end, flywheel – Removal.......................... 0 3.3.15 Radial-lip shaft seal, driving end – Removal......................... 0 3.3.16 PTO flange, driving end, flywheel – Cleaning......................... 0 3.3.17 PTO flange, driving end – Flywheel check............................. 0 3.3.18 Radial-lip shaft seal – Installation................................. 0 3.3.19 PTO flange, driving end, flywheel – Installation..................... 0 3.3.20 Crankshaft PTO, free end – Overview.................................. 0 Crankshaft, PTO......................................................... 0 PTO with vibration damper............................................... 0 Arrangement of driver flange installation/removal tool.................. 0 3.3.21 Vibration damper on PTO, free end – Removal.......................... 0 3.3.22 Vibration damper on PTO, free end – Disassembly...................... 0 Vibration damper – Disassembly.......................................... 0 3.3.23 Vibration damper on PTO, free end – Cleaning......................... 0 3.3.24 Vibration damper on PTO, free end – Check............................ 0 3.3.25 Vibration dampers on PTO, free end – Tolerances...................... 0 Free end crankshaft seal 8/12/16V....................................... 0 Free end crankshaft seal 20V............................................ 0 3.3.26 Vibration damper on PTO, free end – Installation..................... 0 3.3.27 Pistons and conrods – Overview....................................... 0 Pistons and conrods..................................................... 0 Piston details ......................................................... 0 3.3.28 Piston and conrod – Removal.......................................... 0 3.3.29 Piston and conrod – Disassembly...................................... 0 3.3.30 Piston – Cleaning.................................................... 0 3.3.31 Piston – Check....................................................... 0 3.3.32 Piston – Tolerances.................................................. 0 Piston bearings 8/12/16V................................................ 0 Piston bearings 20V..................................................... 0 Piston rings 8/12/16V................................................... 0 Piston rings 20V........................................................ 0 Piston clearance in cylinder liner 8/12/16V............................. 0 Piston clearance in cylinder liner 20V.................................. 0 Piston crown mounting................................................... 0 3.3.33 Piston – Assembly.................................................... 0 3.3.34 Conrod – Disassembly................................................. 0 3.3.35 Conrod – Cleaning.................................................... 0 3.3.36 Conrod – Check....................................................... 0 3.3.37 Conrod – Tolerances.................................................. 0 Conrod bearings......................................................... 0 Conrod bearing, locating pin............................................ 0 Conrod screw length..................................................... 0 Conrod bore parallelism................................................. 0 Small conrod bore....................................................... 0 3.3.38 Conrod – Assembly.................................................... 0 3.3.39 Conrod bearing shell – Assessment.................................... 0 Lower conrod bearing shell (grooved bearing) – Assessment............... 0 Assessment.............................................................. 0 Damage to bearing....................................................... 0 Upper conrod bearing half shell (sputtered bearing) – Assessme.......... 0 Assessment.............................................................. 0 3.3.40 Piston and conrod – Installation..................................... 0 3.4 Cylinder Head........................................................... 0 3.4.1 Cylinder head and attachments – Overview.............................. 0 Overview of cylinder head and attachments............................... 0 3.4.2 Valve-seat turning machine for cylinder head.......................... 0 Working principle of valve-seat turning machine......................... 0 Installing the solid pilot.............................................. 0 Mounting the supporting spider.......................................... 0 Inserting the pilot into the valve guide................................ 0 Locking the pilot....................................................... 0 Setting up valve turning machine........................................ 0 Mounting the cutter..................................................... 0 Placing the valve-turning machine on the pilot.......................... 0 Aligning the cutting edge with the valve-seat center.................... 0 Connecting the machine to power supply.................................. 0 Valve seat turning...................................................... 0 Positioning the cutter at the inner valve-seat edge..................... 0 Setting cutting depth................................................... 0 Lubricating the valve seat.............................................. 0 Valve seat turning...................................................... 0 Repeating the cutting pass.............................................. 0 Replacing the adapter head.............................................. 0 Removing the adapter head............................................... 0 Mounting the adapter head............................................... 0 3.4.3 Cylinder head – Removal............................................... 0 3.4.4 Cylinder head – Cleaning.............................................. 0 3.4.5 Cylinder head – Check................................................. 0 3.4.6 Cylinder head – Tolerances............................................ 0 Inlet and exhaust valve guides.......................................... 0 Valve clearance......................................................... 0 Exhaust valve seats..................................................... 0 Inlet valve seats....................................................... 0 Exhaust valve........................................................... 0 Inlet valve............................................................. 0 Valve springs, exterior................................................. 0 Valve springs, interior................................................. 0 Cylinder head – Mating surface – Protective sleeve – Valve bri.......... 0 Cylinder head screws.................................................... 0 3.4.7 Cylinder head – Repair................................................ 0 3.4.8 Valve seat grinder.................................................... 0 Example: Series 4000 M.................................................. 0 3.4.9 Cylinder head – Plug repair........................................... 0 3.4.10 Cylinder head – Assembly............................................. 0 3.4.11 Cylinder head – Installation......................................... 0 3.5 Valve Gear.............................................................. 0 3.5.1 Valve gear – Overview................................................. 0 Valve gear – Overview................................................... 0 3.5.2 Camshaft overview..................................................... 0 Overview of camshaft.................................................... 0 3.5.3 Camshaft – Removal.................................................... 0 3.5.4 Camshaft – Cleaning................................................... 0 3.5.5 Camshaft – Check...................................................... 0 3.5.6 Camshaft – Tolerances................................................. 0 Coaxiality of bearing points 8/12/16V................................... 0 Coaxiality of bearing points 20V........................................ 0 Axial play.............................................................. 0 3.5.7 Camshaft – Installation............................................... 0 3.5.8 Camshaft drive – Overview............................................. 0 Camshaft drive – Overview............................................... 0 3.5.9 Camshaft drive – Removal.............................................. 0 3.5.10 Camshaft drive – Cleaning............................................ 0 3.5.11 Camshaft drive – Check............................................... 0 3.5.12 Camshaft drive – Installation........................................ 0 3.5.13 Camshaft thrust bearing – Overview................................... 0 Overview of camshaft thrust bearing..................................... 0 3.5.14 Camshaft thrust bearing – Replacement................................ 0 3.5.15 Camshaft thrust bearing – Cleaning................................... 0 3.5.16 Camshaft thrust bearing – Check...................................... 0 3.5.17 Valve drive – Overview............................................... 0 Swing follower, swing follower assembly................................. 0 Rocker shaft support.................................................... 0 Swing follower.......................................................... 0 Valve bridge............................................................ 0 3.5.18 Valve drive – Removal................................................ 0 3.5.19 Valve drive – Disassembly............................................ 0 3.5.20 Valve drive – Cleaning............................................... 0 3.5.21 Valve drive – Check.................................................. 0 3.5.22 Valve drive – Tolerances............................................. 0 Rocker shaft support, inlet and exhaust................................. 0 Swing follower support, inlet and exhaust............................... 0 3.5.23 Valve drive – Assembly............................................... 0 3.5.24 Valve drive – Installation........................................... 0 3.5.25 Valve drive – Overview............................................... 0 Rocker arm assembly..................................................... 0 Rocker arm support...................................................... 0 Swing follower.......................................................... 0 3.5.26 Valve drive – Removal................................................ 0 3.5.27 Valve drive – Disassembly............................................ 0 3.5.28 Valve drive – Cleaning............................................... 0 3.5.29 Valve drive – Check.................................................. 0 3.5.30 Valve drive – Tolerances............................................. 0 Rocker shaft support, inlet and exhaust................................. 0 Swing follower support, inlet and exhaust...............................817 3.5.31 Valve drive – Assembly............................................... 0 3.5.32 Valve drive – Installation........................................... 0 3.5.33 Cylinder head cover – Overview....................................... 0 Overview of cylinder head cover......................................... 0 3.5.34 Cylinder head cover – Removal........................................ 0 3.5.35 Cylinder head cover – Cleaning....................................... 0 3.5.36 Cylinder head cover – Check.......................................... 0 3.5.37 Cylinder head cover – Installation................................... 0 3.6 Fuel System (high-pressure)............................................. 0 3.6.1 H.P. fuel system – overview........................................... 0 H.P. fuel system – overview............................................. 0 3.6.2 H.P. fuel pump – overview............................................. 0 H.P. fuel pump – overview............................................... 0 Front view of H.P. fuel pump............................................ 0 3.6.3 H.P. fuel pump removal................................................ 0 3.6.4 H.P. fuel pump disassembly............................................ 0 3.6.5 H.P. fuel pump inspection............................................. 0 3.6.6 H.P. fuel pump installation........................................... 0 3.6.7 H.P. fuel pump – Control block replacement............................ 0 3.6.8 Fuel injector – overview.............................................. 0 Fuel injector – overview................................................ 0 3.6.9 Fuel injector removal................................................. 0 3.6.10 Fuel injector disassembly............................................ 0 3.6.11 Fuel injector cleaning............................................... 0 3.6.12 Fuel injector inspection............................................. 0 3.6.13 Fuel injector installation........................................... 0 3.6.14 H.P. fuel line – Overview............................................ 0 H.P. line from H.P. accumulator to injector............................. 0 H.P. line from H.P. fuel pump to H.P. accumulator ...................... 0 H.P. accumulator and attachments........................................ 0 H.P. accumulator, left engine side...................................... 0 H.P. accumulator, right engine side..................................... 0 3.6.15 H.P. fuel line – Removal............................................. 0 3.6.16 H.P. fuel line – Disassembly......................................... 0 3.6.17 H.P. fuel line – Cleaning............................................ 0 3.6.18 H.P. fuel line – Check............................................... 0 3.6.19 H.P. fuel line – Assembly............................................ 0 3.6.20 H.P. fuel line – Installation........................................ 0 3.6.21 H.P. fuel system – Leak check........................................ 0 3.7 Fuel System (low-pressure).............................................. 0 3.7.1 L.P. fuel system – Overview........................................... 0 3.7.2 Fuel delivery pump – Overview......................................... 0 Fuel delivery pump – Overview........................................... 0 3.7.3 Fuel delivery pump – Removal.......................................... 0 3.7.4 Fuel delivery pump – Disassembly...................................... 0 Disassembling fuel delivery pump........................................ 0 3.7.5 Fuel delivery pump – Cleaning......................................... 0 3.7.6 Fuel delivery pump – Check............................................ 0 3.7.7 Fuel delivery pump – Installation..................................... 0 3.7.8 L.P. fuel system – Overview........................................... 0 3.7.9 Fuel delivery pump – Overview......................................... 0 Fuel delivery pump – Overview........................................... 0 3.7.10 Fuel delivery pump – Removal......................................... 0 3.7.11 Fuel delivery pump – Disassembly..................................... 0 Disassembling fuel delivery pump........................................ 0 3.7.12 Fuel delivery pump – Cleaning........................................ 0 3.7.13 Fuel delivery pump – Check........................................... 0 3.7.14 Fuel delivery pump – Installation.................................... 0 3.7.15 Fuel line from pump to filter – Overview............................. 0 3.7.16 Fuel lines from pump to filter – Removal............................. 0 3.7.17 Fuel lines from pump to filter – Cleaning............................ 0 3.7.18 Fuel lines from pump to filter – Check............................... 0 3.7.19 Fuel lines from pump to filter – Installation........................ 0 3.7.20 Fuel lines from pump to filter – Overview............................ 0 3.7.21 Fuel lines from pump to filter – Removal............................. 0 3.7.22 Fuel lines from pump to filter – Cleaning............................ 0 3.7.23 Fuel lines from pump to filter – Check............................... 0 3.7.24 Fuel lines from pump to filter – Installation........................ 0 3.7.25 Fuel filter – Overview............................................... 0 3.7.26 Fuel filter – Removal................................................ 0 3.7.27 Fuel filter – Disassembly............................................ 0 3.7.28 Fuel filter – Cleaning............................................... 0 3.7.29 Fuel filter – Check.................................................. 0 3.7.30 Fuel filter – Assembly............................................... 0 3.7.31 Fuel filter – Installation........................................... 0 3.7.32 Fuel filter – Overview............................................... 0 3.7.33 Fuel filter – Removal................................................ 0 3.7.34 Fuel filter – Disassembly............................................ 0 3.7.35 Fuel filter – Cleaning............................................... 0 3.7.36 Fuel filter – Check.................................................. 0 3.7.37 Fuel filter – Assembly............................................... 0 3.7.38 Fuel filter – Installation........................................... 0 3.7.39 Fuel lines from filter to H.P. pump – Overview ...................... 0 3.7.40 Fuel supply pipework from fuel filter to H.P. pump – Re.............. 0 3.7.41 Fuel supply pipework from fuel filter to H.P. pump – Cl.............. 0 3.7.42 Fuel supply pipework from fuel filter to H.P. pump – Ch.............. 0 3.7.43 Fuel supply pipework from fuel filter to H.P. pump – In.............. 0 3.7.44 Leak-off fuel line – Overview........................................ 0 3.7.45 Leak-off fuel line – Removal......................................... 0 3.7.46 Leak-off fuel line – Cleaning........................................ 0 3.7.47 Leak-off fuel line – Check........................................... 0 3.7.48 Leak-off fuel line – Installation.................................... 0 3.8 Exhaust Turbocharger.................................................... 0 3.8.1 Exhaust turbochargers................................................. 0 3.8.2 Exhaust turbocharger – Overview....................................... 0 3.8.3 Exhaust turbochargers – Removal....................................... 0 3.8.4 Turbocharger – Disassembly............................................ 0 Disassemble exhaust turbocharger........................................ 0 3.8.5 Exhaust turbochargers – Cleaning...................................... 0 3.8.6 Exhaust turbochargers – Check......................................... 0 3.8.7 Exhaust turbochargers – Installation.................................. 0 3.9 Charge-Air Cooling...................................................... 0 3.9.1 Charge-air cooling – Overview......................................... 0 Intercooler and attachments............................................. 0 3.9.2 Intercooler – Removal................................................. 0 3.9.3 Intercooler – Disassembly............................................. 0 Intercooler – Disassembly............................................... 0 3.9.4 Intercooler – Cleaning................................................ 0 Air-side cleaning....................................................... 0 Water-side cleaning..................................................... 0 Intercooler flushing.................................................... 0 Intercooler drying and preservation..................................... 0 3.9.5 Intercooler – Check................................................... 0 3.9.6 Charge-air cooler – Installation...................................... 0 3.10 Air Intake / Air Supply................................................818 3.10.1 Air intake / air supply – Overview...................................818 3.10.2 Air filter with retainers – Overview................................. 0 3.10.3 Air filters with retainers – Removal................................. 0 3.10.4 Air filters and retainers – Cleaning................................. 0 3.10.5 Air filters and retainers – Check.................................... 0 3.10.6 Air filters with retainers – Installation............................ 0 3.10.7 Intake air system to cylinders, left – Overview...................... 0 3.10.8 Air supply system to cylinders, left – Removal....................... 0 3.10.9 Air supply system to cylinders, left – Cleaning...................... 0 3.10.10 Air supply system to cylinders, left – Check........................ 0 3.10.11 Air supply system to cylinders, left – Installation................. 0 3.10.12 Air supply system to cylinders, right – Overview.................... 0 3.10.13 Air supply system to cylinders, right – Removal..................... 0 3.10.14 Air supply system to cylinders, right – Cleaning.................... 0 3.10.15 Air supply system to cylinders, right – Check....................... 0 3.10.16 Cylinder air supply pipework, right – Installation.................. 0 3.10.17 Air ducts from turbochargers to intercooler – Overview.............. 0 Air supply, variant A................................................... 0 Air supply, variant B................................................... 0 3.10.18 Intake air pipework from exhaust turbocharger to interco............ 0 3.10.19 Intake air pipework from turbocharger to intercooler –.............. 0 3.10.20 Air ducts from turbochargers to intercooler – Check................. 0 3.10.21 Air ducts from turbochargers to intercooler – Installa.............. 0 3.11 Exhaust System......................................................... 0 3.11.1 Exhaust system – Overview............................................ 0 3.11.2 Exhaust pipework after cylinder head – Overview...................... 0 Exhaust pipework, 12 V plug connection – Overview....................... 0 Exhaust pipework, 12 V screwed joint – Overview......................... 0 Exhaust pipework, 16 V – Overview....................................... 0 3.11.3 Exhaust pipework after cylinder head – Removal....................... 0 3.11.4 Exhaust pipework after cylinder head – Cleaning...................... 0 3.11.5 Exhaust pipework after cylinder head – Check......................... 0 3.11.6 Exhaust pipework after cylinder head – Installation.................. 0 3.12 Starting System........................................................ 0 3.12.1 Electric starter – Overview.......................................... 0 Starting equipment – Overview........................................... 0 Overview of starter (fastened using band clamp)......................... 0 3.12.2 Starter – Removal.................................................... 0 3.12.3 Starter – Disassembly................................................ 0 Starter – Disassembly................................................... 0 3.12.4 Starter – Cleaning................................................... 0 3.12.5 Starter – Inspection................................................. 0 3.12.6 Starter – Installation............................................... 0 3.12.7 Starting equipment – Overview........................................ 0 3.12.8 Starter – Removal.................................................... 0 3.12.9 Starter – Disassembly................................................ 0 Starter – Disassembly................................................... 0 3.12.10 Starter – Cleaning.................................................. 0 3.12.11 Starter – Check..................................................... 0 3.12.12 Starter – Installation.............................................. 0 3.13 Lube Oil System........................................................ 0 3.13.1 Lube oil system – Overview........................................... 0 3.13.2 Lube oil pump with drive – Overview.................................. 0 3.13.3 Lube oil pump with drive – Removal................................... 0 3.13.4 Lube oil pump with drive – Disassembly............................... 0 3.13.5 Lube oil pump with drive – Cleaning.................................. 0 3.13.6 Lube oil pump with drive – Check..................................... 0 3.13.7 Lube oil pump with drive – Installation.............................. 0 3.13.8 Oil filter – Overview................................................ 0 Oil filter assembly..................................................... 0 3.13.9 Oil filter with oil filter housing – Removal......................... 0 3.13.10 Oil filter housing – Disassembly.................................... 0 3.13.11 Oil filter housing – Cleaning....................................... 0 3.13.12 Oil filter housing – Check.......................................... 0 3.13.13 Oil filter housing – Assembly....................................... 0 3.13.14 Oil filter with oil filter housing – Installation................... 0 3.13.15 Centrifugal oil filter– Overview.................................... 0 Centrifugal oil filter with attachments................................. 0 Centrifugal oil filter with flange...................................... 0 Centrifugal oil filter assembly......................................... 0 3.13.16 Centrifugal oil filter – Removal.................................... 0 3.13.17 Centrifugal oil filter – Disassembly................................ 0 3.13.18 Centrifugal oil filter – Cleaning................................... 0 3.13.19 Centrifugal oil filter – Check...................................... 0 3.13.20 Centrifugal oil filter – Bearing clearance check.................... 0 3.13.21 Centrifugal oil filter – Assembly................................... 0 3.13.22 Centrifugal oil filter – Installation............................... 0 3.13.23 Oil cooler – Overview............................................... 0 Oil cooler with attachments............................................. 0 3.13.24 Oil cooler – Removal................................................ 0 3.13.25 Oil cooler – Cleaning............................................... 0 3.13.26 Oil cooler – Check.................................................. 0 3.13.27 Oil cooler – Installation........................................... 0 3.13.28 Oil system in crankcase – Overview.................................. 0 Oil system.............................................................. 0 3.13.29 Oil system in crankcase – Removal................................... 0 3.13.30 Oil system in crankcase – Cleaning.................................. 0 3.13.31 Oil system in crankcase – Check..................................... 0 3.13.32 Oil system in crankcase – Installation.............................. 0 3.13.33 Turbocharger oil supply – Overview.................................. 0 Exhaust turbocharger oil supply......................................... 0 3.13.34 Turbocharger oil supply – Removal................................... 0 3.13.35 Turbocharger oil supply – Cleaning.................................. 0 3.13.36 Turbocharger oil supply – Check..................................... 0 3.13.37 Turbocharger oil supply – Installation.............................. 0 3.14 Cooling System......................................................... 0 3.14.1 Coolant system – Overview............................................ 0 Engine coolant circuit.................................................. 0 3.14.2 Engine coolant pump – Overview....................................... 0 3.14.3 Engine coolant pump – Removal........................................ 0 3.14.4 Engine coolant pump – Disassembly.................................... 0 3.14.5 Engine coolant pump – Cleaning....................................... 0 3.14.6 Engine coolant pump – Check.......................................... 0 3.14.7 Engine coolant pump – Tolerances..................................... 0 3.14.8 Engine coolant pump – Assembly....................................... 0 3.14.9 Engine coolant pump – Installation................................... 0 3.14.10 Coolant supply for engine coolant pump, intake side – .............. 0 Elbow with attached components.......................................... 0 Coolant pipework........................................................ 0 Coolant pipework........................................................ 0 3.14.11 Engine coolant pump pipework, intake side – Removal................. 0 3.14.12 Coolant supply for engine coolant pump, intake side – .............. 0 3.14.13 Engine coolant pump pipework, intake side – Check................... 0 3.14.14 Coolant supply for engine coolant pump, intake side – .............. 0 3.14.15 Coolant pipework after cylinder – Overview.......................... 0 Coolant pipework after cylinder – Overview.............................. 0 3.14.16 Coolant pipework after cylinder – Removal........................... 0 3.14.17 Coolant pipework after cylinder – Cleaning.......................... 0 3.14.18 Coolant pipework after cylinder – Check............................. 0 3.14.19 Coolant pipework after cylinder – Installation...................... 0 3.14.20 Preheating unit – Overview.......................................... 0 3.14.21 Preheating unit – Removal........................................... 0 3.14.22 Preheating unit – Disassembly....................................... 0 Preheating unit – Disassembly........................................... 0 3.14.23 Preheating unit – Installation......................................819 3.14.24 Engine coolant ventilation and charge-air cooling – Ov.............. 0 Coolant vent lines...................................................... 0 3.14.25 Engine coolant ventilation and charge-air cooling – Re.............. 0 3.14.26 Engine coolant ventilation and charge air cooling – Cl.............. 0 3.14.27 Engine coolant and charge air coolant ventilation – Ch.............. 0 3.14.28 Engine coolant ventilation and charge air cooling – In.............. 0 3.14.29 Charge-air coolant pump – Overview.................................. 0 Charge-air coolant pump – Overview...................................... 0 3.14.30 Charge-air coolant pump – Removal................................... 0 3.14.31 Charge-air coolant pump – Disassembly............................... 0 3.14.32 Charge-air coolant pump – Cleaning.................................. 0 3.14.33 Charge-air coolant pump – Check..................................... 0 3.14.34 Charge-air coolant pump – Assembly.................................. 0 3.14.35 Charge-air coolant pump – Installation.............................. 0 3.14.36 Engine coolant pump – Tolerances.................................... 0 3.14.37 Coolant pipework from/to intercooler – Overview..................... 0 Coolant pipework........................................................ 0 3.14.38 Coolant pipework from/to intercooler – Removal...................... 0 3.14.39 Coolant pipework from/to intercooler – Cleaning..................... 0 3.14.40 Coolant pipework from/to intercooler – Check........................ 0 3.14.41 Coolant pipework from/to intercooler – Installation................. 0 3.14.42 Coolant pipework with thermostat — Overview......................... 0 Coolant pipework with thermostat........................................ 0 3.14.43 Coolant pipework with thermostat – Removal.......................... 0 3.14.44 Coolant pipework with thermostat – Cleaning......................... 0 3.14.45 Coolant pipework with thermostat – Check............................ 0 3.14.46 Coolant pipework with thermostat – Installation..................... 0 3.14.47 LT coolant pump – Tolerances........................................ 0 3.15 Power Supply (engine-side)............................................. 0 3.15.1 Battery-charging generator – Overview................................ 0 Battery-charging generator with generator drive – Overview.............. 0 Generator drive......................................................... 0 3.15.2 Battery-charging generator – Removal................................. 0 3.15.3 Battery-charging generator – Disassembly............................. 0 Battery-charging generator – Disassembly................................ 0 3.15.4 Battery-charging generator – Cleaning................................ 0 3.15.5 Battery-charging generator – Check................................... 0 3.15.6 Battery-charging generator – Installation............................ 0 3.16 Engine Mounting / Support.............................................. 0 3.16.1 Engine mounting / support – Overview................................. 0 Variant A............................................................... 0 Variant B............................................................... 0 3.16.2 Engine mounting – Overview........................................... 0 Variant A............................................................... 0 Variant B............................................................... 0 Engine supports......................................................... 0 3.16.3 Engine mounting – Removal............................................ 0 3.16.4 Engine mounts – Cleaning............................................. 0 3.16.5 Engine mounts – Check................................................ 0 3.16.6 Engine mounting – Installation....................................... 0 3.17 Monitoring, Control and Regulation Equipment........................... 0 3.17.1 Monitoring, control and regulation devices – Overview................ 0 Engine Control Unit (ECU)............................................... 0 3.17.2 Wiring and engine wiring harnesses – Overview........................ 0 Engine wiring harness W2................................................ 0 Engine wiring harness W3................................................ 0 Engine wiring harness W4................................................ 0 Connecting cable for external sensor F33 and F57........................ 0 3.17.3 Engine wiring harness – Check........................................ 0 3.17.4 Engine wiring harness – Removal...................................... 0 3.17.5 Engine wiring harnesses – Installation............................... 0 3.17.6 Sensors, actuators, and injectors – Overview......................... 0 3.17.7 Sensors, actuators, and injectors – Removal.......................... 0 3.17.8 Sensors, actuators and injectors – Check............................. 0 3.17.9 Sensors, actuators, and injectors – Installation..................... 0 tables.............................................................................. 0 Application group............................................................... 0 Load profile table, application group 3A........................................ 0 Load profile table, application group 3B........................................ 0 Load profile table, application group 3C........................................ 0 Load profile table, application group 3D........................................ 0 Table of maintenance tasks for Application Groups 3A, 3B, 3C, 3D................ 0 Maintenance schedule matrix..................................................... 0 Maintenance schedule matrix..................................................... 0 Maintenance schedule matrix..................................................... 0 Maintenance schedule matrix..................................................... 0 Thermostat inserts - Technical Data............................................. 0 M020108_00_E_03_05_2004.pdf......................................................... 0 toc............................................................................. 0 1.1 Important Information................................................... 9 1.1.1 Reman assemblies – Prerequisites for maintenance tasks a.......... 9 REMAN assemblies.................................................... 9 Requirements for maintenance tasks.................................. 9 General assembly instructions....................................... 9 Information on installation of Flexmaster pipe connection........... 11 1.2 General Conditions.................................................. 13 1.2.1 General conditions................................................ 13 General............................................................. 13 Correct use......................................................... 13 Modifications or Conversions........................................ 13 Spare parts......................................................... 13 Reworking components................................................ 13 1.2.2 Personnel and organizational requirements ........................ 14 Personnel requirements.............................................. 14 Organizational measures............................................. 14 Working clothes and protective equipment............................ 14 1.2.3 Safety precautions when working on the engine..................... 15 Engine operation.................................................... 15 Maintenance and repair.............................................. 15 Welding work........................................................ 16 Hydraulic installation and removal.................................. 16 Working on electrical/electronic assemblies......................... 16 Working with laser equipment........................................ 17 Operation of electrical equipment................................... 17 1.2.4 Auxiliary materials, fire prevention and environmental pro........ 18 Fire prevention..................................................... 18 Noise............................................................... 18 Environmental protection............................................ 18 Auxiliary materials................................................. 18 Lead................................................................ 18 Acids and alkaline solutions........................................ 18 Paints.............................................................. 18 Liquid nitrogen..................................................... 18 Compressed air...................................................... 19 Used oil............................................................ 19 1.2.5 Standards for warning notices in the publication.................. 20 1.2.6 General information regarding the Tolerances and Wear Limi........ 21 1.2.7 Engine side and cylinder designations............................. 22 1.2.8 Torque specifications for screws, nuts and bolts.................. 23 Crankcase........................................................... 23 Running gear........................................................ 24 Cylinder head....................................................... 25 Valve gear.......................................................... 26 Fuel system - high-pressure......................................... 27 Exhaust turbocharger 20 V ZR 205.................................... 27 Exhaust system...................................................... 27 Charge-air cooler................................................... 28 Staring equipment 12/16 V engines, Bosch starter.................... 28 Staring equipment 12/16 V engines, Nikko starter.................... 28 Lube oil system..................................................... 28 Generator........................................................... 29 Mounting/support.................................................... 29 Tightening specification for setscrew and stud connections as pe.... 30 Tightening torques for stress bolt connections as per standard M.... 32 Tightening torques for plug screws as per standard MTN€5183-1 ...... 33 Tightening torques for DIN€7604C plug screws (with long screwed .... 36 Tightening torques for banjo screws as per standard MTN 5183-2 ..... 37 Tightening torques for banjo screws made of steel................... 38 Tightening torques for banjo screws made of copper/aluminum allo.... 38 Tightening torques for male connectors as per standard MTN€5183-.... 39 Tightening torques for union nuts on screwed plugs ISO 6149-3....... 40 1.2.9 Settings.......................................................... 41 Firing order for Series 4000 engines................................ 41 Direction of rotation, viewed towards driving end................... 41 Valve clearance, engine cold (20 °C)................................ 41 Valve timing with valve clearance adjusted.......................... 42 Cam and valve lift for camshaft adjustment.......................... 42 1.2.10 Conversion tables................................................ 43 Length.............................................................. 43 Area................................................................ 43 Volume.............................................................. 44 Speed............................................................... 44 Mass................................................................ 45 Force............................................................... 45 Density............................................................. 45 Torque.............................................................. 46 Pressure............................................................ 46 Mass moment, 2nd grade.............................................. 46 Energy.............................................................. 47 Power............................................................... 47 Temperature......................................................... 48 Fuel consumption.................................................... 48 1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil........ 49 1.2.12 Transport........................................................ 52 Transport........................................................... 52 Setting the engine down after transport............................. 52 2.1 Engine – Checking condition before a major overhaul..................... 55 2.2 Preface................................................................. 56 General................................................................. 56 MTU maintenance concept................................................. 56 Note.................................................................... 56 Out-of-service periods.................................................. 56 Application group....................................................... 56 Load profile............................................................ 57 2.3 Maintenance tasks....................................................... 58 2.4 Maintenance schedule matrix............................................. 60 Maintenance schedule matrix (10,000-30,000 operating hours) for ........ 60 Maintenance schedule matrix (9,000 operating hours) for applicat........ 60 Maintenance schedule matrix (6,000 operating hours) for applicat........ 61 Maintenance schedule matrix (6,000 operating hours) for applicat........ 61 2.5 Engine – Removal........................................................ 62 2.6 Engine – Disassembly.................................................... 63 2.7 Engine – Assembly....................................................... 65 2.8 Engine – Installation................................................... 67 2.9 Engine – Run-in procedure............................................... 68 Running in engine after component replacement........................... 68 Setting engine operational values....................................... 68 2.10 Initial engine operation............................................... 71 3.1 Crankcase and Attachments............................................... 85 3.1.1 Engine layout..................................................... 85 Also applies to 8/12/16 V 4000 G and R.............................. 85 3.1.2 Crankcase and attachments – Overview.............................. 86 Crankcase and attachments – Overview................................ 86 3.1.3 Crankcase – Overview ............................................. 87 Crankcase with cover................................................ 87 Crankcase........................................................... 88 Oil filler neck with oil dipstick................................... 89 3.1.4 Crankcase – Disassembly........................................... 90 3.1.5 Crankcase – Cleaning.............................................. 94 3.1.6 Crankcase – Check................................................. 96 3.1.7 Crankcase – Tolerances............................................101 Crankcase bore for crankshaft.......................................101 Crankcase bore for camshaft.........................................102 Crankcase bore for cylinder liner...................................103 Main bearing cap....................................................105 Main bearing bore...................................................106 Crankcase crankshaft bore coaxiality................................107 Crankcase camshaft bore coaxiality..................................108 3.1.8 Crankcase – Assembly..............................................109 3.1.9 Cylinder liner – Overview.........................................117 Overview of cylinder liner with scraper ring........................117 Cylinder liner with scraper ring in crankcase.......................118 3.1.10 Cylinder liner – Removal.........................................119 3.1.11 Cylinder liner – Cleaning........................................122 3.1.12 Cylinder liner – Check...........................................123 3.1.13 Cylinder liners – Tolerances.....................................125 Reconditioning instructions:........................................126 3.1.14 Cylinder liner – Installation....................................127 3.1.15 Oil pan – Overview...............................................130 View from free end..................................................131 3.1.16 Oil pan – Removal................................................132 3.1.17 Oil pan – Cleaning...............................................134 3.1.18 Oil pan – Check..................................................135 3.1.19 Oil pan – Installation...........................................136 3.1.20 Oil pan – Tightening sequence for oil pans made of GGG ..........139 3.1.21 Engine lifting equipment - Overview..............................141 Overview............................................................141 Engine lifting equipment............................................142 3.1.22 Engine lifting equipment – Removal...............................143 3.1.23 Engine lifting equipment – Cleaning..............................144 3.1.24 Engine lifting equipment – Check.................................145 3.1.25 Engine lifting equipment - Installation..........................146 3.1.26 End housing overview, driving end................................147 End housing with fittings...........................................147 Guide bush location for end housing removal/installation............148 3.1.27 End housing, driving end – Removal...............................149 3.1.28 End housing, driving end – Disassembly...........................151 3.1.29 End housing, driving end – Cleaning..............................152 3.1.30 End housing, driving end – Check.................................153 3.1.31 End housing , driving end – Tolerances...........................154 3.1.32 End housing, driving end – Assembly..............................155 3.1.33 End housing, driving end – Installation..........................156 3.1.34 Crankcase ventilation – Overview.................................159 Crankcase ventilation, driving end..................................159 Crankcase ventilation, free end.....................................160 3.1.35 Crankcase ventilation – Removal..................................161 3.1.36 Crankcase ventilation – Cleaning.................................162 3.1.37 Crankcase ventilation – Check....................................163 3.1.38 Crankcase ventilation – Installation.............................164 3.2 Gear Train..........................................................165 3.2.1 Gearcase, free end – Overview.....................................165 Arrangement of alignment tool for equipment carrier and equipmen....166 3.2.2 Gearcase, free end – Removal......................................167 3.2.3 Gearcase, free end – Disassembly..................................170 3.2.4 Gearcase, free end – Cleaning.....................................171 3.2.5 Gearcase, free end – Check........................................172 3.2.6 Gearcase, free end – Tolerances...................................173 Crankshaft bearing, free end, 8/12/16V..............................173 Crankshaft bearing, free end, 20V...................................174 3.2.7 Gearcase, free end – Assembly.....................................175 3.2.8 Gearcase, free end – Installation.................................179 3.2.9 Gear train, free end – Overview...................................184 3.2.10 Gear train, free end – Removal...................................186 3.2.11 Gear train, free end – Cleaning..................................188 3.2.12 Gear train, free end – Check.....................................189 3.2.13 Gear train, free end – Tolerances................................190 3.2.14 Bearing bush – Removal and installation..........................192 3.2.15 Gear train, free end – Installation..............................194 3.3 Running Gear........................................................197 3.3.1 Running gear – Overview ..........................................197 Running gear........................................................197 3.3.2 Crankshaft overview...............................................198 Crankshaft, detail..................................................198 Crankshaft..........................................................199 Crankshaft with bearing.............................................200 3.3.3 Crankshaft – Removal..............................................201 3.3.4 Crankshaft – Disassembly..........................................206 3.3.5 Crankshaft – Cleaning.............................................207 3.3.6 Crankshaft – Check................................................208 3.3.7 Crankshaft – Tolerances...........................................212 Crankshaft bearings.................................................212 Conrod bearings.....................................................214 Crankshaft bearings, guide bearing expanding dimension..............215 Crankshaft bearing expansion dimension..............................216 Crankshaft axial play...............................................217 Crankshaft bearing shells...........................................218 Crankshaft gear, free end...........................................219 Main bearing journal concentricity..................................220 3.3.8 Crankshaft – Assembly.............................................221 3.3.9 Crankshaft – Balancing............................................223 3.3.10 Main bearing shells – Check......................................226 Checking main bearing shells........................................226 Main bearing shells (grooved bearing), upper half...................226 Assessment..........................................................226 Main bearing shell (sputtered bearing), lower half..................227 Assessment..........................................................227 Damage to bearing...................................................227 3.3.11 Main bearing bore – Check........................................228 3.3.12 Crankshaft – Installation........................................231 3.3.13 PTO flange, driving end, flywheel – Overview.....................239 Installation/removal device assembly, long..........................240 Installation/removal device assembly, short.........................241 3.3.14 PTO flange, driving end, flywheel – Removal......................242 3.3.15 Radial-lip shaft seal, driving end – Removal.....................245 3.3.16 PTO flange, driving end, flywheel – Cleaning.....................246 3.3.17 PTO flange, driving end – Flywheel check.........................247 3.3.18 Radial-lip shaft seal – Installation.............................248 3.3.19 PTO flange, driving end, flywheel – Installation.................249 3.3.20 Crankshaft PTO, free end – Overview..............................253 Crankshaft, PTO.....................................................253 PTO with vibration damper...........................................253 Arrangement of driver flange installation/removal tool..............254 3.3.21 Vibration damper on PTO, free end – Removal......................255 3.3.22 Vibration damper on PTO, free end – Disassembly..................259 Vibration damper – Disassembly......................................259 3.3.23 Vibration damper on PTO, free end – Cleaning.....................260 3.3.24 Vibration damper on PTO, free end – Check........................261 3.3.25 Vibration dampers on PTO, free end – Tolerances..................262 Free end crankshaft seal 8/12/16V...................................262 Free end crankshaft seal 20V........................................263 3.3.26 Vibration damper on PTO, free end – Installation.................264 3.3.27 Pistons and conrods – Overview...................................269 Pistons and conrods.................................................269 Piston details .....................................................270 3.3.28 Piston and conrod – Removal......................................271 3.3.29 Piston and conrod – Disassembly..................................275 3.3.30 Piston – Cleaning................................................277 3.3.31 Piston – Check...................................................278 3.3.32 Piston – Tolerances..............................................281 Piston bearings 8/12/16V............................................281 Piston bearings 20V.................................................282 Piston rings 8/12/16V...............................................283 Piston rings 20V....................................................284 Piston clearance in cylinder liner 8/12/16V.........................285 Piston clearance in cylinder liner 20V..............................287 Piston crown mounting...............................................289 3.3.33 Piston – Assembly................................................290 3.3.34 Conrod – Disassembly.............................................294 3.3.35 Conrod – Cleaning................................................295 3.3.36 Conrod – Check...................................................296 3.3.37 Conrod – Tolerances..............................................303 Conrod bearings.....................................................303 Conrod bearing, locating pin........................................304 Conrod screw length.................................................305 Conrod bore parallelism.............................................306 Small conrod bore...................................................307 3.3.38 Conrod – Assembly................................................308 3.3.39 Conrod bearing shell – Assessment................................310 Lower conrod bearing shell (grooved bearing) – Assessment...........310 Assessment..........................................................310 Damage to bearing...................................................310 Upper conrod bearing half shell (sputtered bearing) – Assessme......311 Assessment..........................................................311 3.3.40 Piston and conrod – Installation.................................312 3.4 Cylinder Head.......................................................319 3.4.1 Cylinder head and attachments – Overview..........................319 Overview of cylinder head and attachments...........................319 3.4.2 Valve-seat turning machine for cylinder head......................321 Working principle of valve-seat turning machine.....................321 Installing the solid pilot..........................................322 Mounting the supporting spider......................................322 Inserting the pilot into the valve guide............................322 Locking the pilot...................................................322 Setting up valve turning machine....................................323 Mounting the cutter.................................................323 Placing the valve-turning machine on the pilot......................323 Aligning the cutting edge with the valve-seat center................323 Connecting the machine to power supply..............................323 Valve seat turning..................................................324 Positioning the cutter at the inner valve-seat edge.................324 Setting cutting depth...............................................324 Lubricating the valve seat..........................................324 Valve seat turning..................................................324 Repeating the cutting pass..........................................324 Replacing the adapter head..........................................325 Removing the adapter head...........................................325 Mounting the adapter head...........................................325 3.4.3 Cylinder head – Removal...........................................326 3.4.4 Cylinder head – Cleaning..........................................330 3.4.5 Cylinder head – Check.............................................331 3.4.6 Cylinder head – Tolerances........................................334 Inlet and exhaust valve guides......................................334 Valve clearance.....................................................335 Exhaust valve seats.................................................336 Inlet valve seats...................................................337 Exhaust valve.......................................................338 Inlet valve.........................................................339 Valve springs, exterior.............................................340 Valve springs, interior.............................................342 Cylinder head – Mating surface – Protective sleeve – Valve bri......343 Cylinder head screws................................................344 3.4.7 Cylinder head – Repair............................................345 3.4.8 Valve seat grinder................................................348 Example: Series 4000 M..............................................349 3.4.9 Cylinder head – Plug repair.......................................351 3.4.10 Cylinder head – Assembly.........................................352 3.4.11 Cylinder head – Installation.....................................356 3.5 Valve Gear..........................................................360 3.5.1 Valve gear – Overview.............................................360 Valve gear – Overview...............................................360 3.5.2 Camshaft overview.................................................361 Overview of camshaft................................................361 3.5.3 Camshaft – Removal................................................362 3.5.4 Camshaft – Cleaning...............................................364 3.5.5 Camshaft – Check..................................................365 3.5.6 Camshaft – Tolerances.............................................367 Coaxiality of bearing points 8/12/16V...............................367 Coaxiality of bearing points 20V....................................368 Axial play..........................................................369 3.5.7 Camshaft – Installation...........................................370 3.5.8 Camshaft drive – Overview.........................................378 Camshaft drive – Overview...........................................378 3.5.9 Camshaft drive – Removal..........................................379 3.5.10 Camshaft drive – Cleaning........................................382 3.5.11 Camshaft drive – Check...........................................383 3.5.12 Camshaft drive – Installation....................................384 3.5.13 Camshaft thrust bearing – Overview...............................386 Overview of camshaft thrust bearing.................................386 3.5.14 Camshaft thrust bearing – Replacement............................387 3.5.15 Camshaft thrust bearing – Cleaning...............................388 3.5.16 Camshaft thrust bearing – Check..................................389 3.5.17 Valve drive – Overview...........................................390 Swing follower, swing follower assembly.............................390 Rocker shaft support................................................391 Swing follower......................................................392 Valve bridge........................................................393 3.5.18 Valve drive – Removal............................................394 3.5.19 Valve drive – Disassembly........................................396 3.5.20 Valve drive – Cleaning...........................................399 3.5.21 Valve drive – Check..............................................400 3.5.22 Valve drive – Tolerances.........................................403 Rocker shaft support, inlet and exhaust.............................403 Swing follower support, inlet and exhaust...........................404 3.5.23 Valve drive – Assembly...........................................405 3.5.24 Valve drive – Installation.......................................409 3.5.25 Valve drive – Overview...........................................414 Rocker arm assembly.................................................414 Rocker arm support..................................................415 Swing follower......................................................416 3.5.26 Valve drive – Removal............................................417 3.5.27 Valve drive – Disassembly........................................419 3.5.28 Valve drive – Cleaning...........................................421 3.5.29 Valve drive – Check..............................................422 3.5.30 Valve drive – Tolerances.........................................425 Rocker shaft support, inlet and exhaust.............................425 Swing follower support, inlet and exhaust...........................426 3.5.31 Valve drive – Assembly...........................................427 3.5.32 Valve drive – Installation.......................................430 3.5.33 Cylinder head cover – Overview...................................434 Overview of cylinder head cover.....................................434 3.5.34 Cylinder head cover – Removal....................................435 3.5.35 Cylinder head cover – Cleaning...................................436 3.5.36 Cylinder head cover – Check......................................437 3.5.37 Cylinder head cover – Installation...............................438 3.6 Fuel System (high-pressure).........................................439 3.6.1 H.P. fuel system – overview.......................................439 H.P. fuel system – overview.........................................439 3.6.2 H.P. fuel pump – overview.........................................440 H.P. fuel pump – overview...........................................440 Front view of H.P. fuel pump........................................441 3.6.3 H.P. fuel pump removal............................................442 3.6.4 H.P. fuel pump disassembly........................................444 3.6.5 H.P. fuel pump inspection.........................................445 3.6.6 H.P. fuel pump installation.......................................446 3.6.7 H.P. fuel pump – Control block replacement........................449 3.6.8 Fuel injector – overview..........................................451 Fuel injector – overview............................................451 3.6.9 Fuel injector removal.............................................452 3.6.10 Fuel injector disassembly........................................455 3.6.11 Fuel injector cleaning...........................................456 3.6.12 Fuel injector inspection.........................................457 3.6.13 Fuel injector installation.......................................458 3.6.14 H.P. fuel line – Overview........................................461 H.P. line from H.P. accumulator to injector.........................461 H.P. line from H.P. fuel pump to H.P. accumulator ..................462 H.P. accumulator and attachments....................................463 H.P. accumulator, left engine side..................................464 H.P. accumulator, right engine side.................................465 3.6.15 H.P. fuel line – Removal.........................................466 3.6.16 H.P. fuel line – Disassembly.....................................470 3.6.17 H.P. fuel line – Cleaning........................................471 3.6.18 H.P. fuel line – Check...........................................472 3.6.19 H.P. fuel line – Assembly........................................473 3.6.20 H.P. fuel line – Installation....................................476 3.6.21 H.P. fuel system – Leak check....................................481 3.7 Fuel System (low-pressure)..........................................482 3.7.1 L.P. fuel system – Overview.......................................482 3.7.2 Fuel delivery pump – Overview.....................................483 Fuel delivery pump – Overview.......................................483 3.7.3 Fuel delivery pump – Removal......................................484 3.7.4 Fuel delivery pump – Disassembly..................................485 Disassembling fuel delivery pump....................................485 3.7.5 Fuel delivery pump – Cleaning.....................................486 3.7.6 Fuel delivery pump – Check........................................487 3.7.7 Fuel delivery pump – Installation.................................488 3.7.8 L.P. fuel system – Overview.......................................490 3.7.9 Fuel delivery pump – Overview.....................................491 Fuel delivery pump – Overview.......................................491 3.7.10 Fuel delivery pump – Removal.....................................492 3.7.11 Fuel delivery pump – Disassembly.................................493 Disassembling fuel delivery pump....................................493 3.7.12 Fuel delivery pump – Cleaning....................................494 3.7.13 Fuel delivery pump – Check.......................................495 3.7.14 Fuel delivery pump – Installation................................496 3.7.15 Fuel line from pump to filter – Overview.........................498 3.7.16 Fuel lines from pump to filter – Removal.........................499 3.7.17 Fuel lines from pump to filter – Cleaning........................500 3.7.18 Fuel lines from pump to filter – Check...........................501 3.7.19 Fuel lines from pump to filter – Installation....................502 3.7.20 Fuel lines from pump to filter – Overview........................504 3.7.21 Fuel lines from pump to filter – Removal.........................505 3.7.22 Fuel lines from pump to filter – Cleaning........................506 3.7.23 Fuel lines from pump to filter – Check...........................507 3.7.24 Fuel lines from pump to filter – Installation....................508 3.7.25 Fuel filter – Overview...........................................510 3.7.26 Fuel filter – Removal............................................511 3.7.27 Fuel filter – Disassembly........................................512 3.7.28 Fuel filter – Cleaning...........................................513 3.7.29 Fuel filter – Check..............................................514 3.7.30 Fuel filter – Assembly...........................................515 3.7.31 Fuel filter – Installation.......................................516 3.7.32 Fuel filter – Overview...........................................518 3.7.33 Fuel filter – Removal............................................519 3.7.34 Fuel filter – Disassembly........................................520 3.7.35 Fuel filter – Cleaning...........................................521 3.7.36 Fuel filter – Check..............................................522 3.7.37 Fuel filter – Assembly...........................................523 3.7.38 Fuel filter – Installation.......................................524 3.7.39 Fuel lines from filter to H.P. pump – Overview ..................526 3.7.40 Fuel supply pipework from fuel filter to H.P. pump – Re..........527 3.7.41 Fuel supply pipework from fuel filter to H.P. pump – Cl..........528 3.7.42 Fuel supply pipework from fuel filter to H.P. pump – Ch..........529 3.7.43 Fuel supply pipework from fuel filter to H.P. pump – In..........530 3.7.44 Leak-off fuel line – Overview....................................532 3.7.45 Leak-off fuel line – Removal.....................................533 3.7.46 Leak-off fuel line – Cleaning....................................534 3.7.47 Leak-off fuel line – Check.......................................535 3.7.48 Leak-off fuel line – Installation................................536 3.8 Exhaust Turbocharger................................................537 3.8.1 Exhaust turbochargers.............................................537 3.8.2 Exhaust turbocharger – Overview...................................538 3.8.3 Exhaust turbochargers – Removal...................................539 3.8.4 Turbocharger – Disassembly........................................541 Disassemble exhaust turbocharger....................................541 3.8.5 Exhaust turbochargers – Cleaning..................................542 3.8.6 Exhaust turbochargers – Check.....................................543 3.8.7 Exhaust turbochargers – Installation..............................544 3.9 Charge-Air Cooling..................................................547 3.9.1 Charge-air cooling – Overview.....................................547 Intercooler and attachments.........................................547 3.9.2 Intercooler – Removal.............................................548 3.9.3 Intercooler – Disassembly.........................................549 Intercooler – Disassembly...........................................549 3.9.4 Intercooler – Cleaning............................................550 Air-side cleaning...................................................550 Water-side cleaning.................................................550 Intercooler flushing................................................550 Intercooler drying and preservation.................................550 3.9.5 Intercooler – Check...............................................551 3.9.6 Charge-air cooler – Installation..................................553 3.10 Air Intake / Air Supply............................................555 3.10.1 Air intake / air supply – Overview...............................555 3.10.2 Air filter with retainers – Overview.............................556 3.10.3 Air filters with retainers – Removal.............................558 3.10.4 Air filters and retainers – Cleaning.............................559 3.10.5 Air filters and retainers – Check................................560 3.10.6 Air filters with retainers – Installation........................561 3.10.7 Intake air system to cylinders, left – Overview..................562 3.10.8 Air supply system to cylinders, left – Removal...................563 3.10.9 Air supply system to cylinders, left – Cleaning..................564 3.10.10 Air supply system to cylinders, left – Check....................565 3.10.11 Air supply system to cylinders, left – Installation.............566 3.10.12 Air supply system to cylinders, right – Overview................568 3.10.13 Air supply system to cylinders, right – Removal.................569 3.10.14 Air supply system to cylinders, right – Cleaning................570 3.10.15 Air supply system to cylinders, right – Check...................571 3.10.16 Cylinder air supply pipework, right – Installation..............572 3.10.17 Air ducts from turbochargers to intercooler – Overview..........574 Air supply, variant A...............................................574 Air supply, variant B...............................................575 3.10.18 Intake air pipework from exhaust turbocharger to interco........576 3.10.19 Intake air pipework from turbocharger to intercooler –..........577 3.10.20 Air ducts from turbochargers to intercooler – Check.............578 3.10.21 Air ducts from turbochargers to intercooler – Installa..........579 3.11 Exhaust System.....................................................583 3.11.1 Exhaust system – Overview........................................583 3.11.2 Exhaust pipework after cylinder head – Overview..................584 Exhaust pipework, 12 V plug connection – Overview...................584 Exhaust pipework, 12 V screwed joint – Overview.....................585 Exhaust pipework, 16 V – Overview...................................586 3.11.3 Exhaust pipework after cylinder head – Removal...................587 3.11.4 Exhaust pipework after cylinder head – Cleaning..................589 3.11.5 Exhaust pipework after cylinder head – Check.....................590 3.11.6 Exhaust pipework after cylinder head – Installation..............591 3.12 Starting System....................................................595 3.12.1 Electric starter – Overview......................................595 Starting equipment – Overview.......................................595 Overview of starter (fastened using band clamp).....................596 3.12.2 Starter – Removal................................................597 3.12.3 Starter – Disassembly............................................598 Starter – Disassembly...............................................598 3.12.4 Starter – Cleaning...............................................599 3.12.5 Starter – Inspection.............................................600 3.12.6 Starter – Installation...........................................601 3.12.7 Starting equipment – Overview....................................603 3.12.8 Starter – Removal................................................605 3.12.9 Starter – Disassembly............................................606 Starter – Disassembly...............................................606 3.12.10 Starter – Cleaning..............................................607 3.12.11 Starter – Check.................................................608 3.12.12 Starter – Installation..........................................609 3.13 Lube Oil System....................................................610 3.13.1 Lube oil system – Overview.......................................610 3.13.2 Lube oil pump with drive – Overview..............................611 3.13.3 Lube oil pump with drive – Removal...............................612 3.13.4 Lube oil pump with drive – Disassembly...........................614 3.13.5 Lube oil pump with drive – Cleaning..............................615 3.13.6 Lube oil pump with drive – Check.................................616 3.13.7 Lube oil pump with drive – Installation..........................618 3.13.8 Oil filter – Overview............................................620 Oil filter assembly.................................................620 3.13.9 Oil filter with oil filter housing – Removal.....................621 3.13.10 Oil filter housing – Disassembly................................623 3.13.11 Oil filter housing – Cleaning...................................624 3.13.12 Oil filter housing – Check......................................625 3.13.13 Oil filter housing – Assembly...................................626 3.13.14 Oil filter with oil filter housing – Installation...............628 3.13.15 Centrifugal oil filter– Overview................................631 Centrifugal oil filter with attachments.............................631 Centrifugal oil filter with flange..................................632 Centrifugal oil filter assembly.....................................633 3.13.16 Centrifugal oil filter – Removal................................634 3.13.17 Centrifugal oil filter – Disassembly............................635 3.13.18 Centrifugal oil filter – Cleaning...............................637 3.13.19 Centrifugal oil filter – Check..................................638 3.13.20 Centrifugal oil filter – Bearing clearance check................639 3.13.21 Centrifugal oil filter – Assembly...............................640 3.13.22 Centrifugal oil filter – Installation...........................644 3.13.23 Oil cooler – Overview...........................................645 Oil cooler with attachments.........................................645 3.13.24 Oil cooler – Removal............................................646 3.13.25 Oil cooler – Cleaning...........................................648 3.13.26 Oil cooler – Check..............................................649 3.13.27 Oil cooler – Installation.......................................651 3.13.28 Oil system in crankcase – Overview..............................655 Oil system..........................................................655 3.13.29 Oil system in crankcase – Removal...............................657 3.13.30 Oil system in crankcase – Cleaning..............................660 3.13.31 Oil system in crankcase – Check.................................661 3.13.32 Oil system in crankcase – Installation..........................663 3.13.33 Turbocharger oil supply – Overview..............................668 Exhaust turbocharger oil supply.....................................668 3.13.34 Turbocharger oil supply – Removal...............................669 3.13.35 Turbocharger oil supply – Cleaning..............................670 3.13.36 Turbocharger oil supply – Check.................................671 3.13.37 Turbocharger oil supply – Installation..........................672 3.14 Cooling System.....................................................673 3.14.1 Coolant system – Overview........................................673 Engine coolant circuit..............................................673 3.14.2 Engine coolant pump – Overview...................................675 3.14.3 Engine coolant pump – Removal....................................677 3.14.4 Engine coolant pump – Disassembly................................678 3.14.5 Engine coolant pump – Cleaning...................................683 3.14.6 Engine coolant pump – Check......................................684 3.14.7 Engine coolant pump – Tolerances.................................686 3.14.8 Engine coolant pump – Assembly...................................689 3.14.9 Engine coolant pump – Installation...............................695 3.14.10 Coolant supply for engine coolant pump, intake side – ..........697 Elbow with attached components......................................697 Coolant pipework....................................................698 Coolant pipework....................................................699 3.14.11 Engine coolant pump pipework, intake side – Removal.............700 3.14.12 Coolant supply for engine coolant pump, intake side – ..........701 3.14.13 Engine coolant pump pipework, intake side – Check...............702 3.14.14 Coolant supply for engine coolant pump, intake side – ..........703 3.14.15 Coolant pipework after cylinder – Overview......................704 Coolant pipework after cylinder – Overview..........................704 3.14.16 Coolant pipework after cylinder – Removal.......................705 3.14.17 Coolant pipework after cylinder – Cleaning......................706 3.14.18 Coolant pipework after cylinder – Check.........................707 3.14.19 Coolant pipework after cylinder – Installation..................708 3.14.20 Preheating unit – Overview......................................709 3.14.21 Preheating unit – Removal.......................................710 3.14.22 Preheating unit – Disassembly...................................711 Preheating unit – Disassembly.......................................711 3.14.23 Preheating unit – Installation..................................712 3.14.24 Engine coolant ventilation and charge-air cooling – Ov..........714 Coolant vent lines..................................................714 3.14.25 Engine coolant ventilation and charge-air cooling – Re..........716 3.14.26 Engine coolant ventilation and charge air cooling – Cl..........717 3.14.27 Engine coolant and charge air coolant ventilation – Ch..........718 3.14.28 Engine coolant ventilation and charge air cooling – In..........719 3.14.29 Charge-air coolant pump – Overview..............................720 Charge-air coolant pump – Overview..................................720 3.14.30 Charge-air coolant pump – Removal...............................722 3.14.31 Charge-air coolant pump – Disassembly...........................723 3.14.32 Charge-air coolant pump – Cleaning..............................728 3.14.33 Charge-air coolant pump – Check.................................729 3.14.34 Charge-air coolant pump – Assembly..............................731 3.14.35 Charge-air coolant pump – Installation..........................737 3.14.36 Engine coolant pump – Tolerances................................739 3.14.37 Coolant pipework from/to intercooler – Overview.................743 Coolant pipework....................................................743 3.14.38 Coolant pipework from/to intercooler – Removal..................744 3.14.39 Coolant pipework from/to intercooler – Cleaning.................745 3.14.40 Coolant pipework from/to intercooler – Check....................746 3.14.41 Coolant pipework from/to intercooler – Installation.............747 3.14.42 Coolant pipework with thermostat — Overview.....................748 Coolant pipework with thermostat....................................748 3.14.43 Coolant pipework with thermostat – Removal......................749 3.14.44 Coolant pipework with thermostat – Cleaning.....................752 3.14.45 Coolant pipework with thermostat – Check........................753 3.14.46 Coolant pipework with thermostat – Installation.................756 3.14.47 LT coolant pump – Tolerances....................................760 3.15 Power Supply (engine-side).........................................763 3.15.1 Battery-charging generator – Overview............................763 Battery-charging generator with generator drive – Overview..........763 Generator drive.....................................................764 3.15.2 Battery-charging generator – Removal.............................765 3.15.3 Battery-charging generator – Disassembly.........................766 Battery-charging generator – Disassembly............................766 3.15.4 Battery-charging generator – Cleaning............................767 3.15.5 Battery-charging generator – Check...............................768 3.15.6 Battery-charging generator – Installation........................769 3.16 Engine Mounting / Support..........................................771 3.16.1 Engine mounting / support – Overview.............................771 Variant A...........................................................771 Variant B...........................................................772 3.16.2 Engine mounting – Overview.......................................773 Variant A...........................................................773 Variant B...........................................................774 Engine supports.....................................................775 3.16.3 Engine mounting – Removal........................................776 3.16.4 Engine mounts – Cleaning.........................................779 3.16.5 Engine mounts – Check............................................780 3.16.6 Engine mounting – Installation...................................781 3.17 Monitoring, Control and Regulation Equipment.......................787 3.17.1 Monitoring, control and regulation devices – Overview............787 Engine Control Unit (ECU)...........................................787 3.17.2 Wiring and engine wiring harnesses – Overview....................788 Engine wiring harness W2............................................789 Engine wiring harness W3............................................790 Engine wiring harness W4............................................791 Connecting cable for external sensor F33 and F57....................792 3.17.3 Engine wiring harness – Check....................................793 3.17.4 Engine wiring harness – Removal..................................794 3.17.5 Engine wiring harnesses – Installation...........................797 3.17.6 Sensors, actuators, and injectors – Overview.....................800 3.17.7 Sensors, actuators, and injectors – Removal......................801 3.17.8 Sensors, actuators and injectors – Check.........................805 3.17.9 Sensors, actuators, and injectors – Installation.................806 tables.......................................................................... 0 Application group........................................................... 56 Load profile table, application group 3A.................................... 57 Load profile table, application group 3B.................................... 57 Load profile table, application group 3C.................................... 57 Load profile table, application group 3D.................................... 57 Table of maintenance tasks for Application Groups 3A, 3B, 3C, 3D............ 58 Maintenance schedule matrix................................................. 60 Maintenance schedule matrix................................................. 60 Maintenance schedule matrix................................................. 61 Maintenance schedule matrix................................................. 61 Thermostat inserts - Technical Data.........................................754
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MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD
1.2.3 Safety precautions when working on the engine
Engine operation:
- When the engine is running, always wear ear protectors.
- Ensure that the engine room is well ventilated.
- Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
- Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health hazard. The exhaust pipework must be free of leaks and discharge the gases to the atmosphere.
- During engine operation, do not touch battery terminals, generator terminals, or cables.
- Inadequate protection of electrical components can lead to electric shocks and serious injuries.
- When the engine is running, never release coolant, oil, fuel, compressed-air, or hydraulic lines.
Maintenance and repair:
- Compliance with maintenance and repair specifications is an important safety factor.
- Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. Secure the engine against inadvertent starting. With an electric starter, disconnect the battery. With a pneumatic starter, close the main shut-off valve of the compressed-air system and release pressure from the compressed-air supply line. Attach a sign “Do not operate” in the operating area or to control equipment. Persons not involved must keep clear.
- Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required. Maintenance and repair work must only be carried out by authorized, qualified personnel.
- Use only proper, calibrated tools.
- Do not work on engines or components which are only held by lifting equipment or crane. Always support these components in accordance with regulations on suitable frames or stands before beginning any maintenance or repair work.
- Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check that all guards have been installed and that all tools and loose components have been removed from the engine.
- Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before starting work, relieve pressure in systems and H.P. lines which are to be opened.
- Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal connections with caps or covers if a line is removed or opened.
- During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections when installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
- Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other components to avoid contact with them. Do not place fuel or oil lines near hot components, except when necessary for design reasons during installation.
- Elastomers (e.g. “Viton” sealing rings) are stable under normal operating conditions. When subjected to fire or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals if they have a carbonized or resinous appearance. Wear protective gloves!
- Take care with hot fluids in lines, pipes, and chambers. Risk of injury!
- Note cooling period for components which are heated for installation or removal. Risk of injury!
- Do not touch hot components of the compressor and the exhaust system. Risk of injury!
- Take special care when removing ventilation or plugs from the engine. In order to avoid discharge of highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has recently been shut down, as the liquids can still be hot.
- Take special care when draining hot fluids. Risk of injury!
- When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or soak them with a suitable bonding agent.
- When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
- When working high on the engine, always use suitable ladders and work platforms. Make sure components are placed on stable surfaces.
- In order to prevent back injuries when lifting heavy components, adults, depending on age and sex, should only lift weights between max. 10 kg and 30 kg, therefore: Use lifting gear or seek assistance
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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