MTU 12 V 4000M Main Engine Workshop Manual
MTU 12 V 4000M Main Engine Workshop Manual
MTU 12 V 4000M Main Engine Workshop Manual
Diesel Engine
8V 396 TE.4
12V 396 TE.4
16V 396 TE.4
Maintenance Manual
M020046/20E
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Außerhalb dieses Verwendungszwecks darf das Handbuch ohne unsere
vorherige Zustimmung nicht benutzt, vervielfältigt oder Dritten sonstwie zugänglich gemacht werden.
Änderungen bleiben vorbehalten.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Other than for this purpose, the handbook shall not be reproduced, used or disclosed to others without our prior consent.
Subject to alterations and amendments.
Le manuel devra être observé en vue d'éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
l'exploitant de le mettre à la disposition du personnel chargé de l'entretien et de la conduite. En dehors de cet usage, le manuel ne pourra
être utilisé ni reproduit ou rendu accessible de quelque autre manière à des tiers, sans notre consentement préalable.
Nous nous réservons le droit d'entreprendre toute modification.
El Manual debe tenerse presente para evitar anomalias o daños durante el servicio, y, por dicho motivo, el usuario debe ponerlo a
disposición del personal de mantenimiento y de servicio. Fuera de este fin de aplicación, el Manual no se debe utilizar, copiar ni poner
en manos de terceros, sin nuestro consentimiento previo.
Nos reservamos el derecho de introducir modificaciones.
Il manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall' utente al personale addetto
alla manutenzione e alla condotta. Senza nostra approvazione preventiva non è ammesso impiegare il manuale per scopi diversi, riprodurlo
o metterlo a disposizione di terzi.
Con riserva di modifiche.
Amendment Service!
Any changes in contents will be sent to you in the form of an amendment,
provided you complete the reverse of this receipt card and return it to us.
M020046/20E
Maintenance Manual
Postcard
Manufacturer 8.
9.
Department
10.
Fax Telephone 11.
Street 12.
13.
Postal box number
14.
(Postal code) City 15.
Country 16.
General Section 1
Page 1
1 General
Contents
1.4 Settings
1.7 Index
20038/10 E –12.96–
General Section 1.1
Page 1
Assembly classifications
The third main section is further subdivided in assembly sections 01 to 88. The information on these assemblies is the
same in all MTU Product Support documentation.
Every assembly section is further divided into subassembly sections (where required).
Example:
3. 1. 2
Subassembly group
Assembly section
Main section
Because the information on assemblies and subassemblies is produced according to a single building-block system
for all engine types, the numbers are not necessarily in numerical sequence.
Alternative subassemblies are either without an index, or are provided with indices ”a, b, c” etc.
Example: 3.1.2a
There can be only one subassembly group 3.1.2 for any individual engine, thus:
3.1.2 without index
or
3.1.2a
or
3.1.2b etc.
The section on each subassembly group is divided into seven operations; the final digit is always identical for all of
these:
.1 Before-removal operations
.2 Removal
.3 Disassembly
.4 Inspection and repair
.5 Assembly
.6 Installation
.7 After-installation operations
All seven procedures will not be required for every subassembly. In these cases, the corresponding sections will not
appear in either the text or the table of contents, but the remaining sections will retain their respective end digits.
Alternative operations are identified in the index with ”a, b, c” etc., while the basic operation is not provided with an index.
Example:
3.1.2.1 Before-removal operations
3.1.2.2 Removal (8V)
3.1.2.2a Removal (16V)
3.1.2.4 Inspection and repair
3.1.2.6 Assembly (8V)
3.1.2.6a Assembly (16V)
3.1.2.7 After-installation operations
20038/10 E –12.96–
General Section 1.1
Page 2
When several operations are combined in a single section (e.g. where no supplementary illustrations are required),
a corresponding note will appear in the table of contents.
Example:
3.1.9.1 Before-removal operations (see 3.1.9)
3.1.9.2 Removal (see 3.1.9)
3.1.9.4 Inspection and repair (see 3.1.9)
3.1.9.6 Assembly (see 3.1.9)
20038/10 E –12.96–
General Section 1.1
Page 3
This symbol applies to radial-lip shaft seals and its significance depends on its position.
The arrow indicates the position of the sealing lip.
D O-rings and surfaces moving against them during installation (bores and shafts) must be coated with white pe-
troleum jelly, unless otherwise specified.
When installing O-rings with counterrings in coolant pumps, always follow the installation instructions.
D After installing O-rings in shaft grooves, in order to remedy twists caused by installation, pass a rounded mark-
ing tool under the sealing ring in the direction of the circumference if the O-ring diameter is sufficiently large.
Make sure that the O-ring is not damaged.
D Sealing paste must be used to fix the position of flat gaskets. Sealing paste is to be thinly applied in spots on
the flat gaskets or mating faces. Immediately after application of the sealing paste, the flat gaskets must be
fitted to the component and then (no more than 20 minutes later) the seal components screwed together.
Oil, multi-purpose grease or other materials must not be used to fix the position.
D Before installing antifriction bearings, lightly lubricate the bearing seats.
Only remove the bearings from their original packaging immediately before installation so they do not get dirty.
Do not remove the corrosion inhibitor from the bearings in original packaging.
Use petroleum spirit or acid-free kerosene to clean the antifriction bearings.
After cleaning, relubricate the bearings with engine oil.
20038/10 E –05.97–
General Section 1.1
Page 4
During assembly, do not apply (axial) forces to antifriction elements and do not hit the bearing rings with a
hammer (use assembly aids).
Do not use an open flame to heat bearing inner races.
The temperature should be between 80°C und 100 °C and must not exceed 120 °C.
Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate).
D Dry bearings must not be oiled.
D When installing gears, the teeth must be lubricated with SAE30 engine oil.
D All support and mating surfaces of components (e.g. mating surfaces for centering devices, flange and sealing
surfaces, joint surfaces of press fits) must be clean, polished or provided with the specified surface protection
and free from warping and damage. Corrosion inhibitors (e.g. oil, grease) must be removed from support and
mating surfaces.
D After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate must be re-
moved and the parts coated with SAE30 engine oil.
D Sensors must be coated with long-life lubricant before installation in the immersion sleeves.
D Cable connections with cutting ring threaded connections must be installed in a vice and tightened, the thread
first being coated with thin-film lubricant.
D If components are to be marked by etching, after the etching is completed the solution must be removed by
means of neutralization agent. The affected parts must then be preserved with SAE30 engine oil.
D Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes, O-rings) must be coated at the sup-
port and mating surfaces with assembly paste, unless otherwise specified in the drawing.
D The assembly surfaces of screws, nuts, washers and of parts to be tensioned must be clean and polished or
provided with the specified surface protection and free from warping and damage. Corrosion inhibitors (e.g. oil,
grease) must be removed. Threads and screw heads must be coated with lubricant before assembly as per
tightening specifications.
Unless otherwise specified, the following lubricants should be used:
– SAE30 engine oil for general application
– Assembly paste in hot part areas.
20038/10 E –05.97–
General Section 1.1
Page 5
1 Sleeve
2 Sealing ring
3 Seal carrier
4 Clamps
5 Screw
6 Self-locking nut
20038/10 E –05.97–
General Section 1.1
Page 6
20038/10 E –05.97–
General Section 1.1
Page 7
L92_23443
20038/10 E –05.97–
General Section 1.1
Page 8
L92_23443
L92_23443
L92_23443
20038/10 E –05.97–
General Section 1.2
Page 1
Engine sides are always designated as viewed from the driving end (KS).
For the purpose of cylinder designation (in accordance with DIN ISO 1204), the cylinders of left engine side are desig-
nated ”A” and those on the right engine side are designated ”B”.
Each cylinder bank is numbered consecutively from No. 1, starting at the driving end of the engine.
Other components and assemblies are also numbered consecutively starting at No. 1 at the driving end.
20046/20 E –02.96–
General Section 1.3
Page 1
Crankcase
Stress bolt with identification number on front,
for crankshaft bearing cap
New size, overall length:
– long stud 279 mm
– short stud 239 mm
in crankcase
– long stud projection 169.0 mm ± 0.5 mm Thread-locking 3.1.2.4
– short stud projection 169.0 mm ± 0.5 mm agent – Loctite 270
Stress bolt, without identification number on front,
with journal on screw end, for crankshaft bearing cap
New size, overall length:
– long stud 296.2 mm ± 0.2 mm
– short stud 256.2 mm ± 0.2 mm
in crankcase
– long stud projection 169.3 mm ± 0.7 mm Engine oil 3.1.2.4
– short stud projection 169.3 mm ± 0.7 mm
– max. projection 173.0 mm
– Stress bolt in crankcase 70 Nm + 7 Nm Engine oil 3.1.2.4
– inner stud elongation 1.3 mm + 0.05 mm Molykote G-n plus 3.1.2.6
– outer stud elongation 1.1 mm + 0.05 mm
optional tightening with stress bolt with identification
number
– inner collar nut, initial tightening torque 200 Nm
– outer collar nut, initial tightening torque 100 Nm
– inner collar nut, additional angle of rotation °
270 +20 °
– outer collar nut, additional angle of rotation °
270 +20 °
M18 bolt for crankshaft alignment bearing cover 300 Nm + 30 Nm Molykote G-n plus 3.1.2.6
Stress bolt for intermediate frame
New size, overall length:
– long stud 426.7 mm ± 0.2 mm
– short stud 386.7 mm ± 0.2 mm
– max. bolt length prior to assembly 3.1.2b.6
inner stress bolt 431 mm
outer stress bolt 391 mm
Stress bolts in crankcase 70 Nm + 7 Nm Engine oil 3.1.2b.6
Collar nuts for crankcase intermediate frame with
torque
– inner collar nuts 240 Nm + 20 Nm Molykote G-n plus 3.1.2b.6
– outer collar nuts 170 Nm + 20 Nm
M12 bolts for intermediate frame 100 Nm + 10 Nm Engine oil 3.1.2b.6
– Release collar nuts
– Stress bolts to elongation in 2 stages
1st Stage: inner stud 0.50 +0.05 mm
1st Stage: outer stud 0.50 +0.05 mm
2nd Stage: inner stud 1.15 +0.05 mm
Overall length, inner stress bolt 1.65 mm
2nd Stage: outer stud 0.90 +0.05 mm
Molykote G-n plus 3.1.2b.6
Overall length, outer stress bolt 1.40 mm
M18 bolts for intermediate frame (thrust bearing) 300 Nm + 30 Nm
Plug for main oil gallery 300 Nm Engine oil 3.1.1.4
M8 bolt for oil spray nozzle 21 Nm + 2 Nm Engine oil 3.1.4.6
M12 bolt for flywheel housing 100 Nm + 10 Nm Engine oil 3.1.8.6
20046/20 E –11.96–
General Section 1.3
Page 2
Gear train
M10 stress bolt on idler gear for engine coolant pump 45 Nm + 4 Nm Engine oil 3.2.1.6
drive assembly, right side
M12 stress bolt on idler gear for generator drive as- 90 Nm Engine oil 3.2.1.6
sembly, left side
Nut for end cover, right side
Idler gear for coolant pump drive assembly 21 Nm Engine oil 3.2.1.6
Nut for end cover, left side 42 Nm Engine oil 3.2.1.6
Idler gear for generator drive
Stress bolt for idler gear of engine oil pump drive 0.19 mm to 0.21 mm Engine oil 3.2.2.6a
8V/12V, elongation 3.15.1.6a
– test torque in tightening direction 180 Nm
Stress bolt for engine oil pump drive idler gear on oil 200 Nm + 20 Nm Engine oil 3.2.2.6a
pan, 16V 3.15.2.6a
Stress bolt for engine oil pump drive idler gear on 45 Nm + 4 Nm Engine oil 3.2.2.6a
intermediate frame
Running gear
Stress bolt for crankshaft couterweights
– bolt length max. 143 mm
– initial tightening torque 100 Nm + 10 Nm Molykote G-n plus 3.3.1.5
– additional angle of rotation 180° +20°
– test torque in tightening direction 300 Nm +10 Nm
Plug on crankshaft M 22x1.5 120 Nm Engine oil 3.3.1.5
M 36x1.5 360 Nm + 20 Nm Engine oil 3.3.3.6
M 10x1.5 20 Nm +2 Nm Engine oil 3.3.3.6
3.3.3a.6
20046/20 E –11.96–
General Section 1.3
Page 3
Cylinder head
Protective sleeve in cylinder head 60 Nm Engine oil 3.5.1.5
Securing bolts in cylinder heads
– 1st initial tightening torque 20 Nm + 10 Nm Engine oil 3.5.1.6
M18 securing bolt in cylinder head
– 2nd initial tightening torque 90 Nm + 10 Nm Engine oil 3.5.1.6
– additional angle of rotation 90° +10°
M20 securing bolt in cylinder head (clamp bolt)
– 2nd initial tightening torque 180 Nm + 10 Nm
– additional angle of rotation 90° +10° Engine oil 3.5.1.6
End plate bolts, drive and free ends 47 Nm + 10 Nm Engine oil 3.5.1.6
Valve gear
Bolts for camshaft alignment bearings 25 Nm Engine oil 3.6.1.6
Stress bolts for camshaft drive gear 60 Nm + 6 Nm Engine oil 3.6.1.6
Stress bolt (long) for rocker shaft
Max. bolt length prior to assembly 81 mm
– initial tightening torque 50 Nm Engine oil 3.6.3.6
– additional angle of rotation 90°
Stress bolt (short) for rocker shaft
Max. bolt length prior to assembly 51 mm
– initial tightening torque 50 Nm Engine oil 3.6.3.6
– additional angle of rotation 45°
Bolt for valve gear housing 21 Nm Engine oil 3.6.4.6
Collar screw for cylinder head cover 4 Nm + 1 Nm Engine oil 3.6.4.6
20046/20 E –11.96–
General Section 1.3
Page 4
M12 chamber bolts and frame bolts on intercooler in 25 Nm-50 Nm-75 Nm Engine oil 3.10.1a.5
three stages
M12 cover bolt on intercooler 75 Nm Engine oil 3.10.1a.5
Bolt for charge air manifold 42 Nm + 4 Nm Engine oil 3.10.2.6
3.10.2.6a
M8 bolt with nut for corner joint between constant- 16 Nm + 2 Nm Ultra-Therm MTU 3.10.3.5
pressure manifold halves
M8 bolt for exhaust housing cover 20 Nm +2 Nm Ultra-Therm MTU 3.10.3.6
M12 bolt for exhaust pipe housing on cylinder heads 90 Nm + 10 Nm Ultra-Therm MTU 3.10.3.6
M12 bolt for end cover at end of constant-pressure 40 Nm + 4 Nm Ultra-Therm MTU 3.10.3.6
manifold halves on exhaust housing
M8 bolt for constant-pressure manifold half in ex-
haust pipe housing
– initial tightening torque 20 Nm +2 Nm Ultra-Therm MTU 3.10.3.6
– release 0
– final torque 20 Nm +2 Nm
Nut for cam roller on lever 8 Nm + 1 Nm Engine oil 3.10.4.5
Emergency air shut-off flaps
M12 bolts for connection housing on carrier housing 40 Nm + 4 Nm Ultra-Therm MTU 3.10.6a.5
3.10.6a
5.a
Exhaust turbocharger
Clamp for exhaust elbow 9 Nm + 1 Nm Ultra-Therm MTU 3.10.6a.6
M10 bolt for securing turbocharger 40 Nm + 4 Nm Ultra-Therm MTU 3.10.6a.6
M8 nut on link of accumulator link 10 Nm + 1 Nm Engine oil 3.10.8a.5
M10 bolt for exhaust elbow on diverter housing 40 Nm + 4 Nm Ultra-Therm MTU 3.10.11a.5
Fuel injection equipment
Nut for bearing flange on injection pump drive 47 Nm Engine oil 3.11.1.6
Bolt for end cover on injection pump drive 25 Nm Engine oil 3.11.1.6
M12 stress bolt for idler gear on drive shaft
Max. bolt length prior to assembly 38 mm 3.11.2.5
– initial tightening torque 50 Nm + 5 Nm Engine oil 3.11.2a.5
– additional angle of rotation 45° +5° 3.11.2b.5
M14 stress bolt for injection timer cams
Max. bolt length prior to assembly 38 mm
– initial tightening torque 60 Nm + 6 Nm Engine oil 3.11.2a.5
– additional angle of rotation 45° + 5° 3.11.2b.5
M24 nut for coupling (two-part) on fuel injection pump 400 Nm + 30 Nm Engine oil 3.11.3.6
I (IIB)
M24 nut for coupling (single-part) on fuel injection 440 Nm + 30 Nm Engine oil 3.11.3a.6
pump I (IID)
Nut for flanges, pumps I and II 400 Nm + 30 Nm Engine oil 3.11.4.6
3.11.4a.6
20046/20 E –11.96–
General Section 1.3
Page 5
Stress bolt for drive gear on drive shaft 100 Nm + 10 Nm Engine oil 3.15.1.5
3.15.1b.5
3.15.2.5
3.15.2a.5
20046/20 E –11.96–
General Section 1.3
Page 6
Bolt for engine oil pump on oil pan 74 Nm + 7 Nm Engine oil 3.15.1.6
3.15.1.6a
3.15.2.6
3.15.2.6a
Bolt for engine oil pump in intermediate frame, 74 Nm + 7 Nm Engine oil 3.15.1b.6
12V/16V 3.15.2a.6
Bolt for oil delivery and suction lines in oil pan, 42 Nm + 4 Nm Engine oil 3.15.1.6
8V/12V 3.15.1.6a
Bolt for pressurised oil line and intake line in oil pan 42 Nm + 4 Nm Engine oil 3.15.2.6
16V 3.15.2.6a
Bolt for pressurised oil and intake line on crankcase 74 Nm + 7 Nm Engine oil 3.15.3a.6
intermediate frame 3.15.3b.6
Bolt for oil-metering pump 3 Nm + 0.3 Nm Engine oil 3.15.4.5
Oil system
Pretightening: M12 bolt, disc-type oil cooler 40 Nm to 50 Nm Engine oil 3.16.2a.5
on housing lower section 3.16.2b.5
3.16.3a.5
20046/20 E –11.96–
General Section 1.3
Page 7
20046/20 E –11.96–
General Section 1.3
Page 8
Tightening torques = MA
M 6 9 12
M 8 21 28
M 8x1 24 30
M 10 42 55
M 10 x 1.25 46 60
M 12 75 93
M 12 x 1.5 78 99
M 14 120 150
M 14 x 1.5 135 160
M 16 180 225
M 16 x 1.5 200 245
M 18 250 315
M 18 x 1.5 300 360
M 20 350 450
M 20 x 1.5 430 495
M 22 500 620
M 22 x 1.5 560 675
M 24 640 790
M 24 x 2 700 850
M 27 900 1170
M 27 x 2 1000 1230
M 30 1250 1575
20046/20 E –07.96–
General Section 1.3
Page 9
Tightening specification for setscrew and stud connections as per works standard MTN 5008
This works standard applies to setscrews not subjected to dynamic load as per MMN 384, DIN 912, EN 24014 (DIN
931–1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to studs as per DIN 833, DIN
835, DIN 836, DIN 938, DIN 939 and associated nuts.
They do not apply to heat-proof screws in the hot component area.
Tightening torques MA are for screws of strength class 8.8 (bright surface, phosphate coating or galvanised) and 10.9
(bright surface or with phosphate coating).
The values in the table are based on a friction coefficient tot = 0.125.
Precondition: Thread and mating faces of screws and nuts must be coated in engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of + 10% of the table values is permitted
for unavoidable deviations of the tightening torque from the table value during the tightening process – e.g. resulting
from inaccurate readings and overtightening during assembly .
When tightening mechanically, the permitted assembly tolerance is + 15 %
Tightening torques = MA
20046/20 E –07.96–
General Section 1.3
Page 10
This standard applies to plugs as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN 3852, model A
(sealed by sealing ring DIN 7603–Cu).
Tightening torques MA are given for plugs made of steel (St) with surface protected by a phospate coating and
oiled or galvanised.
Thread and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of + 10% of the table values is permitted for unavoidable deviations of the tightening torque
from the table value during the tightening process – e.g. resulting from inaccurate readings and overtightening dur-
ing assembly.
Tightening torques = MA
Tightening torques for plugs DIN 908, DIN 910 and DIN 7604A (with short screwed plug)
Thread inserted in
steel/gray cast iron Al-alloy
MA (Nm) MA (Nm)
M 10 x 1 15 15
M 12 x 1.5 35 25
M 14 x 1.5 35 25
M 16 x 1.5 40 30
M 18 x 1.5 50 35
M 20 x 1.5 55 45
M 22 x 1.5 60 50
M 24 x 1.5 70 60
M 26 x 1.5 80 70
M 27 x 2 80 70
M 30 x 1.5 100 90
M 30 x 2 95 85
M 33 x 2 120 110
M 36 x 1.5 130 115
M 38 x 1.5 140 120
M 42 x 1.5 150 130
M 45 x 1.5 160 140
M 48 x 1.5 170 145
M 52 x 1.5 180 150
M 56 x 2 190 160
M 64 x 2 205 175
20046/20 E –07.97–
General Section 1.3
Page 11
Tightening torques for plugs as per DIN 7604C (with long screwed plug)
Thread inserted in
steel/gray cast iron Al-alloy
MA (Nm) MA (Nm)
M8x1 10 10
M 22 x 1.5 80 65
M 26 x 1.5 105 90
M 30 x 1.5 130 130
M 38 x 1.5 140 120
M 45 x 1.5 160 140
20046/20 E –07.97–
General Section 1.3
Page 12
This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603–Cu
Tightening torques MA are given for banjo screws made of steel (St) with surface protected by a phosphate coating
and oiled or galvanised.
Thread and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of + 10% of the table values is permitted for unavoidable deviations of the tightening torque
from the table value during the tightening process – e.g. resulting from inaccurate readings and overtightening dur-
ing assembly.
Tightening torques = MA
Thread inserted in
steel/gray cast iron/Al-alloy
MA (Nm)
M8x1 10
M 10 x 1 15
M 12 x 1.5 20
M 14 x 1.5 25
M 16 x 1.5 25
M 18 x 1.5 30
M 22 x 1.5 60
M 26 x 1.5 90
M 30 x 1.5 130
M 38 x 1.5 140
M 45 x 1.5 160
20046/20 E –07.97–
General Section 1.3
Page 13
This standard applies to male connectors DIN 2353, series L with screwed plug DIN 3852, model A (sealed by
sealing ring DIN 7603-Cu)
Tightening torques MA are given for male connectors made of steel (St) with surface protected by a phosphate
coating and oiled or galvanised.
Thread and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of + 10% of the table values is permitted for unavoidable deviations of the tightening torque
from the table value during the tightening process – e.g. resulting from inaccurate readings and overtightening dur-
ing assembly.
Tightening torques = MA
Thread inserted in
steel/gray cast iron
MA (Nm)
M 10 x1 10
M 12 x 1.5 20
M 14 x 1.5 40
M 16 x 1.5 50
M 18 x 1.5 60
M 22 x 1.5 70
M 26 x 1.5 100
M 32 x 2 160
M 42 x 2 260
M 48 x 2 320
20046/20 E –07.97–
General Section 1.4
Page 1
1.4 Settings
(Counterclockwise-rotating engine)
Firing order
Note
20046/20 E –02.96–
General Section 1.4
Page 2
Inlet 0.30 mm
Exhaust 0.45 mm
20046/20 E –02.96–
General Section 1.5
Page 1
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
General safety and accident prevention regulations
D In addition to the instructions given in this publication, general safety and accident prevention regulations and
laws must be taken into consideration; these may vary from country to country.
D This MTU engine is a state-of-the-art product and conforms with all the applicable specifications and regula-
tions. Nevertheless, persons and property may be at risk in the event of:
– Incorrect use
– Servicing, maintenance and repair carried out by untrained members of staff
– Modifications or conversions
– Noncompliance with the Safety Instructions
Correct use
D The engine is to be used solely for the purpose stated in the contract. Any other use is considered improper
use. The manufacturer will accept no liability for any resultant damage. The responsibility is borne by the user
alone.
D Correct use also includes observation of the Operating Instructions and Maintenance Manual and compliance
with maintenance and repair instructions.
D Engine plants, assemblies or individual components which have been magnetically treated at MTU must remain
in this condition – see general guidelines on marine magnetics.
Personnel requirements
D Work on the engine must be carried out only by reliable personnel. The specified legal minimum age must be
respected.
D Only fully trained or qualified personnel must be employed. Responsibilities of the operating, maintenance and
repair personnel must be specified.
Modifications or conversions
D Modifications made by the customer to the engine may affect safety. No modifications or conversions must be
carried out without prior consent from MTU.
D No liability will be accepted for damage resulting from unauthorised modifications.
Organisational measures
D This Operation Manual must be made available to maintenance and servicing personnel.
D The personnel must be instructed on engine operation and repair by means of the Operation Manual, and in
particular the safety instructions must be explained. This is especially important for personnel who work on the
engine only on an occasional basis.
Spare parts
D Spare parts must at least satisfy the requirements specified by the manufacturer. This is guaranteed when origi-
nal components are used.
Working clothes and protective equipment
D Always wear protective shoes when working on plant.
D Select appropriate protective goggles for the work to be carried out. Always wear protective goggles when work-
ing with mallets, cutting tools, drift punches and similar tools.
D Work clothing must be tight-fitting so that it does not catch on rotating or projecting components. Do not wear
jewellery (e.g. rings, chains, etc.).
20038/10 97–07
General Section 1.5
Page 2
Welding work
D Never use the engine as earth connection! – (This prevents the welding current passing through the engine and
causing scorching or burning at bearings, sliding surfaces and tooth flanks, which can lead to pitting or other
material damage).
D Welding on the engine or mounted ancillaries is forbidden.
D Never place the welding cable across or near wiring harnesses of MTU plants. – (Welding current could be in-
duced in the wiring harnesses, which may result in damage to the electrical system).
D The earth connection of the welding unit must not be situated more than 60 cm from the weld location.
D If welding has to be carried out on components (e.g. exhaust manifold), these components must first be re-
moved from the engine.
D For the MTU electronics system (ECS) it is not necessary to remove the connectors to carry out welding work if
the power supply master switch is moved from ”ON” to ”OFF” and the cable is disconnected from the battery
negative and positive terminals.
D When carrying out welding work, always wear welding gloves, head protection, goggles, apron and other suit-
able protective clothing.
Transportation
D Lift the engine only with the lifting eyes provided.
D Use only the transportation and lifting equipment approved by MTU.
D The engine must only be transported in installation position.
Engine operation
D When the engine is running, ear protectors must always be worn in the engine room.
D The engine room must be well ventilated.
D To avoid injuries caused by falling, leaked or spilt engine oil and coolant must be cleaned up immediately or ab-
sorbed with appropriate bonding agents.
D Exhaust gases from combustion engines are poisonous and injurious to health if inhaled. The exhaust pipework
must be leak-free and discharge exhaust gases to atmosphere.
D During engine operation, do not touch battery terminals, generator terminals or cables. Inadequate protection of
electrical components can lead to electric shocks and serious injuries.
D Never disconnect coolant, oil, fuel, compressed air or hydraulic lines while the engine is running.
D Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. The
engine must be secured against inadvertent starting and the battery disconnected. Attach sign ”Do not operate”
in operating area or to control equipment. Persons not involved must keep clear.
D Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Maintenance work must only be carried out by authorised, qualified personnel.
D Use only tools in perfect condition.
D Do not work on engines or components which are only held by lifting equipment or crane. Always support these
components on suitable frames or stands before beginning any maintenance or repair work.
D Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
20038/10 97–07
General Section 1.5
Page 3
D Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal
connections with caps or covers if a line is removed or opened.
D During maintenance or repair work, do not hit fuel lines with wrenches or other tools. To tighten connections
when installing lines, use the correct tightening torque and ensure that all retainers and dampers are installed
correctly.
D Ensure that all fuel injection lines and pressurised oil lines have sufficient play to avoid contact with other com-
ponents. Do not place fuel or oil lines near hot components.
D The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
D Do not bend lines under pressure or use force.
D In order to avoid burning, take special care when placing hot components on products when working with hot
liquids in pipelines, pipes and chambers.
D Until the engine has cooled, the breather cap must not be opened. Release the breather cap and allow pressure
to escape, before cap removal.
D Take special care when removing ventilation plugs or screws from engine. In order to avoid being sprayed with
highly-pressurised liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has re-
cently been shut down, as the liquids can still be hot.
D Take special care when draining hot fluids – risk of injury. Drain the fluids into a suitable container and wipe up
any spillages.
D When changing engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
D When working high on the engine, always use suitable ladders and work platforms. Make sure components are
placed on stable surfaces.
D To avoid damaging your back when lifting components weighing 25 kg (50 lb.) or more, use lifting gear or re-
quest aid from other workers. Ensure that all chains, hooks, slings, etc. are in good condition, are sufficiently
strong and that hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
D When electrical equipment is in operation, certain components of these appliances are electrically live.
D Non-observance of the warnings may result in serious, life-threatening injuries or damage to property or equip-
ment.
D Work on electrical equipment may only be carried out by qualified personnel. Switch off all live appliances be-
fore carrying out any work on electrical equipment.
D Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to
come into contact with skin or clothing. Wear protective goggles. Do not place tools on the battery. Before con-
necting the cable to the battery, check battery polarity. Battery pole reversal may lead to injury through the
sudden discharge of acid or bursting of the battery body.
D Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against another component or by a hot surface. Never
connect wiring to a line which carries liquid.
D Before barring the engine, ensure that nobody is within the danger area. After working on the engine, check that
all guards have been reinstalled and that all tools and loose components have been removed from the engine.
Fire prevention
D Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires – there-
fore always keep the engine in a clean condition. Do not leave oil-soaked cloths on the engine. Do not store
combustible fluids near the engine. Do not allow dirt or foreign matter to accumulate near the engine, as this
constitutes a fire hazard.
D Welding work must not be carried out on pipes and components containing oil. Before welding, clean with a
noncombustible fluid.
20038/10 97–07
General Section 1.5
Page 4
D Never mix petrol/gasoline with diesel fuel. If petrol/gasoline is added to diesel fuel, there is increased risk of fire.
D When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoid
sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of
the engine or to the ground terminal of the starter.
D Always keep a fire extinguisher at hand and learn how to operate it.
Noise
D All work areas with a sound pressure level in excess of 85 dB (A) may cause hearing damage.
D Fluids and lubricants must be kept in properly designated containers. When using fluids, lubricants and other
chemical substances, follow the safety instructions applicable to the product. Take special care when using hot
and caustic materials. When using inflammable materials, avoid all sparks and do not smoke.
Lead
D When working with lead or pastes containing lead, ensure that no lead is absorbed by the body (white powder
of lead, lead smoke, dirtied hands).
– Prevent the build-up of white powder of lead!
– Switch on fume extraction system!
– Wash hands before eating any food!
Chlorinated hydrocarbons
D When working with chlorinated hydrocarbons (e.g. perchlorethylene, trichlorethane) or other cold cleaners which
contain declared hazardous substances, health-endangering substances may be inhaled.
– Switch on ventilation and extraction systems!
– Observe fire prevention regulations!
– No smoking and no consumption of alcoholic beverages!
– Do not allow chlorinated hydrocarbons to come into contact with sewage water!
Acids and alkaline solutions
D When working with acids and alkaline solutions, always wear protective goggles/face guard, gloves and protec-
tive clothing.
– If such solutions are spilled onto clothing, remove the affected clothing immediately!
– Rinse injured parts of the body thoroughly with water!
– Rinse eyes immediately with eyedrops or clean mains water!
20038/10 97–07
General Section 1.5
Page 5
Painting
D When carrying out painting work outside the spray stands provided with fume extraction systems, ensure that
the area is well ventilated. Make sure that neighbouring work areas are not impaired.
– Always wear a mask providing protection against paint and solvent vapours!
– Observe fire prevention regulations!
– No smoking!
– No naked flames!
Liquid oxygen
D Liquid oxygen is highly inflammable.
D Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals). Do not
bring liquid oxygen into contact with the body (hands) as this causes frostbite and numbing.
– No smoking, no naked flames (risk of explosion). Oxygen enrichment in the air causes flash combustion!
– Do not store any inflammable substances (e.g. oils and greases) within 5 m of the area of work!
– Under no circumstances should clothing be oily or greasy!
– Make sure that fumes do not accumulate in clothing. Oxygen enrichment in fabric can cause working clothes to ignite
suddenly!
– On completion of work, do not smoke until clothing is completely free of fumes!
– Avoid knocks or impacts during this work!
Liquid nitrogen
D Liquid nitrogen should only be stored in small quantities and in regulation containers (without fixed seals).
D Do not bring liquid nitrogen into contact with the body (eyes, hands) as this causes frostbite and numbing.
– Wear protective clothing (including gloves and closed shoes) and protective goggles!
– Ensure the room is well ventilated (88% contamination of breathing air with nitrogen will result in suffocation)!
– Do not subject containers, fittings and tools to impact or shock!
Compressed air
D Compressed air is air which has been compressed at excess pressure and is stored in tanks from which it can
then be extracted.
D The pressure at which the air is kept can be read off at pressure gauges which must be connected to the com-
pressed air tanks and the compressed air lines.
D Pressure, especially when it acts suddenly, represents a hazard to the human body.
– When working with compressed air, safety precautions must be constantly observed:
– Pay special attention to the pressure level in the compressed air network and pressure vessel!
– Connecting devices and equipment must either be assembled for this pressure, or, if the permitted pressure for the
connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to per-
mitted pressure) must form an intermediate connection. Hose coupling and connections must be securely attached!
– Wear protective goggles when cleaning workpieces with compressed air or when using compressed air to remove
swarf!
– The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents air-borne particles
being reflected and thereby prevents injury to eyes.
– First shut off compressed air lines before compressed air equipment is disconnected from the supply line or before
equipment or tool is to be replaced!
– Unauthorised use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of vessels, re-
sults in a risk of explosion!
– Forcing compressed air into thin-walled containers (e.g. containers made of metal, plastic or glass) for drying pur-
poses or to check for leaks results in a risk of explosion!
20038/10 97–07
General Section 1.5
Page 6
– Removing dirt from soiled clothes while still worn can result in a risk of injury.
Even compressed air at low pressure penetrates clothing and, if the jet is directed at the back, the air can enter the
anal cavity and fatally rupture the intestines!
Used oils
D Used oils may contain combustion residues which are harmful to health.
Caution! Gaskets and seals used in this engine may contain asbestos.
Please pay attention to appropriately marked spare parts ”a” during repair work.
Health risk if asbestos dust is inhaled. Follow safety regulations!
1. Introductory remarks
Asbestos dust is created when asbestos and products containing asbestos are transported, sorted, machined or
processed.
Visible asbestos dust contains a proportion of breathable dust which is not visible, hangs for long periods in air and
is thrown up again by air currents when it settles.
Asbestos dust can cause malignant connective-tissue tumours even in low concentrations and after brief periods of
exposure.
The effects of disease caused by asbestos generally only become evident after decades.
When renovating asbestos-insulated facilities, assume that the asbestos concentration is very high if the asbestos
is not disposed of correctly.
Take special protective measures with breathing equipment (see Point 3).
2. Correct procedure
Do not remove asbestos from enclosed areas (e.g. ships, installations, vehicles) without taking safety precautions.
The asbestos from components which have been removed must be extracted outside enclosed spaces.
When disassembling components containing asbestos (e.g. asbestos-insulated exhaust pipework), ensure that no
asbestos dust is released into the air. This is achieved by following the steps below:
– Wrap the components in plastic sheeting and secure with adhesive tape.
– Moisten and wrap the components in damp cloths (exhaust elbows with fractures on the outer jackets are par-
ticularly dangerous due to the build-up of dust).
– Asbestos from removed components may only be released into sealed containers/receptacles (e.g. handling
sacks).
– Ensuring that no dust is created, carefully remove the components from the container. Leave the extracted as-
bestos in the container, seal the container tightly and forward for waste disposal (see Point 4).
Wear a P2 dust mask during this procedure (damage to the container is possible).
– Remove remaining asbestos thoroughly from the components using a vacuum cleaner authorised for asbestos.
– Remove the remnants of flat gaskets with a scraper only.
(The use of electromechanical devices is not permitted).
20038/10 97–07
General Section 1.5
Page 7
The filter element must be renewed if breathing becomes laboured. The filter element is to be disposed of in the
same way as a P2 mask.
The above-mentioned dust masks do not provide protection against harmful gases and the lack of oxygen, e.g. in
the event of fire or in silos etc.
If it is not possible to extract all asbestos traces from work clothing, the disposable protective suits issued must be
worn.
Caution! Torn handling sacks must be sealed with adhesive tape.
Any released asbestos dust must be bound (moistened) and disposed of (see Point 4).
4. Correct disposal
Deposit waste in marked waste bags.
These bags must then be sealed tightly.
The personal protective equipment which has been used must also be disposed of with the waste.
Empty the vacuum cleaner in accordance with the operating instructions provided with the appliance.
Follow the waste disposal regulations of the relevant country.
In the Federal Republic of Germany, asbestos waste may be disposed of only after consultation with the disposal-
site operator.
Warning notices
D Section 3 of this publication contains especially emphasised safety instructions which begin with one of the fol-
lowing signal words according to the degree of danger:
– Take extreme care in these situations!
– Read and become acquainted with all warning notices and symbols before operating or repairing this product.
– Inform operating and maintenance personnel on all Safety Instructions.
20038/10 97–07
General Section 1.6
Page 1
20038/10 E –11.92–
Engine Model
Data Sheet V 396
Crankcase Bores
Crankshaft bearing bores Specified Value: Serial No.
Bearing or cylinder 1 2 3 4 5 6 7 8
No. Crankcase No.
Specified Value For specified values refer to Tolerances and wear Limits List.
Specified Value
E1213
Engine Model
Data Sheet V 396
Cylinder Liner (Installed) Serial No.
Cylinder Direction Basic Actual Dimensions Cylinder Direc– Basic Actual Dimensions
No
No. dim
dim. No
No. tion dim
dim.
Measuring Planes Measuring Planes
1 2 3 4 1 2 3 4
A1 a B1 a
b b
A2 a B2 a
b b
A3 a B3 a
b b
A4 a B4 a
b b
A5 a B5 a
b b
A6 a B6 a
b b
A7 a B7 a
b b
A8 a B8 a
b b
A9 a B9 a
b b
A10 a B10 a
b b
Remarks:
E2444
Engine Model
Data Sheet V 396
Axial Clearances and Tooth Backlash Engine No.
3. Camshaft
4. Crankshaft
Remarks:
E2442
KURBELWELLEN–KENNBLATT Typ
CRANKSHAFT DATA SHEET Model
Sach–Nr. Wellen–Nr.
Item No. Shaft No.
Zeichnungs–Nr. Abnahme
Drawing No. Classification
Hublager–Ø
Crankpin Dia.
Grundlager–Ø
Main Journal Dia.
Bemerkungen / Remarks:
D/E2437
Engine Model
Data Sheet V 396
Main Bearings Engine No.
Specified dimensions
Bearing ID a
Main journal OD
(actual)
Bearing clearance
(radial)
Bearing ID a
Main journal OD
(actual)
Bearing clearance
(radial)
Remarks:
E2443
Engine Model
Data Sheet V 396
Connecting Rods Engine No.
Connecting rod A1 A2 A3 A4 A5 A6 A7 A8
Conrod No.
Weight class
Charge
Connecting rod B1 B2 B3 B4 B5 B6 B7 B8
Conrod No.
Weight class
Charge
Remarks:
E2350
Engine Model
Data Sheet V 396
Connecting Rod Random Checks
(Bearing Shells Installed) Engine No.
A–bank
Actual dimensions
Cylinder Conrod Basic a b1 b2 Crank- Radial
No. No. pin clear–
ance
1
2
3
4
5
6
7
8
9
10
B–bank
Actual dimensions
Cylinder Conrod Basic a b1 b2 Crank- Radial
No. No. pin clear–
ance
1
2
3
4
5
6
7
8
9
10
Remarks:
E2446
Engine Model
Data Sheet V 396
Valve and Injection Timing Engine No.
1. Timing Diagram
Speci- Actual
fied
Cylinder No.
2. Cam Lift
Speci- Actual
fied
Cylinder No.
Inlet
Exhaust
3. Injection Timing
Remarks:
E2440
Engine Model
Installation Data Sheet V 396
Piston Crown Clearance Adjustment Engine No.
(Drawing No. 555 000 87 99)
1 Piston crown face A Cylinder head gasket thickness 2.0 mm D Cylinder liner projection
2 Cylinder liner B Crankcase top deck–to–piston crown face E Gap “S” before tightening cylinder head
3 Cylinder head gasket C Piston crown clearance bolts
4 Support plate F Support plate thickness
Using a dial gauge. move piston to TDC and measure piston projection projection B above cranckcase top deck.
Verify: Piston clearance ”C” must, in all cases, be at least 1.40 mm.
Measured projection ”B” Gasket thickness required ”A” Piston clearance ”C”
Thickness 0,08 mm
from 8.35 mm to 8.54 mm 2.0 mm from 1.42 mm to 1.79 mm
from 8.55 mm to 8.74 mm 2.2 mm from 1.42 mm to 1.79 mm
from 8.75 mm to 8.98 mm 2.4 mm from 1.40 mm to 1.79 mm
* In the case of 8.96 mm to 8.98 mm, use a gasket which is at least 2.34 mm thick.
Left bank A1 A2 A3 A4 A5 A6 A7 A8
Projection ”B” / actual dimension
Gasket thickness / actual dimension
Right bank B1 B2 B3 B4 B5 B6 B7 B8
Projection ”B” / actual dimension
Gasket thickness / actual dimension
Support plate selection
Measured liner projection ”D” 8.04 mm to 8.06 mm
Required support plate thickness ”F” 7.95 mm to 7.97 mm
Gap ”S” min. 0.090 mm to max. 0.130 mm
Left bank A1 A2 A3 A4 A5 A6 A7 A8
Liner projection ”D”
Support plate thickness ”F”
Right bank B1 B2 B3 B4 B5 B6 B7 B8
Liner projection ”D”
Support plate thickness ”F”
Remarks:
D2441
Engine Model
Installation Data Sheet V 396
Piston Crown Clearance Adjustment Engine No.
1 Piston crown face A Cylinder head gasket thickness 2.0 mm D Cylinder liner projection
2 Cylinder liner B Crankcase top deck–to–piston crown face E Gap ”S” before tightening cylinder head
3 Cylinder head gasket C Piston crown clearance bolts
4 Support plate F Support plate thickness
Using a dial gauge, move piston to TDC and measure piston projection B above crankcase top deck
Verify: Piston crown clearance must, in all cases, be at least 1.40 mm
Measured Projection B Gasket Required Piston Crown Clearance C
from 8.16 mm to 8.52 mm 2.0 mm thick from 1.4 mm to 1.9 mm
E2439/1
Engine Model
Data Sheet V 396
V l G
Valve id
Guides Engine No.
Remarks: –––––––––––––––––––––––––––––––––––––
––––––––––––––––––––––––––––––––––––––––––––––––––––
––––––––––––––––––––––––––––––––––––––––––––––––––––
Specified dia. ––––––––––––––––––––––––
1.7 Index
4/2-way solenoid valve (air and exhaust Checking engine condition prior
flow control flap control) . . . . . . . . . . . . . . . 3.86.10a to W5 maintenance work and
4/2-way directional control valve to major overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
(cylinder cutout) . . . . . . . . . . . . . . . . . . . . . . . 3.86.6a Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.4
Checking oilways . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.4
A Checking operation of injection timer . . . . . . . 3.11.2a.7
Accessories (electric, pneumatic), Group . . . . . . 3.86
Checking pump timing . . . . . . . . . . . . . . . . . . . . 3.11.5.7
Accessories (mechanical), Group . . . . . . . . . . . . . 3.88
Checking start of delivery
Actuating cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 3.86.9 (injection pump removed) . . . . . . . . . . . . . . . 3.11.3.7
Actuating cylinder . . . . . . . . . . . . . . . . . . . . . . . . 3.86.9b Checking valve lift . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1.7
Actuation for turbocharger control . . . . . . . . . . 3.10.8a Clamp ring with grooved ball bearing,
Air and exhaust flow control flap control, driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.4
4/2-way solenoid valve . . . . . . . . . . . . . . . . 3.86.10a Cold starting system . . . . . . . . . . . . . . . . . . . . . . . 3.12.6
Air compressor drive . . . . . . . . . . . . . . . . . . . . . . 3.86.4 Compressed air distributor . . . . . . . . . . . . . . . . . 3.18.1
Air compressor drive . . . . . . . . . . . . . . . . . . . . . . 3.86.4a Connecting housing, fuel injection pump I, 16V 3.11.9
Air intake system . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Connecting rod and piston . . . . . . . . . . . . . . . . . . . 3.3.2
Air starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.4 Control unit for hydraulic fan drive
Air starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.4a with supplementary piston . . . . . . . . . . . . . . 3.20.3a
Air/exhaust system, Group . . . . . . . . . . . . . . . . . . . 3.10 Control unit for hydraulic fan drive . . . . . . . . . . . 3.20.3
Assembly, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
Auxiliary PTO, free end . . . . . . . . . . . . . . . . . . . . . 3.3.9 Cooalnt chamber, replacing end cover . . . . . . . 3.1.1.4
Auxiliary PTO, free end . . . . . . . . . . . . . . . . . . . . 3.3.9a Coolant expansion tank . . . . . . . . . . . . . . . . . . . 3.14.5c
Auxiliary PTO, free end . . . . . . . . . . . . . . . . . . . . 3.86.3 Coolant level monitoring, level switch . . . . . . . 3.84.1a
Coolant pump and generator drive,
B intermediate gears . . . . . . . . . . . . . . . . . . . . . . . 3.2.1
Bilge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13.3 Coolant pump, Group . . . . . . . . . . . . . . . . . . . . . . . . 3.13
Bolts, tightening specifications . . . . . . . . . . . . . . . . . 1.3 Coolant system (see Cooling system)
Coolant system, Group . . . . . . . . . . . . . . . . . . . . . . 3.14
C
Coolant thermostat
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1
(annular slide thermostat) . . . . . . . . . . . . . . 3.14.7b
Camshaft bearing bush . . . . . . . . . . . . . . . . . . . . . 3.1.5
Cover at free end, Group . . . . . . . . . . . . . . . . . . . . . 3.4
Carrier housing with exhaust turbocharger
Crank angle before TDC, determining . . . . . . . 3.11.5.7
and exhaust elbow . . . . . . . . . . . . . . . . . . . . 3.10.6a
Crank angle before TDC, determining . . . . . . 3.11.5a.7
Centrifugal oil filter . . . . . . . . . . . . . . . . . . . . . . . . 3.16.6
Crank gear (see Running gear)
Checking and adjusting valve clearance . . . . . . 3.6.3.7
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1
Checking and replacing dowel pins and studs 3.1.1.4
Crankcase breather (version B) . . . . . . . . . . . . . 3.1.7b
Checking and replacing studs . . . . . . . . . . . . . . . 3.1.1.4
Crankcase intermediate frame and stress
Checking camshaft timing/valve lift . . . . . . . . . . 3.6.1.7
bolts with damper . . . . . . . . . . . . . . . . . . . . . . 3.1.2b
Crankcase breather (version C) . . . . . . . . . . . . . 3.1.7c
20046/20 E –02.96–
Index Section 1.7
Page 2
20046/20 E –02.96–
Index Section 1.7
Page 3
Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.8 Idler gear for engine oil pump drive on oil pan . 3.2.2
20046/20 E –02.96–
Index Section 1.7
Page 4
Pins, dowel pins and studs, check Speed transmitter (left engine side) . . . . . . . . . . 3.84.3
and replace . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.4 Speed transmitter drive (left engine side) . . . . 3.17.3
Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 Speed transmitter drive on camshaft
Pressure limiting valves, pressure relief drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17.1
valves and bypass valves . . . . . . . . . . . . . 3.16.5a Speed transmitter drive, Group . . . . . . . . . . . . . . . 3.17
Pressure relief valve (15 bar) . . . . . . . . . . . . . . . 3.15.5 Starting air lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.3
Pressure testing engine coolant chambers . . . . 3.14.9 Starting equipment (see Starting system)
Proximity switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84.6a Starting system, Group . . . . . . . . . . . . . . . . . . . . . 3.18
Publication summary . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18.2
Push rods and rocker arms . . . . . . . . . . . . . . . . . . 3.6.3 Stress bolts and crankshaft bearings . . . . . . . . . 3.1.2
Supplementary control units, Group . . . . . . . . . . . 3.27
R Support ring, free end . . . . . . . . . . . . . . . . . . . . . 3.3.7a
Rack travel indicator . . . . . . . . . . . . . . . . . . . . . 3.11.10
Raw water lines . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14.3 T
Raw water pump . . . . . . . . . . . . . . . . . . . . . . . . . 3.13.2 Task description, main section . . . . . . . . . . . . . . . . . . . 3
Replacing bearing bushes for fuel injection TC (see Exhaust turbocharger)
pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1.4 Three-phase alternator with V-belt drive . . . . . 3.86.3a
Replacing cover on coolant pump drive . . . . . . 3.1.1.4 Torque specifications for bolts and nuts . . . . . . . . . 1.3
Replacing fuel pump drive, bearing bushes . . . 3.1.1.4 Turbocharger control, actuation . . . . . . . . . . . . 3.10.8a
Replacing oil pipe in main oil gallery . . . . . . . . . 3.1.1.4
Replacing roller tappet guide bush . . . . . . . . . . 3.1.1.4 U
Replacing roller tappet, guide bush . . . . . . . . . . 3.1.1.4 Upper cover, auxiliary PTO end . . . . . . . . . . . . . . 3.1.9
Rockers and pushrods . . . . . . . . . . . . . . . . . . . . . . 3.6.3
V
Roller tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.2
Valve gear, Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Running gear, Group . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Valve seat lubrication . . . . . . . . . . . . . . . . . . . . . . 3.15.4
Running-in V396.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Vent and drain lines . . . . . . . . . . . . . . . . . . . . . . . 3.14.2
S Vibration damper, free end, with drive member 3.3.8a
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Vibration damper, free end, with flange . . . . . . . . 3.3.8
20046/20 E –02.96–
Task Description Section 1.8
Page 1
20046/20 E –12.96–
Operation Schedules Section 2
Page 1
2 Operation Schedules
Contents
20038/10 E –11.92–
Operation Schedules Section 2.1
Page 1
Work listed here which is not relevant to the respective engine version can be disregarded.
20058/0 E –02.96–
Operation Schedules Section 2.2
Page 1
20046/20 E –02.96–
Operation Schedules Section 2.2
Page 2
Disassemble engine coolant pump, visually inspect components, replace sealing material 3.13.1.3
Check engine coolant pump relief bore for obstructions B
Disassemble raw water pump, visually inspect components, replace sealing material 3.13.2.3
Check raw water pump relief bore for obstructions B
Disassemble bilge pump, visually inspect components, replace sealing material 3.13.3.3
Check bilge pump relief bore for obstructions B
Clean strainer in coolant return lines B
Clean raw water filter (not delivered by MTU) H
Disassemble coolant cooler, clean and check for leaks 3.14.6.4
Visually inspect sealing element and slide valve of coolant thermostat 3.14.7b.5
Check function of fluid level monitor B
Check operation of monitoring system B
Check crankcase ventilation for obstructions –
20046/20 E –02.96–
Operation Schedules Section 2.2
Page 3
20046/20 E –02.96–
Operation Schedules Section 2.3
Page 1
Engine weight
For engine weight, see engine nameplate
20042/10 E –12.94–
Operation Schedules Section 2.4
Page 1
20046/20 E –02.96–
Operation Schedules Section 2.4
Page 2
20046/20 E –02.96–
Operation Schedules Section 2.4
Page 3
20046/20 E –02.96–
Operation Schedules Section 2.4
Page 4
20046/20 E –02.96–
Operation Schedules Section 2.5
Page 1
20046/20 E –11.96–
Operation Schedules Section 2.5
Page 2
Mount engine oil pump on crankcase intermediate frame 8V, 12V 3.15.1b.6
Mount engine oil pump on intermediate frame 16V 3.15.2a.6
Connect engine oil delivery and suction lines 12V 3.15.1.6
Connect engine oil delivery and suction lines 16V 3.15.2.6
Connect engine oil delivery and suction lines to intermediate frame 12V 3.15.3.6
Connect engine oil delivery and suction lines to intermediate frame 16V 3.15.3a.6
Install pressure relief valve (8V, 12V) in oil pan 3.15.5.6
Install pressure relief valve (16V) in oil pan 3.15.5.6a
Install pressure relief valve in intermediate frame 3.15.3.6b
Install oil pan 3.1.6.6
Install oil pan 3.1.6a.6
Determine TDC mark 3.5.1.4
Measure and adjust piston top clearance 3.5.1.4
Remove engine from roll-over assembly dolly 3.1.1.6
Install flywheel housing 3.1.8.6
Install oil seal carrier at driving end 3.3.5.6
Install inspection port covers on intermediate frame 3.1.10.6
Install clamp ring and grooved ball bearing on crankcase with bearing caps at driving end 3.3.4.6
Install clamp ring and grooved ball bearing on intermediate frame at driving end 3.3.4.6a
Install flywheel with track ring (order-specific) 3.3.3a.6
Install engine flange with drive member 3.3.3.6
Install roller tappets 3.6.2.6
Install cylinder heads 3.5.1.6
Install rocker bearing bushes 3.6.3.5
Install rockers and pushrods 3.6.3.6
Adjust valve clearance 3.6.3.7
Check camshaft timing/valve lift 3.6.1.7
Install valve gear housing 3.6.4.6
Install pressure limiting, pressure relief and bypass valves 3.16.5a.6
Install engine oil heat exchanger with edge-type filter element 3.16.2a.6
3.16.2b.6
3.16.3a.6
Install engine oil filter 3.16.4a.6
Install suspended oil filter 3.16.4b.6
Install electric starter 3.18.5.6
Install compressed air starter 3.18.4.6
3.18.4a.6
Install fuel injection pump drive 3.11.1.6
Install injection pump coupling at free end, IP I 3.11.3.6
20046/20 E –11.96–
Operation Schedules Section 2.5
Page 3
20046/20 E –11.96–
Operation Schedules Section 2.5
Page 4
20046/20 E –11.96–
Operation Schedules Section 2.5
Page 5
Work listed here which is not relevant to the respective engine equipment can be disregarded.
20046/20 E –11.96–
Operation Schedules Section 2.6
Page 1
20046/20 E –02.96–
Operation Schedules Section 2.6
Page 2
20046/20 E –02.96–
Operation Schedules Section 2.6
Page 3
20046/20 E –02.96–
Operation Schedules Section 2.6
Page 4
20046/20 E –02.96–
Operation Schedules Section 2.6
Page 5
20046/20 E –02.96–
Operation Schedules Section 2.7
Page 1
20038/10 E –11.92–
Operation Schedules Section 2.8
Page 1
The engine section drawings listed refer to general engine version and are not order-specific.
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 2
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 3
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 4
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 5
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 6
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 7
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 8
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 9
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 10
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 11
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 12
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 13
20046/20 E –02.96–
Operation Schedules Section 2.8
Page 14
Engine longitudinal section, free end 16V 396 TE with fan drive
20046/20 E –02.96–
Task Description Section 3
Page 1
3 Group Summary
20046/20 E –05.96–
Task Description Section 3
Page 2
3 Group Summary
20046/20 E –05.96–
Task Description Section 3.1
Page 1
3.1 Crankcase
Contents
3.1.1 Crankcase
3.1.1.1 Before-removal operations
3.1.1.2 Removal
3.1.1.3 Disassembly
3.1.1.4 Inspection and repair
3.1.1.5a Assembly
3.1.1.6 Installation
20046/20 E –03.96–
Task Description Section 3.1
Page 2
20046/20 E –03.96–
Task Description Section 3.1
Page 3
20046/20 E –03.96–
Task Description Section 3.1
Page 4
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturers’ instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –03.96–
Task Description Section 3.1
Page 5
20046/20 E –03.96–
Task Description Section 3.1
Page 6
20046/20 E –03.96–
Task Description Section 3.1.1
Page 1
3.1.1 Crankcase
Crankcase 8V
1 Crankcase 12 Stud
2 Protective cap 13 Stud
3 Plug 14 Camshaft bearing bush
4 Camshaft bearing bush 15 Guide bush
5 Oil pipe for oil canal 16 Bush (only for GGG crankcase)
6 Pin 17 Cover
7 Sealing ring 18 Dowel pin
8 Plug 19 Dowel pin
9 Oil pipe 20 Stud
10 Dowel pin 21 Stud
11 Bearing bush 22 Stud
20046/20 E –03.96–
Task Description Section 3.1.1
Page 2
Crankcase 12V
1 Crankcase 12 Stud
2 Protective cap 13 Camshaft bearing
3 Plug 14 Guide bush
4 Camshaft bearing bush 15 Bush (only for GGG crankcase)
5 Plug 16 Cover
6 Sealing ring 17 Dowel pin
7 Oil pipe for oil canal 18 Dowel pin
8 Pin 19 Stud
9 Oil pipe 20 Stud
10 Bearing bush 21 Dowel pin
11 Stud 22 Stud
20046/20 E –03.96–
Task Description Section 3.1.1
Page 3
Crankcase 16V
1 Crankcase 14 Stud
2 Protective cap 15 Camshaft bearing bush
3 Plug 16 Guide bush
4 Camshaft bearing bush 17 Bush (only for GGG crankcase)
5 Oil pipe 18 Plug
6 Oil pipe 19 Sealing ring
7 Pin 20 Cover
8 Plug 21 Dowel pin
9 Sealing ring 22 Stud
10 Oil pipe 23 Dowel pin
11 Bearing bush 24 Dowel pin
12 Stud 25 Stud
13 Stud
20046/20 E –03.96–
Task Description Section 3.1.1
Page 4
20046/20 E –03.96–
Task Description Section 3.1.1.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.1.1.2
Page 1
3.1.1.2 Removal
Installing crankcase in roll-over assembly dolly
Install crankcase in roll-over assembly dolly with lifting appliance and secure.
Caution
The engine can only be swivelled in the roll-over assembly dolly up to the point where the running gear and the oil pan
are installed, i.e. without cylinder heads and other attachments.
Once the engine has been swivelled, the crankcase must be removed from the roll-over assembly dolly and positioned
on the oil pan in order to continue with the assembly process.
20038/10 E –11.92–
Task Description Section 3.1.1.2
Page 2
20038/10 E –11.92–
Task Description Section 3.1.1.3
Page 1
3.1.1.3 Disassembly
Remove cover from camshaft chamber
Using a mandrel, pierce cover (1) in centre.
Remove cover from bore using an extension.
Take care not to damage the bore.
20046/20 E –03.96–
Task Description Section 3.1.1.4
Page 1
Inspecting oilways
Opening main oil gallery, driving end
Note
Inspect main oil gallery (1) with endoscope (2) and cold
light to ensure that it is clean.
20038/10 E –03.96–
Task Description Section 3.1.1.4
Page 2
20038/10 E –11.92–
Task Description Section 3.1.1.4
Page 3
20038/10 E –03.96–
Task Description Section 3.1.1.4
Page 4
Inspecting studs
Remove studs only as required.
Insert new studs with high-strength thread-locking
liquid.
Check stud length at idler gear bearings.
Studs must not protrude.
Note
20038/10 E –11.92–
Task Description Section 3.1.1.4
Page 5
Note
20038/10 E –11.92–
Task Description Section 3.1.1.4
Page 6
Note
20038/10 E –03.96–
Task Description Section 3.1.1.4
Page 7
Y=Roll-in width
For installation, insert oil pipe in crankcase bearing wall bores.
Use device (pin in bore dia. 12 mm) to locate pipe at designated bearing wall ”A”.
Roll in oil pipe pressure-tight in all penetrations through crankcase.
Starting with a roll-in point next to bearing wall ”A”, roll in pipe progressively, first from the end, then from ”A” to the other
end of the pipe.
Roll in pipe to specified roll-in width (Y), see illustration above.
Use roll-in device only at operating temperature (warm up for 5 minutes).
Lubricate roll-in tool with high-pressure gearbox grease.
After each roll-in procedure, remove scale from tool.
The roll-in device is inserted at all roll-in points from the free end.
After rolling-in, check oil pipe for leaks with fluid. Test pressure 15 bar.
Check that there is no obstruction between oilways and oil pipe in crankcase, and that they are clean.
20038/10 E –03.96–
Task Description Section 3.1.1.4
Page 8
Y=Roll-in width
For installation, insert oil pipes in crankcase bearing wall bores.
Use device (pin in bore 12 mm dia.) to locate pipe at designated bearing wall ”B or C”.
Roll in oil pipes pressure-tight in all penetrations through crankcase, starting with roll-in point next to bearing wall ”B
or C”.
Roll in pipe progressively, first from one end, then starting from ”B or C”, to the other end of the pipe.
Roll in pipe to specified roll-in width (Y), see illustration above.
Use roll-in device only at operating temperature (warm up for 5 minutes).
Lubricate roll-in tool with high-pressure gearbox grease.
After each roll-in procedure, remove scale from tool.
For pipe at free end: Insertion of roll-in tool from free end.
For pipe at driving end: Insertion of roll-in tool from driving end.
After rolling-in, check oil pipe for leaks with fluid. Test pressure 15 bar.
Check that there is no obstruction between oilways and oil pipe in crankcase, and that they are clean.
20038/10 E –03.96–
Task Description Section 3.1.1.4
Page 9
20038/10 E –11.92–
Task Description Section 3.1.1.4
Page 10
Attention
20038/10 E –11.92–
Task Description Section 3.1.1.4
Page 11
Caution
Attention
Attention
20038/10 E –03.96–
Task Description Section 3.1.1.4
Page 12
20038/10 E –11.92–
Task Description Section 3.1.1.4
Page 13
Leak testing
Perform the leak test with the cylinder liners in place.
Position leak-test plate with guides on cylinder liners.
If leak-test plates are not available, use cylinder heads.
Tighten cylinder head nuts to specified torque. For torque setting, see Section 1.3.
Install pressure-testing device.
Caution
20038/10 E –03.96–
Task Description Section 3.1.1.5a
Page 1
3.1.1.5a Assembly
Use drift (1) to drive cover into bore of crankcase (2) until
it contacts the stop.
Make sure the cover is kept vertical to the bore.
20038/10 E –01.96–
Task Description Section 3.1.1.6
Page 1
3.1.1.6 Installation
Removing crankcase from roll-over assembly dolly
Caution
The engine can only be swivelled in the roll-over assembly dolly up to the point where the running gear and the oil pan
are installed, i.e. without cylinder heads and other attachments.
Once the engine has been swivelled, the crankcase must be removed from the roll-over assembly dolly in order to con-
tinue the assembly process.
V0010009a0
20038/10 E –03.96–
Task Description Section 3.1.2
Page 1
20038/10 E –11.92–
Task Description Section 3.1.2
Page 2
20038/10 E –03.96–
Task Description Section 3.1.2.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.1.2.2
Page 1
3.1.2.2 Removal
Removing crankshaft bearing caps
Note
Note
20038/10 E –03.96–
Task Description Section 3.1.2.3
Page 1
3.1.2.3 Disassembly
Removing sleeves
Remove sleeves from crankshaft bearing cap.
Note
20038/10 E –11.92–
Task Description Section 3.1.2.4
Page 1
Attention
If crankshaft bearing caps are replaced, they must be worked together with the crankcase.
Check crankshaft bearing cap for wear and localized galling; remove minor wear and localized galling by polishing –
if necessary recondition to MTU specifications.
Check evenness of mating faces of crankshaft bearing caps with straightedge and feeler gauge.
If irregularities greater than 0.05 mm are detected, recondition the mating faces of the crankshaft bearing cap in accord-
ance with MTU specifications.
Request the relevant work instructions from MTU Friedrichshafen.
Inspecting and replacing crankshaft bearing cap studs.
Measure stress bolts (2) with depth gauge (1) on crank-
case (3) to max. projection.
Remove stress bolts from crankcase only if damage is
detected on screw thread or wear on separation points;
replace stress bolts also if screw projection exceeds 173
mm.
Stress bolts with identification number on the face are
secured with ”high-strength thread-locking agent ” in the
crankcase.
Attention
20038/10 E –08.97–
Task Description Section 3.1.2.4
Page 2
20038/10 E –01.96–
Task Description Section 3.1.2.5
Page 1
3.1.2.5 Assembly
Installing crankshaft bearing caps
Installing sleeves
Smooth mating faces of crankshaft bearing caps and
collar nuts with an oilstone.
Insert sleeves in bearing caps.
Check projection of adapter sleeves.
Note
20038/10 E –11.92–
Task Description Section 3.1.2.6
Page 1
3.1.2.6 Installation
Installing crankshaft bearing caps
Install bearing caps on crankcase in accordance with
markings (1).
Attention
Note
20038/10 E –03.96–
Task Description Section 3.1.2.6
Page 2
20038/10 E –11.92–
Task Description Section 3.1.2.7
Page 1
20038/10 E –11.92–
Task Description Section 3.1.2.b
Page 1
20054/00 E –10.93–
Task Description Section 3.1.2.b
Page 2
1 Crankcase 4 Screw
2 Crankcase intermediate frame 5 Screw
3 Washer 6 Screw
20054/00 E –10.93–
Task Description Section 3.1.2.b
Page 3
20054/00 E –10.93–
Task Description Section 3.1.2b.1
Page 1
1 2 3 Operations See
20054/00 E –10.93–
Task Description Section 3.1.2b.2
Page 1
3.1.2b.2 Removal
Removing crankcase intermediate frame
Prior to removing crankcase intermediate frame, re-
move grooved ball bearing from crankcase bore.
Use socket and extension (1) to remove bolts for
grooved ball bearings on intermediate frame.
20054/00 E –10.93–
Task Description Section 3.1.2b.2
Page 2
20054/00 E –10.93–
Task Description Section 3.1.2b.3
Page 1
3.1.2b.3 Disassembly
Removing sleeves
Remove sleeves from crankcase intermediate frame.
Note
20054/00 E –10.93–
Task Description Section 3.1.2b.4
Page 1
20054/00 E –08.97–
Task Description Section 3.1.2b.5
Page 1
3.1.2b.5 Assembly
Installing sleeves
Smooth mating faces of crankcase intermediate frame
and collar nuts with an oilstone.
Insert adapter sleeves into crankcase intermediate
frame.
Check projection of adapter sleeves,
X = 9.5 mm -0.5 mm
Note
20054/00 E –10.93–
Task Description Section 3.1.2b.6
Page 1
3.1.2b.6 Installation
Installing crankcase intermediate frame
Note
Note
20046/20 E –03.96–
Task Description Section 3.1.2b.6
Page 2
Attention
20046/20 E –03.96–
Task Description Section 3.1.2b.6
Page 3
Note
Note
20046/20 E –03.96–
Task Description Section 3.1.2b.6
Page 4
Note
Note
20046/20 E –03.96–
Task Description Section 3.1.2b.6
Page 5
Note
20046/20 E –03.96–
Task Description Section 3.1.2b.6
Page 6
Note
The two collar nuts of a crankcase partition wall must be tightened simultaneously.
20046/20 E –03.96–
Task Description Section 3.1.2b.6
Page 7
Note
The two collar nuts of a crankcase partition wall must be tightened simultaneously.
20046/20 E –03.96–
Task Description Section 3.1.2b.6
Page 8
Note
The two collar nuts of a crankcase partition wall must be tightened simultaneously.
20046/20 E –03.96–
Task Description Section 3.1.2b.7
Page 1
20054/00 E –10.93–
Task Description Section 3.1.3
Page 1
20038/10 E –01.96–
Task Description Section 3.1.3.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.1.3.2
Page 1
3.1.3.2 Removal
Insert puller with thrust plate (1).
Take care not to damage the oil spray nozzle (2).
Make sure the puller is properly seated.
20038/10 E –11.92–
Task Description Section 3.1.3.2
Page 2
20038/10 E –11.92–
Task Description Section 3.1.3.4
Page 1
20038/10 E –11.95–
Task Description Section 3.1.3.6
Page 1
3.1.3.6 Installation
Installing cylinder liner
Note
Note
Note
20038/10 E –11.95–
Task Description Section 3.1.3.6
Page 2
20038/10 E –11.95–
Task Description Section 3.1.3.7
Page 1
Note
20038/10 E –11.92–
Task Description Section 3.1.4
Page 1
20058/0 E –03.93–
Task Description Section 3.1.4.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.1.4.2
Page 1
3.1.4.2 Removal
Remove screws (1) for oil spray nozzle (2) with socket.
Remove oil spray nozzle.
20038/10 E –11.92–
Task Description Section 3.1.4.4
Page 1
20038/10 E –11.92–
Task Description Section 3.1.4.6
Page 1
3.1.4.6 Installation
Before installing oil spray nozzle, check that mating
faces on crankcase and nozzle are smooth.
Carefully blow out oilways with compressed air.
Install oil spray nozzle (2) with screws and spring
washers in crankcase.
Use socket and torque wrench (1) to tighten screws to
specified torque. For torque setting, see Section 1.3
20054/00 E –10.93–
Task Description Section 3.1.4.7
Page 1
Attention
20038/10 E –11.92–
Task Description Section 3.1.5
Page 1
20038/10 E –11.92–
Task Description Section 3.1.5.1
Page 1
1 2 3 Operations See
20046/20 E –04.96–
Task Description Section 3.1.5.2
Page 1
3.1.5.2 Removal
Note
Remove camshaft bearing bushes only when wear limits are reached or when they are damaged.
Note
Two recesses are machined on draw spindle of installation and extraction tool for left and right engine side.
Left engine side:
Use recesses on draw spindle and thrust plate for left engine side in direction of driving end.
Right engine side:
Use recesses on draw spindle and thrust plate for right engine side in direction of free end.
20038/10 E –11.92–
Task Description Section 3.1.5.2
Page 2
20038/10 E –11.92–
Task Description Section 3.1.5.2
Page 3
20038/10 E –11.92–
Task Description Section 3.1.5.4
Page 1
20038/10 E –11.92–
Task Description Section 3.1.5.6
Page 1
3.1.5.6 Installation
Installed position of bearing bushes as viewed from engine driving end
Note
For instructions on how to use installer for camshaft bearing bushes, see 3.1.5.2.
Prior to installing camshaft bearing, check stage or dimensional accuracy in accordance with Tolerances and Wear
Limits List.
Remove plug on right side of engine at driving end to enable inspection of oilway.
Plug is secured with thread-locking liquid!
20038/10 E –11.92–
Task Description Section 3.1.5.6
Page 2
20038/10 E –11.92–
Task Description Section 3.1.5.6
Page 3
20038/10 E –11.92–
Task Description Section 3.1.5.7
Page 1
20038/10 E –11.92–
Task Description Section 3.1.6
Page 1
20046/20 E –03.96–
Task Description Section 3.1.6
Page 2
20046/20 E –03.96–
Task Description Section 3.1.6
Page 3
20046/20 E –03.96–
Task Description Section 3.1.6.1
Page 1
1 2 3 Operations See
20046/20 E –03.96–
Task Description Section 3.1.6.2
Page 1
20038/10 E –06.94–
Task Description Section 3.1.6.2b
Page 1
3.1.6.2b Removal
Lowering oil pan
Attention
20038/10 E –11.92–
Task Description Section 3.1.6.4
Page 1
20038/10 E –06.94–
Task Description Section 3.1.6.6
Page 1
Note
20038/10 E –04.96–
Task Description Section 3.1.6.6
Page 2
Note
Note
20038/10 E –04.96–
Task Description Section 3.1.6.6b
Page 1
3.1.6.6b Installation
Installing lowered oil pan
Check whether mating surfaces of crankcase and oil
pan (2) are clean.
Note
Note
Note
20038/10 E –04.96–
Task Description Section 3.1.6a
Page 1
20046/20 E –03.96–
Task Description Section 3.1.6a
Page 2
20046/20 E –03.96–
Task Description Section 3.1.6a
Page 3
20046/20 E –03.96–
Task Description Section 3.1.6a.1
Page 1
1 2 3 Operations See
20046/20 E –03.96–
Task Description Section 3.1.6a.2
Page 1
3.1.6a.2 Removal
Removing oil pan
Install lifting appliance for complete engine.
Using lifting gear, raise engine until oil pan is raised
slightly off the ground.
Remove all screws from oil pan.
Note
20046/20 E –04.96–
Task Description Section 3.1.6a.4
Page 1
20046/20 E –03.96–
Task Description Section 3.1.6a.6
Page 1
3.1.6a.6 Installation
Installing oil pan
Note
Note
20046/20 E –04.96–
Task Description Section 3.1.7
Page 1
1 Screw 7 Washer
2 Washer 8 Screw
3 Cover 9 Screw
4 Gasket 10 O-ring
5 Oil separator 11 Plug-in pipe
6 Breather housing
20046/20 E –03.96–
Task Description Section 3.1.7
Page 2
20046/20 E –03.96–
Task Description Section 3.1.7
Page 3
20046/20 E –03.96–
Task Description Section 3.1.7.1
Page 1
1 2 3 Operations See
20038/10 E –03.96–
Task Description Section 3.1.7.2
Page 1
3.1.7.2 Removal
Unscrew vent line (4) and adapter (3) together with seal-
ing ring (2) from cover (1).
20038/10 E –11.92–
Task Description Section 3.1.7.3
Page 1
3.1.7.3 Disassembly
Remove screws (1), washers (2) and cover (3) with
gasket (4).
Remove oil separator (5) and gasket from breather
housing (6).
20038/10 E –03.96–
Task Description Section 3.1.7.4
Page 1
20038/10 E –06.94–
Task Description Section 3.1.7.5
Page 1
3.1.7.5 Assembly
Installing oil separator
Position gasket (4) with oil separator (5) on breather
housing (6).
Install gasket with cover (3) and screws (1) and washers
(2) and tighten.
20038/10 E –03.96–
Task Description Section 3.1.7.6
Page 1
3.1.7.6 Installation
Installing connecting lines
Check whether bores for connecting lines (2) at free end
of crankcase are clean.
Coat O-rings (1) with petroleum jelly.
Fit O-rings on connecting lines.
Insert connecting lines into crankcase bores.
Screw adapter (3) and sealing ring (2) into cover (1) and
tighten.
Attach vent line (4) leading to turbocharger to adapter in
cover.
20038/10 E –03.96–
Task Description Section 3.1.7b
Page 1
20046/20 E –03.96–
Task Description Section 3.1.7b
Page 2
Crankcase ventilation
20046/20 E –03.96–
Task Description Section 3.1.7b
Page 3
Vent line
1 Pipe 17 Pipe
2 Gasket 18 Pipe clamp half
3 Hex screw 19 Hex screw
4 Spring washer 20 Spring washer
5 Pipe 21 Pipe, left side
6 Nut 22 Pipe, right side
7 Rubber sleeve 23 Nut
8 Clamp 24 Sealing ring
9 Retainer 25 Adaptor
10 Hex screw 26 Rubber sleeve
11 Hex screw 27 Clamp
12 Washer 28 Retainer
13 Spring washer 29 Pipe clamp half
14 Spring washer 30 Hex screw
15 Pipe clamp half 31 Washer
16 Hex screw 32 Retainer
The pipe clamp halves (item 15) are installed with grommet (not illustrated).
20046/20 E –03.96–
Task Description Section 3.1.7b
Page 4
20046/20 E –06.96–
Task Description Section 3.1.7b
Page 5
20046/20 E –03.96–
Task Description Section 3.1.7b.1
Page 1
1 2 3 Operations See
20038/10 E –03.96–
Task Description Section 3.1.7b.2
Page 1
3.1.7b.2 Removal
Removing cover with vent line and oil separator
Remove vent line (1) from cover (2).
Remove screws and washer (3) from cover.
Detach cover and oil separator from housing (4).
Remove gasket.
20038/10 E –11.92–
Task Description Section 3.1.7b.2
Page 2
20038/10 E –11.92–
Task Description Section 3.1.7b.3
Page 1
3.1.7b.3 Disassembly
Removing oil separator from cover
Unscrew oil separator (2) from cover (1).
20038/10 E –11.92–
Task Description Section 3.1.7b.4
Page 1
20038/10 E –11.92–
Task Description Section 3.1.7b.5
Page 1
3.1.7b.5 Assembly
Installing oil separator on cover
Install oil separator (2) with screws and spring washers
on cover (1).
Tighten screws.
20038/10 E –11.92–
Task Description Section 3.1.7b.6
Page 1
3.1.7b.6 Installation
Installing lower section of vent housing
Check whether bores for plug-in pipe at free end of
crankcase (5) and in lower section (1) of vent housing
housing are clean.
Fit O-rings (6) on plug-in pipe (7).
Coat O-rings with petroleum jelly.
Insert plug-in pipe into crankcase.
Insert O-ring (4) into groove in lower section (1) of vent
housing.
Coat O-ring with petroleum jelly.
Push lower section of vent housing onto plug-in pipe.
Secure to free end of crankcase with screws (2) and
washers (3).
Tighten screws to specified torque. For torque setting,
see Section 1.3.
Fasten siphon (11) and sealing ring (12) with screws to
lower section of vent housing and tighten.
Connect oil line (10) to siphon (11) and adapter (9).
20038/10 E –11.95–
Task Description Section 3.1.7b.6
Page 2
20038/10 E –11.92–
Task Description Section 3.1.7c
Page 1
20046/20 E –03.96–
Task Description Section 3.1.7c
Page 2
Vent line
20046/20 E –03.96–
Task Description Section 3.1.7c
Page 3
A = Free end
B = Right side
20046/20 E –03.96–
Task Description Section 3.1.7c.1
Page 1
1 2 3 Operations See
20046/20 E –03.96–
Task Description Section 3.1.7c.2
Page 1
3.1.7c.2 Removal
Removing vent line
Unscrew vent line (1), union (2) and sealing ring (3) from
the cover (4).
20046/20 E –03.96–
Task Description Section 3.1.7c.3
Page 1
3.1.7c.3 Disassembly
Removing oil separator
Remove screws (1), washers (2) and cover (3) with
gasket (4).
Remove oil separator (5) and gasket from vent housing
(6).
20046/20 E –03.96–
Task Description Section 3.1.7c.4
Page 1
20058/0 E –03.93–
Task Description Section 3.1.7c.5
Page 1
3.1.7c.5 Assembly
Installing oil separator
Position gasket (4) with oil separator (5) on vent housing
(6).
Mount gasket with cover (3), screws (1) and washers (2)
and tighten.
20046/20 E –03.96–
Task Description Section 3.1.7c.6
Page 1
3.1.7c.6 Installation
Installing vent housing
Check bores for connecting pipes (2) at crankcase, free
end, for contamination.
Coat O-rings (4) with petroleum jelly and place in
grooves of the connecting lines (5).
Insert connecting lines into crankcase bores.
Push vent housing (6) onto connecting lines.
Mount vent housing with screws (1) and (3) and washers
(2) on end plate, free end, and tighten.
20046/20 E –03.96–
Task Description Section 3.1.8
Page 1
20046/20 E –03.96–
Task Description Section 3.1.8
Page 2
1 O-ring 10 Plug
2 Dowel pin 11 Spring washer
3 Spring washer 12 Screw
4 Screw 13 Flywheel housing
5 Screw 14 O-ring
6 Cover 15 Clamp ring
7 Gasket 16 Spring washer
8 Cover 17 Socket-head screw
9 Sealing ring
20046/20 E –03.96–
Task Description Section 3.1.8
Page 3
20046/20 E –03.96–
Task Description Section 3.1.8
Page 4
20046/20 E –03.96–
Task Description Section 3.1.8.1
Page 1
1 2 3 Operations See
20047/10 E –09.95–
Task Description Section 3.1.8.2
Page 1
3.1.8.2 Removal
Removing flywheel housing
Suspend flywheel housing (2) from lifting appliance (1)
with lifting gear.
Remove all screws from flywheel housing.
Remove housing from centring ring and raise from
crankcase.
Remove O-rings from crankcase and flywheel housing.
20038/10 E –01.95–
Task Description Section 3.1.8.3
Page 1
3.1.8.3 Disassembly
Disassembling flywheel housing in accordance
with illustration
1 Flywheel housing
2 Cover
3 Gasket
4 Cover
5 Spring washer
6 Screw
7 Gasket
8 Cover
9 Spring washer
10 Screw
11 Sealing ring
12 Plug
13 Gasket
1 Flywheel housing
2 Gasket
3 Cover
4 Spring washer
5 Screw
6 Cover
20046/20 E –03.96–
Task Description Section 3.1.8.4
Page 1
Attention
20038/10 E –01.95–
Task Description Section 3.1.8.5
Page 1
3.1.8.5 Assembly
1 Flywheel housing
2 Cover
3 Gasket
4 Cover
5 Spring washer
6 Screw
7 Gasket
8 Cover
9 Spring washer
10 Screw
11 Sealing ring
12 Plug
13 Gasket
Coat gasket with sealing paste and mount with cover to
flywheel housing; secure with screws and spring
washers.
1 Flywheel housing
2 Gasket
3 Cover
4 Spring washer
5 Screw
6 Cover
Coat gasket with sealing paste and mount with cover to
flywheel housing; secure with screws and spring
washers.
20046/20 E –03.96–
Task Description Section 3.1.8.6
Page 1
3.1.8.6 Installation
Clean mating surfaces of crankcase and flywheel hous-
ing.
Coat O-rings (1) with petroleum jelly.
Install O-rings in grooves.
Attention
20038/10 E –11.95–
Task Description Section 3.1.8.6
Page 2
20038/10 E –11.92–
Task Description Section 3.1.8a
Page 1
20046/20 E –03.96–
Task Description Section 3.1.8a
Page 2
20046/20 E –03.96–
Task Description Section 3.1.8a.1
Page 1
1 2 3 Operations See
20046/20 E –03.96–
Task Description Section 3.1.8a.2
Page 1
3.1.8a.2 Removal
Removing flywheel housing
Suspend flywheel housing (2) from lifting appliance (1)
with lifting gear.
Remove all screws from flywheel housing.
Remove housing from centring ring and raise from
crankcase.
Remove O-ring from crankcase.
20058/0 E –03.93–
Task Description Section 3.1.8a.3
Page 1
3.1.8a.3 Disassembly
Disassemble flywheel housing in accordance with
illustration
1 Flywheel housing
2 Cover
3 Screw
4 Spring washer
5 Cover
20046/20 E –03.96–
Task Description Section 3.1.8a.4
Page 1
Note
20058/0 E –03.93–
Task Description Section 3.1.8a.5
Page 1
3.1.8a.5 Assembly
1 Flywheel housing
2 Cover
3 Screw
4 Spring washer
5 Cover
Install cover and cap using screws and spring washers/
washer to flywheel housing. See illustration above.
20046/20 E –03.96–
Task Description Section 3.1.8a.6
Page 1
3.1.8a.6 Installation
Install flywheel housing
Suspend flywheel housing (2) with lifting appliance (1)
and lifting gear.
Coat sealing surfaces of crankcase evenly with surface
sealant.
Install flywheel housing on crankcase.
Coat securing screws with engine oil and screw into fly-
wheel but do not tighten.
Remove lifting appliance.
Tightening sequence
Slightly loosen bolts (3) in oil pan (4).
Secure flywheel housing (1) to crankcase
with bolts (2).
Tighten bolts (6) on flywheel housing and oil pan until the
gap (5) is closed; back off again for 1/2 a revolution.
Tighten bolts (3) to specified torque. For torque setting,
see Section 1.3.
Check gap (5). Gap must not exceed 0.05 mm.
Tighten bolts (6) to specified torque. For torque setting,
see Section 1.3.
20046/20 E –03.96–
Task Description Section 3.1.8a.7
Page 1
20046/20 E –03.96–
Task Description Section 3.1.9(.)
Page 1
1 2 3 Operations See
20046/20 E –04.96–
Task Description Section 3.1.9(.)
Page 2
3.1.9.2 Removal
Remove in accordance with illustration on Page 1.
3.1.9.6 Installation
Smooth sealing surfaces.
Install in accordance with illustration on Page 1.
Note
20046/20 E –04.96–
Task Description Section 3.1.10
Page 1
1 Crankcase 4 Cover
2 Crankcase intermediate frame 5 Spring washer
3 O-ring 6 Screw
20038/10 E –11.92–
Task Description Section 3.1.10.1
Page 1
1 2 3 Operations See
20054/00 E –04.96–
Task Description Section 3.1.10.2
Page 1
3.1.10.2 Removal
Remove screw from inspection port cover.
20038/10 E –11.92–
Task Description Section 3.1.10.4
Page 1
20038/10 E –11.92–
Task Description Section 3.1.10.6
Page 1
3.1.10.6 Installation
Insert O-ring (1) in groove on inspection port cover and
coat with petroleum jelly.
Ensure that O-ring is not twisted when installed.
20038/10 E –04.96–
Task Description Section 3.2
Page 1
3.2.2 Idler gears for engine oil pump drive on oil pan
3.2.2.1 Before-removal operations
3.2.2.2 Removal
3.2.2.3 Disassembly
3.2.2.4 Inspection and repair
3.2.2.5 Assembly 8/12V
3.2.2.5a Assembly 16V
3.2.2.6 Installation 8/12V
3.2.2.6a Installation 16V
3.2.2.7 After-installation operations
20038/10 E –11.92–
Task Description Section 3.2
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20038/10 E –04.96–
Task Description Section 3.2
Page 3
20038/10 E –04.96–
Task Description Section 3.2
Page 4
20038/10 E –11.92–
Task Description Section 3.2.1
Page 1
20038/10 E –01.95–
Task Description Section 3.2.1
Page 2
20038/10 E –11.92–
Task Description Section 3.2.1
Page 3
Engine coolant pump idler gear Idler gear for raw water pump/generator
20038/10 E –01.95–
Task Description Section 3.2.1.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.2.1.2
Page 1
3.2.1.2 Removal
Removing end cover/bearing flange
Unscrew nuts for securing end cover (2) for idler gear
(1).
Press the end cover with two screws (3) evenly off the
crankcase.
20038/10 E –01.95–
Task Description Section 3.2.1.2
Page 2
20038/10 E –04.96–
Task Description Section 3.2.1.3
Page 1
3.2.1.3 Disassembly
Removing cylindrical roller bearing from end cover
Insert the clamping element (2) and pressure sleeve (3)
of the removal tool (1) in the cylindrical roller bearing in
the end cover.
Note
20038/10 E –11.92–
Task Description Section 3.2.1.4
Page 1
20038/10 E –01.95–
Task Description Section 3.2.1.5
Page 1
3.2.1.5 Assembly
Press-fit the inner races onto the shaft
Press-fit both inner races of the cylindrical roller bearing
with corresponding sleeve onto the idler gear shaft.
Note
20038/10 E –11.92–
Task Description Section 3.2.1.6
Page 1
3.2.1.6 Installation
Heat idler gears on a hotplate until they are warm to
touch.
20038/10 E –11.92–
Task Description Section 3.2.1.6
Page 2
20038/10 E –11.95–
Task Description Section 3.2.1.6
Page 3
Note
20038/10 E –11.92–
Task Description Section 3.2.1.7
Page 1
20038/10 E –11.92–
Task Description Section 3.2.1.7
Page 2
Checking backlash
Place measuring device (2) on support surface of gear
case on crankcase.
Place dial gauge stylus on a tooth flank.
Set dial gauge with preload to zero.
Measure backlash of idler gears and drive gears (1).
For backlash, see 3.2.
Enter measurement values in data sheet.
If limit values are exceeded, check installation of idler
gears and drive gears.
20038/10 E –11.92–
Task Description Section 3.2.2
Page 1
20038/10 E –11.92–
Task Description Section 3.2.2
Page 2
20038/10 E –11.92–
Task Description Section 3.2.2.1
Page 1
1 2 3 Operations See
20038/10 E –04.96–
Task Description Section 3.2.2.2
Page 1
3.2.2.2 Removal
Unscrew clamping nut at angular-contact ball bearing.
Remove stress bolt from bearing pin.
Mount removal tool to oil pan.
Press bearing pin and idler gear (2) out from oil pan.
If no removal tool is available, drive the bearing pin out
of the oil pan with an aluminium mandrel (1).
20038/10 E –11.92–
Task Description Section 3.2.2.3
Page 1
3.2.2.3 Disassembly
Using a manual press, press the bearing pin out of the
idler gear.
Note
20038/10 E –11.92–
Task Description Section 3.2.2.4
Page 1
20038/10 E –11.95–
Task Description Section 3.2.2.5
Page 1
Note
Note
20038/10 E –11.92–
Task Description Section 3.2.2.5a
Page 1
Note
Note
20038/10 E –11.92–
Task Description Section 3.2.2.6
Page 1
20038/10 E –06.94–
Task Description Section 3.2.2.6a
Page 1
20038/10 E –11.95–
Task Description Section 3.2.2.7
Page 1
20038/10 E –11.92–
Task Description Section 3.2.2a
Page 1
20054/00 E –01.95–
Task Description Section 3.2.2a
Page 2
20054/00 E –01.95–
Task Description Section 3.2.2a.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.2.2a.2
Page 1
3.2.2a.2 Removal
Unscrew nuts at bearing flange.
Remove spring washers.
Using jackscrews (1), press the bearing flange off the
crankcase intermediate frame.
Remove cylindrical roller bearing from bearing flange,
see 3.2.1.3.
Secure gear.
Unscrew stress bolts from idler gear shaft (1).
Screw assembly screw into idler gear shaft.
Pull idler gear shaft forwards.
Release the idler gear from the idler gear shaft by knock-
ing it lightly with a plastic mallet and simultaneously turn-
ing it.
Pull idler gear and idler gear shaft out of crankcase inter-
mediate frame.
Remove the assembly screws from the intermediate
shaft.
20038/10 E –04.96–
Task Description Section 3.2.2a.3
Page 1
3.2.2a.3 Disassembly
Removing cylindrical roller bearing from bearing
flange
Insert the clamping element (2) and pressure sleeve (3)
of the removal tool (1) in the cylindrical roller bearing in
the bearing flange.
20038/10 E –01.95–
Task Description Section 3.2.2a.4
Page 1
20054/00 E –10.93–
Task Description Section 3.2.2a.5
Page 1
3.2.2a.5 Assembly
Press-fitting inner races
Press-fit both inner races of the cylindrical roller bearing
with corresponding sleeve onto the idler gear shaft.
Note
20038/10 E –01.95–
Task Description Section 3.2.2a.6
Page 1
3.2.2a.6 Installation
Installing cylindrical roller bearing in crankcase in-
termediate frame
Coat the cylindrical roller bearing bore in the crankcase
intermediate frame with engine oil.
Using a mandrel (1), knock the cylindrical roller bearing
into the crankcase intermediate frame.
The lettering on the bearing must face the outside.
20038/10 E –11.92–
Task Description Section 3.2.2a.6
Page 2
20038/10 E –04.96–
Task Description Section 3.2.2a.7
Page 1
Place dial gauge stylus at the side collar of the idler gear
to measure axial clearance. Set dial gauge with preload
to zero.
Move idler gear in axial direction.
Read axial clearance off the dial gauge. Enter value in
record sheet.
For limit values, see Tolerances and Wear Limits List.
If the limit values are exceeded, check installation of
idler gear.
20038/10 E –01.95–
Task Description Section 3.3
Page 1
3.3.1 Crankshaft
3.3.1.1 Before-removal operations
3.3.1.2 Removal from crankcase with crankcase bearing caps
3.3.1.2a Removal from crankcase with intermediate frame
3.3.1.3 Disassembly
3.3.1.4 Inspection and repair
3.3.1.5 Assembly
3.3.1.6 Installation in crankcase with crankcase bearing caps
3.3.1.6b Installation in crankcase with intermediate frame
20046/20 E –04.96–
Task Description Section 3.3
Page 2
20046/20 E –04.96–
Task Description Section 3.3
Page 3
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –04.96–
Task Description Section 3.3
Page 4
Running gear
1 Piston 4 Crankshaft
2 Connecting rod 5 Vibration damper
3 Engine flange with ring gear
20046/20 E –04.96–
Task Description Section 3.3.1
Page 1
3.3.1 Crankshaft
Crankshaft (8V)
20046/20 E –04.96–
Task Description Section 3.3.1
Page 2
Crankshaft (12V)
1 Crankshaft 6 Counterweight
2 Sealing tube 7 Adapter sleeve
3 Cover 8 Screw for counterweight
4 Sealing ring 9 Dowel pin
5 Plug 10 Crankshaft gear
20046/20 E –04.96–
Task Description Section 3.3.1
Page 3
Crankshaft (16V)
20046/20 E –04.96–
Task Description Section 3.3.1
Page 4
20046/20 E –04.96–
Task Description Section 3.3.1.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.3.1.2
Page 1
Note
Note
20038/10 E –04.96–
Task Description Section 3.3.1.2a
Page 1
Note
Note
20054/00 E –10.93–
Task Description Section 3.3.1.3
Page 1
3.3.1.3 Disassembly
Removing crankshaft gear
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools for hydraulic removal.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the device annually.
1 Vent plug
2 Pressure bush
3 Support
4 Nut
5 Socket-head screw
6 Stop pin
7 Intermediate element
8 Adjusting screw
9 Puller sleeve
10 O-ring
11 Tension spring
12 Plug
20038/10 E –11.92–
Task Description Section 3.3.1.3
Page 2
Removing counterweights
To remove counterweights, install crankshaft in a stable,
heavy-duty assembly stand.
Ensure that counterweights are numbered consecu-
tively; punch in new numbers if necessary.
Install retaining jig (3) and power amplifier (2) to release
stress bolts.
Unscrew stress bolts with ratchet (1) from counter-
weight.
Remove counterweight and set in suitable transport
trestle.
Note
20038/10 E –06.94–
Task Description Section 3.3.1.3
Page 3
Note
Connect and secure puller (2) to guide bush (5) with hex
screws (4).
Insert extension pipe (1) with appropriate thrust pad (6)
into Lukas press and connection pipe.
Mount H.P. line on quick-action stop connector of Lukas
press (3).
Fill hydraulic hand pump with SAE 10 engine oil.
Operate pump plunger until relevant sealing tube is
forced off.
Remove sealing tube from crankshaft.
Remove puller.
20038/10 E –11.92–
Task Description Section 3.3.1.4
Page 1
Note
Take care not to damage oil bores, bores in bearing journals, counterweight mating faces and threaded bores.
Clamp crankshaft longitudinally between jaws of test rig.
The magnetic field strength required for the test is 20 to 60 A/cm.
Notes on hot-running cracks
Hot-running cracks are characterised by running almost
only parallel to the axis.
Transverse cracks emanating from these parallel crack
lines may also occur.
Severe hot-running cracks are usually as deep as the
case-hardening.
The crankshaft must be replaced in such cases.
Crankshafts with minor hot-running cracks can be re-
paired provided that the cracks can be removed by re-
grinding to the next stage or by localised smoothing.
Consult MTU in this case.
The affected bearing journals must be carefully ground
close to a permissible repair stage, depending on crack
depth.
Minor crack damage can be removed by local grinding.
Pregrinding must be performed prior to rehardening,
otherwise hot-running cracks may be made more se-
vere, both in length and depth, by the rehardening pro-
cess.
Finish-grind the bearing journals to the repair size only
after hardening is completed.
Notes on grinding cracks
Cracks caused by incorrect grinding are characterized
by branching.
The accompanying illustration shows a bearing journal
with such cracks.
Grinding cracks arise from inadequate cooling or ex-
cessive feed during the grinding process.
20054/00 E –10.93–
Task Description Section 3.3.1.4
Page 2
Demagnetizing crankshaft
Demagnetize crankshaft after checking for cracks; residual field strength must not exceed 2 to 4 A/cm during this pro-
cedure.
Note
A component is considered sufficiently demagnetized when a paper clip suspended from a thread is no longer attracted
by that component.
Measuring crankpins
Using an outside micrometer (3), measure main bearing
journal (1) and crankpin (2) of crankshaft at four separ-
ate points each for roundness and evenness.
Record values in data sheet.
If the limit value are exceeded, see Tolerance and Wear
Limits List, regrind crankshaft to the next repair stage.
20054/00 E –10.93–
Task Description Section 3.3.1.4
Page 3
20054/00 E –06.94–
Task Description Section 3.3.1.4
Page 4
Note
Note
20054/00 E –10.93–
Task Description Section 3.3.1.4
Page 5
Hardness of journal check - hardness pattern for main bearing journal and crankpin
X = Hardness pattern for inner main bearing journal – 6V, 8V, 12V, 16V – crankshaft
Y = Hardness pattern for inner main bearing journal – 16V – crankshaft (ESU quality)
Z = Hardness pattern for last main bearing journal (IV, V, VII, IX)
Check hardness of all bearing journals using rebound hardness tester.
Rehardening is required if a journal has lost its hardness due to bearing seizure.
Check journal at at least four points on the circumference with the rebound hardness tester.
When measuring, hold rebound hardness tester perfectly horizontal.
Using the hardness comparison table, convert the read-off value to Rockwell hardness.
For information on hardness, see Tolerances and Wear Limits List.
When testing hardness of main bearing journal ensure that side areas are not hardened.
Crankpin side walls and fillets are hardened.
Rub down all journals with polishing cloth.
Roughness height of all bearing surfaces = Rz 1.
All fillets and radii smooth on crankpin and main bearing journal, Rz max. 4
Oil bores rounded burrfree at inlet points.
20054/00 E –04.96–
Task Description Section 3.3.1.4
Page 6
L8810371
Example 2
Rest with locally limited friction corrosion and localized
galling which do not exceed 5% of the mating face and
do not extend to edge of screw bores.
No reconditioning is necessary if the flatness of
mating face is still within the drawing specification
(> 0.005 mm).
L8810373
Example 2a
Assess as in example 2.
L889442
20054/00 E –01.95–
Task Description Section 3.3.1.4
Page 7
Example 3
Mating face with intensive friction corrosion and local-
ized galling which take up more than 5% of the mating
face or that stretch to the edge of the screw bores.
Mechanical reconditioning is necessary. Check crank-
shaft beforehand for cracks as described on Page 1.
L8812113
Example 3a
Assess as in example 3.
L8812289
Note
20054/00 E –01.95–
Task Description Section 3.3.1.4
Page 8
Note
Check counterweight bolts and counterweights themselves for cracks using magnetic crack-testing method with fluor-
escent magnetic powder.
Ensure threads in crankshaft and screws for counterweights are in perfect condition and check ease of movement; max.
permissible screw length, see Section 1.3.
Check contact surfaces for screw head contact face on counterweights with engineer’s blue for even seating, machine
grind if necessary, refer to illustration.
Inspecting crankshaft gear
Check gear for cracks using magnetic crack-testing method with fluorescent magnetic powder; replace gear if necess-
ary.
Inspect gear for wear; rub down with oilstone or polishing cloth if necessary, otherwise replace gear.
Adjust bore gauge, measure crankshaft gear I.D. and record readings.
Inspecting main bearing shells
Check bearing shells of crankshaft for surface characteristics and wear; replace worn or broken bearing shells. Also
refer to checking and assessment of conrod bearing (grooved bearing) Section 3.3.2.4 Page 14, replace crankshaft
bearing shells at W6.
Inspecting crankshaft axial alignment bearing
Check condition of crankshaft axial alignment bearing; replace if not in perfect condition (see Page 4).
Regrinding crankshaft
When regrinding, always try to limit operations to next repair size.Adhere precisely to specified dimensions and toler-
ances. This also includes those applicable to fillets and surface condition.
Pay special attention to markings of actual value diameter for main bearing journal and crankpin of crankshafts.
The following tasks must be carried out after grinding:
– Check dimension and roughness of all journals
– Check transfer radii on journals
– Check whether oil duct outlets are perfectly rounded and smooth. Take special care when carrying out this task in order
to avoid damaging the bearing shells and to ensure perfect lubrication.
– Concentricity and flatness check
– Hardness check
– Crack check
20054/00 E –01.95–
Task Description Section 3.3.1.4
Page 9
Note
T003 620b0
20054/00 E –01.95–
Task Description Section 3.3.1.4
Page 10
Dynamic balancing
For the purpose of balancing, the crankshaft must be assembled with crankshaft gear, sealing components and
counterweights. Seal bore diameter 14 on free end with pin (50 g) for the purpose of balancing.
Assembly, see 3.3.1.5.
20054/00 E –06.96–
Task Description Section 3.3.1.5
Page 1
3.3.1.5 Assembly
Thoroughly clean all crankshaft oilways with cold cleaner or diesel fuel and suitable bristle brush.
Blow out oilways with compressed air.
20038/10 E –06.96–
Task Description Section 3.3.1.5
Page 2
1 Crankpin of crankshaft
2 Cover
3 Roller expander
4 Contact surface
5 Bolt
A Adjustment
20038/10 E –11.92–
Task Description Section 3.3.1.5
Page 3
20038/10 E –11.92–
Task Description Section 3.3.1.5
Page 4
20038/10 E –11.92–
Task Description Section 3.3.1.5
Page 5
A = Roll-in depth 11 mm ±2 mm
X = Roller radius R1
Pressure-testing crankshaft
Mount locking device (1) on crankshaft stub at driving
end.
Seal oilways in crankshaft stub.
Insert pressure-test segments (2) into covers of crank-
shaft stub.
Mount blanking brackets (3) and (4) on main bearing
journal and crankpin in such a way that the oil bores are
covered.
Tighten clamping levers to secure clamps.
20038/10 E –11.92–
Task Description Section 3.3.1.5
Page 6
Installing counterweights
Check adapter sleeves (4) for damage.
Insert adapter sleeves into counterweight (2) so that di-
mension A = 7 mm -0.5 mm is achieved as indicated
with illustration opposite.
Note
Note
20038/10 E –04.96–
Task Description Section 3.3.1.5
Page 7
20038/10 E –06.94–
Task Description Section 3.3.1.6
Page 1
Note:
No sickle groove X = cross-section of oil
Locating groove Insufficient crankshaft and No crankshaft and conrod supply to crankshaft
Oil bore not on all plane sufaces conrod bearing oil supply bearing oil supply bearings
for lower shell
In order to use new
2. Old crankcase version
New crankcase version
YES NO NO crankshaft bearings, the
crankcase must receive
new sickle grooves
oil oil
oil
Note:
No sickle groove X = cross-section of oil
Insufficient crankshaft and No crankshaft and conrod supply to crankshaft
Locating groove for lower shell conrod bearing oil supply bearing oil supply bearings
Oil bore on all plane surfaces
Sickle groove
Locating lug on lower
No locating groove Oil bore not on all plane surfaces shell
Note:
4. New crankcase version
New crankshaft version NO YES YES X = Cross-section of oil
supply to crankshaft
bearings
oil
Óleo oil
Sickle groove
No locating groove Oil bore on all plane surfaces Locating lug on lower shell
20038/10 E –11.92–
Task Description Section 3.3.1.6
Page 2
Note
Install upper bearing shell (1) with oil groove and oilways
in main bearing bore, observing correct location of
identification number.
Install lower bearing shell (2), without oil groove, with
one butting face against corresponding face of upper
bearing shell (1).
Exert thumb pressure on shell and seat other end in
crankcase.
Make sure butting faces of shells are parallel.
The identification numbers must point towards driving
end when bearing shells are installed.
Mark new bearing shells with 2 mm punch numerals
pointing towards driving end.
Note
20038/10 E –09.95–
Task Description Section 3.3.1.6
Page 3
Installing crankshaft
Remove plastic plugs from crankshaft oilways.
Use inspection lamp to inspect oil ducts and clean bear-
ings thoroughly.
Wipe bearing shells and crankshaft journals with clean
chamois leather.
Spray bearing shells with clean engine oil, making sure
that no oil film reaches bearing shell butting faces.
Install protective sleeves (1) on studs of first and last
bearings.
20038/10 E –11.92–
Task Description Section 3.3.1.6
Page 4
Note
Installing crankshaft axial alignment jig, see 3.3.4.6. Check crankshaft end float after installing flywheel/en-
Installing grooved ball bearing, see 3.3.4.6. gine coupling.
Tighten crankshaft bearing cover nuts, see 3.1.2.6 Installing oil pan, see 3.1.6.6.
Tighten screws on alignment bearing cap, see 3.1.2.6 Installing flywheel, see 3.3.3.6.
Installing engine coupling, see 3.88.
Idler gear backlash, see 3.2.
Installing clamp ring, see 3.3.4.6.
20038/10 E –06.94–
Task Description Section 3.3.1.6b
Page 1
Note
Note
20054/00 E –01.95–
Task Description Section 3.3.1.6b
Page 2
20054/00 E –10.93–
Task Description Section 3.3.1.6b
Page 3
Installing crankshaft
Insert inner stress bolts (1) (assembly screws without
rubber) on driving end and free end.
Slide protective sleeves (2) over studs at driving and
free ends.
Mount top bearing shells with oil groove in crankcase,
See Page 1.
Remove plastic plugs from crankshaft oilways.
Use inspection lamp to inspect oil ducts and clean bear-
ings thoroughly.
Wipe bearing shells and crankshaft journals with clean
chamois leather.
Spray bearing shells with clean engine oil, making sure
that no oil film reaches bearing shell butting faces.
Attach lifting appliance (3) to crankshaft (4).
Lower crankshaft horizontally into bearing shells.
Ensure that gears mesh correctly.
Remove protective sleeves (2) and remove stress bolts
(1) on free end and driving end.
Note
20054/00 E –10.93–
Task Description Section 3.3.1.6b
Page 4
Note
20054/00 E –10.93–
Task Description Section 3.3.2
Page 1
20038/10 E –11.92–
Task Description Section 3.3.2
Page 2
1 Conrod bush
2 Conrod
3 Bearing shell
4 Conrod cap
5 Conrod cap bolt
6 Locating pin
20038/10 E –11.92–
Task Description Section 3.3.2.1
Page 1
1 2 3 Operations See
20038/10 E –04.96–
Task Description Section 3.3.2.2
Page 1
20038/10 E –04.96–
Task Description Section 3.3.2.2
Page 2
Note
F0030018a0
Slowly push piston back into cylinder liner until long arm
of conrod contacts cylinder liner.
Using removal tool (1), drive out piston (2) and conrod
through cylinder liner.
Note
20038/10 E –04.96–
Task Description Section 3.3.2.2a
Page 1
Note
1 Crankshaft
2 Bearing shell
3 Conrod cap bolt
4 Conrod cap
5 Oil spray nozzle
6 Cylinder liner
7 Conrod
A Removal position
20038/10 E –11.92–
Task Description Section 3.3.2.2a
Page 2
Note
F0030018a0
Using removal tool (1), drive out piston (2) and conrod
through cylinder liner.
Note
20038/10 E –04.96–
Task Description Section 3.3.2.3
Page 1
3.3.2.3 Disassembly
Removing snap rings
Place piston and conrod on assembly bench.
Remove snap rings with snap ring pliers.
Remove backup rings.
Note
20038/10 E –06.94–
Task Description Section 3.3.2.3
Page 2
Note
20038/10 E –04.96–
Task Description Section 3.3.2.4
Page 1
Note
Attention
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 2
Attention
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 3
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 4
Note
Clean tapped holes coated with thin-film lubricant and serrations with cold cleaner.
Using a bottle brush (cylinder wiper 40x100x300 perlon), brush threads with a turning, oscillating motion in cleaning
bath.
Brush serrations in cleaning bath until clean.
Blow dry with dry compressed air to remove all cleaning residues.
Brush conrod cap bolts in cleaning bath (cold cleaner) until clean and blow dry with compressed air to remove all clean-
ing residues.
Measure length of conrod cap bolts: max. length = 85 mm.
Polish out all traces of nicks in conrods; replace conrod if necessary.
Check conrods, conrod caps and conrod cap bolts for cracks using magnetic crack-testing method with fluorescent
magnetic powder.
Replace components exhibiting cracks.
Checking axial fit of conrod bush
Using test mandrel (3) and hydraulic press (1), check
axial fit of conrod bush, see Tolerances and Wear Limits
List.
If limit value is not obtained, force bush out of conrod (2)
using mandrel and hydraulic press.
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 5
Note
Caution
20038/10 E –02.97–
Task Description Section 3.3.2.4
Page 6
Marking Stage
two grooves 2
one groove 1
no groove 0
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 7
Note
Attention
20038/10 E –06.96–
Task Description Section 3.3.2.4
Page 8
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 9
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 10
1 Conrod
2 Test mandrel, large conrod eye
3 Securing screw for test mandrel
4 V-block
5 Spring stop
6 Locknut
7 Installation housing
8 Adjustable spring stop
9 Dial gauge for axial twist
10 Securing screw for test mandrel
11 Base plate
12 Dial gauge for axial parallelism
13 Adjustable dial gauge carrier
14 Test mandrel, small conrod eye
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 11
Note
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 12
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 13
20038/10 E –11.93–
Task Description Section 3.3.2.4
Page 14
F 003 0017 a
Note
To evaluate the wear condition of the running surface more accurately, it is necessary to use a magnifying glass (mag-
nifying strength at least 5x).
In doing so, the wear layer is to be seen as the dark zone and the light-metal ridge as the light zone. The relationship
between the width of the light-metal ridge and the width of the groove and the extent of the worn area are decisive factors
when evaluating the wear condition of the grooved bearings.
The grooved bearing can still be used if the wear layer is partially missing in the grooves. Practical experience has
shown that the grooved bearing with partially empty grooves can continue to operate without negatively influencing the
function of the bearing.
Each time when evaluating the groove condition, the running surface subjected to less load (mostly new values for
groove condition) should be used for the purposes of comparison.
The groove condition is evaluated in five groups:
1. Continue to use
2. Wear
3. Borderline – wear and levelling
4. Wear layer – continuous fraction
5. Borderline case – wear layer, continuous fraction and empty grooves
Damage to bearing:
The bearing is mainly damaged by scoring by foreign bodies, indentations and embedded particles, cavitation and cor-
rosion, pitting, thermal fatigue and assembly errors.
Bearings with such damage must be replaced.
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 15
1. Continue to use
Condition:
The groove geometry corresponds to new condition. The wear layer is completely maintained within the grooves. Dark
dots are mainly embedded oil coke particles.
Evaluation:
The relationship of wear layer/light-metal ridge is approx. 25% to 75%. Continue to use!
Condition:
The wear layer is uniformly removed from grooves by approx. 0.005 mm. The light-metal ridge does not show any wear.
Dark dots are mainly embedded oil coke particles.
Evaluation:
The removal of the wear layer results in the light-metal ridges appear slightly widened. Continue to use
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 16
Continue in use
Condition:
Minor foreign bodies distributed over the entire running surface. No great changes to the light-metal ridges.
Evaluation:
The bearing shell can continue to be used.
Condition:
The wear layer was ”dragged” and ”lubricated” via the light-metal ridges. The light-metal ridges cannot be seen to some
extent.
Evaluation:
The bearing shell can continue to be used.
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 17
2. Wear
3
F 003 0009 a
b d
a c
F 003 0010 a
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 18
2
F 003 0011 a
Condition:
The bearing metal ridges are locally worn.
Wear limits:
c e
a
b d
F 003 0012 a
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 19
1
F 003 0013 a
Condition:
Wear layer continuous fraction in the grooves due to local overload.
Wear limits:
b d
a c
F 003 0014 a
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 20
3
F 003 0015 a
e
a c
b d
F 003 0016 a
20038/10 E –01.95–
Task Description Section 3.3.2.4
Page 21
Note
Note
20038/10 E –06.96–
Task Description Section 3.3.2.4
Page 22
20038/10 E –01.95–
Task Description Section 3.3.2.5
Page 1
3.3.2.5 Assembly
Checking nuts in piston skirt
Prior to assembling piston crown, check hex nut (2) in
piston skirt (1) for specified tightening torque to tighten-
ing specification 1.3, retighten as necessary.
Note
Note
20038/10 E –11.95–
Task Description Section 3.3.2.5
Page 2
Note
20038/10 E –06.96–
Task Description Section 3.3.2.5
Page 3
Note
Note
Note
20038/10 E –11.93–
Task Description Section 3.3.2.5
Page 4
20038/10 E –11.93–
Task Description Section 3.3.2.6
Page 1
Note
1 Conrod
2 Short connecting rod arm
3 Bottom edge, crankcase
4 Conrod cap
5 Bearing shell
6 Installation tool
7 Long connecting rod arm
8 Oil spray nozzle
9 Funnel in piston
20038/10 E –06.96–
Task Description Section 3.3.2.6
Page 2
Note
Note
20038/10 E –11.92–
Task Description Section 3.3.2.6
Page 3
20038/10 E –11.92–
Task Description Section 3.3.2.6
Page 4
Turn compression ring and oil control ring until gaps are
at opposite sides of piston.
Spray piston and piston rings with engine oil.
Check that bore of assembly sleeve (3) is clean.
Slide assembly sleeve over piston (2), bevelled end first.
Position protective strip (4) with connector on conrod
(1).
F0030018a0
20038/10 E –06.96–
Task Description Section 3.3.2.6
Page 5
Attention
Initial pretightening:
Using torque wrench, pretighten conrod cap bolt on
short arm (2) until conrod and conrod cap serrations are
closed on both short and long arms. For torque setting,
see Section 1.3.
Then pretighten conrod cap bolt on long arm.
When tightening bolts, check whether conrod moves
freely in axial direction.
If conrod cannot move in axial direction, locating pin is
not seated in groove of conrod bearing and is stuck.
Disassemble conrod and discard damaged bearing
shells.
Attention
Attention
20038/10 E –06.96–
Task Description Section 3.3.2.6
Page 6
20038/10 E –06.96–
Task Description Section 3.3.2.6a
Page 1
Note
Note
20038/10 E –06.96–
Task Description Section 3.3.2.6a
Page 2
Note
Attention
20038/10 E –11.93–
Task Description Section 3.3.2.6a
Page 3
20038/10 E –11.93–
Task Description Section 3.3.2.6a
Page 4
Turn compression ring and oil control ring until gaps are
at opposite ends of piston.
Spray piston and piston rings with engine oil.
Check that bore of assembly sleeve (1) is clean.
Slide assembly sleeve over piston (2), bevelled end first.
Position protective strip with connector on conrod.
F0030018a0
20038/10 E –06.96–
Task Description Section 3.3.2.6a
Page 5
Attention
20038/10 E –06.96–
Task Description Section 3.3.2.6a
Page 6
Initial pretightening:
Using torque wrench, pretighten conrod cap bolt on
short arm until conrod and conrod cap serrations are
closed on both short and long arms. For torque setting,
see Section 1.3.
Then pretighten conrod cap bolt on long arm.
When tightening bolts, check whether conrod moves
freely in axial direction.
If conrod cannot move in axial direction, locating pin is
not seated in groove of conrod bearing and is stuck.
Disassemble conrod and discard damaged bearing
shells.
Attention
L87_9331
Subsequent pretightening:
Using torque wrench, pretighten conrod cap bolts to
specified torque. For torque setting, see Section 3.
Sequence:
Short connecting rod arm – long connecting rod arm
When tightening bolts, check whether conrod moves
freely in axial direction.
If conrod cannot move in axial direction, locating pin is
not seated in groove of conrod bearing and is stuck.
Disassemble conrod.
Discard damaged bearing shells.
Attention
20038/10 E –06.96–
Task Description Section 3.3.2.6a
Page 7
1 Funnel in piston
2 Oil spray nozzle
3 Conrod
4 Crankcase
5 Short connecting rod arm
6 Crankcase intermediate frame
7 Access port B side
8 Bearing shell
9 Conrod cap
10 Installation tool
11 Long connecting rod arm
20038/10 E –11.93–
Task Description Section 3.3.2.6a
Page 8
Note
20038/10 E –11.93–
Task Description Section 3.3.3
Page 1
20054/00 E –01.95–
Task Description Section 3.3.3.1
Page 1
1 2 3 Operations See
20062/00 E –04.95–
Task Description Section 3.3.3.2
Page 1
3.3.3.2 Removal
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools for hydraulic removal.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the flange must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Pressing off engine flange
Unscrew plug at driving end of crankshaft.
Screw in draw spindle (1) of hydraulic puller as far as it
will go.
Measure reference dimension ”K” = 201 mm.
Insert and secure adapter (2) for expanding engine
flange.
20038/10 E –11.92–
Task Description Section 3.3.3.2
Page 2
Push pressure sleeve (1) and hydraulic nut (2) onto draw
spindle (4).
Mount hex nut (3), tighten fully and back off approx.
17 mm.
Note
Actuate oil pressure hand pump for expansion of engine flange until half max. expansion pressure is reached. Maintain
this pressure for approx. 5 minutes.
Increase expansion pressure in stages, waiting approx. 2 minutes between each increase, until movement becomes
noticeable at joint.
Operate pump to make up loss in expansion pressure until engine flange is released or until it is necessary to increase
pressure further.
Max. expansion pressure is stamped on engine flange: do not exceed this pressure.
Pressure in hydraulic puller increases when engine flange is released.
Gradually drain oil from hydraulic nut.
Relieve pressure in hydraulic hand pumps.
Turn hex nut to force piston of hydraulic nut to limit of travel.
Disconnect H.P. lines and remove hydraulic puller.
Remove engine flange from crankshaft taper.
20038/10 E –11.92–
Task Description Section 3.3.3.3
Page 1
3.3.3.3 Disassembly
Removing driver from engine flange
Note
1
Caution
20038/10 E –11.95–
Task Description Section 3.3.3.4
Page 1
20038/10 E –07.94–
Task Description Section 3.3.3.5
Page 1
3.3.3.5 Assembly
Shrink-fitting driver onto engine flange
Heat driver (3) to 150° +30 °C.
Using protective gloves, push driver into position all way
round.
Oil bore in driver lug (2) and engine flange (1) must be
flush.
Ensure that there is no gap at engine flange mating face.
20038/10 E –11.92–
Task Description Section 3.3.3.5
Page 2
20038/10 E –11.95–
Task Description Section 3.3.3.6
Page 1
3.3.3.6 Installation
Guaranteeing distance ”S”
min. 0.08 mm, max. 0.26 mm
Before installing engine flange (2) with shrink-fitted
driver (3), measure distance ”C” between grooved ball
bearing inner race (4) and crankshaft end face ”A”.
To do this, displace crankshaft (1) towards driving end
until ball bearing inner race (4) butts against crankshaft.
Measured dimension must be between 81.35 mm and
81.47 mm.
Measure distance ”B” to flange.
Measured dimension must be between 81.23 mm and
81.27 mm.
Protrusion ”U” of engine flange over crankshaft: max.
0.02 mm
Gap clearance ”S” = C - B + U
Note
20038/10 E –11.92–
Task Description Section 3.3.3.6
Page 2
20038/10 E –11.92–
Task Description Section 3.3.3.6
Page 3
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the engine flange must not be
exceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Pressing on engine flange
Unscrew plug at driving end of crankshaft.
Screw in draw spindle (1) of hydraulic installer as far as
it will go.
Measure reference dimension ”K” = 201 mm.
Insert and secure adapter (2) for expanding engine
flange.
20038/10 E –04.96–
Task Description Section 3.3.3.6
Page 4
Caution
20038/10 E –11.92–
Task Description Section 3.3.3.7
Page 1
20038/10 E –11.92–
Task Description Section 3.3.3a
Page 1
20038/10 E –04.96–
Task Description Section 3.3.3a.1
Page 1
1 2 3 Operations See
20038/10 E –04.96–
Task Description Section 3.3.3a.2
Page 1
3.3.3a.2 Removal
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools for hydraulic removal.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the flywheel must not be ex-
ceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
20038/10 E –11.92–
Task Description Section 3.3.3a.2
Page 2
Push pressure sleeve (1) and hydraulic nut (2) onto draw
spindle (4).
Mount hex nut (3), tighten fully and back off approx.
17 mm.
Note
Actuate oil pressure hand pump for expansion of flywheel until half max. expansion pressure is reached. Maintain this
pressure for approx. 5 minutes.
Increase expansion pressure in stages, waiting approx. 2 minutes between each increase, until movement becomes
noticeable at joint.
Operate pump to make up loss in expansion pressure until flywheel is released or until it is necessary to increase pres-
sure further.
Max. expansion pressure is stamped on flywheel; do not exceed this pressure.
Pressure in hydraulic puller increases when flywheel is released.
Gradually drain oil from hydraulic nut.
Relieve pressure in hydraulic hand pumps.
Turn hex nut to force piston of hydraulic nut to limit of travel.
Disconnect H.P. lines and remove hydraulic puller.
Remove flywheel from crankshaft taper.
20038/10 E –11.92–
Task Description Section 3.3.3a.3
Page 1
3.3.3a.3 Disassembly
Removing track ring from flywheel
Note
Caution
20038/10 E –04.96–
Task Description Section 3.3.3a.4
Page 1
20038/10 E –11.92–
Task Description Section 3.3.3a.5
Page 1
3.3.3a.5 Assembly
Shrink-fitting track ring onto flywheel
Insert new O-ring (3) in groove in track ring (4).
Coat O-ring with petroleum jelly.
When shrinking on, clean and degrease mating face on
track ring and flywheel for .
Heat track ring to 150°+20 °C.
Using fixture, push track ring into position all way round.
When installing track ring, oil bore (1) in flywheel and
track ring lug (2) must be flush.
Ensure that there is no gap at mating face of flywheel
flange (5).
Use fixture to force track ring against mating face while
it is cooling.
Note
20038/10 E –04.96–
Task Description Section 3.3.3a.6
Page 1
3.3.3a.6 Installation
Guaranteeing distance ”S”
min. 0.13 mm, max. 0.30 mm
Before installing flywheel (1) with shrink-fitted track ring
(2), measure distance ”E” between grooved ball bearing
inner race (3) and crankshaft end face.
To do this, displace crankshaft (4) towards driving end
until ball bearing inner race butts against crankshaft.
Measured dimension must be between 39.03 mm and
39.10 mm.
Measure distance ”F” to flange.
Measured dimension must be between 39.23 mm and
39.33 mm.
Note
20038/10 E –04.96–
Task Description Section 3.3.3a.6
Page 2
Note
20038/10 E –04.96–
Task Description Section 3.3.3a.6
Page 3
Installation aids:
If an alignment tool is not available, installation is aided
by alignment bores (1) in flywheel and markings ”A” on
crankshaft end face.
They must be aligned during installation.
1 Register bores
A Marking on crankshaft
Pressing on flywheel
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the flywheel must not be
exceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
20038/10 E –11.92–
Task Description Section 3.3.3a.6
Page 4
Caution
20038/10 E –11.92–
Task Description Section 3.3.3a.7
Page 1
20038/10 E –11.92–
Task Description Section 3.3.4
Page 1
20046/20 E –04.96–
Task Description Section 3.3.4
Page 2
20046/20 E –04.96–
Task Description Section 3.3.4
Page 3
20046/20 E –04.96–
Task Description Section 3.3.4
Page 4
20046/20 E –04.96–
Task Description Section 3.3.4
Page 5
20046/20 E –04.96–
Task Description Section 3.3.4
Page 6
20046/20 E –04.96–
Task Description Section 3.3.4.1
Page 1
1 2 3 Operations See
20038/10 E –04.96–
Task Description Section 3.3.4.2
Page 1
20038/10 E –04.96–
Task Description Section 3.3.4.2a
Page 1
20038/10 E –04.96–
Task Description Section 3.3.4.4
Page 1
Note
In order to compensate any misalignment with the thrust collar when the crankshaft thrust bearing has been recondi-
tioned, a crankshaft thrust collar with repair stage on outer ring (B) must be installed. For repair stages and marking,
see Table.
Crankshaft Thrust bearing
C± 0.02
(stamped on No. of identifica-
crankshaft front, driving tion grooves
Stage end)
0 8.80 none
I 8.50 1x
II 8.20 2x
III 7.90 3x
If a crankshaft axial alignment bearing with a repair size is installed, it is essential to install a clamp ring with an identifica-
tion groove.
Check clamp ring for cracks using magnetic crack-testing method with fluorescent magnetic powder.
If cracks are detected, replace clamp ring.
Check clamp ring for damage and flatness, recondition if necessary, replace as necessary.
If an engine is being repaired, the original clamp ring can be removed, machined to size and marked with an identifica-
tion groove (see circular 10 11 90).
Replace O-ring.
20038/10 E –10.95–
Task Description Section 3.3.4.6
Page 1
Note
20038/10 E –11.92–
Task Description Section 3.3.4.6
Page 2
Note
20038/10 E –11.96–
Task Description Section 3.3.4.6a
Page 1
Note
20038/10 E –04.96–
Task Description Section 3.3.5
Page 1
20038/10 E –04.96–
Task Description Section 3.3.5
Page 2
20038/10 E –04.96–
Task Description Section 3.3.5
Page 3
20038/10 E –04.96–
Task Description Section 3.3.5.1
Page 1
1 2 3 Operations See
20038/10 E –04.96–
Task Description Section 3.3.5.2
Page 1
3.3.5.2 Removal
Unscrew bolts from oil seal carrier (1).
Remove spring washers.
Use three jackscrews to press carrier off clamp ring.
Remove O-ring and jackscrews from carrier.
20038/10 E –04.96–
Task Description Section 3.3.5.3
Page 1
3.3.5.3 Disassembly
Press oil seal (1) out of carrier (2) using a suitable thrust
plate and hand press.
20038/10 E –11.92–
Task Description Section 3.3.5.4
Page 1
20038/10 E –07.94–
Task Description Section 3.3.5.5
Page 1
3.3.5.5 Assembly
Installing oil seal
Coat rubberized outer casing of oil seal with denaturated
ethanol.
Denaturated ethanol serves as a lubricant and must not
be wiped off with a cloth or blown away with compressed
air.
Clean and degrease bore for shaft seal in seal carrier (2)
and blow out with compressed air.
Using a press-in plate (1) and manual press, press shaft
seal with lip facing inwards into seal carrier.
Oil seal must be correctly seated on bore collar.
20038/10 E –04.96–
Task Description Section 3.3.5.6
Page 1
3.3.5.6 Installation
Insert O-rings in grooves in oil seal carrier.
Coat O-rings with petroleum jelly.
Coat lip on shaft seal with ”petroleum jelly”.
Mount oil seal carrier (1) on clamp ring using bolts and
spring washers.
Tighten screws with torque wrench. For torque settings,
see Section 1.3.
20038/10 E –04.96–
Task Description Section 3.3.6
Page 1
20038/10 E –11.92–
Task Description Section 3.3.6
Page 2
1 Plug
2 Washer
3 Hex bolt
4 O-ring
5 O-ring
6 Crankshaft bearing (one-piece)
7 Crankshaft
8 Bearing retaining plate
20038/10 E –11.92–
Task Description Section 3.3.6.1
Page 1
1 2 3 Operations See
20038/10 E –07.94–
Task Description Section 3.3.6.2
Page 1
3.3.6.2 Removal
Using ratchet wrench (2), remove bolts from bearing re-
taining plate (1).
Release retaining plate from fitted pins using two pry
bars and remove.
Remove O-ring from groove.
20038/10 E –11.92–
Task Description Section 3.3.6.4
Page 1
Note
20038/10 E –11.92–
Task Description Section 3.3.6.4
Page 2
Caution
Caution
20038/10 E –11.95–
Task Description Section 3.3.6.6
Page 1
3.3.6.6 Installation
Insert O-rings (2) in grooves in intermediate piece (1).
Coat O-rings with petroleum jelly.
Insert intermediate piece in crankcase bore so that re-
cess in collar engages dowel pin in crankcase.
20038/10 E –04.96–
Task Description Section 3.3.6.6
Page 2
Attention
20038/10 E –11.92–
Task Description Section 3.3.7
Page 1
20038/10 E –04.96–
Task Description Section 3.3.7
Page 2
1 Flange
20038/10 E –04.96–
Task Description Section 3.3.7
Page 3
20038/10 E –04.96–
Task Description Section 3.3.7.1
Page 1
1 2 3 Operations See
20038/10 E –04.96–
Task Description Section 3.3.7.2
Page 1
3.3.7.2 Removal
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified and tested equipment for hydraulic removal.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the flange must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Pressing off flange, free end
Unscrew plug at free end of crankshaft (1).
Screw draw spindle (2) of hydraulic puller into crank-
shaft as far as it will go and secure.
Measure reference dimension ”B” = 260 mm.
20038/10 E –11.92–
Task Description Section 3.3.7.2
Page 2
Fit intermediate ring (4) on draw spindle (9); for this pur-
pose insert centering bushing (3) over pin (2).
Insert adapter (10) for expanding flange (1).
Push pressure sleeve (5) and hydraulic nut (6) with
carrier (7) onto draw spindle.
Mount hex nut (8) on draw spindle until it contacts the
stop and back off approx. 12 mm to 15 mm (A).
Note
A Setting 12 mm to 15 mm
B Reference dimension 260 mm
Connect and secure H.P lines to adapter and hydraulic nut.
Observe guidelines for using H.P. lines, see Section 1.5.
Fill hydraulic hand pumps with SAE 10 engine oil.
Bleed pumps and lines until bubble-free oil emerges.
Close valve.
Operate hydraulic hand pump for hydraulic nut until pressure sleeve contacts flange.
Hydraulic nut acts as a buffer and stop for flange when it is released from crankshaft taper, thus preventing flange from
being released suddenly from crankshaft.
Actuate oil pressure hand pump for expansion of flange until half max. expansion pressure is reached. Maintain this
pressure for approx. 5 minutes.
Increase expansion pressure in stages, waiting approx. 2 minutes between each increase, until movement becomes
noticeable at joint.
Operate pump to make up loss in expansion pressure until flange is released or until it is necessary to increase pressure
further.
Max. expansion pressure is stamped on flange: do not exceed this pressure.
Pressure in hydraulic puller increases when flange is released.
Gradually drain oil from hydraulic nut.
Relieve pressure in hydraulic hand pumps.
Turn hex nut to force piston of hydraulic nut to limit of travel.
Disconnect H.P. lines and remove hydraulic puller.
Remove flange from crankshaft taper (11) and O-rings from flange.
Take care not to damage crankshaft bearing.
Removing bearing retaining plate, see 3.3.6.2.
20038/10 E –04.96–
Task Description Section 3.3.7.4
Page 1
20038/10 E –04.96–
Task Description Section 3.3.7.6
Page 1
3.3.7.6 Installation
Degrease crankshaft bearing (1) and contact surfaces
(2) of flange and crankshaft.
Coat contact surfaces of crankshaft taper and crank-
shaft bearing with SAE 10 engine oil.
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified and tested equipment for hydraulic installation. Check the equipment annually (draw spindle crack
test). The installation pressure stamped on the tool and the expansion pressure stamped on the flange must not be
exceeded. During the installation procedure, make sure that nobody is standing behind the tool.
20038/10 E –11.92–
Task Description Section 3.3.7.6
Page 2
Note
20038/10 E –04.96–
Task Description Section 3.3.7a
Page 1
20038/10 E –04.96–
Task Description Section 3.3.7a.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.3.7a.2
Page 1
3.3.7a.2 Removal
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified and tested equipment for hydraulic removal.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the flange must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Forcing off support ring, free end
Unscrew plug at free end of crankshaft (1).
Screw draw spindle (2) of hydraulic puller into crank-
shaft as far as it will go and secure.
Measure reference dimension ”B” = 260 mm.
20038/10 E –11.92–
Task Description Section 3.3.7a.2
Page 2
Note
20038/10 E –04.96–
Task Description Section 3.3.7a.4
Page 1
20038/10 E –11.92–
Task Description Section 3.3.7a.6
Page 1
3.3.7a.6 Installation
20038/10 E –04.96–
Task Description Section 3.3.7a.6
Page 2
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified and tested equipment for hydraulic installation.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the support ring must not be
exceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Pressing on support ring, free end
Unscrew plug at free end of crankshaft (1).
Screw draw spindle (2) of hydraulic installer into crank-
shaft as far as it will go.
Measure reference dimension ”B” = 260 mm.
20038/10 E –11.92–
Task Description Section 3.3.7a.6
Page 3
Beginning with installation pressure, alternately actuate oil pressure hand pumps for installation and expansion pres-
sures and allow pressure to increase until push-on distance stamped on support ring has been reached.
Select force-on pressure so that final position is reached after approx. 5 steps.
When beginning hydraulic installation, ensure that permissible expansion pressure is not exceeded!
Max. expansion pressure is stamped on support ring face.
When press-fitting operation is completed, relieve expansion pressure and reduce force-on pressure to 270 bar. Allow
reduced force-on pressure to act on support ring for a minimum of 60 minutes.
Relieve force-on pressure and remove hand pumps and hydraulic installer.
Seal end of crankshaft with plug and sealing ring. For torque setting, see Section 1.3.
Recheck force-on distance with depth gauge.
20038/10 E –04.96–
Task Description Section 3.3.8
Page 1
20038/10 E –11.92–
Task Description Section 3.3.8
Page 2
1 Vibration damper
2 Inner side plate
3 Driver
4 Bolt
5 Inertia member
6 Outer side plate
7 Pin
8 Sleeve spring
20038/10 E –10.95–
Task Description Section 3.3.8.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.3.8.2
Page 1
3.3.8.2 Removal
Unscrew stress bolts (3) from vibration damper (1) with
extension wrench (1).
Force intermediate ring (4) off flange on crankshaft
using jackscrews.
20038/10 E –11.92–
Task Description Section 3.3.8.3
Page 1
3.3.8.3 Disassembly
Remove bolts from outer side plate (1).
Detach side plate from inertia member.
20038/10 E –11.92–
Task Description Section 3.3.8.4
Page 1
20038/10 E –10.95–
Task Description Section 3.3.8.5
Page 1
3.3.8.5 Assembly
Position inertia and drive members on inner side plate.
Pay attention to spring pin.
Rotate drive member so that markings (1) are in align-
ment.
20038/10 E –11.92–
Task Description Section 3.3.8.5
Page 2
Notes on assembly:
Before installing outer side plate, check serial numbers
of inertia and drive members.
These numbers must be the same.
A = serial number.
20038/10 E –10.95–
Task Description Section 3.3.8.5
Page 3
20038/10 E –10.95–
Task Description Section 3.3.8.6
Page 1
3.3.8.6 Installation
Use plastic mallet to drive fitted pins (1) into crankshaft
(3) and flange (2) so that pins are in alignment as shown
in adjoining illustration.
20038/10 E –10.95–
Task Description Section 3.3.8.6
Page 2
20038/10 E –11.92–
Task Description Section 3.3.8a
Page 1
20038/10 E –11.92–
Task Description Section 3.3.8a
Page 2
20038/10 E –10.95–
Task Description Section 3.3.8a
Page 3
20038/10 E –04.96–
Task Description Section 3.3.8a
Page 4
20038/10 E –10.95–
Task Description Section 3.3.8a
Page 5
20038/10 E –04.96–
Task Description Section 3.3.8a.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.3.8a.2
Page 1
3.3.8a.2 Removal
Removing sealing disc
Remove socket head screws.
Force sealing ring (1) off drive member using jack-
screws (2).
Remove O-ring from sealing disc.
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified and tested equipment for hydraulic removal.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the driver must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Screw draw spindle (9) of hydraulic puller into crank-
shaft (1) as far as it will go and secure.
Measure reference dimension ”B” = 260 mm.
Push intermediate ring (3) onto draw spindle.
Insert adapter (4) for expanding drive member (2).
Push pressure sleeve (5) and hydraulic nut (6) with
carrier (7) onto draw spindle.
Mount hex nut (8) on draw spindle until it contacts the
stop and then back off approx. 12 mm to 15 mm (dis-
tance ”A”).
Note
A Setting 12 mm to 15 mm
B Reference dimension 260 mm
20038/10 E –11.92–
Task Description Section 3.3.8a.2
Page 2
Connect and secure H.P. lines (1) and (4) to adapter (3)
and hydraulic nut (2).
Observe guidelines for using H.P. lines, see Section 1.5.
Fill hydraulic hand pumps with SAE 10 engine oil.
Bleed pumps and lines until bubble-free oil emerges.
Close valves.
Operate hydraulic hand pump for hydraulic nut until pressure sleeve contacts drive member.
Hydraulic nut acts as a buffer and stop for vibration damper when it is released from crankshaft taper, thus preventing
damper from being released suddenly from crankshaft.
Actuate oil pressure hand pump for expansion of driver until half max. expansion pressure is reached. Maintain this
pressure for approx. 5 minutes.
Increase expansion pressure in stages, waiting approx. 2 minutes between each increase, until movement becomes
noticeable at joint.
Operate pump to make up loss in expansion pressure until vibration damper is released or until it is necessary to in-
crease pressure further.
Max. expansion pressure is stamped on drive member: do not exceed this pressure.
Pressure in hydraulic puller increases when vibration damper is released.
Gradually drain oil from hydraulic nut.
Relieve pressure in hydraulic hand pump.
Turn hex nut to force piston of hydraulic nut to limit of travel.
Disconnect H.P. lines and remove hydraulic puller.
20038/10 E –11.92–
Task Description Section 3.3.8a.2
Page 3
20038/10 E –11.92–
Task Description Section 3.3.8a.3
Page 1
3.3.8a.3 Disassembly
Position vibration damper on assembly ring.
Remove bolts from outer side plate (1) with ratchet
wrench (2).
Detach side plate.
Note
20038/10 E –10.95–
Task Description Section 3.3.8a.4
Page 1
20038/10 E –10.95–
Task Description Section 3.3.8a.5
Page 1
3.3.8a.5 Assembly
Ensure that oil bore in drive member is particularly clean
and seal with plug (2).
Observe distance 1.3 mm.
Coat thread of restrictor (1) with high-strength pipe
thread sealant and screw into drive member as far as
end of thread.
Using insertion tool, drive spring pin (1) into driver (2).
Note: Dimension A = 5 mm –0.5 mm
Drive dowel pin (3) into inertia member (4).
Note: Dimension A = 5 mm –0.5 mm
Note
20038/10 E –10.95–
Task Description Section 3.3.8a.5
Page 2
20038/10 E –10.95–
Task Description Section 3.3.8a.5
Page 3
20038/10 E –11.92–
Task Description Section 3.3.8a.5
Page 4
20038/10 E –07.94–
Task Description Section 3.3.8a.6
Page 1
3.3.8a.6 Installation
Installing bearing retaining plate, see 3.3.6.6.
Degrease contact surfaces of crankshaft (2) and vibra-
tion damper.
Coat crankshaft taper and crankshaft bearing (1) with
SAE 10 engine oil.
20038/10 E –07.94–
Task Description Section 3.3.8a.6
Page 2
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified and tested equipment for hydraulic installation.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the driver must not be exceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Screw draw spindle (9) of hydraulic installer into crank-
shaft (1) as far as it will go and secure.
Measure reference dimension ”B” = 260 mm.
Push intermediate ring (3) onto draw spindle.
Insert adapter (4) for expanding drive member (2).
Push pressure sleeve (5) and hydraulic nut (6) with
carrier (7) onto draw spindle.
Mount hex nut (8) on draw spindle and tighten fully.
A Push-on dimension 12 mm to 15 mm
B Reference dimension 260 mm
Connect and secure H.P. lines (1) and (4) to adapter (3)
and hydraulic nut (2).
Observe guidelines for using H.P. lines, see Section 1.5.
Fill hydraulic hand pumps with SAE 10 engine oil.
Bleed pumps and lines until bubble-free oil emerges.
Close valves.
20038/10 E –11.92–
Task Description Section 3.3.8a.6
Page 3
Actuate oil pressure hand pump to increase installation pressure and expansion pressure alternately, starting with in-
stallation pressure, until installation dimension stamped on driver is reached and driver front face is flush with crankshaft
front face.
Select force-on pressure so that final position is reached after approx. 5 steps.
Ensure that expansion pressure is not exceeded!
Max. expansion pressure is stamped on face of drive member.
When press-fitting operation is completed, relieve expansion pressure and reduce force-on pressure to 270 bar.
Allow reduced force-on pressure to act on drive member for a minimum of 60 minutes.
Relieve force-on pressure and remove hand pump and hydraulic installer.
Note
Note
20038/10 E –04.96–
Task Description Section 3.3.9
Page 1
20038/10 E –04.96–
Task Description Section 3.3.9.1
Page 1
1 2 3 Operations See
20038/10 E –04.96–
Task Description Section 3.3.9.2
Page 1
3.3.9.2 Removal
Removing seal carrier
Unscrew bolts (2) from oil seal carrier (6).
Remove screws and washers (3).
Force oil seal carrier out of bell housing (1) using jack-
screws.
Remove plug (5) from intermediate flange (4).
20038/10 E –04.96–
Task Description Section 3.3.9.2
Page 2
20038/10 E –04.96–
Task Description Section 3.3.9.3
Page 1
3.3.9.3 Disassembly
Disassemble seal carrier
Remove radial-lip shaft seal (2) with suitable drift from
seal carrier (3).
Remove O-ring (1) from seal carrier.
20038/10 E –04.96–
Task Description Section 3.3.9.4
Page 1
20038/10 E –11.92–
Task Description Section 3.3.9.5
Page 1
3.3.9.5 Assembly
Installing track ring on intermediate flange
Prior to shrinking track ring onto intermediate flange,
clean and degrease joint surfaces of components.
Heat track ring to 150 °C (do not exceed temperature of
180 °C).
Thinly coat O-ring (3) with ”petroleum jelly” and insert
into groove in track ring (2).
Wearing protective gloves, force track ring with O-ring
onto intermediate flange (1) as far as it will go. Ensure
that there is no gap at intermediate flange mating face.
Note
20038/10 E –04.96–
Task Description Section 3.3.9.6
Page 1
3.3.9.6 Installation
Installing intermediate flange
Fit intermediate flange (1) on driver (4).
Note
20038/10 E –04.96–
Task Description Section 3.3.9a
Page 1
20038/10 E –04.96–
Task Description Section 3.3.9a.1
Page 1
1 2 3 Operations See
20038/10 E –04.96–
Task Description Section 3.3.9a.2
Page 1
3.3.9a.2 Removal
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified and tested equipment for hydraulic removal.
Check the equipment annually (draw spindle crack test).
The installation pressure stamped on the tool and the expansion pressure stamped on the hub must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Pressing off hub
Unscrew plug (1) from hub (4).
Remove plug (2) from intermediate flange (3).
Note
A Adjustment
B Reference distance
7 Dial gauge for pushing on
20038/10 E –04.96–
Task Description Section 3.3.9a.2
Page 2
20038/10 E –04.96–
Task Description Section 3.3.9a.2
Page 3
20038/10 E –04.96–
Task Description Section 3.3.9a.3
Page 1
3.3.9a.3 Disassembly
Disassembling seal carrier
Press oil seal (2) out of carrier (3) using a suitable thrust
plate and hand press.
Remove O-ring (1) from seal carrier.
20038/10 E –04.96–
Task Description Section 3.3.9a.4
Page 1
20038/10 E –04.96–
Task Description Section 3.3.9a.5
Page 1
3.3.9a.5 Assembly
Installing track ring on intermediate flange
Prior to shrinking track ring onto intermediate flange,
clean and degrease joint surfaces of components.
Heat track ring to 150 °C (do not exceed temperature of
180 °C).
Thinly coat O-ring (3) with ”petroleum jelly” and insert
into groove in track ring (2).
Wearing protective gloves, force track ring with O-ring
onto intermediate flange (1) as far as it will go. Ensure
that there is no gap at intermediate flange mating face.
Note
20038/10 E –04.96–
Task Description Section 3.3.9a.6
Page 1
3.3.9a.6 Installation
Installing intermediate flange
Fit intermediate flange (1) on flange (2) of free end.
Coat thread of screws (3) with ”engine oil” and insert on
flange.
Note
20038/10 E –04.96–
Task Description Section 3.3.9a.6
Page 2
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified and tested equipment for hydraulic installation. Check the equipment annually (draw spindle crack
test). The installation pressure stamped on the tool and the expansion pressure stamped on the hub must not be ex-
ceeded. During the installation procedure, make sure that nobody is standing behind the tool.
Pressing on hub
Fit hub (2) on intermediate flange (1).
Measure distance from front of hub to front of intermedi-
ate flange and record measurement.
Screw draw spindle (6) of hydraulic installation tool into
intermediate flange(1) as far as it will go and secure.
Measure reference dimension ”B” = 260 mm.
Fit pressure bush (3) on draw spindle (6) and insert con-
nector (9) to expand hub (2).
Fit hydraulic nut (4) on draw spindle.
Mount hex nut (5) on draw spindle and tighten fully.
Note
20038/10 E –04.96–
Task Description Section 3.3.9a.6
Page 3
Remove measuring device, oil pressure hand pump and installation tool.
Recheck force-on distance with depth gauge.
Note
20038/10 E –04.96–
Task Description Section 3.4
Page 1
20054/00 E –10.93–
Task Description Section 3.4
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20054/00 E –10.95–
Task Description Section 3.4.1
Page 1
20046/20 E –05.96–
Task Description Section 3.4.1
Page 2
20046/20 E –05.96–
Task Description Section 3.4.1
Page 3
20046/20 E –05.96–
Task Description Section 3.4.1
Page 4
20046/20 E –05.96–
Task Description Section 3.4.1
Page 5
20046/20 E –05.96–
Task Description Section 3.4.1.1
Page 1
1 2 3 Operations See
20046/20 E –05.96–
Task Description Section 3.4.1.2
Page 1
3.4.1.2 Removal
Unscrew bolts (3) securing end cover (1).
Use two pry bars to detach end cover from bearing re-
taining plate.
Remove plug-in pipe with O-rings.
Unscrew elbow (2) from oil pan.
Remove O-ring and gasket.
Note
20046/20 E –05.96–
Task Description Section 3.4.1.4
Page 1
20038/10 E –11.92–
Task Description Section 3.4.1.6
Page 1
3.4.1.6 Installation
Install O-ring (1) in groove in bearing retaining plate.
Coat O-ring with petroleum jelly.
Mount elbow (6) with O-ring (7) and gasket on oil pan.
Insert O-ring (2) in the grooves on plug-in pipe (3) and
coat with ”petroleum jelly”.
Insert plug-in pipe in elbow.
Note
20046/20 E –05.96–
Task Description Section 3.5
Page 1
20038/10 E –11.92–
Task Description Section 3.5
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20038/10 E –08.97–
Task Description Section 3.5
Page 3
Cylinder head
20038/10 E –11.92–
Task Description Section 3.5.1
Page 1
6V 8V 16V
12V
ET05013717B
20038/10 E –07.94–
Task Description Section 3.5.1
Page 2
Inlet and exhaust valves with valve guides and protective sleeve
1 Cylinder head
2 Valve rotator
3 Inlet valve
4 Exhaust valve
5 Valve spring, outer
6 Valve spring, inner
7 Spring retainer, top
8 Valve collet
9 Valve stem seal, inlet
10 Sealing ring
11 Plug
1 Cylinder head
2 Protective sleeve
3 O-ring
4 Cover
5 Cover
6 Cover
7 Sealing ring
8 Plug
9 Sealing ring
10 Plug
11 Valve guide, exhaust
12 Valve guide, inlet
13 Valve seat insert, inlet
14 Valve seat insert, exhaust
20038/10 E –05.96–
Task Description Section 3.5.1
Page 3
20038/10 E –11.92–
Task Description Section 3.5.1.1
Page 1
1 2 3 Operations See
20058/0 E –05.96–
Task Description Section 3.5.1.2
Page 1
3.5.1.2 Removal
Removing cylinder head bolts
Prior to removing cylinder heads, remove engine oil re-
turn line from cylinder head.
Using ratchet (1) and extension, remove bolts securing
cylinder head in diagonally opposite sequence.
Remove clamps (2) with shims.
Remove lifting bracket.
Detach end plates from end cylinders.
Remove cylinder head.
Remove O-rings from crankcase.
20038/10 E –11.92–
Task Description Section 3.5.1.3
Page 1
3.5.1.3 Disassembly
Removing valve springs
Removing fuel injector, see 3.11.5.2.
Before removal, use electric engraver to apply identify-
ing marks to valve heads.
Insert securing screw of valve spring compressor (1)
into tapped bore of cylinder head.
Position cylinder head on workbench so that valve
heads are seated.
Compress valve springs with valve spring compressor
and remove valve collets.
Remove upper valve spring retainer (2).
Caution
Spring tension
20038/10 E –02.95–
Task Description Section 3.5.1.3
Page 2
20038/10 E –11.92–
Task Description Section 3.5.1.3
Page 3
20038/10 E –11.92–
Task Description Section 3.5.1.4
Page 1
Note
Caution
Attention
The contact surface of the protective sleeve in the cylinder head can only be remachined once.
Check valve collets for indentations and replace as required.
Check valve rotator for ease of movement by turning in direction of rotation; for this purpose, press against the lower
section. Replace valve rotator if sluggish or as part of every W6 major overhaul.
Clean cylinder head gaskets and sandblast as necessary. Check for flateness.
Check sealing surface for scoring and damage, if necessary nickle-plate and/or replace cylinder head gaskets.
Clean support plates, check for flatness and damage and replace as necessary.
Check condition of oil transfer pipes, sleeves, end plates, clamping elements and spacer plates, replace components
as necessary.
Check transfer pipes for engine coolant for damage, replace as necessary.
Using surface-crack test procedure, check lifting bracket for cracks, replace component if cracks are detected.
Check oil return pipes for damage, replace as necessary.
Replace sealing rings, O-rings and valve stem seals.
Inspecting cylinder head face
Check cylinder head face and valve seats for cracks using surface crack-testing method with red penetrant dye.
Cracks in cylinder head face can be removed by machining concentrically to limit size.
Repeat crack test after machining.
Replace cylinder head if further cracks are found.
Replace valve seats if cracked.
20038/10 E –01.96–
Task Description Section 3.5.1.4
Page 2
Using a straightedge or measuring jig, check seating face of cylinder head for irregularities and indentations.
Indentations can be removed by concentric machining on a lathe. Machine towards centre of cylinder head.
Attention
Do not remove more material than is necessary in order to obtain a perfect seating face; see Tolerances and Wear
Limits List.
If corrosion indentations remain in vicinity of high-pressure seal once cylinder head has been machined, seating face
can be chrome-plated in vicinity of high-pressure seal to MTU specifications.
Attention
When reconditioning the cylinder mating face, the mating face of the cylinder liner on the crankcase must also be
checked and reconditioned if necessary.
The height difference between neighbouring cylinder heads must not exceed max. 0.5 mm.
This also applies between cylinder head and end plate on the corner cylinders.
After concentrically reconditioning the mating face, check the depth 28 mm +0.1 mm at the pushrod penetrations.
Bores must be milled is this value is not obtained, see MTU Circular.
Checking clearance between seating face of cylinder head and face of valve head, see Page 7.
20038/10 E –01.96–
Task Description Section 3.5.1.4
Page 3
Attention
Using suitable drift (1), drive cap (2) into cylinder head
bore.
Rim of cap must be recessed to a depth of approx. 1 mm
in cylinder head bore.
20038/10 E –05.96–
Task Description Section 3.5.1.4
Page 4
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 5
20038/10 E –05.96–
Task Description Section 3.5.1.4
Page 6
Attention
Caution
Note
20038/10 E –01.95–
Task Description Section 3.5.1.4
Page 7
Note
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 8
Note
L94_005_01
Insert head spindle (1) into extractor sleeve (2) and turn
until stop on dowel pin.
1
3
2
L94_005_2
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 9
L94_005_3
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 10
Caution
20038/10 E –01.95–
Task Description Section 3.5.1.4
Page 11
Attention
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 12
Attention
Inpsecting valves
Measure valve stem (2) with outside micrometer (1).
For wear limits, see Tolerances and Wear Limits List
Replace valves if specified limits are exceeded.
Check valves for damage, pitting, scoring and indenta-
tions on stem, plate, neck and pressure surface.
Replace valve if chrome plating is damaged or worn
through, if indentations are found, if valve stem reveals
scores or if pitting is found at transition from valve head
to valve stem.
Remove severe indentations at pressure face of valve
by machining to MTU specifications. Replace valve if
necessary.
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 13
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 14
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 15
Example:
Piston to 6° before TDC = 0.50 mm
Piston to 6° after TDC = 0.42 mm
Both measurements = 0.92 mm
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 16
20038/10 E –07.94–
Task Description Section 3.5.1.4
Page 17
Measuring piston gap and setting for pistons with epsilon = 15.5
20038/10 E –05.96–
Task Description Section 3.5.1.5
Page 1
3.5.1.5 Assembly
Installing protective sleeves
Check that tapped bores in cylinder head and threads of
protective sleeves (3) are clean.
Blow groove for O-ring (4) in cylinder head clear with
compressed air and check that it is clean.
Insert new O-ring into groove. Coat O-ring with ”petro-
leum jelly”.
Coat thread of protective sleeve with engine oil.
Install sleeve in cylinder head with pronged wrench (2).
Tighten sleeve with torque wrench to specified torque.
For torque setting, see Section 1.3.
When tightening sleeve, make sure that pronged
wrench is correctly engaged in sleeve recess.
Once sleeves have been installed, check cylinder head
for leaks, see 3.5.1.4.
Installing valves
Clean valve guides with suitable cylinder wiper and fuel.
Thoroughly clean valves and spray with engine oil.
Install exhaust valves (1) and inlet valves (2).
20038/10 E –11.95–
Task Description Section 3.5.1.5
Page 2
Note
Fit dry valve stem seals (1) over assembly sleeves onto
valve stems.
Remove assembly sleeves.
20038/10 E –11.92–
Task Description Section 3.5.1.5
Page 3
20038/10 E –11.92–
Task Description Section 3.5.1.5
Page 4
Caution
Spring tension
Relieve pressure on valve spring compressor and re-
move.
Place cylinder head on its side and tap valve stem lightly
with plastic mallet to settle valve collets correctly on
valve stem.
Check valve recess.
20038/10 E –02.95–
Task Description Section 3.5.1.6
Page 1
3.5.1.6 Installation
Installing support plate with coolant transfer pipes
and sealing rings
Check supporting plate (1) for surface irregularities and
ensure that it is clean; replace plate if necessary.
Clean mating face for support plate on crankcase.
Position supporting plate with matching number on
crankcase.
Insert coolant transfer pipes (3) into bores in supporting
plate.
Mount new sealing rings (2) on coolant transfer pipes.
20038/10 E –05.96–
Task Description Section 3.5.1.6
Page 2
Note
20038/10 E –05.96–
Task Description Section 3.5.1.6
Page 3
Install end plates (1) on free end and driving end with
socket-head screws M10 (2), – only fit screws only but
do not tighten.
Install lifting bracket with screws M18, – only fit screws
but do not tighten.
Note
Note
20038/10 E –05.96–
Task Description Section 3.5.1.6
Page 4
First pretightening:
Pretighten all cylinder head screws on all cylinder heads
with torque wrench (1) in accordance with tightening
specification 1.3 and tightening diagram for individual
cylinder head, see next Page.
Pretighten stress bolts M20 for clamps with torque
wrench in accordance with tightening specification 1.3
in sequence as shown in tightening diagram for individ-
ual cylinder head, see next Page.
Second pretightening:
Pretighten cylinder head screws M18 with torque
wrench in accordance with tightening specification 1.3
in sequence as shown in tightening diagram, see next
Page.
Pretighten all cylinder head screws M20 (clamp screws)
with torque wrench in accordance with tightening spec-
ification 1.3 in sequence as shown in tightening diagram,
see next Page.
20038/10 E –07.94–
Task Description Section 3.5.1.6
Page 5
Tightening diagram: Cylinder head, 6V, 8V, 12V, 16V and individual cylinder head
20038/10 E –05.96–
Task Description Section 3.6
Page 1
3.6.1 Camshaft
3.6.1.1 Before-removal operations
3.6.1.2 Removal
3.6.1.4 Inspection and repair
3.6.1.6 Installation
3.6.1.7 After-installation operations
20038/10 E –01.95–
Task Description Section 3.6
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Liquid nitrogen
Cleaner P3-Solvclean KW 40022
Engine oil
Kerosene or diesel fuel
High-strength thread-locking liquid Loctite 270 40083
Dry compressed air
Caution
When using these miscellaneous materials, it is essential to observe the manufacturers’ instructions for use, safety
instructions and waste disposal specifications.
20038/10 E –08.97–
Task Description Section 3.6
Page 3
Valve gear
20038/10 E –11.92–
Task Description Section 3.6.1
Page 1
3.6.1 Camshaft
20038/10 E –11.92–
Task Description Section 3.6.1.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.6.1.2
Page 1
3.6.1.2 Removal
Setting crankshaft to firing TDC of cylinder A1
Turn crankshaft until markings (1) on camshaft (3) and
crankcase (2) are aligned.
Installation and removal of injection timer and camshaft
are carried out when crankshaft is in this position (firing
TDC position of piston of cylinder A1).
20038/10 E –11.92–
Task Description Section 3.6.1.2
Page 2
Attention
Remove camshaft.
Carefully remove camshaft (2) with guide sleeve (1)
from crankcase in direction of free end.
20038/10 E –11.92–
Task Description Section 3.6.1.4
Page 1
20038/10 E –04.95–
Task Description Section 3.6.1.6
Page 1
3.6.1.6 Installation
Installing camshaft
Attention
20038/10 E –11.92–
Task Description Section 3.6.1.6
Page 2
Note
20038/10 E –12.95–
Task Description Section 3.6.1.7
Page 1
20038/10 E –11.92–
Task Description Section 3.6.1.7
Page 2
20038/10 E –07.94–
Task Description Section 3.6.2
Page 1
20038/10 E –11.92–
Task Description Section 3.6.2.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.6.2.2
Page 1
3.6.2.2 Removal
Remove screw (1) from stop (2).
Remove stop from guide pin.
20038/10 E –11.92–
Task Description Section 3.6.2.3
Page 1
3.6.2.3 Disassembly
To press out guide pin, insert roller tappet (2) between
two V-blocks (3) so that there is sufficient support on
either end of pin bore.
Using mandrel (1), press guide pin out of tappet.
Insert bush, roller, pin and tappet into protective basket
and protect against damage.
20038/10 E –11.92–
Task Description Section 3.6.2.4
Page 1
20038/10 E –11.92–
Task Description Section 3.6.2.5
Page 1
3.6.2.5 Assembly
Heat tappet (1) on heating plate to approx. 80 °C to
120 °C.
Chill pin (2) in liquid nitrogen.
Insert bush (4) into roller (3).
Caution
Caution
20038/10 E –01.95–
Task Description Section 3.6.2.5
Page 2
Insert pin (2) with retaining pliers (4) into bore on tappet
(1).
Using mandrel (3), press in pin by hand until the stop.
Once tappet has cooled to room temperature, check
ease of movement and axial clearance of roller.
Using outside micrometer, measure roundness of
tappet.
Axial clearance: 0.6 mm to 0.7 mm
20038/10 E –11.92–
Task Description Section 3.6.2.6
Page 1
3.6.2.6 Installation
Spray roller tappet (1) with ”engine oil” and insert into
guide bush in crankcase.
Fit O-ring (2) and circlip (1) on guide pin and coat with
”engine oil”.
Insert guide pin into bore in crankcase until the stop on
circlip.
Friction surfaces must engage in guide slot of roller
tappet.
To check ease of movement, turn camshaft of roller
tappet to be checked into base circle.
When raised, the roller tappet must fall back into its bot-
tom initial position through its own weight.
When all roller tappets are installed, bar camshaft sev-
eral times by hand.
Ensure that all roller tappets fall back to their initial posi-
tion due to their own weight.
20038/10 E –07.94–
Task Description Section 3.6.2.6
Page 2
20038/10 E –11.92–
Task Description Section 3.6.3
Page 1
20038/10 E –11.92–
Task Description Section 3.6.3
Page 2
Rocker, inlet
20038/10 E –11.92–
Task Description Section 3.6.3
Page 3
Rocker, exhaust
20038/10 E –11.92–
Task Description Section 3.6.3.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.6.3.2
Page 1
3.6.3.2 Removal
Unscrew stress bolts (2) from rocker shafts (1).
20038/10 E –11.92–
Task Description Section 3.6.3.3
Page 1
3.6.3.3 Disassembly
Remove rocker shaft (1) from inlet rocker (2) at side with
installed spring pin (arrow).
Remove rocker shaft (4) from exhaust rocker (3) on side
with chamfer (arrow).
Store rockers and rocker shafts in transport trestle and
protect against damage.
20038/10 E –01.95–
Task Description Section 3.6.3.4
Page 1
20038/10 E –01.95–
Task Description Section 3.6.3.4
Page 2
Caution
Caution
20038/10 E –01.95–
Task Description Section 3.6.3.5
Page 1
3.6.3.5 Assembly
Check oil bores in rocker, ball stud and shaft for cleanli-
ness and blow through with compressed air.
Air must emerge at ball stud!
Insert adjusting screws into threaded bores of rocker.
Ensure adjusting screws can move easily!
Fit locknuts on adjusting screws.
Coat rocker shafts with ”engine oil”.
Insert rocker shaft (1) with installed spring pin (see
arrow) into inlet rocker (2).
Insert rocker shaft (4) with chamfer (see arrow) without
spring pin into exhaust rocker (3).
20038/10 E –11.92–
Task Description Section 3.6.3.6
Page 1
3.6.3.6 Installation
Coat ball heads of push rods (1) with ”engine oil”.
Insert push rods into roller tappet with ball head end.
Exhaust push rod 260 mm long
Inlet push rod 273 mm long
Note
20038/10 E –11.92–
Task Description Section 3.6.3.6
Page 2
Securing rocker
Check long stress bolts for inlet rockers.
Max. screw length 81 mm
Check short stress bolts for exhaust rockers.
Max. screw length 51 mm
If max. screw length is achieved before installation,
replace stress bolts.
Coat thread of stress bolts (2) with engine oil.
Insert stress bolts into cylinder head and pretighten with
torque wrench (1) to tightening specification 1.3.
Note
20038/10 E –11.92–
Task Description Section 3.6.3.7
Page 1
Note
20038/10 E –11.93–
Task Description Section 3.6.3.7
Page 2
Note
20038/10 E –11.93–
Task Description Section 3.6.3.7
Page 3
Note
V8
V12
20038/10 E –07.94–
Task Description Section 3.6.3.7
Page 4
V16
After setting valve, remove adjusting shim and pointer from fuel injection pump drive on free end.
Install end cover.
Remove engine barring tool from flywheel housing.
Install cylinder head cover, see 3.6.4.6
20038/10 E –07.94–
Task Description Section 3.6.4
Page 1
ET 06 134 1
20038/10 E –11.92–
Task Description Section 3.6.4.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.6.4.2
Page 1
3.6.4.2 Removal
Remove cylinder head cover
Remove gasket.
Remove internal leak-off fuel line.
Disconnect H.P. fuel line
Remove collar screw as necessary.
20038/10 E –01.95–
Task Description Section 3.6.4.4
Page 1
20038/10 E –11.92–
Task Description Section 3.6.4.6
Page 1
3.6.4.6 Installation
Smooth contact surfaces on cylinder head and gear
case with oilstone and clean.
Insert O-ring in groove on gear case.
Position gear case on cylinder head.
Insert screws with washers and tighten with torque
wrench (1) to tightening specification 1.3.
Check ease-of-movement of rockers.
Install internal leak-off fuel line and H.P. fuel line.
Install leak-off fuel collecting line with new sealing rings.
20038/10 E –11.95–
Task Description Section 3.7
Page 1
20038/10 E –10.95–
Task Description Section 3.8
Page 1
20038/10 E –11.92–
Task Description Section 3.9
Page 1
20038/10 E –11.92–
Task Description Section 3.10
Page 1
3.10.1a Intercooler
3.10.1a.1 Before-removal operations
3.10.1a.2 Removal
3.10.1a.3 Disassembly
3.10.1a.4 Inspection and repair
3.10.1a.5 Assembly
3.10.1a.6 Installation
20046/20 E –05.96–
Task Description Section 3.10
Page 2
20046/20 E –05.96–
Task Description Section 3.10
Page 3
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturers’ instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –05.96–
Task Description Section 3.10
Page 4
20046/20 E –05.96–
Task Description Section 3.10
Page 5
20046/20 E –05.96–
Task Description Section 3.10
Page 6
20046/20 E –05.96–
Task Description Section 3.10.1a
Page 1
3.10.1a Intercooler
20058/0 E –03.93–
Task Description Section 3.10.1a
Page 2
20058/0 E –03.93–
Task Description Section 3.10.1a
Page 3
Intercooler
20058/0 E –05.96–
Task Description Section 3.10.1a.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.10.1a.2
Page 1
3.10.1a.2 Removal
Removing intercooler
Unscrew screws (1) securing intercooler (2) on carrier
(3).
Removing carrier
Prior to removing carrier, remove elbow and plug–in pipe
from right carrier, see 3.14.1.2 and 3.14.3.2.
Unscrew screws (2) from carrier (1).
Remove carrier from flywheel housing.
20058/0 E –03.93–
Task Description Section 3.10.1a.3
Page 1
3.10.1a.3 Disassembly
Removing air inlet cover
Release screws (1) and (5) and spring washers (2) from
cover (6).
Remove cover and gasket (3) from intercooler (4).
20046/20 E –05.96–
Task Description Section 3.10.1a.3
Page 2
Note
20046/20 E –05.96–
Task Description Section 3.10.1a.3
Page 3
20046/20 E –05.96–
Task Description Section 3.10.1a.4
Page 1
20058/0 E –05.96–
Task Description Section 3.10.1a.4
Page 2
Note
After cleaning the air side, blow out and dry with dry compressed air.
Checking connnection between cooler tubes and tube plate for leaks
Seal cooler core without coolant chambers on air side with stable plates and rubber seals. One of the inspection plates
must be equipped with a connection for pressure-testing with compressed air.
Immerse cooler core in a testing tank filled with water at approx. 60 – 80°C. With a reduced test pressure of 0.5 bar
(pay attention to accident prevention regulations), check water side for leaks. Leaking connections between tube and
tube plate are indicated by air bubbles emerging.
Turn cooler core 180° about its transverse axis to test second tube plate
If tube plate leaks are detected, return intercooler to the manufacturer or to MTU Friedrichshafen for repair.
Note
20058/0 E –03.93–
Task Description Section 3.10.1a.5
Page 1
3.10.1a.5 Assembly
Assembling intercooler (GEA)
Clean all sealing surfaces, smooth with oilstone if
necessary.
Note
20046/20 E –05.96–
Task Description Section 3.10.1a.5
Page 2
8V
Mount bottom diverter chamber (3) with gasket (2) and
damping ring (7) on cooler core (1).
Tighten socket-head screws (4), (6) and washers diag-
onally and evenly to tightening specification 1.3.
For cover installation, also refer to bottom illustration.
Note
20046/20 E –05.96–
Task Description Section 3.10.1a.5
Page 3
Note
Note
20046/20 E –05.96–
Task Description Section 3.10.1a.6
Page 1
3.10.1a.6 Installation
Installing intercooler carriers
Check spring pins for damage and replace as necess-
ary.
Install intercooler carriers (2) on right and left engine
sides with screws and spring washers (1) and tighten.
Installing intercooler
Check sealing surfaces and mating faces on intercooler
(1) for cleanliness.
Screw lifting eyes (2) into intercooler.
Use rope and lifting gear to place intercooler on the
carrier on the flywheel housing. Push in direction of free
end.
Do not damage plug-in sleeves and O-rings when insert-
ing into bores in the intercooler.
20058/0 E –05.96–
Task Description Section 3.10.1a.6
Page 2
20058/0 E –05.96–
Task Description Section 3.10.2
Page 1
20046/20 E –05.96–
Task Description Section 3.10.2
Page 2
1 Manifold 18 Cover
2 Gasket 19 O-ring
3 O-ring 20 Washer
4 Washer 21 Hex screw
5 Socket-head screw 22 Sealing ring
6 Sealing ring 23 Plug
7 Plug 24 Cover
8 Sealing ring 25 Cover (order-specific)
9 Plug 26 Gasket
10 Threaded bush 27 Washer
11 Sealing ring 28 Hex screw
12 Plug 29 Cover
13 Threaded bush 30 Cover
14 Sealing ring 31 Gasket
15 Plug 32 Washer
16 Sealing ring 33 Hex screw
17 Plug 34 Hex screw
20046/20 E –05.96–
Task Description Section 3.10.2
Page 3
20046/20 E –05.96–
Task Description Section 3.10.2
Page 4
Air intake system between intercooler and exhaust turbocharger (8V, 12)
1 Sleeve 6 Flange
2 Sleeve 7 Flange
3 O-ring 8 O-ring
4 O-ring 9 Washer
5 O-ring 10 Hex screw
20046/20 E –05.96–
Task Description Section 3.10.2
Page 5
1 Sleeve 5 Flange
2 O-ring 6 O-ring
3 O-ring 7 Washer
4 Flange 8 Bolt
20046/20 E –05.96–
Task Description Section 3.10.2.1
Page 1
1 2 3 Operations See
20042/10 E –07.94–
Task Description Section 3.10.2.2
Page 1
20046/20 E –05.96–
Task Description Section 3.10.2.2
Page 2
20046/20 E –05.96–
Task Description Section 3.10.2.2a
Page 1
20054/00 E –05.96–
Task Description Section 3.10.2.2a
Page 2
20054/00 E –05.96–
Task Description Section 3.10.2.4
Page 1
Note
20038/10 E –11.92–
Task Description Section 3.10.2.6
Page 1
20042/10 E –05.96–
Task Description Section 3.10.2.6
Page 2
20042/10 E –05.96–
Task Description Section 3.10.2.6a
Page 1
20054/00 E –05.96–
Task Description Section 3.10.2.6a
Page 2
20054/00 E –05.96–
Task Description Section 3.10.3
Page 1
20046/20 E –05.96–
Task Description Section 3.10.3
Page 2
20046/20 E –05.96–
Task Description Section 3.10.3
Page 3
20046/20 E –05.96–
Task Description Section 3.10.3
Page 4
Exhaust system - housing for exhaust manifold, carrier housing, connection housing
20046/20 E –05.96–
Task Description Section 3.10.3.1
Page 1
1 2 3 Operations See
20046/20 E –05.96–
Task Description Section 3.10.3.2
Page 1
3.10.3.2 Removal
Removing exhaust manifold cover
Remove screws (1) securing flange (2) to housing for
exhaust manifold (3).
Unscrew securing screws from cover for exhaust mani-
fold (4).
20054/00 E –10.93–
Task Description Section 3.10.3.2
Page 2
Note
20054/00 E –10.93–
Task Description Section 3.10.3.2
Page 3
Removing cover
Remove screw securing cover (1).
Remove cover.
20054/00 E –10.93–
Task Description Section 3.10.3.3
Page 1
3.10.3.3 Disassembly
Disassembling connecting flange
Press flanges (1) off protective tube (2).
Press plug-in pipe out of flanges.
Remove O-rings.
Note
20054/00 E –10.93–
Task Description Section 3.10.3.4
Page 1
Caution
20054/00 E –10.93–
Task Description Section 3.10.3.5
Page 1
3.10.3.5 Assembly
Preassembling connecting flange
Insert O-ring (7) into flange (9).
Insert O-ring (4) into flange (1).
Insert two O-rings (6) into grooves of plug-in pipe (8).
Coat O-rings with petroleum jelly.
On cover side, insert screw (5) with washer into flange
(1).
Fit flanges (1) and (9), with coolant side facing outwards,
onto plug-in pipe (8) so that small coolant transfers (3)
on flanges are flush.
Fit flanges flush with plug-in pipe on protective tube (2).
Note
Insert O-rings (2), (3) and (4) into flange (1) on coolant
side and coat with ”petroleum jelly”.
Note
20054/00 E –05.96–
Task Description Section 3.10.3.5
Page 2
Note
20054/10 E –10.93–
Task Description Section 3.10.3.6
Page 1
3.10.3.6 Installation
Installing exhaust manifolds, left and right engine
sides
Before installing exhaust manifold housing (1), check
that all cylinder heads on one engine side are mounted
flush using a steel ruler (permissible deviation: 0.1 mm).
Coat screw threads (2) and washer mating face with ”as-
sembly paste”.
Evenly coat sealing surfaces of housing for exhaust
manifold on flange surface with ”sealing paste”.
Install housing with screws and washers on cylinder
heads.
Tighten screws with torque wrench. For torque settings,
see Section 1.3.
Installing cover
Install cover (1) on exhaust manifold housing (2).
Coat screw threads (3) and washer mating face with ”as-
sembly paste”.
Pay attention to correct installation of cover (4).
Using torque wrench, tighten screw to specified torque.
For torque setting see Section 1.3.
Note
Note
20054/00 E –05.96–
Task Description Section 3.10.3.6
Page 2
20054/00 E –05.96–
Task Description Section 3.10.3.6
Page 3
Note
20054/00 E –05.96–
Task Description Section 3.10.3.6
Page 4
20054/00 E –05.96–
Task Description Section 3.10.4a
Page 1
20046/20 E –05.96–
Task Description Section 3.10.4a
Page 2
20046/20 E –05.96–
Task Description Section 3.10.4a
Page 3
20046/20 E –05.96–
Task Description Section 3.10.4a.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.10.4a.2
Page 1
3.10.4a.2 Removal
Removing solenoid
Remove flange (4) for securing solenoid.
Remove solenoid (3) from carrier (5).
Twist grease nipple (1) out of shaft (2).
Unscrew shaft on lever (6) from carrier.
Remove lever with shaft from holder.
20058/0 E –03.93–
Task Description Section 3.10.4a.2
Page 2
20058/0 E –03.93–
Task Description Section 3.10.4a.3
Page 1
3.10.4a.3 Disassembly
Disassembling cover with emergency air shut-off
flaps
Release and pull out split pin (4).
Remove adjusting shim (3).
Press pin (2) out of lever (5).
Remove pull rod (1).
20058/0 E –05.96–
Task Description Section 3.10.4a.3
Page 2
Note
20058/0 E –05.96–
Task Description Section 3.10.4a.3
Page 3
Disassembling lever
Remove lockwashers (5) from pin (2).
Place back-up washer for pressing out pin in cutout on
lever (1).
Use mandrel to press pin out of short lever side.
Note
20058/0 E –05.96–
Task Description Section 3.10.4a.3
Page 4
20058/0 E –05.96–
Task Description Section 3.10.4a.4
Page 1
20058/0 E –05.96–
Task Description Section 3.10.4a.5
Page 1
3.10.4a.5 Assembly
Assembling emergency air shut-off flaps
Insert keys (1) into shaft grooves.
20058/0 E –05.96–
Task Description Section 3.10.4a.5
Page 2
Insert emergency air shut-off flap (2) with shaft (1) into
cover.
The sealing lip of rubber strip must face flap seat.
20058/0 E –05.96–
Task Description Section 3.10.4a.5
Page 3
20058/0 E –05.96–
Task Description Section 3.10.4a.5
Page 4
Fit washer (2) on shaft end and secure with snap ring (1).
Fit washer (1), sleeve (3) and flexible spring (2) on shaft.
End of flexible spring must engage in bore on collar of
bearing bush.
20058/0 E –03.93–
Task Description Section 3.10.4a.5
Page 5
Assembling pull-rod
Install nuts (2) on joints (1).
Screw joints in pull-rods (3) and (4). Fill pull-rods 2/3 full
with grease.
Assemble both pull-rods with pin (5), shim (6) and split
pin (7).
Adjust joints to lengths ”A” and ”B”.
Dimension ”A” = 297.5 mm 6V, 8V, 12V
Dimension ”B” = 368.5 mm ±0.5 mm 6V, 8V, 12V
Dimension ”B” = 267.5 mm ±0.5 mm 16V
Dimension ”A” = 196.5 mm 16V
Pay special attention to surface parallelity of swivel
heads and position of pins.
Check length of pull rod when removed in accordance
with illustration; reset as necessary.
20058/0 E –05.96–
Task Description Section 3.10.4a.5
Page 6
Installing pull-rod
Install pull rod (1) with pins (2) on lever (5) of emergency
air shut-off flap.
Position adjusting shim (3) on pin, insert split pin (4) in
pin and secure.
Assembling lever
Press bush (1) with mandrel into lever (2).
Insert two adjusting shims (2) and one back-up ring (3)
for pin (1) installation into fork of lever.
Insert pin on short lever side.
Note
20058/0 E –07.94–
Task Description Section 3.10.4a.5
Page 7
Install cam roller (1) with spring washer (3) and hex nut
(4) on long lever arm (2).
Tighten nut to tightening specification 1.3.
20058/0 E –07.94–
Task Description Section 3.10.4a.6
Page 1
3.10.4a.6 Installation
Installing cover with emergency air shut-off flaps
Clean sealing surfaces on intercooler (3) and cover (1),
smooth with oilstone if necessary.
Place gasket (2) on intercooler.
Coat sealing surfaces (2) with sealing paste. (Order-
specific)
Install cover with emergency air shut-off flaps in inter-
cooler using screws and spring washers.
Tighten screws diagonally and evenly.
For intercooler installation – see 3.10.1a.6
20046/20 E –05.96–
Task Description Section 3.10.4a.6
Page 2
Installing solenoid
Coat axle threads (2) with ”thread-locking liquid”.
Place lever (6) on carrier. Install and secure axle (2) in
carrier (5).
Install lubricating nipple (1) in axle.
Place solenoid (3) in carrier in such a way that slot in pull
rod points towards axle.
Insert solenoid in carrier and install with flange (4),
screws and spring washers.
20046/20 E –05.96–
Task Description Section 3.10.4a.6
Page 3
20046/20 E –05.96–
Task Description Section 3.10.6a
Page 1
20058/0 E –03.93–
Task Description Section 3.10.6a
Page 2
20058/0 E –05.96–
Task Description Section 3.10.6a
Page 3
Carrier housing with connection housing and exhaust flow control flap
20058/0 E –03.93–
Task Description Section 3.10.6a
Page 4
20058/0 E –05.96–
Task Description Section 3.10.6a
Page 5
20058/0 E –05.96–
Task Description Section 3.10.6a
Page 6
20058/0 E –05.96–
Task Description Section 3.10.6a
Page 7
T0100770a0
20058/0 E –05.96–
Task Description Section 3.10.6a
Page 8
20058/0 E –05.96–
Task Description Section 3.10.6a
Page 9
20058/0 E –05.96–
Task Description Section 3.10.6a.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.10.6a.2
Page 1
3.10.6a.2 Removal
Remove securing screws (3) of flanges (4) on cover (1)
and carrier housing (2).
Remove cover from carrier housing.
Remove flanges with plug-in pipe and protective tube.
Remove O-rings.
Removing flange
Remove flange (1) securing screws.
Remove flange.
20058/0 E –03.93–
Task Description Section 3.10.6a.2
Page 2
20058/0 E –03.93–
Task Description Section 3.10.6a.2
Page 3
20058/0 E –03.93–
Task Description Section 3.10.6a.3
Page 1
Note
20058/0 E –05.96–
Task Description Section 3.10.6a.3a
Page 1
20058/0 E –05.96–
Task Description Section 3.10.6a.4
Page 1
Caution
20058/0 E –05.96–
Task Description Section 3.10.6a.5
Page 1
Note
20058/0 E –05.96–
Task Description Section 3.10.6a.5a
Page 1
20058/0 E –05.96–
Task Description Section 3.10.6a.5a
Page 2
Note
20058/0 E –05.96–
Task Description Section 3.10.6a.6
Page 1
3.10.6a.6 Installation
Installing carrier housing
Note
Coat exhaust pipe joint (1) with ”assembly paste” and in-
sert into connection housing (2).
20058/0 E –05.96–
Task Description Section 3.10.6a.6
Page 2
Note
Note
Note
Do not damage rubber sealing ring and sleeve (5) for oil
return.
20058/0 E –05.96–
Task Description Section 3.10.6a.6
Page 3
20058/0 E –05.96–
Task Description Section 3.10.6a.6
Page 4
Note
20058/0 E –05.96–
Task Description Section 3.10.6a.6
Page 5
Installing flange
Mount flange (2) on cooling jacket top section.
Check gap (S) intermediate flange and exhaust elbow
(1).
S = 0.5 mm to 2.0 mm
Installing cover
Clean sealing surfaces on cover (1) and carrier housing
(2).
Apply ”sealing paste” to sealing surfaces of cover for
carrier housing.
Mount cover on carrier housing
Note
20058/0 E –05.96–
Task Description Section 3.10.7
Page 1
20058/0 E –03.93–
Task Description Section 3.10.7
Page 2
20058/0 E –03.93–
Task Description Section 3.10.7
Page 3
20058/0 E –03.93–
Task Description Section 3.10.7.1
Page 1
1 2 3 Operations See
20058/0 E –05.96–
Task Description Section 3.10.7.2
Page 1
3.10.7.2 Removal
Removing intake funnel
Remove intake funnel (1) from housing (2).
Note
Note
20058/0 E –05.96–
Task Description Section 3.10.7.3
Page 1
3.10.7.3 Disassembly
20038/10 E –05.96–
Task Description Section 3.10.7.3
Page 2
Removing socket
Remove socket-head screws (5) with toothed washers
(4) from socket (2).
Remove connector with gasket (3) from intake housing
(1).
Unsolder connections.
Note
20038/10 E –11.92–
Task Description Section 3.10.7.4
Page 1
20038/10 E –05.96–
Task Description Section 3.10.7.5
Page 1
3.10.7.5 Assembly
20038/10 E –05.96–
Task Description Section 3.10.7.5
Page 2
Installing socket
Install connections in socket.
Coil 1: Pin A = yellow; Pin B = brown
Coil 2: Pin D = yellow; Pin E = brown
Install socket (5) with gasket (2) on intake housing (1).
Pay attention to correct position of groove ”X”.
Secure with screws (3) and toothed washers (4).
20038/10 E –11.92–
Task Description Section 3.10.7.6
Page 1
3.10.7.6 Installation
Installing intake housing, B side
Coat O-ring (2) and (3) with ”petroleum jelly” and insert
into grooves on compressor housing (1).
Note
20058/0 E –05.96–
Task Description Section 3.10.7.6
Page 2
Note
20058/0 E –05.96–
Task Description Section 3.10.7a
Page 1
20058/0 E –05.96–
Task Description Section 3.10.7a
Page 2
20058/0 E –03.93–
Task Description Section 3.10.7a.1
Page 1
1 2 3 Operations See
20058/0 E –05.96–
Task Description Section 3.10.7a.2
Page 1
3.10.7a.2 Removal
Removing intake funnel
Remove intake funnel (1) from housing (2).
Remove gasket from housing.
20058/0 E –05.96–
Task Description Section 3.10.7a.4
Page 1
20058/0 E –05.96–
Task Description Section 3.10.7a.6
Page 1
3.10.7a.6 Installation
Installing intake housing
Coat O-ring (2) and (3) with ”petroleum jelly” and insert
into grooves on compressor housing (1).
20058/0 E –05.96–
Task Description Section 3.10.8a
Page 1
20058/0 E –05.96–
Task Description Section 3.10.8a
Page 2
20058/0 E –05.96–
Task Description Section 3.10.8a
Page 3
1 Retainer 18 Bolt
2 Bolt 19 Spring washer
3 Bolt 20 Air flap lever, right
4 Bolt 21 Key
5 Spring washer 22 Spring washer
6 Actuating cylinder 23 Bolt
7 Union 24 Control rod
8 Sealing ring 25 Bush
9 Bolt 26 Bolt
10 Spring washer 27 Nut
11 Retainer 28 Shim
12 Spring washer 29 Split pin
13 Bolt 30 Control rod
14 Spring washer 31 Castle nut
15 Bolt 32 Split pin
16 Exhaust flap lever, right 33 Shim
17 Key
20058/0 E –05.96–
Task Description Section 3.10.8a
Page 4
1 Exhaust turbocharger B side 6 Intake housing with air flow control flap
2 Solenoid valve/distributor 7 Control rod
3 Actuating cylinder 8 Exhaust flap lever, right
4 Accumulator link 9 Diverter housing
5 Air flap lever
20058/0 E –05.96–
Task Description Section 3.10.8a.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.10.8a.2
Page 1
3.10.8a.2 Removal
Removing accumulator link
Remove split pin from castle nuts (4).
Unscrew castle nuts and accumulator link (2) from air
flap lever (1) and exhaust flap lever (3).
20058/0 E –05.96–
Task Description Section 3.10.8a.3
Page 1
3.10.8a.3 Disassembly
Removing boot and connector from actuating cylin-
der
Release clamp (2) with pliers on boot (5) and remove
boot and clamp.
Release hex nut (3) on plunger (6) from connector (1).
Remove connector from plunger.
For actuating cylinder disassembly, see 3.86.9.3
Release hex nuts (3) and (11) on swivel heads (1) and (12) and unscrew swivel head from rod (4) and end element
(10).
Unscrew end element from spacer tube (9) and remove compression spring (13) from spacer tube.
Remove rod with intermediate element (7) from spacer tube. Remove guide bush (6) with scraper (5) from spacer tube
and remove intermediate element from rod only if necessary.
Remove scraper from guide bush.
L1 = setting dimension
L2 = setting dimension
20046/20 E –05.96–
Task Description Section 3.10.8a.3
Page 2
Note
L = setting dimension
20046/20 E –05.96–
Task Description Section 3.10.8a.4
Page 1
20046/20 E –10.95–
Task Description Section 3.10.8a.5
Page 1
3.10.8a.5 Assembly
Boot and connector on actuating cylinder
Install hex nut (3) and connector (1) on plunger (6).
Set dimension ”A” = 95 mm ±0.3 mm.
Lock connector with hex nut.
Ensure installation position of connector is correct.
Fit boot (5) with clamps (2) on actuating cylinder (4) and
connector and secure clamps with pliers.
20046/20 E –05.96–
Task Description Section 3.10.8a.5
Page 2
Press scraper (5) into guide bush (6) and insert rod (4) with insertion sleeve into guide bush.
Install intermediate element (7) on rod and tighten with hex nut (8) to specified torque. For torque setting, see Section
1.3.
Note
20046/20 E –05.96–
Task Description Section 3.10.8a.6
Page 1
3.10.8a.6 Installation
Installing actuating cylinder
Install retaining plate (5) on diverter housing and tighten.
Install mounting bracket (3) on actuating cylinder (2) and
tighten.
Mount actuating cylinder with securing screws (1) and
(4) and tighten.
Note
20058/0 E –05.96–
Task Description Section 3.10.11a
Page 1
20058/0 E –03.93–
Task Description Section 3.10.11a
Page 2
20058/0 E –03.93–
Task Description Section 3.10.11a
Page 3
20058/0 E –03.93–
Task Description Section 3.10.11a
Page 4
T0100770a0
20058/0 E –05.96–
Task Description Section 3.10.11a.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.10.11a.2
Page 1
3.10.11a.2 Removal
Removing shaft of exhaust flow-control flap
Remove seal carrier (1) for shaft of exhaust flow-control
flap (3) from right diverter housing (5).
Remove Mototherm ring (2).
Remove shaft (3) from diverter housing.
Remove bush (4).
From diverter housing, remove securing screws which
reach into cover of exhaust manifold (6).
20058/0 E –05.96–
Task Description Section 3.10.11a.3
Page 1
3.10.11a.3 Disassembly
Disassembling diverter housing and connecting
cable
Disconnect diverter housing (1) from plug-in pipe (4).
Disconnect diverter housing (7) from plug-in pipe (5).
Disconnect plug-in pipe (5) from plug-in pipe (4).
Remove O-rings (2) and (6), check dowel pins (3) for
damage and remove as necessary.
20058/0 E –03.93–
Task Description Section 3.10.11a.4
Page 1
Caution
20058/0 E –05.96–
Task Description Section 3.10.11a.5
Page 1
3.10.11a.5 Assembly
Assembling diverter housing and connecting line
Insert exhaust elbow (2) into diverter housing (1).
Mount exhaust elbow with hex bolts (4) and washers (3)
on diverter housing.
Tighten bolts to specified torque. For torque setting, see
Section 1.3.
Pay attention to ”GA” screw markings.
Note
Dowel pin (3) for locating inner plug-in pipe (5) on bottom
diverter housing (7) not applicable for second version.
Insert plug-in pipe (2) and (4) into diverter housing (1).
Note
20058/0 E –05.96–
Task Description Section 3.10.11a.6
Page 1
3.10.11a.6 Installation
Installing exhaust connection, left and right engine
side
Insert bush (3) into bore on carrier housing (2).
Mount plug-in pipes (5) with diverter housing (6) on inter-
cooler (1), and/or with diverter housing (4) on carrier
housing (2).
Fit screws with washers.
Note
20058/0 E –05.96–
Task Description Section 3.11
Page 1
20046/20 E –06.96–
Task Description Section 3.11
Page 2
3.11.8b Cylinder cutout, fuel injection pump 8V/12V with 4/2-way solenoid valve
3.11.8b.1 Before-removal operations
3.11.8b.2 Removal
3.11.8b.4 Inspection and repair
3.11.8b.6 Installation
20046/20 E –06.96–
Task Description Section 3.11
Page 3
20046/20 E –06.96–
Task Description Section 3.11
Page 4
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –06.96–
Task Description Section 3.11.1
Page 1
20046/20 E –06.96–
Task Description Section 3.11.1
Page 2
Fuel injection pump drive (IIb injection pump) with drive gear
1 Nut 13 Crankcase
2 Spring washer 14 Centering ring
3 Bearing flange 15 Grooved ball bearing
4 O-ring 16 Washer
5 Stress bolt 17 Bolt
6 Drive gear 18 O-ring
7 Camshaft idler gear 19 Cover
8 Drive shaft 20 Stress bolt
9 Bearing bush 21 Shaft seal
10 Thrust washer 22 Collared bush
11 Locknut 23 Bearing bush
12 Collared bush
20046/20 E –06.96–
Task Description Section 3.11.1
Page 3
Fuel injection pump drive (IId injection pump) – with injection timer or drive gear
20046/20 E –07.97–
Task Description Section 3.11.1
Page 4
Fuel injection pump drive (IIb injection pump) with injection timer
20046/20 E –06.96–
Task Description Section 3.11.1
Page 5
20046/20 E –06.96–
Task Description Section 3.11.1.1
Page 1
1 2 3 Operations See
20046/20 E –06.96–
Task Description Section 3.11.1.2
Page 1
3.11.1.2 Removal
Removing drive gear
If only the drive gear is replaced or repaired, the piston
of cylinder A1 must firstly be set to firing TDC.
Both markings on camshaft on driving end must be
aligned with markings on crankcase (3.11.1.4)
Remove end cover from bearing flange of injection pump
drive and remove O-ring.
Release stress bolt for drive shaft by one rotation.
Using a plastic mallet, tap ring side of screw head so that
lock ring is released.
20054/00 E –02.95–
Task Description Section 3.11.1.2
Page 2
20054/00 E –10.93–
Task Description Section 3.11.1.2
Page 3
20054/00 E –10.93–
Task Description Section 3.11.1.3
Page 1
3.11.1.3 Disassembly
Disassembling bearing flange
Remove O-ring (2) from bearing flange (1).
Remove dished washers with centering ring (3) from
bearing flange.
Note
20054/00 E –06.96–
Task Description Section 3.11.1.4
Page 1
20038/10 E –06.96–
Task Description Section 3.11.1.5
Page 1
3.11.1.5 Assembly
Note
20038/10 E –10.95–
Task Description Section 3.11.1.6
Page 1
3.11.1.6 Installation
Installing adjusting shim with swivel head and
pointer
Mount swivel head with screws on free end of crank-
shaft.
Tighten screws.
Mount adjusting shim (2) on swivel head and timing
pointer (1) on crankcase.
Determine TDC mark, see 3.5.1.4
20054/00 E –10.93–
Task Description Section 3.11.1.6
Page 2
20054/00 E –10.93–
Task Description Section 3.11.1.6
Page 3
Coat lock ring (1) with ”engine oil” and fit on drive shaft
(2).
Ensure lock ring is installed in correct position.
20054/00 E –10.93–
Task Description Section 3.11.1.6
Page 4
20054/00 E –06.96–
Task Description Section 3.11.1.6
Page 5
Note
Note
Stress bolt with collar for shaft seal and end cover with
shaft seal is order-specific.
20054/00 E –06.96–
Task Description Section 3.11.2
Page 1
20038/10 E –06.96–
Task Description Section 3.11.2
Page 2
Drive gear with fuel injection pump drive (IIb injection pump)
1 Nut 13 Crankcase
2 Spring washer 14 Centering ring
3 Bearing flange 15 Grooved ball bearing
4 O-ring 16 Washer
5 Stress bolt 17 Bolt
6 Drive gear 18 O-ring
7 Camshaft idler gear 19 Cover
8 Drive shaft 20 Stress bolt
9 Bearing bush 21 Shaft seal
10 Thrust washer 22 Collared bush
11 Locknut 23 Bearing bush
12 Collared bush
20038/10 E –06.96–
Task Description Section 3.11.2
Page 3
Fuel injection pump drive (IId injection pump) with drive gear
20038/10 E –07.97–
Task Description Section 3.11.2.1
Page 1
1 2 3 Operations See
20046/20 E –06.96–
Task Description Section 3.11.2.2
Page 1
3.11.2.2 Removal
See 3.11.1.2
20038/10 E –11.92–
Task Description Section 3.11.2.3
Page 1
3.11.2.3 Disassembly
Disassembling drive gear
If idler gear (2) or drive gear (1) must be replaced, re-
lease stress bolts (3) and remove.
Remove idler gear from drive gear.
Remove spring pin (4) as necessary.
20038/10 E –11.92–
Task Description Section 3.11.2.4
Page 1
20038/10 E –08.94–
Task Description Section 3.11.2.5
Page 1
3.11.2.5 Assembly
Assembling drive gear
Note
20038/10 E –08.94–
Task Description Section 3.11.2.6
Page 1
3.11.2.6 Installation
See 3.11.1.6
20038/10 E –11.92–
Task Description Section 3.11.2a
Page 1
20038/10 E –11.92–
Task Description Section 3.11.2a
Page 2
Injection timer
20038/10 E –11.92–
Task Description Section 3.11.2a.1
Page 1
1 2 3 Operations See
20046/20 E –06.96–
Task Description Section 3.11.2a.2
Page 1
3.11.2a.2 Removal
See 3.11.1.2
20038/10 E –11.92–
Task Description Section 3.11.2a.3
Page 1
3.11.2a.3 Disassembly
Disassembling injection timer
Note
Caution
Spring tension
Remove compression springs and control weights.
20038/10 E –10.95–
Task Description Section 3.11.2a.3
Page 2
Note
Using drift (1), drive guide pin (2) out of hub of drive gear.
20038/10 E –11.92–
Task Description Section 3.11.2a.3
Page 3
Removing cams
Remove stress bolts for cams (1) from drive gear.
Using plastic mallet, gently tap cams to release them
from drive gear and remove.
Remove dowel pin.
20038/10 E –11.92–
Task Description Section 3.11.2a.4
Page 1
Note
If the removed guide pin is used again and if there is no chamfer on the outer edge of the pin, rework in accordance
with Circular 15 10 91 (provide a chamfer) to achieve better lubricating and sliding conditions and to avoid edge carriers.
Check compression springs with spring test unit; if limit values are exceeded, replace compression springs.
Adjust bore gauge and measure interior diameter of fitted bores on companion flange. If limit values are exceeded,
replace parts. For specified limits, see Tolerances and Wear Limits List.
Check thread and length of stress bolts; max. length 38 mm prior to assembly.
20038/10 E –11.92–
Task Description Section 3.11.2a.5
Page 1
3.11.2a.5 Assembly
Prior to assembly, clean all components, ensuring they are perfectly clean.
Installing cam
Chill dowel pin (1) in ”liquid nitrogen”.
Caution
Caution
20038/10 E –06.96–
Task Description Section 3.11.2a.5
Page 2
20038/10 E –06.96–
Task Description Section 3.11.2a.5
Page 3
Installing flyweight
1 Flyweight
2 Spring retainer
3 Compression spring
4 Sleeve
Caution
20038/10 E –06.96–
Task Description Section 3.11.2a.5
Page 4
Caution
Using insertion tool (1), drive guide pin via guide groove,
hub and flyweight into sleeve until it contacts the stop.
Check clearance of guide pin to hub of drive gear.
Check flyweight for ease of movement.
20038/10 E –06.96–
Task Description Section 3.11.2a.5
Page 5
Installing cams
Note
20038/10 E –06.96–
Task Description Section 3.11.2a.5
Page 6
Installing flyweight
Coat sliding surfaces of flyweight (2) and control weights
(1) with ”thin-film lubricant”.
Insert control weights into drive gear to hub.
Pay special attention to installation position:
Control weight with large groove (3) facing upwards.
20038/10 E –11.92–
Task Description Section 3.11.2a.5
Page 7
Caution
Spring tension
Note
20038/10 E –10.95–
Task Description Section 3.11.2a.6
Page 1
3.11.2a.6 Installation
See 3.11.1.6
20038/10 E –11.92–
Task Description Section 3.11.2a.7
Page 1
20038/10 E –11.92–
Task Description Section 3.11.2b
Page 1
20047/10 E –10.95–
Task Description Section 3.11.2b
Page 2
Injection timer
20047/10 E –10.95–
Task Description Section 3.11.2b.1
Page 1
1 2 3 Operations See
20046/20 E –06.96–
Task Description Section 3.11.2b.2
Page 1
3.11.2b.2 Removal
For injection timer removal, see 3.11.1.2
20047/10 E –10.95–
Task Description Section 3.11.2b.3
Page 1
3.11.2b.3 Disassembly
1 Injection pump drive gear
2 Companion flange
3 Camshaft idler gear
4 Control weight
5 Stress bolt
6 Stress bolt
7 Spacer sleeve
8 Cam
9 Spring pin
10 Spring pin
11 Compression spring
12 Torsion spring (radial)
13 Dowel pin
Caution
Spring tension
Remove compression springs and control weights.
Removing cams
Remove stress bolts for cams (1) from drive gear.
Using plastic mallet, gently tap cams to release them
from drive gear and remove.
Do not damage spring pin; remove only if necessary.
20047/10 E –10.95–
Task Description Section 3.11.2b.3
Page 2
20047/10 E –10.95–
Task Description Section 3.11.2b.4
Page 1
20047/10 E –10.95–
Task Description Section 3.11.2b.5
Page 1
3.11.2b.5 Assembly
Prior to assembly, clean all components, ensuring they
are perfectly clean.
Preassemble drive gear
1 2 3
Chill dowel pin (1) in ”liquid nitrogen”.
Caution
SG11 0002a0
Mount idler gear (1) on drive gear (2) and locate in posi-
1 2 tion.
SG11 0003a0
20047/10 E –11.95–
Task Description Section 3.11.2b.5
Page 2
3 2
SG11 0005a0
SG11 0006a0
SG11 0007a0
20047/10 E –11.95–
Task Description Section 3.11.2b.5
Page 3
Insert torsion springs (1) via dowel pin (2), ensuring that
installation position is correct, see arrangement 3.11.2b.
1 2 1
SG11 0008a0
Installing cams
Using insertion mandrel (1), drive spring pins (2) into
1
cams (3).
3
2
SG11 0010a0
Note
1 2
SG11 0012a0
20047/10 E –11.95–
Task Description Section 3.11.2b.5
Page 4
SG11 0013a0
SG11 0014a0
2
Prior to installing control weights, ensure that the correct
control weight version is used!
Coat sliding surfaces of cams and control weights (2)
with ”thin-film lubricant”.
Insert control weights into drive gear to hub (1).
Ensure installation position is correct:
Control weights installed with large groove (2) facing up-
2 wards, see illustration 3.11.2b.
SG11 0015a0
20047/10 E –11.95–
Task Description Section 3.11.2b.5
Page 5
SG11 0016a0
20047/10 E –11.95–
Task Description Section 3.11.2b.6
Page 1
3.11.2b.6 Installation
See 3.11.1.6
20047/10 E –11.95–
Task Description Section 3.11.2b.7
Page 1
20047/10 E –11.95–
Task Description Section 3.11.3
Page 1
1 Plug-in sleeve
2 Coupling sleeve
3 Hex nut
4 O-ring
5 Coupling half
20042/10 E –08.94–
Task Description Section 3.11.3
Page 2
20042/10 E –08.94–
Task Description Section 3.11.3
Page 3
ET 11 255 13
20042/10 E –08.94–
Task Description Section 3.11.3.1
Page 1
1 2 3 Operations See
20046/20 E –06.96–
Task Description Section 3.11.3.2
Page 1
3.11.3.2 Removal
Removing coupling half, fuel injection pump I
Insert retaining unit (2) into teeth of coupling half of injec-
tion pump.
Ensure injection pump (3) and retaining unit are secure!
Clamp retaining unit securely.
Remove nut on coupling half with box wrench (1).
Remove retaining unit from teeth of coupling half.
Install removal tool on coupling half.
Remove coupling half from camshaft of injection pump;
for this purpose, hold removal tool in position.
Remove removal tool from coupling half.
For removal of connection housing with locking device,
see 3.11.7.2
20038/10 E –08.94–
Task Description Section 3.11.3.3
Page 1
3.11.3.3 Disassembly
Disassembling coupling half
Press tapered flange (2) with suitable assembly levers
off coupling half (3).
Remove spring pin (1) from coupling half.
X – Taper surface
S – Distance 1 mm – 0.3 mm
20038/10 E –08.94–
Task Description Section 3.11.3.4
Page 1
20038/10 E –08.94–
Task Description Section 3.11.3.5
Page 1
3.11.3.5 Assembly
Assembling coupling half
Insert spring pin (1) into tapered flange (2).
Clean taper surfaces ”X” with ”denaturated ethanol”.
Place dry and degreased coupling half (3) on tapered
flange; locate with spring pin.
Press coupling half onto tapered flange with a press-on
force of 200 N to 500 N.
Note
20038/10 E –11.95–
Task Description Section 3.11.3.6
Page 1
3.11.3.6 Installation
Installing coupling half, fuel injection pump I
For installation of connection housing with locking de-
vice, see 3.11.7.6
When injection pump is newly delivered from manufac-
turer, with the aid of locating device, the camshaft of in-
jection pump is located with locating pin (2) at pump tim-
ing.
Set/check start of delivery, see 3.11.3.7
20038/10 E –11.92–
Task Description Section 3.11.3.6
Page 2
Note
20038/10 E –08.94–
Task Description Section 3.11.3.6
Page 3
20038/10 E –11.92–
Task Description Section 3.11.3.7
Page 1
20038/10 E –08.94–
Task Description Section 3.11.3.7
Page 2
20038/10 E –11.95–
Task Description Section 3.11.4
Page 1
20038/10 E –08.94–
Task Description Section 3.11.4.1
Page 1
1 2 3 Operations See
20046/20 E –06.96–
Task Description Section 3.11.4.2
Page 1
3.11.4.2 Removal
Removing intermediate element, disc pack and coupling flange, fuel injection pump I
Removing intermediate element
Remove securing screws (2) and spring washers (1)
from intermediate element.
Remove intermediate element (3) from disc pack.
20054/00 E –10.93–
Task Description Section 3.11.4.2
Page 2
20054/00 E –10.93–
Task Description Section 3.11.4.4
Page 1
20054/00 E –10.93–
Task Description Section 3.11.4.6
Page 1
3.11.4.6 Installation
Installing coupling flange, disc pack and intermediate element, fuel injection pump I
Install flange (1) with screws and spring washers on in-
jection pump.
20054/00 E –10.93–
Task Description Section 3.11.4.6
Page 2
20054/00 E –10.93–
Task Description Section 3.11.4.6
Page 3
20054/00 E –10.93–
Task Description Section 3.11.4.6
Page 4
20054/00 E –10.93–
Task Description Section 3.11.4a
Page 1
Multiple disc clutch, coupling flange and dirt-proof enclosure for fuel injection pump I and II, 16V
1 Flange 17 Gasket
2 O-ring 18 Clamp
3 Washer 19 Clamp
4 Bolt 20 Mandrel
5 Flange 21 Nut
6 Woodruff key 22 Pipe
7 Spring washer 23 Elbow
8 Nut 24 Sealing ring
9 Disc pack 25 Union
10 Intermediate element 26 Clamp
11 Bolt 27 Washer
12 Washer 28 Bolt
13 Protective tube 29 Bolt
14 Gasket 30 Bolt
15 Cover 31 Washer
16 Stop
20046/20 E –06.96–
Task Description Section 3.11.4a
Page 2
20046/20 E –06.96–
Task Description Section 3.11.4a.1
Page 1
1 2 3 Operations See
20046/20 E –06.96–
Task Description Section 3.11.4a.2
Page 1
3.11.4a.2 Removal
Removing protective tube, intermediate element, disc pack, coupling flange and flange from fuel injection
pump I and II
SG110018a0
SG110019a0
20046/20 E –06.96–
Task Description Section 3.11.4a.2
Page 2
2
SG110020a0
SG110021a0
1 3
SG110022a0
20046/20 E –06.96–
Task Description Section 3.11.4a.2
Page 3
SG110023a0
SG110024a0
20046/20 E –06.96–
Task Description Section 3.11.4a.4
Page 1
20046/20 E –06.96–
Task Description Section 3.11.4a.6
Page 1
3.11.4a.6 Installation
Installing coupling flange, flange, disc pack, intermediate element and protective tube on fuel injection pump
I and II
1 3
SG110022a0
Note
SG110025a0
20046/20 E –06.96–
Task Description Section 3.11.4a.6
Page 2
SG110021a0
2
SG110020a0
4 3
SG110026a0
20046/20 E –06.96–
Task Description Section 3.11.4a.6
Page 3
1 2
SG110019a0
SG110018a0
SG110024a0
20046/20 E –06.96–
Task Description Section 3.11.4a.6
Page 4
Note
20046/20 E –06.96–
Task Description Section 3.11.5
Page 1
20046/20 E –06.96–
Task Description Section 3.11.5
Page 2
20046/20 E –06.96–
Task Description Section 3.11.5
Page 3
1 O-ring
2 Plug-in sleeve
3 Snap ring
4 Coupling sleeve
20046/20 E –06.96–
Task Description Section 3.11.5.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.11.5.2
Page 1
3.11.5.2 Removal
Using a socket (2), remove screws from the injection
pump (1).
20042/10 E –08.94–
Task Description Section 3.11.5.2
Page 2
20042/10 E –08.94–
Task Description Section 3.11.5.4
Page 1
20038/10 E –08.94–
Task Description Section 3.11.5.6
Page 1
3.11.5.6 Installation
Engage barring tool (2) in ring gear (1) and secure to fly-
wheel housing.
Bar crankshaft with barring tool in direction of engine
rotation until piston A1 is at firing TDC.
As a control, check the freedom of movement of the
rocker arm at cylinder A1.
Both rocker arms must be unloaded and free to move.
20038/10 E –11.92–
Task Description Section 3.11.5.6
Page 2
Using a box wrench, rotate the collared bush (1) until the
appropriate marking is facing upwards.
Example:
Marking ”8” at 8V
Marking ”12” at 12V
20038/10 E –11.92–
Task Description Section 3.11.5.6
Page 3
Fit coupling sleeve (1) onto drive shaft with snap ring
pointing to drive shaft.
20038/10 E –06.96–
Task Description Section 3.11.5.6
Page 4
20038/10 E –06.96–
Task Description Section 3.11.5.6
Page 5
Note
20038/10 E –07.97–
Task Description Section 3.11.5.7
Page 1
Note
Note
20038/10 E –08.94–
Task Description Section 3.11.5.7
Page 2
20038/10 E –08.94–
Task Description Section 3.11.5.7
Page 3
20038/10 E –11.92–
Task Description Section 3.11.5.7
Page 4
20038/10 E –06.96–
Task Description Section 3.11.5.7
Page 5
Note
20038/10 E –11.92–
Task Description Section 3.11.5.7
Page 6
7.0 0.876
8.0 1.143
9.0 1.446
10.0 1.784
11.0 2.157
12.0 2.564
13.0 3.006
14.0 3.483
15.0 3.993
16.0 4.538
17.0 5.116
18.0 5.727
19.0 6.372
20.0 7.049
21.0 7.759
22.0 8.501
23.0 9.274
24.0 10.079
25.0 10.915
26.0 11.718
27.0 12.678
28.0 13.604
29.0 14.559
30.0 15.544
31.0 16.556
32.0 17.597
33.0 18.665
34.0 19.760
35.0 20.831
36.0 22.028
37.0 23.201
38.0 24.398
39.0 25.619
40.0 26.865
20038/10 E –07.97–
Task Description Section 3.11.5a
Page 1
20038/10 E –11.92–
Task Description Section 3.11.5a
Page 2
20038/10 E –07.96–
Task Description Section 3.11.5a
Page 3
20038/10 E –07.96–
Task Description Section 3.11.5a
Page 4
20038/10 E –07.96–
Task Description Section 3.11.5a
Page 5
ET 11/274A
20038/10 E –07.96–
Task Description Section 3.11.5a.1
Page 1
1 2 3 Operations See
20046/20 E –07.96–
Task Description Section 3.11.5a.2
Page 1
3.11.5a.2 Removal
Removing fuel injection pump II
Remove snap ring on plug-in pipe (4) with circlip pliers
from groove.
Insert plug-in pipe into plug-in pipe flange (2).
Remove split pin from securing screw of connecting rod
(1) to injection pump I.
Unscrew nut with ratchet wrench.
Remove screws from cover plate (3) and remove cover
plate.
Remove plug-in pipe flange (3) with plug-in pipe (2) from
cut-out control housing (4).
20046/20 E –07.96–
Task Description Section 3.11.5a.2
Page 2
SG110027a0
1 2
4 3
SG110028a0
Unscrew screws (4) and washers (3) from disc pack (1)
1 2 3 4 5 by means of window of protective tube (5) on intermedi-
ate element (2).
Note
SG110029a0
20046/20 E –07.96–
Task Description Section 3.11.5a.2
Page 3
Note
SG110030a0
20046/20 E –07.96–
Task Description Section 3.11.5a.2
Page 4
20046/20 E –07.96–
Task Description Section 3.11.5a.3
Page 1
3.11.5a.3 Disassembly
Removing connecting rod with swivel head
Release split pin (6) on eccentric screw (2) and remove.
Remove eccentric screw from connector (5) and swivel
head of connecting rod (1) to injection pump I.
Remove connecting rod.
Remove pin (3) and locating spring (4) from connector.
20038/10 E –07.96–
Task Description Section 3.11.5a.4
Page 1
20038/10 E –08.94–
Task Description Section 3.11.5a.5
Page 1
3.11.5a.5 Assembly
Assembling connecting rod
Fit nuts (2) on swivel heads (1).
Insert swivel heads into connecting rod (3) and set to
setting dimensions ”A” and ”B”.
Lock nuts on connecting rod.
Note
20038/10 E –11.95–
Task Description Section 3.11.5a.6
Page 1
3.11.5a.6 Installation
Installing fuel injection pump I
Engage barring tool (2) in ring gear (1) and secure to fly-
wheel housing.
Bar crankshaft with barring tool in direction of engine
rotation until piston A5 is at firing TDC.
As a control, check freedom of movement of rockers at
cylinder A5.
Both rockers must be unloaded and free to move.
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 2
Using a box wrench, rotate the collared bush (1) until the
appropriate marking ”FB” is pointing vertically upwards.
Using a box wrench, rotate the collared bush (1) until the
appropriate marking is facing upwards.
Example:
Marking ”6” for 6V
Marking ”8” for 8V and 16V IP I
Marking ”12” for 12V
Marking ”16” for 16V IP II
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 3
Fit coupling sleeve with marking (1) and (2) onto gear of
drive shaft until both markings are aligned.
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 4
Note
Note
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 5
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 6
Note
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 7
SG110031a0
Note
SG110030a0
Note
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 8
SG110032a0
4 3
SG110028a0
SG110027a0
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 9
SG110033a0
Note
SG110034a0
SG110035a0
20046/20 E –07.96–
Task Description Section 3.11.5a.6
Page 10
SG110036a0
SG110037a0
Note
20046/20 E –07.96–
Task Description Section 3.11.5a.7
Page 1
Note
20038/10 E –11.95–
Task Description Section 3.11.5a.7
Page 2
Insert adjusting jig with dial gauge (1) into injection pump
(2) cylinder A5 and tighten manually (do not tighten se-
curely).
Clamp dial gauge.
20038/10 E –08.94–
Task Description Section 3.11.5a.7
Page 3
Example:
Prestroke actual dimension (1) stamped on surface of
fuel injection pump.
For example 4.70 mm.
20038/10 E –08.94–
Task Description Section 3.11.5a.7
Page 4
Insert adjusting jig with dial gauge (1) into injection pump
(2) cylinder A1 and tighten manually (do not tighten se-
curely).
Clamp dial gauge .
20038/10 E –11.95–
Task Description Section 3.11.5a.7
Page 5
20038/10 E –11.92–
Task Description Section 3.11.5a.7
Page 6
Example:
Prestroke actual dimension is stamped on injection
pump.
20038/10 E –11.95–
Task Description Section 3.11.5a.7
Page 7
Note
20038/10 E –08.94–
Task Description Section 3.11.5a.7
Page 8
7.0 0.876
8.0 1.143
9.0 1.446
10.0 1.784
11.0 2.157
12.0 2.564
13.0 3.006
14.0 3.483
15.0 3.993
16.0 4.538
17.0 5.116
18.0 5.727
19.0 6.372
20.0 7.049
21.0 7.759
22.0 8.501
23.0 9.274
24.0 10.079
25.0 10.915
26.0 11.718
27.0 12.678
28.0 13.604
29.0 14.559
30.0 15.544
31.0 16.556
32.0 17.597
33.0 18.665
34.0 19.760
35.0 20.831
36.0 22.028
37.0 23.201
38.0 24.398
39.0 25.619
40.0 26.865
4.0 0.286
20038/10 E –07.96–
Task Description Section 3.11.5a.7a
Page 1
Note
20038/10 E –11.95–
Task Description Section 3.11.5a.7a
Page 2
Using a box wrench, rotate the collared bush (1) until the
appropriate marking ”8” on collared bush is pointing
vertically upwards.
Note
20038/10 E –11.95–
Task Description Section 3.11.5a.7a
Page 3
Note
20038/10 E –11.95–
Task Description Section 3.11.5a.7a
Page 4
20038/10 E –11.95–
Task Description Section 3.11.6
Page 1
20038/10 E –11.95–
Task Description Section 3.11.6
Page 2
20038/10 E –11.95–
Task Description Section 3.11.6.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.11.6.2
Page 1
3.11.6.2 Removal
Removing leak-off fuel line
Unscrew cap nut (2).
Remove sealing ring and leak-off fuel line (1) from banjo
union.
20038/10 E –11.92–
Task Description Section 3.11.6.2
Page 2
20038/10 E –11.92–
Task Description Section 3.11.6.4
Page 1
20038/10 E –11.95–
Task Description Section 3.11.6.6
Page 1
3.11.6.6 Installation
Installing nozzle holder
Fix support ring and CE ring with ”lubricating grease” on
nozzle holder so that, when installing, the gap between
nozzle and protective sleeve is sufficiently filled with
grease.
Insert nozzle holder into cylinder head.
Locating pin must engage in groove in cylinder head.
Note
20038/10 E –11.95–
Task Description Section 3.11.6.6
Page 2
20038/10 E –11.95–
Task Description Section 3.11.7
Page 1
20038/10 E –11.92–
Task Description Section 3.11.7
Page 2
Connection housing with locking device, fuel injection pump I 8V, 12V, 16V
20038/10 E –07.96–
Task Description Section 3.11.7.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.11.7.2
Page 1
3.11.7.2 Removal
Remove securing screws for end housing (1).
Remove end housing with gasket and O-ring.
20038/10 E –11.92–
Task Description Section 3.11.7.3
Page 1
3.11.7.3 Disassembly
Removing locking device from housing
Remove locking screw (1) from housing (8).
Remove sealing ring (2).
Remove O-ring (9) from housing.
Note
20038/10 E –11.92–
Task Description Section 3.11.7.4
Page 1
20038/10 E –08.94–
Task Description Section 3.11.7.5
Page 1
3.11.7.5 Assembly
Installing locking device in housing
Insert circlip (5) into groove on locating pin (4).
Coat locating pin with ”thin-film lubricant”.
Fit spring retainer (6) and compression spring (7) on lo-
cating pin.
Insert locating pin with compression spring in housing
(8).
Coat threaded connection (3) with ”pipe-thread sealant”
and insert into housing bore until the stop.
Ensure locating pin is free to move.
Coat O-ring (9) with ”petroleum jelly” and insert into
housing groove.
Fit sealing ring (2) on thread on short end of locking
screw (1).
Insert locking screw into housing and tighten.
20038/10 E –11.95–
Task Description Section 3.11.7.6
Page 1
3.11.7.6 Installation
Mount end housing (1) with gasket, O-ring, screws and
washers on injection pump.
Check control rack for ease of movement.
Note
20038/10 E –11.92–
Task Description Section 3.11.8
Page 1
20038/10 E –11.92–
Task Description Section 3.11.8
Page 2
1 Injection pump
2 End housing with cylinder cutout
3 Control rack
20038/10 E –11.92–
Task Description Section 3.11.8.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.11.8.2
Page 1
3.11.8.2 Removal
For removal of end housing, see 3.11.7.2
Remove oil supply sleeves (2) and (3) with compression
spring (1).
20038/10 E –11.92–
Task Description Section 3.11.8.4
Page 1
20038/10 E –07.96–
Task Description Section 3.11.8.6
Page 1
3.11.8.6 Installation
Make sure components are perfectly clean.
Fit oil supply sleeves (2) and (3) with compression spring
(1) on control rack.
Note
Note
20038/10 E –07.96–
Task Description Section 3.11.8a
Page 1
20038/10 E –11.92–
Task Description Section 3.11.8a
Page 2
20038/10 E –11.92–
Task Description Section 3.11.8a.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.11.8a.2
Page 1
3.11.8a.2 Removal
Unscrew securing screws and nuts for cut-out control
housing (1).
Remove cut-out control housing and gasket.
20038/10 E –11.92–
Task Description Section 3.11.8a.2
Page 2
20038/10 E –11.92–
Task Description Section 3.11.8a.4
Page 1
20038/10 E –11.92–
Task Description Section 3.11.8a.6
Page 1
3.11.8a.6 Installation
Make sure components are perfectly clean.
Fit oil supply sleeves (2) and (3) with compression spring
(1) on control rack.
Push back oil supply sleeve (1) and insert connector (2)
with snap ring (3).
Press snap ring for connector (1) into groove of oil sup-
ply sleeve.
20038/10 E –11.92–
Task Description Section 3.11.8a.6
Page 2
Note
Note
20038/10 E –11.95–
Task Description Section 3.11.8b
Page 1
20046/20 E –07.96–
Task Description Section 3.11.8b
Page 2
20046/20 E –07.96–
Task Description Section 3.11.8b
Page 3
Cylinder cutout
20046/20 E –07.96–
Task Description Section 3.11.8b.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.11.8b.2
Page 1
3.11.8b.2 Removal
Unscrew securing screws for housing (1) and remove
with washers.
Remove housing with O-rings.
20058/0 E –03.93–
Task Description Section 3.11.8b.4
Page 1
20046/20 E –07.96–
Task Description Section 3.11.8b.6
Page 1
3.11.8b.6 Installation
Attention
20058/0 E –03.93–
Task Description Section 3.11.8b.6
Page 2
Note
20058/0 E –07.96–
Task Description Section 3.11.8c
Page 1
20047/10 E –11.95–
Task Description Section 3.11.8c
Page 2
20047/10 E –11.95–
Task Description Section 3.11.8c.1
Page 1
1 2 3 Operations See
20047/10 E –11.95–
Task Description Section 3.11.8c.2
Page 1
3.11.8c.2 Removal
Removing cut-out control housing
Unscrew securing screws and nuts for cut-out control
housing (1).
Remove cut-out control housing and O-ring (2).
1 2
SG11 0017a0
20047/10 E –11.95–
Task Description Section 3.11.8c.2
Page 2
20047/10 E –11.95–
Task Description Section 3.11.8c.4
Page 1
20047/10 E –11.95–
Task Description Section 3.11.8c.6
Page 1
3.11.8c.6 Installation
Note
1 2
SG11 0009a0
20047/10 E –11.95–
Task Description Section 3.11.8c.6
Page 2
1 Note
SG11 0011a0
Note
20047/10 E –11.95–
Task Description Section 3.11.9
Page 1
1 2 3 Operations See
3.11.9.2 Removal
Remove hex bolts from connecting housing. Remove connecting housing with gasket.
3.11.9.6 Installation
Mount connecting housing with gasket, spring washers and hex bolts on fuel injection pump I.
20038/10 E –11.92–
Task Description Section 3.11.10
Page 1
20042/10 E –08.94–
Task Description Section 3.11.10
Page 2
20042/10 E –08.94–
Task Description Section 3.11.10
Page 3
20042/10 E –11.95–
Task Description Section 3.11.10.1
Page 1
1 2 3 Operations See
20042/10 E –08.94–
Task Description Section 3.11.10.2
Page 1
3.11.10.2 Removal
Remove cover (1) from lower section.
Remove lower section (3) and gasket (2) from end hous-
ing (1).
20042/10 E –08.94–
Task Description Section 3.11.10.2
Page 2
Remove scale plate (2) and cover plate (1) from rack
travel indicator (3).
Remove pointer from housing of rack travel indicator
only if necessary.
Note
20042/10 E –08.94–
Task Description Section 3.11.10.4
Page 1
20038/10 E –11.92–
Task Description Section 3.11.10.6
Page 1
3.11.10.6 Installation
Mount scale plate (2) and cover plate (1) with screws on
rack travel indicator (3).
Pointer of rack travel indicator must be free to move.
20042/10 E –08.94–
Task Description Section 3.11.10.6
Page 2
Note
20042/10 E –08.94–
Task Description Section 3.11.10.6
Page 3
20042/10 E –08.94–
Task Description Section 3.12
Page 1
20046/20 E –07.96–
Task Description Section 3.12
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –07.96–
Task Description Section 3.12.1
Page 1
20046/20 E –07.96–
Task Description Section 3.12.1
Page 2
20046/20 E –07.96–
Task Description Section 3.12.1
Page 3
20046/20 E –07.96–
Task Description Section 3.12.1
Page 4
20046/20 E –07.96–
Task Description Section 3.12.1
Page 5
20046/20 E –07.96–
Task Description Section 3.12.1
Page 6
T012 045 c0
Arrangement of H.P. fuel lines (double-walled) at injection pump and nozzle holder
20046/20 E –07.96–
Task Description Section 3.12.1
Page 7
Arrangement of H.P. lines at injection pump and nozzle holder (shrink-fitted H.P. line)
20046/20 E –07.96–
Task Description Section 3.12.1
Page 8
Attention
Emergency injection is only permissible when the engine is operated for a limited period only and when the engine room
is monitored.
20046/20 E –07.96–
Task Description Section 3.12.1.1
Page 1
1 2 3 Operations See
20038/10 E –08.94–
Task Description Section 3.12.1.2
Page 1
3.12.1.2 Removal
Detach H.P. line (1) from nozzle holder (2).
20038/10 E –08.94–
Task Description Section 3.12.1.4
Page 1
Attention
20038/10 E –11.92–
Task Description Section 3.12.1.6
Page 1
3.12.1.6 Installation
Connecting H.P. lines
Note
Using a torque wrench (2), tighten the H.P. line (1) union
nut at the nozzle holder. For torque setting, see Section
1.3.
Install the H.P. line (1) union nut to the injection pump
and, using special wrench (2) and torque wrench,
tighten to tightening specification 1.3.
Install H.P. line between unions and pipe clamps so that
it is free from strain; use bending lever to end line to cor-
rect shape if necessary.
Attention
gree (± 2°).<F>).
Designation of autofretted H.P. line: ”A” on the union nut
on nozzle holder side.nut on nozzle holder side.
In event of leaking connections, release union nuts and
retighten to specified torque.
Repeat procedure if connections are still leaking.
20038/10 E –07.96–
Task Description Section 3.12.2
Page 1
20046/20 E –07.96–
Task Description Section 3.12.2
Page 2
Fuel supply and return lines to fuel injection pumps 8V, 12V (Injection pump IIB)
20046/20 E –07.96–
Task Description Section 3.12.2
Page 3
20046/20 E –07.96–
Task Description Section 3.12.2
Page 4
Fuel return lines from fuel injection pumps, 16 V (injection pump IIB)
20046/20 E –07.96–
Task Description Section 3.12.2
Page 5
Fuel supply and return lines to fuel injection pumps, 8V, 12V (Injection pump IID)
20046/20 E –07.96–
Task Description Section 3.12.2
Page 6
Fuel supply lines to fuel injection pumps, 16V (injection pump IID)
20046/20 E –07.96–
Task Description Section 3.12.2
Page 7
Fuel return lines from fuel injection pumps, 16V (injection pump IID)
20046/20 E –07.96–
Task Description Section 3.12.2
Page 8
20046/20 E –07.96–
Task Description Section 3.12.2
Page 9
20046/20 E –07.96–
Task Description Section 3.12.2
Page 10
20046/20 E –07.96–
Task Description Section 3.12.2
Page 11
20046/20 E –07.96–
Task Description Section 3.12.2
Page 12
20046/20 E –07.96–
Task Description Section 3.12.2
Page 13
20046/20 E –07.96–
Task Description Section 3.12.2
Page 14
20046/20 E –07.96–
Task Description Section 3.12.2
Page 15
20046/20 E –07.96–
Task Description Section 3.12.2.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.12.2.2
Page 1
3.12.2.2 Removal
Before removing fuel lines, it is useful to take photographs of all sides of engine or to identify fuel lines with numbered
markers to avoid confusion during reassembly.
After removing fuel lines, seal all connections immediately with suitable plugs.
Remove non-return valves from fuel lines, fuel duplex filter and connector.
Remove leak-off fuel tank and buffer from carrier, remove carrier from crankcase upper section, see Table 3.12.2
20042/10 E –11.95–
Task Description Section 3.12.2.3
Page 1
3.12.2.3 Disassembly
Disassembling non-return valve
L59 889 V
Remove circlip (1), valve guide (6) with spring (2), taper
sleeve (3) and valve head (4) from housing (5).
20042/10 E –08.94–
Task Description Section 3.12.2.4
Page 1
20042/10 E –08.94–
Task Description Section 3.12.2.5
Page 1
3.12.2.5 Assembly
Assembling non-return valve
Note
Install valve head (4), taper sleeve (3) and spring (2) in
housing (5); secure with circlip (1).
Note
1 Float switch
2 Nut
3 Spring washer
4 Sealing ring
5 Cover
6 Stud
7 Plug
8 Sealing ring
9 Housing
10 Spring washer
11 Bolt
12 Plug
13 Sealing ring
14 Union
20042/10 E –08.94–
Task Description Section 3.12.2.6
Page 1
3.12.2.6 Installation
Blow out the fuel lines with compressed air before installation; check that they are particularly clean.
Do not remove blanking plug until just before installation.
Install fuel lines with gaskets and securing elements ensuring that they are tension-free; see photos or markings.
Install non-return valves.
Note
The arrow on the non-return valve must point in the same direction as the direction of the fuel supply.
Mount carrier with securing screws and spring washers on crankcase upper section.
Mount buffer with screws and spring washers to carrier, see Table 3.12.2, Page 15.
Mount leak-off fuel tank with screws and spring washers on carrier, see Table 3.12.2.
20038/10 E –07.96–
Task Description Section 3.12.3
Page 1
ET 12 507 5
20042/10 E –08.94–
Task Description Section 3.12.3
Page 2
20042/10 E –08.94–
Task Description Section 3.12.3
Page 3
20042/10 E –08.94–
Task Description Section 3.12.3.1
Page 1
1 2 3 Operations See
20038/10 E –04.95–
Task Description Section 3.12.3.2
Page 1
3.12.3.2 Removal
Removing duplex filter with intermediate plate
Unscrew bolts (1) on intermediate plate.
Remove duplex filter with intermediate plate
20038/10 E –08.94–
Task Description Section 3.12.3.3
Page 1
3.12.3.3 Disassembly
Removing connector
Clamp duplex filter (3) in a vice.
Unscrew bolts (1).
Remove connector (2).
Remove O-rings from connector.
20038/10 E –11.92–
Task Description Section 3.12.3.3
Page 2
20038/10 E –11.92–
Task Description Section 3.12.3.4
Page 1
20038/10 E –11.92–
Task Description Section 3.12.3.5
Page 1
3.12.3.5 Assembly
Installing diverter valve
Ensure that all components are particularly clean.
Insert new O-rings (5) in grooves in diverter valve (4).
Coat O-ring with petroleum jelly.
Install spring (7) and shaped seal (6).
Insert diverter valve into filter housing (1).
Insert washer.
Install circlip (3).
Ensure that circlip is correctly seated in groove.
Note
20038/10 E –11.95–
Task Description Section 3.12.3.5
Page 2
20038/10 E –11.95–
Task Description Section 3.12.3.6
Page 1
3.12.3.6 Installation
Installing intermediate plate
Mount the intermediate plate (2) with screws and spring
washers to the duplex filter (1) and tighten.
20038/10 E –11.92–
Task Description Section 3.12.4
Page 1
20042/10 E –08.94–
Task Description Section 3.12.4
Page 2
ET 12 409 2
20042/10 E –08.94–
Task Description Section 3.12.4
Page 3
20042/10 E –08.94–
Task Description Section 3.12.4
Page 4
ET 12 409 6
20042/10 E –08.94–
Task Description Section 3.12.4
Page 5
20042/10 E –08.94–
Task Description Section 3.12.4
Page 6
20042/10 E –08.94–
Task Description Section 3.12.4.1
Page 1
1 2 3 Operations See
20054/00 E –04.95–
Task Description Section 3.12.4.2
Page 1
3.12.4.2 Removal
Remove fuel delivery pump
Release securing screws (1) and remove.
Remove delivery pump (2) from bearing housing.
20038/10 E –11.92–
Task Description Section 3.12.4.3
Page 1
3.12.4.3 Disassembly
Removing drive sleeve and drive shaft
Remove snap ring (4) from groove in drive sleeve (3).
Remove drive shaft (5) from drive sleeve.
Release socket head screw (2) on drive sleeve.
Remove drive sleeve with seal carrier from shaft of gear-
type pump (1).
20038/10 E –11.92–
Task Description Section 3.12.4.3
Page 2
Note
Disassembling cover
Unscrew cap nut (1) from valve spindle (5).
Remove USIT ring (2).
Release pipe nut (3) from valve spindle.
Carefully unscrew valve spindle from cover (8) and re-
move with USIT ring (4).
Note
20038/10 E –11.92–
Task Description Section 3.12.4.3
Page 3
Removing gears
Remove drive shaft with gear (1) and pump gear shaft
with gear (3) from flanged body (2).
20038/10 E –11.92–
Task Description Section 3.12.4.4
Page 1
20038/10 E –02.95–
Task Description Section 3.12.4.5
Page 1
3.12.4.5 Assembly
Assembling gear-type pump
Note
Installing gears
Coat bearing bushes, drive shaft and gear pump shaft
with engine oil.
Insert drive shaft (1) and gear pump shaft (3) into bear-
ing bushes in flanged body (2).
20038/10 E –11.92–
Task Description Section 3.12.4.5
Page 2
Assembling cover
Note
Installing cover
Position cover (1) on preassembled gear carrier plate
(3).
Tapered pin must engage corresponding bore in cover.
Mount cover with socket head screws (4).
Tighten screws diagonally and evenly.
20038/10 E –11.92–
Task Description Section 3.12.4.5
Page 3
Note
The sealing lip of the oil seal must face the pump when
installed.
Coat radial-lip oil seal (2) sealing lip with petroleum jelly.
Press radial-lip oil seal with suitable protective sleeve
over drive shaft into preassembled gear-type pump (1).
Insert snap ring (3) into groove in flanged body using
snap ring pliers.
Make sure that snap ring is securely seated.
20038/10 E –11.95–
Task Description Section 3.12.4.5
Page 4
20038/10 E –11.95–
Task Description Section 3.12.4.6
Page 1
3.12.4.6 Installation
Installing bearing housing
Rub down sealing surfaces of crankcase and bearing
housing (2) with oilstone.
Insert O-ring into groove on bearing housing and coat
with petroleum jelly.
Install bearing housing on crankcase with nuts (1) and
spring washers and tighten.
20038/10 E –11.95–
Task Description Section 3.12.5
Page 1
20046/20 E –07.96–
Task Description Section 3.12.5
Page 2
20046/20 E –07.96–
Task Description Section 3.12.5
Page 3
20046/20 E –07.96–
Task Description Section 3.12.5
Page 4
1 Housing 5 Cover
2 Piston rod 6 Handle
3 Gasket 7 Sleeve
4 O-ring
20046/20 E –07.96–
Task Description Section 3.12.5
Page 5
20046/20 E –07.96–
Task Description Section 3.12.5.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.12.5.2
Page 1
3.12.5.2 Removal
Removing collecting housing
Release and remove screws for securing the fuel col-
lecting housing (1).
20038/10 E –11.92–
Task Description Section 3.12.5.3
Page 1
3.12.5.3 Disassembly
Disassembling collecting housing
Release and remove hand pump (2) at collecting hous-
ing (1).
Removing elbow
Remove elbow (3) with flange (2) from collecting hous-
ing (1).
Removing union
Release and remove union (2) at collecting housing (1).
20038/10 E –11.92–
Task Description Section 3.12.5.3
Page 2
Removing valve
Take valve (2) out of collecting housing (1).
20038/10 E –11.95–
Task Description Section 3.12.5.3
Page 3
Attention
Caution
20038/10 E –11.95–
Task Description Section 3.12.5.4
Page 1
20038/10 E –11.95–
Task Description Section 3.12.5.5
Page 1
3.12.5.5 Assembly
Assembling hand pump
Clean all components.
Fit O-ring (4) and gasket (3) on plunger rod (2).
Coat O-ring with petroleum jelly.
Install plunger rod (2) in housing (1).
Slip sleeve (7) over housing.
Bolt cover (5) to housing.
Coat thread of plunger rod with high-strength thread-
locking liquid and screw on handle (6).
Connect handle to sleeve.
Check operation of hand pump.
Note
20038/10 E –08.94–
Task Description Section 3.12.5.5
Page 2
20038/10 E –11.95–
Task Description Section 3.12.5.5
Page 3
Installing elbow
Connect elbow (3) with flange (2) and O-ring to collect-
ing housing (1).
20038/10 E –11.92–
Task Description Section 3.12.5.6
Page 1
3.12.5.6 Installation
Installing connecting line
Install O-rings (2) in grooves in connecting line (3).
Coat O-rings with petroleum jelly.
Install connecting line in collecting housing (1).
20038/10 E –11.95–
Task Description Section 3.12.6
Page 1
20046/20 E –07.96–
Task Description Section 3.12.6
Page 2
20046/20 E –07.96–
Task Description Section 3.12.6
Page 3
20046/20 E –07.96–
Task Description Section 3.12.6
Page 4
Note
Install the solenoid valve so that the arrow at the bottom of the valve body points in the direction of flow; take note of
the integrally cast digits on the valve body (1 = inlet; 2 = outlet).
20046/20 E –07.96–
Task Description Section 3.12.6
Page 5
Note
Install the solenoid valve so that the arrow at the bottom of the valve body points in the direction of flow; take note of
the integrally cast digits on the valve body (1 = inlet; 2 = outlet).
20046/20 E –07.96–
Task Description Section 3.12.6.1
Page 1
1 2 3 Operations See
20046/20 E –07.96–
Task Description Section 3.12.6.2
Page 1
3.12.6.2 Removal
Remove flame torch
Remove protective shroud (4).
Unscrew fuel line (10) union nut (9).
Mark electrical cables (8), disconnect cable connections
(5), (6) and disconnect from flame torch.
Release locknut and unscrew flame torch.
Remove sealing element (7).
Unscrew bolts from flange (11).
Remove flange and gasket.
Remove flange (2) and jacket (1) from charge air mani-
fold.
Unscrew fuel nipple as required.
20046/20 E –07.96–
Task Description Section 3.12.6.4
Page 1
20046/20 E –07.96–
Task Description Section 3.12.6.6
Page 1
3.12.6.6 Installation
Install flame torch
Insert jacket (1) with gasket at charge air manifold.
Coat flame torch (3) thread with sealing paste.
Screw flange (2) onto flame torch.
Insert gasket into jacket.
Set flame torch distance to 34 mm ±1 mm and secure
with a locknut.
Fit flange (11) with gasket on jacket.
Screw fuel nipple onto flame torch.
Press sealing element (7) onto fuel nipple.
Connect electrical cables to flame torch according to
their markings and secure with nuts (5) and (6).
Fit protective shroud (4) and make sure that sealing el-
ement is correctly positioned.
Mount fuel line (10) on fuel nipple and secure with union
nut (9).
20046/20 E –07.96–
Task Description Section 3.13
Page 1
20038/10 E –11.92–
Task Description Section 3.13
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20038/10 E –07.96–
Task Description Section 3.13.1
Page 1
20046/20 E –07.96–
Task Description Section 3.13.1
Page 2
20046/20 E –07.96–
Task Description Section 3.13.1
Page 3
1 Housing 10 Impeller
2 Rotary seal 11 O-ring
3 Shaft seal 12 Counterring
4 Pump shaft 13 Thrust washer
5 Bearing housing 14 Stress bolt
6 Angular-contact ball bearing 15 Connector
7 Tab washer 16 O-ring
8 Nut 17 Screw
9 Screw
20046/20 E –07.96–
Task Description Section 3.13.1
Page 4
20046/20 E –07.96–
Task Description Section 3.13.1
Page 5
20046/20 E –07.96–
Task Description Section 3.13.1
Page 6
1 Housing 10 Screw
2 Rotary seal 11 Impeller
3 Shaft seal 12 O-ring
4 Counterring 13 Thrust washer
5 Pump shaft 14 Stress bolt
6 Bearing housing 15 Connector
7 Angular-contact ball bearing 16 O-ring
8 Tab washer 17 Socket-head screw
9 Slotted nut
20046/20 E –07.96–
Task Description Section 3.13.1
Page 7
20046/20 E –07.96–
Task Description Section 3.13.1
Page 8
20046/20 E –07.96–
Task Description Section 3.13.1
Page 9
20046/20 E –07.96–
Task Description Section 3.13.1.1
Page 1
1 2 3 Operations See
20038/10 E –07.96–
Task Description Section 3.13.1.2
Page 1
3.13.1.2 Removal
Removing cover
Remove securing screw (1) with spring washer (2).
Remove cover (3).
Remove O-ring (4) from bearing flange (5).
Caution
Danger !
Hydraulic removal must only be carried out by trained personnel.
Use only those tools and equipment stipulated for hydraulic removal.
The equipment must be checked once a year for cracks in draw spindle.
It is not permitted for personnel to remain within the danger area behind the equipment during the removal operations.
The max. expansion pressure (Pmax = 1500 bar) must not be exceeded.
Removing sleeve
Screw draw spindle (1) into coolant pump shaft and
tighten.
Install removal tool so that there is at least 5 mm clear-
ance between catcher plate (5) and sleeve.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Catcher plate
6 Grub screw
20038/10 E –11.92–
Task Description Section 3.13.1.2
Page 2
Removing vent
Remove banjo bolt (3) on vent pipe from engine coolant
pump (4).
Remove vent pipe from bracket (1).
Remove bracket from screw fitting.
Remove screw fitting from crankcase.
Note
20038/10 E –11.92–
Task Description Section 3.13.1.2
Page 3
20038/10 E –11.92–
Task Description Section 3.13.1.3
Page 1
3.13.1.3 Disassembly
Removing connector
Insert coolant pump in retaining device.
Remove screw (2) from connector.
Release connector with jackscrew (1).
Removing impeller
Use socket wrench (1) to remove stress bolt from im-
peller.
Remove thrust washer.
20038/10 E –11.92–
Task Description Section 3.13.1.3
Page 2
20038/10 E –11.92–
Task Description Section 3.13.1.3
Page 3
20038/10 E –11.92–
Task Description Section 3.13.1.3
Page 4
20038/10 E –11.92–
Task Description Section 3.13.1.3
Page 5
20038/10 E –11.92–
Task Description Section 3.13.1.3
Page 6
20038/10 E –11.92–
Task Description Section 3.13.1.4
Page 1
20038/10 E –08.94–
Task Description Section 3.13.1.5
Page 1
3.13.1.5 Assembly
Installing rotary seal
Clean and dry seating surface of rotary seal so that it is
free from grease, then coat with surface sealant.
Use drift (1) and manual press or plastic mallet to drive
rotary seal (2) into pump housing until seated.
Turn over pump housing.
Note
20038/10 E –11.92–
Task Description Section 3.13.1.5
Page 2
Note
20038/10 E –11.92–
Task Description Section 3.13.1.5
Page 3
Install slotted nut and tighten with socket wrench (1). For
torque settings, see Section 1.3.
20038/10 E –11.92–
Task Description Section 3.13.1.5
Page 4
20038/10 E –11.92–
Task Description Section 3.13.1.5
Page 5
Installing impeller
Clean taper on pump shaft and running surface of rotary
seal (1) with denaturated ethanol.
Taper and running surface must be free of grease and
dry before installation of impeller.
20038/10 E –11.92–
Task Description Section 3.13.1.5
Page 6
Tightening impeller
Install thrust washer.
Coat contact surface and thread of stress bolt with en-
gine oil.
Install stress bolt (1) and pretighten with torque wrench
(2) according to specifications. For torque settings, see
Section 1.3.
20038/10 E –11.92–
Task Description Section 3.13.1.5
Page 7
Installing connector
Insert O-ring (2) into groove on connector and coat with
petroleum jelly.
Place connector (1) on pump housing so that retaining
bolt aligns with threaded bore.
Align connector with bolt and drive into pump housing
with plastic mallet.
Screw in and secure retaining bolts.
Measuring clearance
Use feeler gauge to measure clearance between im-
peller (1) and connector (2).
Gap clearance: max. 1.5 mm; min. 0.6 mm
Caution
20038/10 E –11.95–
Task Description Section 3.13.1.5
Page 8
20038/10 E –11.92–
Task Description Section 3.13.1.6
Page 1
3.13.1.6 Installation
Installing bearing housing for engine coolant pump
Insert O-ring (1) into groove on bearing housing and coat
with petroleum jelly.
Insert bearing flange into corresponding bore in crank-
case.
20038/10 E –11.95–
Task Description Section 3.13.1.6
Page 2
Installing sleeve
Check sleeve and drive shaft tapers for damage.
Check for burrs at transition areas between contact and
lateral surfaces, and oil distribution and discharge
grooves.
Machining scores and transition radii must be polished
smooth if necessary.
Clean press-fit surfaces with denaturated ethanol and
coat with SAE 10 engine oil.
Push sleeve (1) onto drive shaft taper (2) and measure
distance from shaft end to sleeve end.
Installing sleeve
Caution
Danger !
Hydraulic installation may only be carried out by trained personnel.
Use only those tools and equipment stipulated for hydraulic removal.
The equipment must be checked once a year for cracks in draw spindle.
The max. expansion pressure (Pmax = 1500 bar) must not be exceeded.
It is not permitted for personnel to remain within the danger area behind the equipment during the installation oper-
ations.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Catcher plate/thrust washer
6 Grub screw
20038/10 E –11.92–
Task Description Section 3.13.1.6
Page 3
Installing vent
Install threaded adapter with sealing ring in crankcase.
Insert O-ring on screw element and vent pipe (2) and
coat with petroleum jelly.
Introduce elbow (1) into union in crankcase.
Insert ventilation pipe (2) with O-ring into bracket.
Install vent pipe with banjo bolt (3) and sealing rings on
engine coolant pump (4).
20038/10 E –07.96–
Task Description Section 3.13.1.6
Page 4
Mounting cover
Coat O-ring (4) with petroleum jelly and insert into
groove of bearing flange (5).
Install cover (3) with washer (2) and hex screw (1) on
bearing flange.
20038/10 E –07.96–
Task Description Section 3.13.2
Page 1
20046/20 E –07.96–
Task Description Section 3.13.2
Page 2
20046/20 E –07.96–
Task Description Section 3.13.2
Page 3
20046/20 E –07.96–
Task Description Section 3.13.2.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.13.2.2
Page 1
3.13.2.2 Removal
Removing bearing flange, driving end
Note
20047/10 E –11.95–
Task Description Section 3.13.2.3
Page 1
3.13.2.3 Disassembly
Removing cover
Install raw water pump in retaining device.
Secure latch.
Remove cover (1) and seal from pump housing.
20038/10 E –11.92–
Task Description Section 3.13.2.3
Page 2
Removing impeller
Install removal tool (1) on impeller (2).
Remove impeller with thrust bolt from drive shaft.
Remove O-ring.
Note
20038/10 E –11.92–
Task Description Section 3.13.2.3
Page 3
20038/10 E –11.92–
Task Description Section 3.13.2.3
Page 4
20038/10 E –11.92–
Task Description Section 3.13.2.3
Page 5
20038/10 E –11.92–
Task Description Section 3.13.2.4
Page 1
20038/10 E –11.92–
Task Description Section 3.13.2.5
Page 1
3.13.2.5 Assembly
Installing grooved ball bearing in bearing housing
Clean all components.
Press grooved ball bearing with thrust plate (1) into bear-
ing housing (2) bore.
20038/10 E –11.93–
Task Description Section 3.13.2.5
Page 2
20038/10 E –11.93–
Task Description Section 3.13.2.5
Page 3
20038/10 E –11.93–
Task Description Section 3.13.2.5
Page 4
Inserting O-rings
Coat O-ring with petroleum jelly and insert into inner
groove on bearing housing.
Coat O-ring (1) with petroleum jelly and insert into outer
groove on bearing housing.
20038/10 E –11.95–
Task Description Section 3.13.2.5
Page 5
Note
Note
20038/10 E –11.93–
Task Description Section 3.13.2.5
Page 6
20038/10 E –11.95–
Task Description Section 3.13.2.5
Page 7
Installing impeller
Degrease and dry drive shaft and impeller tapers.
Push impeller onto drive shaft.
Install thrust ring.
20038/10 E –11.93–
Task Description Section 3.13.2.5
Page 8
Note
20038/10 E –11.95–
Task Description Section 3.13.2.5
Page 9
Installing cover
Install cover (1) with new gasket on pump housing.
Secure with nuts and spring washers.
Note
Note
20038/10 E –11.93–
Task Description Section 3.13.2.6
Page 1
3.13.2.6 Installation
Install raw water pump
Smooth sealing surfaces on crankcase (3) and raw
water pump with oilstone.
Insert O-ring (2) into groove in bearing housing of raw
water pump (1).
Coat O-ring with petroleum jelly.
Insert raw water pump into crankcase bore so that relief
bore for leak-off water faces downwards.
20047/10 E –11.95–
Task Description Section 3.13.3
Page 1
20038/10 E –11.92–
Task Description Section 3.13.3
Page 2
20038/10 E –11.92–
Task Description Section 3.13.3
Page 3
Bilge pump
20038/10 E –11.92–
Task Description Section 3.13.3.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.13.3.2
Page 1
3.13.3.2 Removal
Removing bilge pump
Disconnect engine oil line (1) from intermediate flange
(2).
Remove securing bolts.
Remove bilge pump with coupling sleeve.
Remove intermediate flange from bilge pump.
Remove O-rings.
Remove coupling (see 3.86.4.2).
20038/10 E –11.92–
Task Description Section 3.13.3.3
Page 1
3.13.3.3 Disassembly
Removing cover
Install bilge pump in retaining device (2).
Mark relative positions of cover, flow-control disc and
pump housing.
Remove cover (1) from bilge pump, then remove
gasket.
Removing impeller
Remove stress bolt (1) from impeller (2).
20038/10 E –11.92–
Task Description Section 3.13.3.3
Page 2
20038/10 E –11.92–
Task Description Section 3.13.3.3
Page 3
20038/10 E –11.92–
Task Description Section 3.13.3.4
Page 1
20038/10 E –11.92–
Task Description Section 3.13.3.5
Page 1
3.13.3.5 Assembly
Installing grooved ball bearing
Clean all components.
Use manual press (1) and drift to press grooved ball
bearing into pump housing (2).
20038/10 E –11.92–
Task Description Section 3.13.3.5
Page 2
20038/10 E –07.96–
Task Description Section 3.13.3.5
Page 3
20038/10 E –11.92–
Task Description Section 3.13.3.5
Page 4
Installing impeller
Clean and degrease fits on impeller and drive shaft.
Push impeller onto drive shaft.
Screw installation device (2) with thrust screw (1) into
drive shaft.
Push impeller (3) onto drive shaft with thrust nut.
Measure gap clearance 0.15 mm to 0.25 mm between
impeller and flow-control disc with feeler gauge (4).
Remove installation device.
20038/10 E –07.96–
Task Description Section 3.13.3.5
Page 5
Adjusting impeller
With depth gauge (1), measure distance between flow-
control disc (3) and upper edge of impeller (2).
Example: Distance = 24.0 mm
Note
20038/10 E –07.96–
Task Description Section 3.13.3.6
Page 1
3.13.3.6 Installation
Insert O-ring (4) into groove on bilge pump (5) and coat
with petroleum jelly.
Install intermediate flange (3) on bilge pump and secure
with bolts and spring washers.
Installing coupling element (8), see 3.86.4.6
Install snap rings (2) in coupling sleeve (7), making sure
that they are correctly seated.
Lubricate coupling sleeve with engine oil and push onto
coupling.
Insert O-ring (6) on bearing cap (1) into groove and coat
with petroleum jelly.
20038/10 E –07.96–
Task Description Section 3.14
Page 1
20046/20 E –07.96–
Task Description Section 3.14
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Ink-check plate
Pressure-testing equipment
Pressure gauge, to 10 bar
Water bath with temperature tester
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –07.96–
Task Description Section 3.14.1
Page 1
20046/20 E –07.96–
Task Description Section 3.14.1
Page 2
20046/20 E –07.96–
Task Description Section 3.14.1
Page 3
20046/20 E –07.96–
Task Description Section 3.14.1
Page 4
20046/20 E –07.96–
Task Description Section 3.14.1
Page 5
Engine coolant lines from intercooler to engine oil heat exchanger and to coolant pump, 12V
20046/20 E –07.96–
Task Description Section 3.14.1
Page 6
1 Elbow 20 Gasket
2 Gasket 21 Spring washer
3 Washer 22 Hex bolt
4 Hex bolt 23 Plug
5 Hex bolt 24 Sealing ring
6 Washer 25 Mounting bracket
7 Hex bolt 26 Washer
8 Washer 27 Hex bolt
9 Hex bolt 28 Pipe clamp half
10 Plug-in socket pipe 29 Pipe clamp half
11 O-ring 30 Washer
12 Coolant line 31 Hex bolt
13 O-ring 32 O-ring
14 Socket-head screw 33 Plug-in pipe
15 Washer 34 Elbow
16 Mounting bracket 35 Gasket
17 Coolant line 36 Washer
18 Sealing ring 37 Hex bolt
19 Plug 38 Hex bolt
20046/20 E –07.96–
Task Description Section 3.14.1
Page 7
1 Elbow 12 Washer
2 Plug 13 Screw
3 Sealing ring 14 Plug-in pipe
4 Gasket 15 O-ring
5 Washer 16 Elbow
6 Screw 17 Sealing ring
7 Screw 18 Plug
8 Plug-in pipe 19 Gasket
9 O-ring 20 Washer
10 Elbow 21 Screw
11 Gasket
20046/20 E –07.96–
Task Description Section 3.14.1
Page 8
20046/20 E –07.96–
Task Description Section 3.14.1
Page 9
1 Flange 17 Plug
2 Gasket 18 Screw
3 Socket-head screw 19 Screw
4 Plug-in pipe 20 Screw
5 O-ring 21 Screw
6 Elbow 22 Washer
7 Screw 23 Spring washer
8 Screw 24 O-ring
9 Washer 25 Coolant line
10 O-ring 26 Connecting pipe
11 Plug-in pipe 27 O-ring
12 O-ring 28 Screw
13 Elbow, left 29 Washer
14 Elbow, right 30 O-ring (order-specific)
15 Restrictor 31 Plug-in pipe (order-specific)
16 Sealing ring 32 O-ring (order-specific)
20046/20 E –07.96–
Task Description Section 3.14.1
Page 10
1 Elbow 16 Washer
2 Washer 17 Socket-head screw
3 Hex bolt 18 Plug-in pipe
4 Sealing ring 19 O-ring
5 Plug 20 O-ring
6 Plug-in pipe 21 O-ring
7 O-ring 22 Washer
8 Sealing ring 23 Hex bolt
9 Injector 24 Hex bolt
10 Sealing cone 25 Sealing ring
11 Nut 26 Plug
12 Annular slide thermostat 27 Threaded bush
13 Elbow 28 Sealing ring
14 Flow restrictor 29 Plug
15 O-ring
20046/20 E –07.96–
Task Description Section 3.14.1
Page 11
1 Elbow 16 Washer
2 Washer 17 Socket-head screw
3 Hex bolt 18 Plug-in pipe
4 Sealing ring 19 O-ring
5 Plug 20 O-ring
6 Plug-in pipe 21 O-ring
7 O-ring 22 Washer
8 Sealing ring 23 Hex bolt
9 Injector 24 Hex bolt
10 Sealing cone 25 Sealing ring
11 Nut 26 Plug
12 Annular slide thermostat 27 Threaded bush
13 Elbow 28 Sealing ring
14 O-ring 29 Plug
15 Flow restrictor
20046/20 E –07.96–
Task Description Section 3.14.1
Page 12
20046/20 E –07.96–
Task Description Section 3.14.1
Page 13
20046/20 E –07.96–
Task Description Section 3.14.1
Page 14
20046/20 E –07.96–
Task Description Section 3.14.1
Page 15
Engine coolant lines from coolant expansion tank to intake elbow of engine coolant pump
1 Elbow 13 Union
2 Plug 14 Mounting bracket
3 Sealing ring 15 Pipe clamp half
4 Washer 16 Grommet
5 Hex bolt 17 Spring washer
6 Threaded bush 18 Hex bolt
7 Drain line 19 Hex bolt
8 Sealing ring 20 Pipe clamp half
9 Adapter 21 Grommet
10 Banjo bolt 22 Spring washer
11 Pipe 23 Hex bolt
12 Sealing ring
20046/20 E –07.96–
Task Description Section 3.14.1
Page 16
20046/20 E –07.96–
Task Description Section 3.14.1
Page 17
20046/20 E –07.96–
Task Description Section 3.14.1
Page 18
20046/20 E –07.96–
Task Description Section 3.14.1
Page 19
20046/20 E –07.96–
Task Description Section 3.14.1.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.14.1.2
Page 1
3.14.1.2 Removal
Before removing coolant lines, it is advisable to take photographs of engine from all sides or to identify lines with
markers so as to avoid confusion during subsequent reassembly.
Remove all monitoring instruments.
After removing coolant lines, seal all connections with suitable plugs.
20038/10 E –11.92–
Task Description Section 3.14.1.4
Page 1
20038/10 E –11.93–
Task Description Section 3.14.1.6
Page 1
3.14.1.6 Installation
Before installation, blow coolant lines, plug-in pipes and connecting lines clear with compressed air.
Ensure that components are particularly clean.
Do not remove blanking plug until just before installation.
Coat O-rings with petroleum jelly and insert into grooves of plug-in pipes and flanges.
Install coolant lines, plug-in pipes, connecting lines and flanges with new gaskets and O-rings and attaching hardware
so that they are free from strain in accordance with photographs, markers and layout in illustrations in 3.14.1.
Ensure that strainers are installed in correct position, see 3.14.1.
Once coolant distribution has been finally set, mark position of flow restrictor on elbow flange with a notch, see 3.14.1.
20038/10 E –07.96–
Task Description Section 3.14.2
Page 1
Vent line from intercooler and turbocharger casing connecting line to distributor, 8V
20046/20 E –07.96–
Task Description Section 3.14.2
Page 2
Vent line from intercooler and turbocharger casing connecting line to distributor, 12V, 16V
20046/20 E –07.96–
Task Description Section 3.14.2
Page 3
20046/20 E –07.96–
Task Description Section 3.14.2
Page 4
20046/20 E –07.96–
Task Description Section 3.14.2
Page 5
20046/20 E –07.96–
Task Description Section 3.14.2
Page 6
20046/20 E –07.96–
Task Description Section 3.14.2
Page 7
20046/20 E –07.96–
Task Description Section 3.14.2
Page 8
20046/20 E –07.96–
Task Description Section 3.14.2
Page 9
20046/20 E –07.96–
Task Description Section 3.14.2
Page 10
20046/20 E –07.96–
Task Description Section 3.14.2
Page 11
20046/20 E –07.96–
Task Description Section 3.14.2.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.14.2.2
Page 1
3.14.2.2 Removal
Before removing vent and drain lines, it is advisable to take photographs of engine from all sides or to identify lines with
markers so as to avoid confusion during subsequent reassembly.
After removing lines, seal all connections with suitable plugs.
20038/10 E –11.92–
Task Description Section 3.14.2.4
Page 1
20038/10 E –11.92–
Task Description Section 3.14.2.6
Page 1
3.14.2.6 Installation
Before installation, blow vent and drain lines clear with compressed air.
Ensure that components are particularly clean.
Do not remove blanking plug until just before installation.
Fit vent and drain lines with new sealing rings and attaching hardware so that they are free from strain in accordance
with photographs, markers and layout in illustrations in 3.14.2.
20038/10 E –07.96–
Task Description Section 3.14.3
Page 1
20046/20 E –07.96–
Task Description Section 3.14.3
Page 2
1 Elbow 12 Plug
2 Gasket 13 Restrictor (order-specific)
3 Spring washer 14 Gasket (order-specific)
4 Screw 15 Screw (order-specific)
5 Screw 16 Spring washer (order-specific)
6 Elbow 17 Nut (order-specific)
7 Gasket 18 Reduction union
8 Flange segment 19 Nut
9 Spring washer 20 Sealing taper
10 Screw 21 End taper
11 Sealing ring
20046/20 E –07.96–
Task Description Section 3.14.3
Page 3
20046/20 E –07.96–
Task Description Section 3.14.3.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.14.3.2
Page 1
3.14.3.2 Removal
Before removing raw water lines, it is advisable to take photographs of engine from all sides or to identify lines with
markers so as to avoid confusion during subsequent reassembly.
After removing raw water lines, seal all connections with suitable plugs.
20038/10 E –11.92–
Task Description Section 3.14.3.4
Page 1
20038/10 E –11.92–
Task Description Section 3.14.3.6
Page 1
3.14.3.6 Installation
Before installing, blow raw water lines clear with compressed air.
Make sure parts are perfectly clean.
Do not remove blanking plug until just before installation.
Fit raw water lines with new sealing rings and O-rings and attaching hardware so that they are free from strain in accord-
ance with photographs and layout in illustrations in (3.14.3).
Note
20038/10 E –07.96–
Task Description Section 3.14.5c
Page 1
20046/20 E –07.96–
Task Description Section 3.14.5c.1
Page 1
1 2 3 Operations See
20046/20 E –07.96–
Task Description Section 3.14.5c.2
Page 1
3.14.5c.2 Removal
Remove screws (2) and washers (3) from expansion
tank (1).
Lift expansion tank from cooler housing (5).
Remove sealing ring (4) from cooler housing.
Remove cooler housing 3.14.6.2
20046/20 E –07.96–
Task Description Section 3.14.5c.3
Page 1
3.14.5c.3 Disassembly
Removing blind flanges
Release bolts (2) in both blind flanges (4) and remove
together with spring washers (3).
Remove blind flanges with gaskets (5) from expansion
tank (1).
20046/20 E –07.96–
Task Description Section 3.14.5c.3
Page 2
20046/20 E –07.96–
Task Description Section 3.14.5c.4
Page 1
Caution
When using chemical agents, always follow the manufacturer’s instructions for use.
Clean expansion tank and fitted parts with cold cleaner and brush.
Remove scale with a descaling product that does not attack the metal surface (e.g. P3 T288 from Henkel or Euron 1308
amidosulfonic acid from Hoechst).
Once cleaning is completed, rinse all parts with a powerful jet of water.
Check expansion tank for wear and cavitation, smooth sealing surfaces and mating faces with oilstone if necessary,
replace as required.
Check threaded bores for ease of movement, recut thread if necessary, or install threaded inserts.
Clean coolant level sight glass; replace if necessary.
Check seal on valve cover, replace valve cover if necessary.
Replace gaskets.
Inspect flange, cover, blind flanges and coolant level indicator for surface irregularities.
Rub down screw-down and sealing surfaces with oilstone.
20046/20 E –07.96–
Task Description Section 3.14.5c.5
Page 1
3.14.5c.5 Assembly
Installing breather valve
Clean sealing surfaces, smooth with oilstone if necess-
ary.
Correctly position flange (3) with a new gasket (2) on ex-
pansion tank.
Secure flange to expansion tank (1) with hex bolts (5)
and washers (6).
Note
Note
20046/20 E –07.96–
Task Description Section 3.14.5c.5
Page 2
20046/20 E –07.96–
Task Description Section 3.14.5c.6
Page 1
3.14.5c.6 Installation
Install new sealing ring (4) in cooler housing (5).
Place expansion tank (1) in position.
Tighten bolts (2) and washers (3) diagonally and evenly.
Mount cooler housing 3.14.6.6
20046/20 E –07.96–
Task Description Section 3.14.6
Page 1
20046/20 E –07.96–
Task Description Section 3.14.6
Page 2
20046/20 E –07.96–
Task Description Section 3.14.6
Page 3
20046/20 E –07.96–
Task Description Section 3.14.6.1
Page 1
1 2 3 Operations See
20046/20 E –07.96–
Task Description Section 3.14.6.2
Page 1
3.14.6.2 Removal
Identify plate pack with a coloured diagonal stroke
(arrowed) in correct installation sequence for purposes
of subsequent reassembly.
T0140421b0
20038/10 E –11.92–
Task Description Section 3.14.6.2
Page 2
20038/10 E –11.92–
Task Description Section 3.14.6.3
Page 1
3.14.6.3 Disassembly
Disassembling cooler housing
Use a suitable mandrel and plastic mallet, remove bush
(6) from cooler housing (1) from flange side.
Remove socket head screw (3).
Use suitable mandrel and plastic mallet to drive flange
(4) out of cooler housing (1).
Remove O-rings (5) from flange (4).
Note
20038/10 E –11.92–
Task Description Section 3.14.6.3
Page 2
20038/10 E –11.92–
Task Description Section 3.14.6.4
Page 1
Caution
When using chemical agents, always follow the manufacturer’s instructions for use.
Clean cooler housing and pressure plate with cold cleaner and brush.
To remove scale deposits, use a decalcifying agent which is non-harmful to metal (e.g. P3 T288 manufactured by Hen-
kel or amidosulfonic acid Euron 1308 manufactured by Hoechst).
Attention
Attention
Attention
Note
20038/10 E –11.95–
Task Description Section 3.14.6.4
Page 2
Note
Attention
Attention
20038/10 E –11.95–
Task Description Section 3.14.6.4
Page 3
Clean the plate profile gaskets and check them for damage.
If a damaged gasket is found, replace the affected channel plate.
Repair work can possibly involve the manufacturer replacing the rubber.
Check leak-off grooves (breaks in the rubber profile) in the profile gaskets.
Before the leak-off grooves are compressed, they must be approx. 8 mm wide.
If a leak-off groove is pressed together, it has to be recut with a knife.
Inspect screw-down surfaces, sealing surfaces and bores in cooler housing and pressure plate for damage; rub down
with oilstone if necessary.
Check condition of threads and recut if necessary.
Fit thread inserts if required.
Inspect flanges, bushes and mounting brackets for wear; rub down with oilstone or polishing cloth if necessary.
Check stud threads and threaded sleeves for ease of movement.
Replace parts as required.
Check components for cracks using surface crack-testing method with red penetrant dye; replace components if cracks
are found.
Leak-check cooler housing with fluid as required.
Test pressure, select 4.5 bar – 7.0 bar.
Replace O-rings.
20038/10 E –11.95–
Task Description Section 3.14.6.5
Page 1
3.14.6.5 Assembly
Assembling cooler housing
Make sure parts are perfectly clean.
Coat jacket surface of bush (6) with petroleum jelly and,
using a plastic mallet, drive into cooler housing (1) as il-
lustrated in drawing.
Insert O-rings (5) into flange (4).
Coat O-rings (5) with petroleum jelly.
Press flange (4) into cooler housing (1), taking care not
to damage screw holes. Installation position: see il-
lustration.
Secure flange (4) with socket head screw (3) and spring
washer (2).
20038/10 E –11.95–
Task Description Section 3.14.6.5
Page 2
20038/10 E –11.95–
Task Description Section 3.14.6.6
Page 1
3.14.6.6 Installation
Installing cooler housing
Secure mounting brackets (4) and (8) to crankcase with
bolts (6) and spring washers (5).
Use torque wrench to tighten to specified torque. For
torque setting, see Section 1.3.
Position cooler housing (1) on mounting brackets.
Using screws (2) and (7), secure washers (3) and spring
washers (5) to mounting bracket.
Using torque wrench, tighten bolts to specified torque.
For torque setting, see Section 1.3.
Note
20038/10 E –11.92–
Task Description Section 3.14.6.6
Page 2
Note
20038/10 E –11.92–
Task Description Section 3.14.7b
Page 1
20038/10 E –11.95–
Task Description Section 3.14.7b
Page 2
Coolant thermostat
20038/10 E –11.95–
Task Description Section 3.14.7b
Page 3
Coolant thermostat
20038/10 E –11.92–
Task Description Section 3.14.7b
Page 4
20038/10 E –11.95–
Task Description Section 3.14.7b1
Page 1
1 2 3 Operations See
20038/10 E –11.95–
Task Description Section 3.14.7b2
Page 1
3.14.7b2 Removal
Removing securing screws (1) from annular slide ther-
mostat.
Remove annular slide thermostat from cooler housing.
Remove O-ring from thermostat.
20038/10 E –11.95–
Task Description Section 3.14.7b3
Page 1
3.14.7b3 Disassembly
Removing governor insert
Release and remove securing screws (1) for governor
insert.
20038/10 E –11.95–
Task Description Section 3.14.7b3
Page 2
Caution
Spring tension
20038/10 E –11.95–
Task Description Section 3.14.7b3
Page 3
Remove pin (1) and pressure spring (2) from stop pin
(3).
20038/10 E –11.95–
Task Description Section 3.14.7b3
Page 4
Note
20038/10 E –11.95–
Task Description Section 3.14.7b4
Page 1
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 1
3.14.7b5 Assembly
Installing threaded bush
Coat thread of threaded bush (1) with high-strength pipe
thread sealant.
Coat friction face with long-life grease.
Insert threaded bush (1) with sealing ring (2) in cover (3)
and secure.
Note
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 2
Note
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 3
Coat stop pin (1) with long-life grease and insert in slide
(2).
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 4
Clearance R = 5 mm +1 mm
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 5
Caution
Spring tension
Remove assembly tool.
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 6
Note
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 7
Note
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 8
Preassembling housing
Insert scraper rings in grooves in housing.
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 9
20038/10 E –11.95–
Task Description Section 3.14.7b5
Page 10
20038/10 E –11.95–
Task Description Section 3.14.7b6
Page 1
3.14.7b6 Installation
Insert O-ring into groove on annular slide housing and
coat with petroleum jelly.
Mount annular slide thermostat with O-ring, screws (1)
and washers on the cooler housing and tighten.
20038/10 E –11.95–
Task Description Section 3.14.9
Page 1
Note
L91 3218
20038/10 E –11.95–
Task Description Section 3.15
Page 1
3.15.3a Engine oil suction line and delivery line with suction housing on crankcase intermediate frame, 16V
3.15.3a.1 Before-removal operations
3.15.3a.2 Removal
3.15.3a.4 Inspection and repair
3.15.3a.6 Installation
3.15.3b Engine oil suction line and delivery line with suction basket on crankcase intermediate frame, 12V
3.15.3b.1 Before-removal operations
3.15.3b.2 Removal
3.15.3b.4 Inspection and repair
3.15.3b.6 Installation
20046/20 E –07.96–
Task Description Section 3.15
Page 2
20046/20 E –07.96–
Task Description Section 3.15
Page 3
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –07.96–
Task Description Section 3.15.1
Page 1
20046/20 E –07.96–
Task Description Section 3.15.1
Page 2
20046/20 E –07.96–
Task Description Section 3.15.1
Page 3
20046/20 E –07.96–
Task Description Section 3.15.1
Page 4
Length of item 5
8V = 435 mm
12V = 327 mm
20046/20 E –07.96–
Task Description Section 3.15.1
Page 5
20046/20 E –07.96–
Task Description Section 3.15.1.1
Page 1
1 2 3 Operations See
20038/10 E –07.96–
Task Description Section 3.15.1.2
Page 1
20042/10 E –10.94–
Task Description Section 3.15.1.2a
Page 1
20038/10 E –11.92–
Task Description Section 3.15.1.2a
Page 2
Release idler gear (1) and bearing pin from oil pan using
pry bar or puller.
Release oil pump (2) from both dowel pins and remove
together with idler gear.
Note
20038/10 E –11.92–
Task Description Section 3.15.1.2a
Page 3
20038/10 E –11.92–
Task Description Section 3.15.1.3
Page 1
3.15.1.3 Disassembly
Removing shroud
Remove screws (2).
Remove shroud (1) from engine oil pump (3).
Removing cover
Remove engine oil pump from assembly jig.
Unscrew bolts (1) securing cover (2) to oil pump housing
(3).
20038/10 E –11.92–
Task Description Section 3.15.1.3
Page 2
Note
20038/10 E –11.92–
Task Description Section 3.15.1.4
Page 1
20038/10 E –11.92–
Task Description Section 3.15.1.4
Page 2
Note
20038/10 E –07.96–
Task Description Section 3.15.1.5
Page 1
3.15.1.5 Assembly
Installing drive and secondary shafts
Clean parts.
Ensure that oilways are particularly clean.
Spray oil pump gears (1) and (2) with engine oil and in-
stall in pump housing (3).
Note
Insert drive shaft with taper (2) into pump housing oppo-
site supports (4), as shown in illustration.
Installing cover
Ensure that contact surfaces of pump housing (2) and
cover (3) are clean.
Coat bearing bushes in cover (1) with engine oil.
Position cover on pump housing until dowel pins are cor-
rectly engaged.
Using torque wrench, tighten hex bolts with spring
washers to specified torque. For torque setting, see
Section 1.3.
It must be possible to turn the pump by hand without
feeling resistance.
20038/10 E –10.94–
Task Description Section 3.15.1.5
Page 2
Installing shroud
Install and secure shroud (1) to pump housing (3) with
bolts (2) and spring washers.
20038/10 E –11.92–
Task Description Section 3.15.1.6
Page 1
20038/10 E –07.96–
Task Description Section 3.15.1.6
Page 2
Secure suction line (4) with bolts and tab washers to oil
pan.
Tighten bolts on suction strainer (3) with torque wrench
to specified torque. For torque setting, see Section 1.3.
Insert H.P. fuel line (1) with new O-ring into engine oil
pump.
Tighten elbow (2) with bolts and spring washers with
torque wrench to specified torque. For torque setting,
see Section 1.3.
Installing pressure relief valve in elbow, see 3.15.5.6.
Install oil pump idler gear, see 3.2.2.6.
20038/10 E –11.92–
Task Description Section 3.15.1.6a
Page 1
Note
Fit idler gear (1) with bearing pin and oil pump simulta-
neously in oil pan.
Pay attention to dowel pins.
Do not bend bearing pin in oil pan bore during installa-
tion.
Force bearing pin into inner race of angular-contact ball
bearing using drift.
Seat bearing pin in oil pan by means of locknut.
20038/10 E –11.92–
Task Description Section 3.15.1.6a
Page 2
Insert suction line (1) with new O-ring into oil pump.
Tighten and secure suction strainer to oil pan with bolts
and tab washers.
20038/10 E –11.92–
Task Description Section 3.15.1.6a
Page 3
Check seal (2) for damage; fit new seal in oil pan if
necessary.
To ensure driving end is sealed correctly in the range of
bore dia. 360 H8 on oil pan and crankcase, coat both
sides of gaskets with sealing paste.
Raise oil pan by means of four lowering appliances (1).
Ensure locating pins are correctly positioned.
Note
Note
20038/10 E –07.96–
Task Description Section 3.15.1b
Page 1
20046/20 E –07.96–
Task Description Section 3.15.1b
Page 2
20046/20 E –07.96–
Task Description Section 3.15.1b
Page 3
20046/20 E –07.96–
Task Description Section 3.15.1b
Page 4
20046/20 E –07.96–
Task Description Section 3.15.1b.1
Page 1
1 2 3 Operations See
20046/20 E –07.96–
Task Description Section 3.15.1b.2
Page 1
3.15.1b.2 Removal
Removing oil pump
Unscrew securing screws (3), (4) on engine oil pump (1)
with socket from crankcase intermediate frame and re-
move together with washers (2).
Press engine oil pump (1) with pry bar off dowel pins (5)
on crankcase intermediate frame and remove.
20046/20 E –07.96–
Task Description Section 3.15.1b.3
Page 1
3.15.1b.3 Disassembly
Removing shroud
Remove screws (2) on cover.
Remove shroud (1) from engine oil pump (3).
20046/20 E –07.96–
Task Description Section 3.15.1b.3
Page 2
Removing cover
Unscrew bolts (1) securing cover (2) to oil pump housing
(3).
Note
20046/20 E –07.96–
Task Description Section 3.15.1b.4
Page 1
20046/20 E –07.96–
Task Description Section 3.15.1b.4
Page 2
Caution
20046/20 E –07.96–
Task Description Section 3.15.1b.5
Page 1
3.15.1b.5 Assembly
Installing drive and secondary shafts
Clean parts.
Ensure that oilways are particularly clean.
Spray pump gears (1) and (3) with engine oil and install
in pump housing (2).
Ensure that drive shaft is installed correctly (see illustra-
tion).
Installing cover
Ensure that contact surface of pump housing (2) and
cover (1) are clean.
Coat bearing bushes in cover with engine oil.
Fit cover on oil pump housing so that dowel pins (3) en-
gage in bore.
Note
20046/20 E –07.96–
Task Description Section 3.15.1b.5
Page 2
Installing shroud
Install and secure shroud (1) to pump housing (3) with
bolts (2) and spring washers.
20046/20 E –07.96–
Task Description Section 3.15.1b.6
Page 1
3.15.1b.6 Installation
Installing oil pump
Rub down contact surfaces of intermediate frame and
oil pump with oilstone and clean.
Insert dowel pins (2) into bores in oil pump housing.
Position engine oil pump (1) on intermediate frame in
such a way that the dowel pins engage the bores.
Coat screws (3) and (4) with engine oil and insert with
washers (5) in crankcase intermediate frame.
Tighten securing screws with torque wrench to tighten-
ing specification 1.3.
Measuring backlash
Mount dial gauge holder with dial gauge (1) on inter-
mediate frame.
Use screwdriver to lock oil pump idler gear (3).
Position dial gauge with preload on tooth profile of oil
pump drive gear (2).
Measure backlash.
For backlash, see 3.2.
20046/20 E –07.96–
Task Description Section 3.15.2
Page 1
1 Oil pump
2 Spring washer
3 Screw
20038/10 E –10.94–
Task Description Section 3.15.2
Page 2
ET 15 285 2
20038/10 E –11.92–
Task Description Section 3.15.2
Page 3
20038/10 E –11.92–
Task Description Section 3.15.2
Page 4
ET 15 286
20038/10 E –10.94–
Task Description Section 3.15.2
Page 5
20038/10 E –11.95–
Task Description Section 3.15.2.1
Page 1
1 2 3 Operations See
20038/10 E –07.96–
Task Description Section 3.15.2.2
Page 1
20038/10 E –11.92–
Task Description Section 3.15.2.2
Page 2
20038/10 E –11.92–
Task Description Section 3.15.2.2a
Page 1
1 Idler gear
2 Snap ring
3 Angular-contact ball bearing
4 Bearing pin
5 Stress bolt
6 Washer
7 Washer
8 Oil pan
9 O-ring
10 Clamping nut
20038/10 E –11.92–
Task Description Section 3.15.2.2a
Page 2
20038/10 E –11.92–
Task Description Section 3.15.2.2a
Page 3
Note
Rotate the crankshaft with the barring tool so that the en-
gine oil pump can be removed from between the inter-
mediate frame and the oil pan.
20038/10 E –11.92–
Task Description Section 3.15.2.3
Page 1
3.15.2.3 Disassembly
Remove connecting housing (1) from oil pump housing.
20038/10 E –11.92–
Task Description Section 3.15.2.3
Page 2
Withdraw pump gears (1), (2) and (3) from pump hous-
ing (4).
Note
20038/10 E –11.92–
Task Description Section 3.15.2.4
Page 1
Caution
20038/10 E –11.95–
Task Description Section 3.15.2.4
Page 2
20038/10 E –11.92–
Task Description Section 3.15.2.4
Page 3
(rpm)
Pump speed
20038/10 E –11.95–
Task Description Section 3.15.2.5
Page 1
3.15.2.5 Assembly
Installing drive and secondary shafts
Ensure that oilways are particularly clean.
Spray pump gears (1), (2) and (3) with engine oil.
Install in oil pump housing (4) as shown in adjoining il-
lustration.
Ensure that drive shaft (1) is correctly installed.
Installing cover
Check whether contact surfaces of oil pump housing
and cover are clean.
Coat bearing bushes in cover with engine oil.
Position cover (1) on pump housing (2) so that dowel
pins are correctly engaged.
Tighten bolts and spring washers with torque wrench to
specified torque. For torque setting, see Section 1.3.
Check ease of movement of oil pump.
It must be possible to turn the pump by hand without
feeling resistance.
20038/10 E –11.92–
Task Description Section 3.15.2.5
Page 2
20038/10 E –11.92–
Task Description Section 3.15.2.5
Page 3
20038/10 E –11.92–
Task Description Section 3.15.2.6
Page 1
20038/10 E –11.95–
Task Description Section 3.15.2.6
Page 2
20038/10 E –11.95–
Task Description Section 3.15.2.6a
Page 1
1 Idler gear
2 Snap ring
3 Angular-contact ball bearing
4 Bearing pin
5 Stress bolt
6 Washer
7 Washer
8 Oil pan
9 O-ring
10 Clamping nut
Note
20038/10 E –11.92–
Task Description Section 3.15.2.6a
Page 2
20038/10 E –11.95–
Task Description Section 3.15.2.6a
Page 3
Note
Note
20038/10 E –11.95–
Task Description Section 3.15.2a
Page 1
20054/00 E –10.93–
Task Description Section 3.15.2a
Page 2
20054/00 E –10.93–
Task Description Section 3.15.2a
Page 3
20054/00 E –10.93–
Task Description Section 3.15.2a.1
Page 1
1 2 3 Operations See
20046/20 E –07.96–
Task Description Section 3.15.2a.2
Page 1
3.15.2a.2 Removal
Use socket and ratchet (1) to remove securing screws
from engine oil pump (2) on crankcase intermediate
frame.
Using pry bars, ease engine oil pump off dowel pins in
intermediate frame.
20054/00 E –10.93–
Task Description Section 3.15.2a.3
Page 1
3.15.2a.3 Disassembly
Clamp engine oil pump in assembly jig.
Secure drive gear (1) against turning with retaining jig.
Remove bolt from drive gear.
Detach drive gear from drive shaft with puller.
Remove engine oil pump from assembly jig.
20038/10 E –11.92–
Task Description Section 3.15.2a.3
Page 2
Note
20038/10 E –02.95–
Task Description Section 3.15.2a.4
Page 1
Caution
20038/10 E –02.95–
Task Description Section 3.15.2a.4
Page 2
20038/10 E –11.92–
Task Description Section 3.15.2a.5
Page 1
3.15.2a.5 Assembly
Clean parts.
Ensure that oilways are particularly clean.
Spray oil pump gear (1) with engine oil and insert into oil
pump housing.
Spray drive shaft with gear (1) with engine oil and insert
in oil pump housing (2).
Make sure drive shaft is installed properly as shown in
illustration.
Coat oil pump shaft (1) with engine oil and insert into oil
pump housing.
20038/10 E –11.92–
Task Description Section 3.15.2a.5
Page 2
20038/10 E –11.92–
Task Description Section 3.15.2a.5
Page 3
20038/10 E –11.92–
Task Description Section 3.15.2a.6
Page 1
3.15.2a.6 Installation
Smooth and clean mating faces on crankcase inter-
mediate frame and engine oil pump with oilstone.
Insert dowel pins into bores in oil pump housing.
Position engine oil pump (2) on intermediate frame in
such a way that the dowel pins engage the bores.
Coat screws with engine oil and install in intermediate
frame.
Using torque wrench (1) and socket, tighten as per
Tightening Specification 1.3.
20054/00 E –10.93–
Task Description Section 3.15.3a
Page 1
3.15.3a Engine Oil Suction Line and Delivery Line with Suction Housing on
Crankcase Intermediate Frame, 16 V
20054/00 E –07.96–
Task Description Section 3.15.3a.1
Page 1
1 2 3 Operations See
20046/20 E –07.96–
Task Description Section 3.15.3a.2
Page 1
3.15.3a.2 Removal
Removing suction housing
Release and remove bolts securing suction housing (1).
Remove suction housing from oil pan.
Remove strainer.
Remove suction line (1) with connecting line (2) from in-
termediate frame and oil pump.
Detach connecting line (3) from suction line.
20054/00 E –02.95–
Task Description Section 3.15.3a.2
Page 2
1
1
L879348/1
Remove delivery line (1) with connecting line (2) from in-
termediate frame and oil pump.
20054/00 E –02.95–
Task Description Section 3.15.3a.4
Page 1
20038/10 E –11.92–
Task Description Section 3.15.3a.6
Page 1
3.15.3a.6 Installation
Installing suction housing
Install strainer on suction housing with bolts and tab
washers.
Tighten and secure bolts.
Insert suction housing (1) with screws and tab washers
in oil pan.
Tighten and secure bolts.
Note
Insert delivery line (1) with connecting line (2) into oil
pump.
Ensure that O-rings do not become twisted.
20054/00 E –07.96–
Task Description Section 3.15.3a.6
Page 2
1
1
L879348/1
Note
20054/00 E –02.95–
Task Description Section 3.15.3b
Page 1
3.15.3b Engine Oil Suction Line and Delivery Line with Suction Basket on
Crankcase Intermediate Frame, 12V
20046/20 E –07.96–
Task Description Section 3.15.3b.1
Page 1
1 2 3 Operations See
20046/20 E –07.96–
Task Description Section 3.15.3b.2
Page 1
3.15.3b.2 Removal
Release tab washers (4) on screws (2).
Remove bolts securing suction line (1).
Remove suction line and connecting line (3) from inter-
mediate frame and oil pump.
Remove O-rings (5).
20046/20 E –07.96–
Task Description Section 3.15.3b.4
Page 1
20046/20 E –07.96–
Task Description Section 3.15.3b.6
Page 1
3.15.3b.6 Installation
Insert O-rings (4) into grooves of plug-in pipe (5) and
coat with petroleum jelly.
Insert plug-in pipe with O-ring into engine oil pump (7);
when doing so, do not twist or damage O-ring.
Fit elbow (6) on plug-in pipe; in doing so, do not twist or
damage O-ring.
Mount elbow (6) with screws (3) and washers on inter-
mediate frame.
Insert O-ring (4) into grooves of plug-in pipe (5) and coat
with petroleum jelly.
Fit elbow (1) on plug-in pipe; in doing so, do not twist or
damage O-ring.
Mount elbow with screws (3) and washers (2) on inter-
mediate frame.
Using torque wrench, tighten bolts to specified torque.
For torque setting, see Section 1.3.
Insert O-rings (5) into groove of link (3) and coat with pe-
troleum jelly.
Connect connecting line to suction line (1).
Insert link with O-ring into engine oil pump.
Do not twist or damage O-ring.
Mount suction line on intermediate frame with bolts (2)
and tab washers.
Using torque wrench, tighten bolts to specified torque.
For torque setting, see Section 1.3.
Secure bolts with tab washers.
20046/20 E –07.96–
Task Description Section 3.15.4
Page 1
20042/10 E –10.94–
Task Description Section 3.15.4
Page 2
20042/10 E –10.94–
Task Description Section 3.15.4
Page 3
20042/10 E –10.94–
Task Description Section 3.15.4
Page 4
20042/10 E –10.94–
Task Description Section 3.15.4.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.15.4.2
Page 1
3.15.4.2 Removal
Remove lube oil pump (1) with intermediate housing (2)
from camshaft end, right side.
Detach lube oil pump from intermediate housing and re-
move O-ring.
20038/10 E –11.92–
Task Description Section 3.15.4.3
Page 1
3.15.4.3 Disassembly
Release tab washers (12).
Remove screws (14).
Remove cover (13).
Remove O-ring (3) from housing (5).
Remove adjusting screw (23), plug (21) with compres-
sion spring (22) and locking bolt (20).
Remove O-ring (1) from adjusting screw.
Remove snap ring (2) from cover.
Pull plunger (18) with cam plate (19) and driver (4) out
of housing.
Remove screw (15), compression spring (16) and stop
pin (17) from lower section of housing.
Remove screw (8).
Remove lube oil pump shaft (6) with bearing bush (7),
taking care not to damage washers (9) and (10).
Remove needle bush (11).
20042/10 E –10.94–
Task Description Section 3.15.4.4
Page 1
Note
Oil pump housing and plunger must not be replaced individually, as both parts must be matched.
Inspect drive flange and journal of lube oil pump shaft for wear and indentations; rub down as required and replace if
necessary.
Check drive shaft and plunger for signs of wear; if necessary, polish with emery cloth, or replace.
Check bearing bush and coil springs for wear; replace as required.
Check stop pin, adjusting screw and pin for wear; replace as required.
Replace sealing rings and needle bush.
Inspect sealing surfaces of cover for wear; rub down as required and replace cover if necessary.
Replace O-rings and sealing rings.
Checking operation of lube oil pump
Mount lube oil pump on test stand. Check flow rate and inspect for leaks.
Delivery quantity per outlet 0.7 cm3/min ±0.1 cm3/min at:
- Pump speed 1300 rpm
- Supply pressure 6 bar
- Back pressure 1.3 bar
- Temperature 100 °C
- Test oil SAE 30
If specified flow rate is not achieved, turn adjusting screw one notch clockwise or counterclockwise; replace lube oil
pump if necessary.
- Turn adjusting screw counterclockwise to increase the delivery rate
- Turn adjusting screw clockwise to decrease the delivery rate
Secure adjusting screw with locking paint.
20042/10 E –10.94–
Task Description Section 3.15.4.5
Page 1
3.15.4.5 Assembly
Coat outer surface of needle bush with surface sealant.
Insert the needle bush (11) flush with inner edge of hous-
ing.
Push washers (9) and (10) onto lube oil pump shaft (6)
and install with bearing bush (7) in housing (5).
Compensate axial clearance ”A” of lube oil pump shaft
from 0.05 mm to 0.20 mm with washers.
Install bearing bush (7) in such a way that locating pin
of screw (8) engages in bore of bearing bush.
Install stop pin (17) and compression spring (16) with
plug (15) and sealing ring in housing (5); tighten screw.
Coat plunger (18) with cam plate (19) and driver (4) with
engine oil, insert into cover (13) and secure with snap
ring (2).
Coat O-ring (3) with petroleum jelly and mount with
cover on housing.
Secure cover with screw (14) and tab washer (12), using
torque wrench to tighten in accordance with Tightening
Specification 1.3.
Secure screw with tab washer.
Fit blocking pin (20) and compression spring (22) with
plug (21) and sealing ring in housing; tighten plug.
Tighten adjusting screw (23) in cover, and secure with
locking paint after function check.
Function check, see 3.15.4.4.
20042/10 E –07.96–
Task Description Section 3.15.4.6
Page 1
3.15.4.6 Installation
Mount driver (1) on camshaft (right side) and secure with
bolts and spring washers.
20038/10 E –07.96–
Task Description Section 3.15.5
Page 1
1 Oil pan
2 Pressure relief valve
3 Sealing ring
4 O-ring
20038/10 E –11.95–
Task Description Section 3.15.5.1
Page 1
1 2 3 Operations See
20042/10 E –07.96–
Task Description Section 3.15.5.2
Page 1
1 Elbow
2 O-ring
3 Sealing ring
4 Pressure relief valve
20038/10 E –11.92–
Task Description Section 3.15.5.2a
Page 1
Remove valve from oil pan (3) with socket wrench (1)
and extension (2).
Remove O-ring and sealing ring.
20038/10 E –11.92–
Task Description Section 3.15.5.2b
Page 1
1 Elbow
2 O-ring
3 Sealing ring
4 Pressure relief valve
20038/10 E –11.95–
Task Description Section 3.15.5.3
Page 1
3.15.5.3 Disassembly
Press valve plunger downwards using hand press and
suitable drift (2).
Remove snap ring (3) with snap ring pliers.
Release pressure from hand press and remove valve
seat insert (4), plunger and spring (5) from valve housing
(1).
A = Start of opening 15 bar +2.5 bar
–1.5 bar
Caution
Spring tension
20038/10 E –02.95–
Task Description Section 3.15.5.4
Page 1
20038/10 E –11.92–
Task Description Section 3.15.5.5
Page 1
3.15.5.5 Assembly
Clean all components.
Make sure parts are perfectly clean.
Insert plunger (2) and spring (5) in valve housing (1).
Fit valve seat insert (4) and snap ring (3).
A = Start of opening 15 bar +2.5 bar
–1.5 bar
Caution
Spring tension
Ensure that snap ring is correctly seated in groove.
Inspect valve for leaks and check operation on test
pump.
20038/10 E –02.95–
Task Description Section 3.15.5.6
Page 1
Note
Make sure that O-ring is not shorn off when valve is in-
serted.
20038/10 E –11.95–
Task Description Section 3.15.5.6a
Page 1
Screw valve into oil pan (3) with socket wrench (1) and
extension (2).
Note
Make sure that O-ring is not shorn off when valve is in-
serted.
20038/10 E –11.95–
Task Description Section 3.15.5.6b
Page 1
20038/10 E –11.95–
Task Description Section 3.16
Page 1
20046/20 E –08.96–
Task Description Section 3.16
Page 2
3.16.5a Pressure limiting valve, pressure relief valves and bypass valves
3.16.5a.1 Before-removal operations
3.16.5a.2 Removal
3.16.5a.3 Disassembly
3.16.5a.4 Inspection and repair
3.16.5a.5 Assembly
3.16.5a.6 Installation
20046/20 E –08.96–
Task Description Section 3.16
Page 3
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –08.96–
Task Description Section 3.16.1
Page 1
1 Connector 17 Bracket
2 Gasket 18 Nut
3 Spring washer 19 Screw
4 Screw 20 Spacer sleeve
5 Sealing ring 21 Oil line, left
6 Plug 22 Oil line, right
7 Sealing ring 23 O-ring
8 Plug 24 Spring washer
9 Sealing ring 25 Screw
10 Union 26 Bracket
11 Oil line 27 Grommet
12 Oil line, right 28 Pipe clamp half
13 Grommet 29 Pipe clamp half
14 Pipe clamp half 30 Spacer tube
15 Spring washer 31 Spring washer
16 Screw 32 Screw
20046/20 E –07.96–
Task Description Section 3.16.1
Page 2
20046/20 E –07.96–
Task Description Section 3.16.1
Page 3
Measuring block
20046/20 E –07.96–
Task Description Section 3.16.1
Page 4
20046/20 E –07.96–
Task Description Section 3.16.1
Page 5
20046/20 E –07.96–
Task Description Section 3.16.1
Page 6
20046/20 E –07.96–
Task Description Section 3.16.1
Page 7
20046/20 E –07.96–
Task Description Section 3.16.1
Page 8
20046/20 E –07.96–
Task Description Section 3.16.1
Page 9
Oil supply from intermediate element / injection pump II to cut-out control housing
20046/20 E –07.96–
Task Description Section 3.16.1
Page 10
20046/20 E –07.96–
Task Description Section 3.16.1
Page 11
1 Pipe 13 Sleeve
2 Union 14 Pipe clamp half
3 Sealing ring 15 Grommet
4 Oil line 16 Hex screw
5 Straightway valve 17 Hex screw
6 Oil line 18 Spring washer
7 Reduction union 19 Bracket
8 Sealing ring 20 Pipe clamp half
9 Reduction union 21 Grommet
10 Plug 22 Hex screw
11 Bracket 23 Spring washer
12 Washer 24 Hex screw
20046/20 E –07.96–
Task Description Section 3.16.1
Page 12
20046/20 E –07.96–
Task Description Section 3.16.1
Page 13
20046/20 E –07.96–
Task Description Section 3.16.1
Page 14
20046/20 E –07.96–
Task Description Section 3.16.1
Page 15
20046/20 E –07.96–
Task Description Section 3.16.1
Page 16
20046/20 E –07.96–
Task Description Section 3.16.1
Page 17
20046/20 E –07.96–
Task Description Section 3.16.1
Page 18
20046/20 E –07.96–
Task Description Section 3.16.1
Page 19
20046/20 E –07.96–
Task Description Section 3.16.1
Page 20
20046/20 E –07.96–
Task Description Section 3.16.1
Page 21
Oil supply and return lines from control unit to hydraulic coupling for fan drive
20046/20 E –07.96–
Task Description Section 3.16.1
Page 22
Oil supply and return lines from control unit to hydraulic coupling for fan drive
20046/20 E –07.96–
Task Description Section 3.16.1
Page 23
Oil return line (drainage) from fan wheel flange to housing ventilation
20046/20 E –07.96–
Task Description Section 3.16.1
Page 24
20046/20 E –07.96–
Task Description Section 3.16.1
Page 25
20046/20 E –07.96–
Task Description Section 3.16.1.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.16.1.2
Page 1
3.16.1.2 Removal
Prior to removing engine oil lines, it is advisable either to take photographs from all sides of the engine
or to mark the engine oil lines with metal tabs.
Disconnect oil lines with seals and pipe clamp halves from engine.
After removing oil lines, seal all connections with suitable plugs.
Protect thin-walled oil lines against damage.
20038/10 E –11.92–
Task Description Section 3.16.1.4
Page 1
20038/10 E –11.92–
Task Description Section 3.16.1.6
Page 1
3.16.1.6 Installation
Before installation, blow engine oil lines clear with compressed air and make sure that they are completely clean.
Do not remove blanking plug until just before installation.
Install oil lines and secure with new seals, attaching hardware, plug-in pipes and O-rings.
Coat O-rings with petroleum jelly.
Install oil lines so that they are free of strain in accordance with photographs, markers and layout (3.16.1).
20038/10 E –08.96–
Task Description Section 3.16.2a
Page 1
20046/20 E –08.96–
Task Description Section 3.16.2a
Page 2
20046/20 E –08.96–
Task Description Section 3.16.2a
Page 3
20046/20 E –08.96–
Task Description Section 3.16.2a
Page 4
Engine oil heat exchanger 12V with oil return to crankcase intermediate frame and oil supply to oil heat ex-
changer
1 Elbow 7 O-ring
2 Gasket 8 O-ring
3 Washer 9 Elbow
4 Screw 10 Plug-in pipe
5 Screw 11 Oil heat exchanger
6 Plug-in pipe
20046/20 E –08.96–
Task Description Section 3.16.2a
Page 5
1 O-ring 9 O-ring
2 Retaining pin 10 Winding element
3 Clamp 11 Stud
4 Hex nut 12 Screw
5 Ratchet, right 13 O-ring
6 Scraper 14 Spring washer
7 Spring 15 Stud
8 Spring washer
20046/20 E –08.96–
Task Description Section 3.16.2a
Page 6
1 Nut 8 Screw
2 Spring washer 9 Spring washer
3 Ratchet, right 10 Sealing ring
4 Scraper 11 Stud
5 Spring 12 O-ring
6 Winding element
7 O-ring A – Wire inserted and peaned
20046/20 E –08.96–
Task Description Section 3.16.2a
Page 7
20046/20 E –08.96–
Task Description Section 3.16.2a
Page 8
20046/20 E –08.96–
Task Description Section 3.16.2a.1
Page 1
1 2 3 Operations See
20038/10 E –08.96–
Task Description Section 3.16.2a.2
Page 1
3.16.2a.2 Removal
Removing oil feed plug-in pipe from oil heat ex-
changer
Unscrew securing screw (3) with bracket (4) from oil pan
(6).
Using pry bar, press plug-in pipe (2) out of elbow (5) on
heat exchanger (1) downwards into bore in oil pan.
After removing heat exchanger, withdraw plug-in pipe
from oil pan.
20038/10 E –11.92–
Task Description Section 3.16.2a.3
Page 1
3.16.2a.3 Disassembly
Removing elbow
Remove securing bolts (5) and (6) with washers (4) from
elbow (3).
Remove elbow from heat exchanger (1).
Remove gasket (2) and oil transfer pipe (7) from heat ex-
changer.
20038/10 E –11.92–
Task Description Section 3.16.2a.3
Page 2
20038/10 E –11.92–
Task Description Section 3.16.2a.3
Page 3
Note
20038/10 E –11.92–
Task Description Section 3.16.2a.3
Page 4
Note
Screw two guide pins (1) into oil cooler core (3) at each
end.
Lift housing base (2) off oil cooler.
Remove guide pins from oil cooler.
Remove O-rings and sleeves.
20038/10 E –11.92–
Task Description Section 3.16.2a.4
Page 1
Note
Cleaning solution must be pumped through oil cooler in direction opposite to normal oil flow, i.e. opposite to direction
of arrow on cooler.
Cleaning can be improved by ultrasonic means.
In event of severe contamination, e.g. in case of piston seizure or bearing damage, replace the disc-type oil cooler.
After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are roughly equal
(permissible difference 1 pH).
This releases contaminants, particularly particles from wear parts, from swirl plates of cooling core, so that they are
flushed out with water.
Continue cleaning process until flushing medium leaving cooler is same as that entering.
Flushing pressure 3 to 4 bar at 150 to 300 litres/minute.
After this cleaning procedure, dry oil side with hot air to remove remaining flushing water from swirl plates and oil ducts.
After drying, oil cooler must be rinsed with engine oil or Haku rinsing oil in order to preserve swirl plates.
This preservation is not necessary if plate-type oil cooler is reinstalled on engine and put into operation immediately
after cleaning.
Insert protective caps in inlet and outlet bore and protect disc-type oil cooler against damage.
20038/10 E –08.96–
Task Description Section 3.16.2a.4
Page 2
Note
Edge-type filter element with metallic and plastic sealing must not be disassembled.
The plastic connection on the front cover must not be damaged; in addition the components must not be subjected to
hard impacts during assembly.
Replace damaged edge-type filter element.
With engines with high load profile, only use edge-type filter with metallic seal.
Check ratchet lever for filter element for freedom of movement; replace if necessary.
20038/10 E –08.96–
Task Description Section 3.16.2a.5
Page 1
3.16.2a.5 Assembly
Preassembling plate-type oil cooler
Remove protective caps on disc-type oil cooler.
Check screw-down surfaces for irregularities with
straightedge.
Insert sleeves (2) into flanges and position gaskets (1)
on flange surfaces.
Coat O-ring (3) with petroleum jelly and fit over sleeves.
20038/10 E –08.96–
Task Description Section 3.16.2a.5
Page 2
Note
20038/10 E –08.96–
Task Description Section 3.16.2a.5
Page 3
Note
20038/10 E –08.96–
Task Description Section 3.16.2a.5
Page 4
Using snap ring pliers (3), install snap ring (2) to secure
blanking plug (1).
Make sure that snap ring is correctly seated.
20038/10 E –08.96–
Task Description Section 3.16.2a.5
Page 5
20038/10 E –08.96–
Task Description Section 3.16.2a.5
Page 6
Note
Only tighten the hex nut firmly enough to turn the edge-
type filter.
20038/10 E –11.92–
Task Description Section 3.16.2a.5
Page 7
Installing elbow
Rub down sealing surfaces of elbow.
Connect oil transfer pipe (7) to heat exchanger (1).
Install and tighten elbow (3) on heat exchanger with
gasket (2), washers (4) and securing bolts (5) and (6).
Do not damage oil transfer pipe during installation.
Note
20038/10 E –08.96–
Task Description Section 3.16.2a.6
Page 1
3.16.2a.6 Installation
Installing engine oil heat exchanger, 12V
Coat O-rings (4) and (10) with petroleum jelly.
Insert O-rings in grooves of oil transfer bores on elbows
(3) and (7) and heat exchanger (13).
Fit O-rings (5) and (8) on plug-in pipes (6) and (9) and
coat with petroleum jelly.
Secure elbow to heat exchanger with washers (2) and
screws (1).
Insert plug-in pipe (9) into bore in oil pan.
Insert plug-in pipe (6) into bore in elbow.
Install two eyebolts in upper section of heat exchanger.
Raise heat exchanger with lifting gear and mount with se-
curing screws (12), (14) and (15) and washers (11) on
crankcase.
20038/10 E –08.96–
Task Description Section 3.16.2a.6
Page 2
20038/10 E –11.92–
Task Description Section 3.16.2b
Page 1
20058/0 E –03.93–
Task Description Section 3.16.2b
Page 2
20058/0 E –03.93–
Task Description Section 3.16.2b
Page 3
20058/0 E –08.96–
Task Description Section 3.16.2b
Page 4
20058/0 E –08.96–
Task Description Section 3.16.2b
Page 5
1 O-ring 9 O-ring
2 Retaining pin 10 Winding element
3 Clamp 11 Stud
4 Hex nut 12 Hex screw
5 Ratchet 13 O-ring
6 Scraper 14 Spring washer
7 Spring 15 Stud
8 Spring washer
20058/0 E –08.96–
Task Description Section 3.16.2b
Page 6
20058/0 E –08.96–
Task Description Section 3.16.2b
Page 7
20058/0 E –08.96–
Task Description Section 3.16.2b.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.16.2b.2
Page 1
3.16.2b.2 Removal
Removing engine oil heat exchanger
Remove one securing bolt (1) from both left and right
sides of heat exchanger (2).
Insert assembly pins.
Remove remaining securing bolts.
Remove heat exchanger from crankcase with lifting
gear.
Remove assembly pins, plug-in pipes, elbows and O-
rings.
20058/0 E –03.93–
Task Description Section 3.16.2b.3
Page 1
3.16.2b.3 Disassembly
Removing engine oil filter, see 3.16.4.2
Removing elbow
Remove securing bolts (6) and (7) with washers (5) from
elbow (4).
Remove elbow from driving-end heat exchanger (1).
Remove O-rings (2), (3) and (9) and sealing ring (8) from
elbow.
20058/0 E –08.96–
Task Description Section 3.16.2b.3
Page 2
ET16/832B
20058/0 E –08.96–
Task Description Section 3.16.2b.3
Page 3
Note
20058/0 E –08.96–
Task Description Section 3.16.2b.3
Page 4
Note
Screw two guide pins (1) into oil cooler core (3) at each
end.
Lift housing base (2) off oil cooler.
Remove guide pins from oil cooler.
Remove O-rings and sleeves.
20058/0 E –08.96–
Task Description Section 3.16.2b.4
Page 1
Note
Cleaning solution must be pumped through oil cooler in direction opposite to normal oil flow, i.e. opposite to direction
of arrow on cooler.
Cleaning can be improved by ultrasonic means.
In event of severe contamination, e.g. in case of piston seizure or bearing damage, replace the disc-type oil cooler.
After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are roughly equal
(permissible difference 1 pH).
This releases contaminants, particularly particles from wear parts, from swirl plates of cooling core, so that they are
flushed out with water.
Continue cleaning process until flushing medium leaving cooler is same as that entering.
Flushing pressure 3 to 4 bar at 150 to 300 litres/minute.
After this cleaning procedure, dry oil side with hot air to remove remaining flushing water from swirl plates and oil ducts.
After drying, oil cooler must be rinsed with engine oil or Haku rinsing oil in order to preserve swirl plates.
This preservation is not necessary if plate-type oil cooler is reinstalled on engine and put into operation immediately
after cleaning.
Insert protective caps in inlet and outlet bore and protect disc-type oil cooler against damage.
20058/0 E –08.96–
Task Description Section 3.16.2b.4
Page 2
Note
Edge-type filter element with metallic sealing and plastic sealing must not be disassembled.
The plastic connection on the front cover must not be damaged; in addition the components must not be subjected to
hard impacts during assembly.
Replace damaged edge-type filter element.
With engines with high load profile, only use edge-type filter with metallic seal.
Check ratchet lever for filter element for freedom of movement; replace if necessary.
Checking housing, elbow and plug-in pipe
Check housing upper section and base, connecting housing and elbow for cracks using surface crack-testing method
with red penetrant dye; replace components if cracks are found.
Pressure-test housing and elbow as required.
Check screw-down surfaces for irregularities and damage; rub down as required.
Check condition of threads; recut if necessary or install Helicoil inserts or threaded bushes.
Check plug-in pipe locating bores for indentation and wear; rub down if necessary and box to MTU specifications as
required.
Ensure that oil ducts are perfectly clean.
Inspect connecting points and sealing ring grooves for wear; rub down as required.
Replace O-rings and gaskets.
20058/0 E –08.96–
Task Description Section 3.16.2b.5
Page 1
3.16.2b.5 Assembly
Preassembling plate-type oil cooler
Remove protective caps on disc-type oil cooler.
Check screw-down surfaces for irregularities with
straightedge.
Insert sleeves (2) into flanges and position gaskets (1)
on flange surfaces.
Coat O-ring (3) with petroleum jelly and fit over sleeves.
20058/0 E –08.96–
Task Description Section 3.16.2b.5
Page 2
Note
ET16/832B
20058/0 E –08.96–
Task Description Section 3.16.2b.5
Page 3
Note
20058/0 E –08.96–
Task Description Section 3.16.2b.5
Page 4
20058/0 E –08.96–
Task Description Section 3.16.2b.5
Page 5
20058/0 E –08.96–
Task Description Section 3.16.2b.5
Page 6
Note
Only tighten the hex nut firmly enough to turn the edge-
type filter.
Installing elbow
Insert O-rings (2), (3), (9) and sealing ring (8) into annu-
lar grooves of elbow (4) and coat with petroleum jelly.
Using washers (5) and securing screws (6) and (7),
secure elbow to heat exchanger (1).
Note
20058/0 E –08.96–
Task Description Section 3.16.2b.6
Page 1
3.16.2b.6 Installation
Installing engine oil heat exchanger, driving end
Coat O-rings (4) and (5) with petroleum jelly and insert
into grooves of oil transfer bores on elbow (3) and heat
exchanger (8).
Secure elbow to heat exchanger with washers (11) and
screws (12).
Insert O-rings (1) and (4) into grooves of plug-in pipes
(2) and (13) and coat with petroleum jelly.
Insert plug-in pipes into oil pan bores.
20058/0 E –08.96–
Task Description Section 3.16.3a
Page 1
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 2
Engine oil heat exchanger, free end, with edge-type filter, 16V
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 3
20038/10 E –11.92–
Task Description Section 3.16.3a
Page 4
Engine oil heat exchanger, driving end, 16V with oil return to crankcase intermediate frame and oil supply to
oil heat exchanger
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 5
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 6
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 7
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 8
1 O-ring 9 O-ring
2 Retaining pin 10 Winding element
3 Clamp 11 Stud
4 Hex nut 12 Hex screw
5 Ratchet 13 O-ring
6 Scraper 14 Spring washer
7 Spring 15 Stud
8 Spring washer
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 9
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 10
20038/10 E –08.96–
Task Description Section 3.16.3a
Page 11
20038/10 E –08.96–
Task Description Section 3.16.3a.1
Page 1
1 2 3 Operations See
20038/10 E –08.96–
Task Description Section 3.16.3a.2
Page 1
3.16.3a.2 Removal
Removing plug-in pipes from driving-end heat ex-
changer, 16V
Release bolts on brackets (1).
Withdraw brackets from grooves in plug-in pipes.
Using pry bars, press plug-in pipes (2), (3) and (4) into
driving or free-end heat exchanger bores.
Note
20038/10 E –11.92–
Task Description Section 3.16.3a.3
Page 1
3.16.3a.3 Disassembly
Removing elbow, driving end
Unscrew securing bolts (6) and (7) and washers (5) from
elbow (4).
Remove elbow from driving-end heat exchanger (1).
Remove O-rings (2), (3) and (9) and sealing ring (8) from
elbow.
20038/10 E –11.92–
Task Description Section 3.16.3a.3
Page 2
ET16/832B
20038/10 E –11.92–
Task Description Section 3.16.3a.3
Page 3
Note
20038/10 E –11.92–
Task Description Section 3.16.3a.3
Page 4
Note
Screw two guide pins (1) into oil cooler core (3) at each
end.
Lift housing base (2) off oil cooler.
Remove guide pins from oil cooler.
Remove O-rings and sleeves.
20038/10 E –11.92–
Task Description Section 3.16.3a.4
Page 1
Note
Cleaning solution must be pumped through oil cooler in direction opposite to normal oil flow, i.e. opposite to direction
of arrow on cooler.
Cleaning can be improved by ultrasonic means.
In event of severe contamination, e.g. piston seizure or bearing damage, replace the disc-type oil cooler.
After cleaning, oil side must be flushed with water until pH values of fresh water and flushing water are roughly equal
(permissible difference 1 pH).
This releases contaminants, particularly particles from wear parts, from swirl plates of cooling core, so that they are
flushed out with water.
Continue cleaning process until flushing medium leaving cooler is same as that entering.
Flushing pressure 3 to 4 bar at 150 to 300 litres/minute.
After this cleaning procedure, dry oil side with hot air to remove remaining flushing water from swirl plates and oil ducts.
After drying, oil cooler must be rinsed with engine oil or Haku rinsing oil in order to preserve swirl plates.
This preservation is not necessary if plate-type oil cooler is reinstalled on engine and put into operation immediately
after cleaning.
Insert protective caps in inlet and outlet bore and protect disc-type oil cooler against damage.
20038/10 E –02.95–
Task Description Section 3.16.3a.4
Page 2
Note
Edge-type filter element with metallic and plastic sealing must not be disassembled.
The plastic bonded joint on the front cover must not be damaged; in addition the components must not be subjected
to hard impacts during assembly.
Replace damaged edge-type filter element.
With engines with high load profile, only use edge-type filter with metallic seal.
Check ratchet lever for filter element for freedom of movement; replace if necessary.
20038/10 E –08.96–
Task Description Section 3.16.3a.5
Page 1
3.16.3a.5 Assembly
Preassembling plate-type oil cooler
Remove protective caps on disc-type oil cooler.
Check screw-down surfaces for irregularities with
straightedge.
Insert sleeves (2) into flanges and position gaskets (1)
on flange surfaces.
Coat O-rings (3) with petroleum jelly and fit over sleeves.
20038/10 E –08.96–
Task Description Section 3.16.3a.5
Page 2
Note
ET16/832B
20038/10 E –02.95–
Task Description Section 3.16.3a.5
Page 3
Note
20038/10 E –08.96–
Task Description Section 3.16.3a.5
Page 4
20038/10 E –08.96–
Task Description Section 3.16.3a.5
Page 5
20038/10 E –08.96–
Task Description Section 3.16.3a.5
Page 6
Note
Only tighten the hex nut firmly enough to turn the edge-
type filter.
20038/10 E –11.92–
Task Description Section 3.16.3a.5
Page 7
Note
Coat O-rings (1) and (3) with petroleum jelly and insert
into grooves of oil transfer bores on elbow (4) and heat
exchanger (2).
Secure elbow (4) to driving-end heat exchanger with
washers (5) and bolts (6).
20038/10 E –08.96–
Task Description Section 3.16.3a.6
Page 1
3.16.3a.6 Installation
Installing engine oil heat exchanger, driving end
Insert O-rings (1) and (5) into grooves of plug-in pipes
(2) and (6) and coat with petroleum jelly.
Insert plug-in pipes into oil pan bores.
Coat O-rings (3) with petroleum jelly and insert into
grooves on housing of heat exchanger, driving end (4).
20038/10 E –08.96–
Task Description Section 3.16.3a.6
Page 2
20038/10 E –08.96–
Task Description Section 3.16.3a.6
Page 3
20038/10 E –11.92–
Task Description Section 3.16.4a
Page 1
20046/20 E –08.96–
Task Description Section 3.16.4a
Page 2
20046/20 E –08.96–
Task Description Section 3.16.4a
Page 3
20046/20 E –08.96–
Task Description Section 3.16.4a.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.16.4a.2
Page 1
3.16.4a.2 Removal
Removing filter bowl
Release central securing bolt (1) in filter bowl.
Do not remove bolt completely from filter bowl unless
necessary.
20038/10 E –11.92–
Task Description Section 3.16.4a.2
Page 2
20038/10 E –11.92–
Task Description Section 3.16.4a.3
Page 1
3.16.4a.3 Disassembly
Disassembling filter bowl
Press central securing bolt (1) out of spring retainer (4)
and filter bowl (3).
Remove spring retainer from filter bowl and remove seal
(5) from spring retainer.
Remove sealing ring (2) from securing bolt.
Unscrew plug (7) on filter bowl and remove with sealing
ring (6).
Note
20038/10 E –02.95–
Task Description Section 3.16.4a.4
Page 1
20038/10 E –11.92–
Task Description Section 3.16.4a.5
Page 1
3.16.4a.5 Assembly
Completing spring washer
Fit seal (2) on spring retainer (1).
Insert sealing ring (3) in spring retainer bore.
20038/10 E –11.93–
Task Description Section 3.16.4a.5
Page 2
Note
Attention
20038/10 E –12.95–
Task Description Section 3.16.4a.6
Page 1
3.16.4a.6 Installation
Installing filter guide
Mount filter guide (2) on housing base and secure with
bolts and washers (1).
Insert O-ring (3) in annular groove on filter guide and
coat with petroleum jelly.
Fit gasket (4) via journal of filter guide and coat with pe-
troleum jelly.
Note
Place filter bowl (3) over filter element onto filter guide.
Secure bowl with central bolt (2) and tighten with torque
wrench (1) to specified torque. For torque setting, see
Section 1.3.
20038/10 E –12.95–
Task Description Section 3.16.4b
Page 1
1 O-ring 12 O-ring
2 O-ring 13 Spring washer
3 Cover 14 Screw
4 Spring washer 15 Connector
5 Screw 16 O-ring
6 Intermediate housing 17 O-ring
7 O-ring 18 Spring washer
8 Blanking plug 19 Screw
9 Snap ring 20 Throwaway oil filter
10 Sealing ring 21 Oil heat exchanger, driving end
11 Plug 22 Oil heat exchanger, free end
20046/20 E –08.96–
Task Description Section 3.16.4b
Page 2
20046/20 E –08.96–
Task Description Section 3.16.4b.1
Page 1
1 2 3 Operations See
20046/20 E –08.96–
Task Description Section 3.16.4b.2
Page 1
3.16.4b.2 Removal
Removing throwaway oil filter
Release throwaway oil filter (1) with strap wrench from
connector (2).
Removing connector
Unscrew securing screws (1) on connector (2), (3) and
(4).
Remove screws and washers.
Remove connector from intermediate housing.
20046/20 E –08.96–
Task Description Section 3.16.4b.2
Page 2
Removing cover
Unscrew securing screws (2) on cover (3).
Remove screws and washers.
Remove cover from housing lower section and O-rings
from cover.
20046/20 E –08.96–
Task Description Section 3.16.4b.3
Page 1
3.16.4b.3 Disassembly
Disassembling intermediate housing
Remove snap ring (4) with snap ring pliers.
Remove blanking plug (3) and O-ring (2) from bore on
intermediate housing (1).
Remove O-ring from blanking plug.
Unscrew plug (6) and sealing ring (5) if necessary.
20046/20 E –08.96–
Task Description Section 3.16.4b.4
Page 1
20046/20 E –08.96–
Task Description Section 3.16.4b.5
Page 1
3.16.4b.5 Assembly
Assembling intermediate housing
Make sure parts are perfectly clean.
Coat O-ring (2) with petroleum jelly and insert into
groove of blanking plug (3) without twisting.
Insert blanking plug into bore on intermediate housing
(1).
Insert snap ring (4) with snap ring pliers into groove of
bore.
Ensure that snap ring is correctly seated in groove.
Insert plug (6) and sealing ring (5) on intermediate hous-
ing and tighten.
20046/20 E –08.96–
Task Description Section 3.16.4b.6
Page 1
3.16.4b.6 Installation
Installing cover
Coat O-rings (2) and (3) with petroleum jelly and insert
into grooves in cover (1).
20046/20 E –08.96–
Task Description Section 3.16.4b.6
Page 2
20046/20 E –08.96–
Task Description Section 3.16.4b.6
Page 3
Note
20046/20 E –08.96–
Task Description Section 3.16.5a
Page 1
3.16.5a Pressure Limiting Valve, Pressure Relief Valves and Bypass Valves
20054/00 E –10.93–
Task Description Section 3.16.5a
Page 2
20054/00 E –10.93–
Task Description Section 3.16.5a
Page 3
Bypass valves
1 Housing base
2 Pressure spring
3 Valve cone
4 Initial pressure after filter element
5 Supply pressure before filter element
6 Valve seat
20054/00 E –10.93–
Task Description Section 3.16.5a.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.16.5a.2
Page 1
3.16.5a.2 Removal
Removing bypass valve
Remove valve seats (1) from housing base (2) and con-
necting housing (3).
Remove valve cone (1) and spring (2) from bore in hous-
ing base (3).
20038/10 E –11.92–
Task Description Section 3.16.5a.2
Page 2
20038/10 E –11.92–
Task Description Section 3.16.5a.2
Page 3
20038/10 E –11.92–
Task Description Section 3.16.5a.3
Page 1
3.16.5a.3 Disassembly
Disassembling pressure limiting and relief valves
Note
Caution
Spring tension
Disassemble pressure relief valve in same way.
20038/10 E –02.95–
Task Description Section 3.16.5a.4
Page 1
20038/10 E –11.92–
Task Description Section 3.16.5a.5
Page 1
3.16.5a.5 Assembly
Pressure relief valve
Caution
Spring tension
Ensure that snap ring is correctly seated in groove.
Relieve pressure in hand press and remove locating
ring.
20038/10 E –02.95–
Task Description Section 3.16.5a.5
Page 2
Caution
Spring tension
Ensure that snap ring is correctly seated in groove.
Check start of opening: 5.5 bar +
1.5 bar at an oil tem-
°
perature of 90 C with SAE30 oil.
Caution
Spring tension
Ensure that snap ring is correctly seated in groove.
Inspect pressure relief valves for leaks on test pump and
check operation.
Start of opening: 6 bar ±0.8 bar
Note
20038/10 E –12.95–
Task Description Section 3.16.5a.6
Page 1
3.16.5a.6 Installation
Note
Insert O-ring (3) into groove on valve seat (2) and coat
with petroleum jelly.
Position O-ring (4) on sealing surface of housing base
(1) and connecting housing.
Install valve seat over valve cone and spring in bore in
housing base and connecting housing.
20038/10 E –12.95–
Task Description Section 3.16.5a.6
Page 2
20038/10 E –12.95–
Task Description Section 3.16.5a.6
Page 3
20038/10 E –12.95–
Task Description Section 3.16.6
Page 1
20058/0 E –10.94–
Task Description Section 3.16.6
Page 2
ET 16/297–2
1 Housing 9 Nozzle
2 Eyebolt 10 Housing cover
3 Grooved pin 11 Seal
4 Rotor 12 Nut
5 Seeger V-ring 13 Plug
6 Nut 14 Sealing ring
7 Sleeve 15 Valve
8 O-ring 16 Spring
20058/0 E –03.93–
Task Description Section 3.16.6.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.16.6.2
Page 1
3.16.6.2 Removal
Removing centrifugal oil filter, 8V, 12V
Unscrew nut (2) securing centrifugal oil filter (1) from
vent housing (5) and remove with washer (3).
Remove centrifugal oil filter and gasket (4).
For vent housing removal, see Section 3.1.7c.2
20046/20 E –08.96–
Task Description Section 3.16.6.3
Page 1
3.16.6.3 Disassembly
Removing cover
Slacken nuts (1) until eyebolts (2) can be disengaged
and swung out.
Removing rotor
Raise cover (1).
Carefully remove rotor assembly (3) from housing (4).
Allow oil to drain.
Take care not to damage bearings and journals.
Remove gasket (2).
20058/0 E –03.93–
Task Description Section 3.16.6.3
Page 2
Disassembling rotor
Clamp rotor (2) in bench vice. Do not overtighten vice (3)
and make sure jaws engage flats on rotor base.
Remove nut (1) of rotor cap with socket wrench.
20058/0 E –03.93–
Task Description Section 3.16.6.3
Page 3
Removing nozzle
Unscrew nozzle (2) from base of rotor (1).
20058/0 E –03.93–
Task Description Section 3.16.6.3
Page 4
20058/0 E –03.93–
Task Description Section 3.16.6.4
Page 1
20058/0 E –08.96–
Task Description Section 3.16.6.5
Page 1
3.16.6.5 Assembly
Note
Installing nozzle
Install nozzle (2) in base of rotor (1) and tighten.
Check that nozzle is free of obstruction.
20058/0 E –03.93–
Task Description Section 3.16.6.5
Page 2
Assembling rotor
Clamp base of rotor (5) in bench vice. Do not overtighten
and make sure jaws engage flats of base.
Insert new filter element (3) in rotor cap (2).
Carefully place cap in position on base of rotor and turn
cap on shaft until guides (1) of cap engage recesses (4)
in base of rotor.
Fit O-ring (6) on rotor lower section and coat with petro-
leum jelly.
Tightening rotor
Mount nut (1) on rotor spindle and tighten to correct
torque with torque wrench.
For torque settings, see Section 1.3.
Note
When tightening nut on rotor cap (2) ensure that cap and
base of rotor are in metal-to-metal contact.
The O-ring forms a seal inside the rotor cap and does not
provide a seating face.
Remove rotor from bench vice (3).
20058/0 E –08.96–
Task Description Section 3.16.6.5
Page 3
Installing cover
Place gasket (2) in position on housing base (4).
Install preassembled rotor (3) in housing base.
Check that rotor rotates freely.
Carefully place cover (1) in position.
Securing cover
Swing eyebolts (2) into position.
Tighten nuts (1) diagonally and evenly.
20058/0 E –03.93–
Task Description Section 3.16.6.6
Page 1
3.16.6.6 Installation
Installing centrifugal oil filter, 8V, 12V
For vent housing installation, see Section 3.1.7c.6
Mount centrifugal oil filter (1) with gasket (4), nuts (2)
and washers (3) on vent housing (5) and tighten.
20046/20 E –08.96–
Task Description Section 3.17
Page 1
20046/20 E –12.95–
Task Description Section 3.17
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –12.95–
Task Description Section 3.17.1
Page 1
20042/10 E –10.94–
Task Description Section 3.17.1
Page 2
20042/10 E –10.94–
Task Description Section 3.17.1.1
Page 1
1 2 3 Operations See
20038/10 E –10.94–
Task Description Section 3.17.1.2
Page 1
3.17.1.2 Removal
Remove nuts from flange (1).
Remove flange from crankcase.
Remove O-ring from groove on flange.
Remove carrier from camshaft drive gear (see 3.6.1.2).
20038/10 E –11.92–
Task Description Section 3.17.1.4
Page 1
20038/10 E –11.92–
Task Description Section 3.17.1.6
Page 1
3.17.1.6 Installation
Installing flange
Install driver on camshaft drive gear, see 3.6.1.6.
Insert O-rings (2) and (4) into grooves of flange (3) and
coat with petroleum jelly.
Mount flange with O-ring on crankcase (1), tighten with
nuts (5) and spring washers (6).
Install speed transmitter (see 3.84.2.6).
20042/10 E –08.96–
Task Description Section 3.17.3
Page 1
20038/10 E –11.93–
Task Description Section 3.17.3
Page 2
20038/10 E –11.93–
Task Description Section 3.17.3.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.17.3.2
Page 1
3.17.3.2 Removal
Removing drive
Remove bolts (1) from housing (2).
Remove housing from bearing flange.
1
2
L87 10368.a
Caution
Danger!
The flange shall be hydraulically removed from the pump shaft by specially trained personnel only.
Use only specified tools for hydraulic removal.
Check the equipment annually (draw spindle crack test).
Max. permissible expansion pressure must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
20038/10 E –11.92–
Task Description Section 3.17.3.2
Page 2
Removing flange
Screw draw spindle (1) into pump shaft and tighten.
Install hydraulic puller so that catcher plate (5) has at
least 5 mm clearance.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Washer
6 Grub screw
20038/10 E –11.92–
Task Description Section 3.17.3.4
Page 1
20038/10 E –11.92–
Task Description Section 3.17.3.6
Page 1
3.17.3.6 Installation
Installing intermediate flange
Insert O-ring into groove on intermediate flange and
coat with ”petroleum jelly”.
Installing flange
Clean press-fit surface on drive shaft (2) and in flange
(1) with denaturated ethanol.
Coat surfaces with expansion fluid (SAE 10 engine oil).
Push flange onto drive shaft taper.
Measure and make note of clearance between end of
shaft and end of flange (for calculating installation
travel).
20038/10 E –08.96–
Task Description Section 3.17.3.6
Page 2
Caution
Danger!
The flange shall be hydraulically mounted on the pump shaft by specially trained personnel only.
Use only specified tools for hydraulic removal.
Check the equipment annually (draw spindle crack test).
Max. permissible expansion pressure must not be exceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Installing installation device
Install and secure installation device with draw spindle
(1) on coolant pump shaft.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Washer
6 Grub screw
20038/10 E –11.92–
Task Description Section 3.17.3.6
Page 3
L87 10368.a
20038/10 E –08.96–
Task Description Section 3.18
Page 1
20046/20 E –08.96–
Task Description Section 3.18
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –08.96–
Task Description Section 3.18.1
Page 1
ET18/244A
20046/20 E –08.96–
Task Description Section 3.18.1
Page 2
20046/20 E –08.96–
Task Description Section 3.18.1
Page 3
20046/20 E –08.96–
Task Description Section 3.18.1
Page 4
20046/20 E –08.96–
Task Description Section 3.18.1
Page 5
20046/20 E –08.96–
Task Description Section 3.18.1.1
Page 1
1 2 3 Operations See
20046/20 E –08.96–
Task Description Section 3.18.1.2
Page 1
3.18.1.2 Removal
Remove compressed air distributor
Remove securing bolts (1).
Remove compressed air distributor (2) and drive shaft
from flange.
Withdraw drive shaft from driver on camshaft gear.
Removing flange
Remove nuts (2) from flange (1).
Remove spring washers.
Remove flange from crankcase with jackscrews.
Remove O-ring from groove on flange.
20038/10 E –11.92–
Task Description Section 3.18.1.3
Page 1
3.18.1.3 Disassembly
Disassembling compressed air distributor
Remove cover (1) from compressed air distributor (2).
Remove cover gasket.
Remove distributor shaft with distributor disc (7) from
compressed air distributor.
Remove drive shaft (5) and snap ring (6) from coupling
(4).
Heat coupling on drive shaft (3) to approx. 200 °C and
remove.
Note
L 63 015V
20038/10 E –11.92–
Task Description Section 3.18.1.4
Page 1
20038/10 E –11.92–
Task Description Section 3.18.1.5
Page 1
3.18.1.5 Assembly
Assembling distributor disc
Clean taper surface in the distributor disc and on the dis-
tributor shaft with denaturated ethanol and blow clear
with compressed air.
Mount distributor disc on distributor shaft.
Coat thread of nut with engine oil.
Screw nut manually onto distributor shaft, place in posi-
tion with box wrench but do not tighten.
L 63 015V
Caution
20038/10 E –08.96–
Task Description Section 3.18.1.6
Page 1
3.18.1.6 Installation
Installing flange
Insert O-ring into groove on flange and coat with ”petro-
leum jelly”.
Install flange (1) in crankcase and secure with nuts (2)
and spring washers.
20038/10 E –08.96–
Task Description Section 3.18.1.7
Page 1
Note
20046/20 E –08.96–
Task Description Section 3.18.1.7
Page 2
Note
20046/20 E –08.96–
Task Description Section 3.18.1.7
Page 3
20046/20 E –08.96–
Task Description Section 3.18.1.7
Page 4
Fitting cover
Place gasket on cover (1).
Install and secure cover (1) with bolts (2) and spring
washers.
20046/20 E –08.96–
Task Description Section 3.18.1.7a
Page 1
Note
20046/20 E –08.96–
Task Description Section 3.18.1.7a
Page 2
Note
a Connection cylinder B5
b Setting of distributor disc
20046/20 E –08.96–
Task Description Section 3.18.1.7a
Page 3
20046/20 E –08.96–
Task Description Section 3.18.1.7a
Page 4
Fitting cover
Place gasket on cover (1).
Install and secure cover with bolts (2) and spring
washers.
20046/20 E –08.96–
Task Description Section 3.18.1.7b
Page 1
Note
Note
20046/20 E –08.96–
Task Description Section 3.18.1.7b
Page 2
20046/20 E –08.96–
Task Description Section 3.18.1.7b
Page 3
Fitting cover
Place gasket on cover (1).
Install and secure cover (1) with bolts (2) and spring
washers.
20046/20 E –08.96–
Task Description Section 3.18.2
Page 1
1 Sealing ring
2 Non-return valve
3 Union
20058/0 E –03.93–
Task Description Section 3.18.2
Page 2
20058/0 E –03.93–
Task Description Section 3.18.2.1
Page 1
1 2 3 Operations See
20058/0 E –03.93–
Task Description Section 3.18.2.2
Page 1
3.18.2.2 Removal
Removing starting valve
For removal of banjo screw and compressed air line, see
3.18.3.2.
1 Union
2 Cylinder head
20046/20 E –08.96–
Task Description Section 3.18.2.2
Page 2
20038/10 E –11.92–
Task Description Section 3.18.2.4
Page 1
Note
1 Union
2 Starting valve insert
3 Sealing ring
4 Spring
5 Test device
6 Compressed air supply
20046/20 E –08.96–
Task Description Section 3.18.2.6
Page 1
3.18.2.6 Installation
Installing starting valve
Coat sealing rings with assembly paste.
Place sealing rings on both sides of starting valve insert
collar.
Use curved removal tool (2) to install starting valve insert
(1) in cylinder head bore.
Note
20046/20 E –08.96–
Task Description Section 3.18.3
Page 1
20046/20 E –08.96–
Task Description Section 3.18.3
Page 2
20046/20 E –08.96–
Task Description Section 3.18.3
Page 3
20046/20 E –08.96–
Task Description Section 3.18.3
Page 4
20046/20 E –08.96–
Task Description Section 3.18.3.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.18.3.2
Page 1
3.18.3.2 Removal
Removing compressed air lines
Before disconnecting compressed air lines, mark them
with cylinder numbers in order to prevent confusion
when reconnecting.
Remove banjo screw (3) from union on cylinder head
while holding the union firmly in position.
Remove compressed air line (2) and sealing rings (1).
After removing air lines, seal all connections immedi-
ately with blanking plugs.
20046/20 E –08.96–
Task Description Section 3.18.3.4
Page 1
20038/10 E –11.92–
Task Description Section 3.18.3.6
Page 1
3.18.3.6 Installation
Installing compressed air lines
Note
20046/20 E –08.96–
Task Description Section 3.18.4
Page 1
20046/20 E –08.96–
Task Description Section 3.18.4
Page 2
20046/20 E –08.96–
Task Description Section 3.18.4
Page 3
20046/20 E –08.96–
Task Description Section 3.18.4.1
Page 1
1 2 3 Operations See
20046/20 E –08.96–
Task Description Section 3.18.4.2
Page 1
3.18.4.2 Removal
Remove compressed air starter
Remove air lines (1) and (5) at solenoid valve (4), air
starter (6) and retainer (3), release pipe clamp halves.
Remove compressed air hose (2) and (7) from com-
pressed air starter.
Remove solenoid valve from retainer.
20046/20 E –08.96–
Task Description Section 3.18.4.4
Page 1
20046/20 E –08.96–
Task Description Section 3.18.4.6
Page 1
3.18.4.6 Installation
Install compressed air starter
Push the O-ring (5) onto the air starter (2) as far as it will
go and ensure that it is twist-free.
Fit O-ring (6) in groove on spacer ring (4).
Coat O-rings with petroleum jelly.
Push spacer ring onto air starter as far as it will go.
Using lifting gear, insert air starter in flywheel housing
bore until it reaches the spacer ring stopper.
Secure air starter with clamping bracket (7), screws and
washers (1) to oil pan and/or crankcase intermediate
frame.
The spacer ring guarantees that the distance between
pinion and ring gear remains constant.
It is important that the installation position of the air
starter is correct.
20046/20 E –08.96–
Task Description Section 3.18.4a
Page 1
20046/20 E –08.96–
Task Description Section 3.18.4a
Page 2
20046/20 E –08.96–
Task Description Section 3.18.4a.1
Page 1
1 2 3 Operations See
20046/20 E –08.96–
Task Description Section 3.18.4a.2
Page 1
3.18.4a.2 Removal
Remove bolts (2) from clamps (1).
Withdraw pneumatic starter (4) from the fit on the fly-
wheel housing (3) and lift off with lifting gear.
Remove O-ring (5) from pneumatic starter.
20046/20 E –08.96–
Task Description Section 3.18.4a.4
Page 1
20062/00 E –03.95–
Task Description Section 3.18.4a.6
Page 1
3.18.4a.6 Installation
Check whether mating surfaces of oil pan and crank-
case intermediate section are clean.
Fit gaskets (2) to oil pan and crankcase intermediate
frame (1).
It is important that the installation position of the spring
pin (3) is correct.
20046/20 E –08.96–
Task Description Section 3.18.4a.6
Page 2
20046/20 E –08.96–
Task Description Section 3.18.5
Page 1
1 Starter 5 Bracket
2 Spacer 6 Washer
3 O-ring 7 Socket-head screw
4 O-ring
20038/10 E –08.96–
Task Description Section 3.18.5
Page 2
20038/10 E –08.96–
Task Description Section 3.18.5.1
Page 1
1 2 3 Operations See
20038/10 E –08.96–
Task Description Section 3.18.5.2
Page 1
3.18.5.2 Removal
Unscrew ground lead.
Disconnect positive lead 30 and both control cables 48
and 50.
Remove bolts from brackets (2).
Withdraw starter (1) from flywheel housing and remove
with lifting gear.
Use plastic mallet to remove spacer from flywheel hous-
ing.
Remove O-rings.
20038/10 E –11.92–
Task Description Section 3.18.5.4
Page 1
20038/10 E –11.92–
Task Description Section 3.18.5.6
Page 1
3.18.5.6 Installation
Install O-ring in grooves of spacer (1).
Coat O-ring with petroleum jelly.
Use installation tool (2) to insert spacer in bore on fly-
wheel housing.
20038/10 E –11.95–
Task Description Section 3.18.5.6
Page 2
20038/10 E –11.92–
Task Description Section 3.19
Page 1
20046/20 E –08.96–
Task Description Section 3.19
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –08.96–
Task Description Section 3.19.1
Page 1
20046/20 E –08.96–
Task Description Section 3.19.1
Page 2
20046/20 E –08.96–
Task Description Section 3.19.1
Page 3
20046/20 E –08.96–
Task Description Section 3.19.1
Page 4
20046/20 E –08.96–
Task Description Section 3.19.1
Page 5
20046/20 E –08.96–
Task Description Section 3.19.1
Page 6
20046/20 E –08.96–
Task Description Section 3.19.1
Page 7
20046/20 E –08.96–
Task Description Section 3.19.1
Page 8
20046/20 E –08.96–
Task Description Section 3.19.1
Page 9
1 Carrier 5 Carrier
2 Hex bolt 6 Cover
3 Resilient bush 7 Hex bolt
4 Stud 8 Housing
20046/20 E –08.96–
Task Description Section 3.19.1
Page 10
20046/20 E –08.96–
Task Description Section 3.19.1.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.19.1.2
Page 1
3.19.1.2 Removal
Removing engine mount, driving end
Detach engine mount (2) from flywheel housing (1).
20046/20 E –08.96–
Task Description Section 3.19.1.2
Page 2
20046/20 E –08.96–
Task Description Section 3.19.1.3
Page 1
3.19.1.3 Disassembly
Disassembling engine mount, driving end
Remove split pins for castle nuts (1).
Unscrew castle nuts and nuts (2).
20046/20 E –08.96–
Task Description Section 3.19.1.3
Page 2
Remove securing bolt (1) and locking bolt (13) with nuts
(11) and washers (12) from engine carrier lower section
(10).
Remove washer (2), cover plate (3), stop plate (4) and
engine carrier lower section.
Remove bolts (9) and spring washers (8) securing tap-
ered mount (6) and flange (7) from engine carrier upper
section (5).
Remove tapered mount and flange.
20046/20 E –08.96–
Task Description Section 3.19.1.3
Page 3
20046/20 E –08.96–
Task Description Section 3.19.1.4
Page 1
Note
Do not use petrol, benzene or other substances harmful to rubber to clean the rubber surfaces on the rubber mount.
Using the surface crack-testing method and red penetrant dye, check engine carrier and carrier for cracks.
Replace relevant components if cracks are found.
Check the condition of the tapered mount, rubber ring and resilient bush and make a visual inspection for cracks and
deformation; if necessary, check the rubber quality with the testing device.
Replace parts that are cracked, deformed or badly contaminated (oily).
Check protective coating of rubber mounts, renew if necessary.
Check contact surfaces on engine carrier and rubber mount for evenness, smooth with an oilstone if necessary.
Check condition of threads and recut if necessary.
Release locknut on jackscrew, check condition of threads and recut if necessary.
Replace spring pins as required.
20046/20 E –08.96–
Task Description Section 3.19.1.5
Page 1
3.19.1.5 Assembly
Assembling engine mount, driving end
Insert bolts (2) in engine carrier lower section (6).
Position flange (5), tapered mounts (4), spacers (3) and
engine carrier (1) on engine carrier lower section (6).
20046/20 E –08.96–
Task Description Section 3.19.1.5
Page 2
20046/20 E –08.96–
Task Description Section 3.19.1.5
Page 3
Install tapered mount (6) and flange (7) with bolts (9) and
spring washers (8) on engine carrier upper section (5).
Using torque wrench, tighten bolts to specified torque.
For torque setting, see Section 1.3.
Install engine carrier lower section (10) with bolt (1),
washer (2), cover plate (3) and stop plate (4) on tapered
mount.
Using torque wrench, tighten bolt to specified torque.
For torque setting, see Section 1.3.
Screw in locking bolt (13) with washers (12) and nuts
(11) only to secure during transportation.
20046/20 E –08.96–
Task Description Section 3.19.1.5
Page 4
Note
20046/20 E –08.96–
Task Description Section 3.19.1.6
Page 1
3.19.1.6 Installation
Installing engine mount, driving end
Install engine mount (1) on flywheel housing with bolts
and spring washers and tighten with torque wrench to
specified torque. For torque setting, see Section 1.3.
20046/20 E –08.96–
Task Description Section 3.19.1.6
Page 2
20046/20 E –08.96–
Task Description Section 3.19.1.7
Page 1
Note
Attention
The locking device must not be removed before the engine is aligned on the engine foundation.
Refer also to the instructions regarding engine mount transportation.
20046/20 E –08.96–
Task Description Section 3.19.1.7
Page 2
Note
Lock engine mount for transportation, unscrew jackscrews (5) to dimension ”A” = 54 mm and lock with nut (6).
Bolt together flange (2) and engine carrier lower section (1) manually with the locking screws (3) and lock with nut (4).
Attention
The locking device must not be removed before the engine is aligned on the engine foundation.
Refer also to the instructions regarding engine mount transportation.
20046/20 E –08.96–
Task Description Section 3.19.1.7a
Page 1
Attention
20046/20 E –08.96–
Task Description Section 3.19.1.7a
Page 2
Note
Lock engine mount for transportation, unscrew jackscrews (2) to dimension ”A” = 54 mm and lock with nut (3).
Bolt together flange (4) and engine carrier lower section (1) manually with the locking screws (5) and lock with nut (6).
Attention
The locking device must not be removed before the engine is aligned on the engine foundation.
Refer also to the instructions regarding engine mount transportation.
20046/20 E –08.96–
Task Description Section 3.20
Page 1
3.20.3a Control unit for hydraulic fan drive with supplementary piston
3.20.3a.1 Before-removal operations
3.20.3a.2 Removal
3.20.3a.3 Disassembly
3.20.3a.4 Inspection and repair
3.20.3a.5 Assembly
3.20.3a.6 Installation
3.20.3a.7 After-installation operations
20046/20 E –10.96–
Task Description Section 3.20
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Attention
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –10.96–
Task Description Section 3.20.1a
Page 1
20046/20 E –10.96–
Task Description Section 3.20.1a
Page 2
1 Flange 21 Disc
2 Shaft 22 Spring washer
3 Intermediate housing 23 Hex screw
4 Spacer sleeve (optional) 24 Shaft seal
5 Angular-contact ball bearing 25 Fan flange
6 Disc 26 Spring pin
7 Spring washer 27 Stress bolt
8 Hex screw 28 O-ring
9 Cover 29 Spring washer
10 Cover 30 Hex screw
11 O-ring 31 Cylindrical roller bearing
12 Spring washer 32 Sealing ring
13 Hex screw 33 Plug
14 Shaft 34 Gasket
15 Plug 35 Dowel pin
16 Sealing ring 36 Spring washer
17 Ring 37 Hex screw
18 Snap ring 38 Gear
19 Angular-contact ball bearing 39 Gear
20 Spacer sleeve (optional)
20046/20 E –10.96–
Task Description Section 3.20.1a
Page 3
20046/20 E –10.96–
Task Description Section 3.20.1a
Page 4
20046/20 E –10.96–
Task Description Section 3.20.1a.1
Page 1
1 2 3 Operations See
20046/20 E –10.96–
Task Description Section 3.20.1a.2
Page 1
3.20.1a.2 Removal
Disconnecting oil line
Disconnect oil line (1) for oil supply on cover of fan drive.
Remove pipe clamp halves, grommets and oil line.
Seal oil line connection.
Gently tap cover (1) with fan flange with a plastic mallet
to release and remove via guide pins.
Attention
Note
20046/20 E –10.96–
Task Description Section 3.20.1a.2
Page 2
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools.
The installation pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Screw draw spindle (5) of removal tool (3) into coupling
shaft (1) as far as it will go.
Note
Note
When the hex nut is being screwed on, the removal tool
must be at its initial position (0 stroke).
Screw reducer (9) into gear (10) and union (6) of installa-
tion tool and tighten.
Connect H.P. lines for expansion pressure (8) and in-
stallation pressure (7).
20046/20 E –10.96–
Task Description Section 3.20.1a.2
Page 3
Fill oil pressure hand pumps with engine oil SAE 10.
Vent pumps and pipework until bubble-free oil emerges.
Close valves.
Actuate oil pressure hand pump for removal tool (3) until
pressure plate of removal tool is in contact with gear (1).
The tool is intended to catch the gear sliding off the tap-
ered seat smoothly and to ensure safety as the gear is
released.
Note:
Actuate oil pressure hand pump for expansion of gear until half max. expansion pressure is reached. Maintain this pres-
sure for approx. 5 minutes.
Increase expansion pressure in stages, holding for approx. 2 minutes between each stage, until hex nut (4) takes up
removal force.
If expansion pressure drops, continue pumping to maintain pressure at a constant level until gear is released or further
pressure increase is required.
Max. expansion pressure = 1600 bar
The max. expansion pressure is stamped on gear and must not be exceeded.
Release of gear is signalled by increasing pressure in removal tool.
Back off hex nut with wrench.
Gradually drain oil from removal tool.
Relieve pressure at oil pressure hand pumps.
Press piston of removal tool with hex nut to final position.
Remove H.P. lines and removal tool.
Remove gear from coupling shaft.
20046/20 E –10.96–
Task Description Section 3.20.1a.2
Page 4
20046/20 E –10.96–
Task Description Section 3.20.1a.2
Page 5
20046/20 E –10.96–
Task Description Section 3.20.1a.2
Page 6
Removing housing
Unscrew securing screws (1) and (3) on housing (4)
from bearing retaining plate (5) and remove with spring
washers (2).
Attach housing to lifting gear with rope and tension.
Using two assembly levers, press housing off bearing
retaining plate of crankcase and remove with lifting gear.
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 1
3.20.1a.3 Disassembly
Disassembling cover with fan flange
Removing cover
Remove securing screws and remove cover (1) for oil
supply.
Remove O-ring from cover.
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 2
Caution
Danger
Hydraulic removal must be carried out only by trained personnel. Use only specified tools for hydraulic removal. The
installation pressure stamped on the tool and the expansion pressure stamped on the gear must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Screw draw spindle (6) of removal tool (4) into fan shaft
(1) on gear (10) as far as it will go.
Note
Note
Before the hex nut is screwed on, the removal tool must
be at its initial position (0 stroke).
Screw reducer (2) for H.P. connection into gear and
tighten.
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 3
Fit H.P. lines for expansion pressure (3) and installation pressure (8).
Fill oil pressure hand pumps with engine oil SAE 10.
Vent pumps and pipework until bubble-free oil emerges.
Close valves.
Actuate oil pressure hand pump for removal tool until pressure plate of removal tool is in contact with gear.
The tool is intended to catch the gear sliding off the tapered seat smoothly and to ensure safety as the gear is released.
Expand gear with oil pressure hand pump until gear is released from fan shaft.
The max. expansion pressure = 1600 bar is stamped on gear and must not be exceeded.
For further information, see Section 3.20.1a.2, Page 3.
Use wrench to unscrew hex nut and relieve pressure on oil pressure hand pumps.
Remove H.P. lines and reducers (3), (4).
Remove removal tool (1) from fan shaft.
Remove gear (2) from fan shaft.
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 4
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 5
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools.
The installation pressure stamped on the tool and the expansion pressure stamped on the fan flange must not be ex-
ceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Screw draw spindle (6) M22x1.5 of removal tool (4) as
far as it will go into fan shaft (1) on fan flange (10).
Measure reference dimension ”K” = 185 mm.
Fit pressure plate (9) and hydraulic removal tool on draw
spindle.
Screw hex nut (5) onto draw spindle as far as it will go,
then unscrew by approx. 7 mm.
Note
Expand fan flange with oil pressure hand pump until max. expansion pressure is reached and flange is released from
fan shaft.
Max. expansion pressure = 1600 bar is stamped on fan flange and must not be exceeded.
For further information, see Section 3.20.1a.2, Page 3.
Disconnect H.P. lines, remove reducer and removal tool, remove fan flange.
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 6
1 Coupling shaft
2 Coupling flange
3 Intermediate housing
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 7
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools.
The installation pressure stamped on the tool and the expansion pressure stamped on the coupling flange must not
be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Note
Fill oil pressure hand pumps with engine oil SAE 10.
Vent pumps and pipework until bubble-free oil emerges.
Close valves.
Actuate oil pressure hand pump for removal tool until
pressure plate of removal tool (2) is in contact with
flange (1).
The tool is intended to catch the flange sliding off the tap-
ered seat smoothly and to ensure safety as the flange
is released.
Expand flange (3) with oil pressure hand pump until
flange is released from coupling shaft.
Max. expansion pressure = 1600 bar is stamped on
coupling flange.
For further information, see Section 3.20.1a.2, Page 3. Unscrew hex nut (1) with wrench.
Relieve pressure on oil pressure hand pump. Disconnect H.P. lines and remove reducer and removal tool.
Remove flange from coupling shaft.
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 8
20046/20 E –10.96–
Task Description Section 3.20.1a.3
Page 9
Note
20046/20 E –10.96–
Task Description Section 3.20.1a.4
Page 1
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 1
3.20.1a.5 Assembly
Assembling intermediate housing
Check that bore for angular-contact ball bearing in inter-
mediate housing is clean.
Using mandrel (1), press angular-contact ball bearing
for coupling shaft, with contact surfaces on outer race
facing outwards, into intermediate housing.
Note
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 2
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the coupling flange must not
be exceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 3
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 4
Note
Assembling cover
Check that bore for fan gear bearing in cover (4) is clean.
Insert snap ring (3) with Seeger assembly pliers.
Ensure that snap ring is correctly seated in groove.
Fit ring (2) in bore.
Use mandrel to install angular-contact ball bearing (1),
with one contact surface facing down and one facing up
as shown in illustration.
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 5
Use installation tool (1) to drive shaft seal into bore (2).
Coat sealing lip with ”petroleum jelly”.
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 6
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the fan flange must not be ex-
ceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 7
Note
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 8
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Note
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 9
Note
Caution
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 10
Installing cover
Insert O-ring (2) in groove of cover (1) and coat with pe-
troleum jelly.
Fit cover with oil supply connection for coupling shaft in
housing cover.
Note
20046/20 E –10.96–
Task Description Section 3.20.1a.5
Page 11
20046/20 E –10.96–
Task Description Section 3.20.1a.6
Page 1
3.20.1a.6 Installation
Installing housing
Insert O-rings (5) into grooves on coolant line (6).
Coat O-rings with petroleum jelly.
Insert coolant line into bore on housing (7).
Install housing with rope and lifting gear on bearing re-
taining plate of crankcase; in doing so, install coolant line
(6) on crankcase.
Mount cover (3) and gasket (4) with screws (1) and
spring washers (2) on housing (7).
Insert O-rings (8) and (9) into grooves on housing and
coat with petroleum jelly.
Securing housing
Coat thread of screws with engine oil.
Mount housing (4) with screw (1), (3) and spring
washers (2) on bearing retaining plate (5) of crankcase
and tighten.
20046/20 E –10.96–
Task Description Section 3.20.1a.6
Page 2
20046/20 E –10.96–
Task Description Section 3.20.1a.6
Page 3
20046/20 E –10.96–
Task Description Section 3.20.1a.6
Page 4
20046/20 E –10.96–
Task Description Section 3.20.1a.6
Page 5
Example
Fit lower gear with 50 teeth to coupling shaft.
Fit upper gear with 55 teeth to fan shaft.
Fan speed
20046/20 E –10.96–
Task Description Section 3.20.1a.6
Page 6
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Note
20046/20 E –10.96–
Task Description Section 3.20.1a.6
Page 7
)
Compare measured push-on distance with specified
push-on distance 5.6 0.3 mm.
–1.3
819827/31
Note
Caution
Note
20046/20 E –10.96–
Task Description Section 3.20.1a.6
Page 8
20046/20 E –10.96–
Task Description Section 3.20.1a.7
Page 1
20046/20 E –10.96–
Task Description Section 3.20.1b
Page 1
20046/20 E –10.96–
Task Description Section 3.20.1b
Page 2
1 Flange 24 Shaft
2 Shaft 25 Cylindrical roller bearing
3 Intermediate housing 26 Ring
4 Spacer sleeve 27 Cover
5 Angular-contact ball bearing 28 O-ring
6 Disc 29 Spring washer
7 Spring washer 30 Hex screw
8 Hex screw 31 Stress bolt
9 Cover 32 O-ring
10 Cover 33 Gear T = 56
11 O-ring 34 Spring washer
12 Spring washer 35 Hex screw
13 Hex screw 36 Cylindrical roller bearing
14 Fan gear shaft 37 Gasket
15 Spacer sleeve 38 Spring washer
16 Cylindrical roller bearing 39 Hex screw
17 Angular-contact ball bearing 40 Dowel pin
18 Retaining pin 41 Gear T = 35
19 Spacer screw 42 Gear T = 51
20 Disc 43 Flange
21 Spring washer 44 O-ring
22 Hex screw 45 Socket-head screw
23 Shaft seal
20046/20 E –10.96–
Task Description Section 3.20.1b
Page 3
20046/20 E –10.96–
Task Description Section 3.20.1b
Page 4
20046/20 E –10.96–
Task Description Section 3.20.1b.1
Page 1
1 2 3 Operations See
20046/20 E –10.96–
Task Description Section 3.20.1b.2
Page 1
3.20.1b.2 Removal
Disconnecting oil line
Remove oil line (4) for oil supply from cover of fan drive,
oil line from intermediate housing and oil line (2) for
drainage from flange.
Remove pipe clamp halves, grommets and oil lines and
unscrew union (1).
1 Seal oil line connections.
2
4
3
1
SG200001a0
Gently tap cover (1) with fan flange with a plastic mallet
to release and remove via guide pins.
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.2
Page 2
20046/20 E –10.96–
Task Description Section 3.20.1b.2
Page 3
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools.
The removal pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Screw draw spindle (5) of removal tool (3) into coupling
shaft (1) as far as it will go.
Note
Note
When the hex nut is being screwed on, the removal tool
must be at its initial position (0 stroke).
Screw reducer (9) into gear (10) and union (6) of removal
tool and tighten.
Connect H.P. lines for expansion pressure (8) and re-
moval pressure (7).
Fill oil pressure hand pumps with engine oil SAE 10.
Vent pumps and pipework until bubble-free oil emerges.
Close valves.
Actuate oil pressure hand pump for removal tool (3) until
pressure plate of removal tool is in contact with gear
(10).
The tool is intended to catch the gear sliding off the tap-
ered seat smoothly and to ensure safety as the gear is
released.
20046/20 E –10.96–
Task Description Section 3.20.1b.2
Page 4
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.2
Page 5
20046/20 E –10.96–
Task Description Section 3.20.1b.2
Page 6
20046/20 E –10.96–
Task Description Section 3.20.1b.2
Page 7
Removing housing
Unscrew securing screws (1) and (3) on housing (4)
from bearing retaining plate (5) and remove with spring
washers (2).
Attach housing to lifting gear with rope and tension.
Using two assembly levers, press housing (4) off bear-
ing retaining plate on crankcase.
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 1
3.20.1b.3 Disassembly
Disassembling cover with fan flange
1 Cover 13 Screw
2 Gear 14 O-ring
3 Screw 15 Cover, coupling shaft
4 Disc 16 Screw
5 Spacer disc 17 O-ring
6 Bearing inner race 18 Cover, intermediate shaft
7 Spacer sleeve 19 Flange
8 Four-point bearing 20 Fan gear shaft
9 Cylindrical roller bearing 21 Shaft seal
10 Ring 22 Spring pin
11 Cylindrical roller bearing – intermediate shaft 23 Socket-head screw
12 Cylindrical roller bearing – coupling shaft 24 O-ring
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 2
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools. The installation pressure stamped on the tool and the expansion pressure stamped on the
gear must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Screw draw spindle (6) of removal tool (4) into fan shaft
(1) on gear (10) as far as it will go.
Note
Note
Before the hex nut is screwed on, the removal tool must
be at its initial position (0 stroke).
Screw reducer (2) for H.P. connection into gear and tighten.
Fit H.P. lines for expansion pressure (3) and installation pressure (8).
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 3
Fill oil pressure hand pumps with engine oil SAE 10.
Vent pumps and pipework until bubble-free oil emerges.
Close valves.
Actuate oil pressure hand pump for removal tool until pressure plate of removal tool is in contact with gear.
The tool is intended to catch the gear sliding off the tapered seat smoothly and to ensure safety as the gear is released.
Expand gear with oil pressure hand pump until gear is released from fan shaft.
The max. expansion pressure = 1600 bar is stamped on gear and must not be exceeded.
For further information, see Section 3.20.1b.2, Page 4.
Use wrench to unscrew hex nut and relieve pressure on oil pressure hand pumps.
Remove H.P. lines and reducer (2), (3) and unscrew nut
(5).
Remove removal tool (1) from fan shaft.
Remove gear (4) from fan shaft.
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 4
SG200005a0
Note
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 5
Note
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools. The installation pressure stamped on the tool and the expansion pressure stamped on the
gear must not be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 6
Note
Before the hex nut is screwed on, the removal tool must
be at its initial position (0 stroke).
Screw reducer (2) into gear (10) and tighten.
Fit H.P. lines for expansion pressure (3) and installation
pressure (8).
Fill oil pressure hand pumps with engine oil SAE 10.
Vent oil pressure hand pumps until bubble-free oil
emerges.
Close valves.
Actuate oil pressure hand pump for removal tool (3) until
pressure plate (6) of removal tool is in contact with gear
(7).
The tool is intended to catch the gear sliding off the tap-
ered seat smoothly and to ensure safety as the gear is
released.
During removal, pay special attention to instructions
3.20.1b.2, Page 4.
Max. expansion pressure = 1900 bar.
Max. expansion pressure is stamped on gear; do not ex-
ceed this pressure.
Use wrench to unscrew hex nut (4) and relieve pressure
on oil pressure hand pumps.
Remove H.P. lines (2) and (5) with reducer and removal
tool from intermediate shaft.
Remove gear from intermediate shaft.
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 7
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 8
Caution
Danger
Hydraulic removal must be carried out only by trained personnel.
Use only specified tools.
The installation pressure stamped on the tool and the expansion pressure stamped on the coupling flange must not
be exceeded.
During the removal procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Screw draw spindle (6) M22x1.5 of hydraulic removal
tool (4) as far as it will go into coupling shaft (1).
Measure reference dimension ”K” = 185 mm.
Fit pressure plate (9) and hydraulic removal tool on draw
spindle.
Screw hex nut (5) onto draw spindle as far as it will go,
then unscrew by approx. 8 mm.
Note
Fill oil pressure hand pumps with engine oil SAE 10.
Vent pumps and pipework until bubble-free oil emerges.
Close valves.
Actuate oil pressure hand pump for removal tool until
pressure plate of removal tool (2) is in contact with
flange (1).
The tool is intended to catch the flange sliding off the tap-
ered seat smoothly and to ensure safety as the flange
is released.
Expand flange (3) with oil pressure hand pump until
flange is released from coupling shaft.
Max. expansion pressure = 2600 bar is stamped on
coupling flange.
For further information, see Section 3.20.1b.2, Page 4. Unscrew hex nut (1) with wrench.
Relieve pressure on oil pressure hand pump. Disconnect H.P. lines and remove reducer and removal tool.
Remove flange from coupling shaft.
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 9
20046/20 E –10.96–
Task Description Section 3.20.1b.3
Page 10
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.4
Page 1
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 1
3.20.1b.5 Assembly
Assembling intermediate housing
Check that bore for angular-contact ball bearing in inter-
mediate housing is clean.
Using mandrel (2), press angular-contact ball bearing
for coupling shaft, with contact surfaces on outer race
facing outwards, into intermediate housing (2).
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 2
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the coupling flange must not
be exceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Clean taper surfaces on coupling shaft (1) and coupling
flange (10) with denaturated ethanol and coat with en-
gine oil SAE 10.
Install flange on shaft and measure distance between
surface of shaft and flange.
Screw draw spindle (6) M22 as far as it will go into shaft.
Measure reference dimension ”K” = 185 mm.
Fit pressure plate (9) and hydraulic installation tool (4)
on draw spindle.
Screw hex nut (5) as far as it will go onto draw spindle.
Install reducer (2) on flange and tighten.
Connect H.P. line (3) for expansion and H.P. line (8) for
installation and tighten.
Fill oil pressure hand pumps with engine oil SAE 10.
Vent oil pressure hand pumps and pipework until
bubble-free oil emerges.
Close shut-off valves.
Actuate oil pressure hand pumps to increase installation
pressure and expansion pressure alternately, starting
with installation pressure, until flange (4) is in contact
with shoulder of shaft (3).
The max. expansion pressure = 2600 bar is stamped on
flange and must not be exceeded.
After completion of installation procedure, relieve ex-
pansion pressure and maintain installation pressure on
flange for a further approx. 60 minutes.
Relieve expansion pressure, remove H.P. lines (1) and
(2) and nut (6).
Remove installation tool (5).
Again measure distance between surfaces of shaft and
flange.
Compare measured push-on distance with specified
push-on distance 6.8 mm -1.3 mm.
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 3
Note
SG200003a0
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 4
Assembling cover
Positioning correctly, install cover (1) with oil return (2)
on cover (3).
Tighten securing screws with torque wrench to tighten-
ing specification 1.3.
1
SG200004a0
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 5
2 Note
SG200002a0
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 6
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Screw draw spindle (6) as far as it will go into fan shaft
(1).
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 7
Caution
Note
Installing cover
Insert O-ring (2) in groove of cover (1) and coat with pe-
troleum jelly.
Fit cover with oil supply connection for coupling shaft in
housing cover.
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 8
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 9
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools for hydraulic installation.
The installation pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Clean taper surfaces on intermediate shaft (1) and idler
gear (10) with denaturated ethanol and blow with com-
pressed air.
Coat taper surfaces with engine oil SAE 10.
Fit idler gear on shaft and measure distance between
surface of shaft and idler gear.
Screw draw spindle (6) as far as it will go into fan shaft
(1).
Measure reference dimension ”K” = 185 mm.
Fit pressure plate (9) and hydraulic installation tool (4)
on draw spindle.
Screw hex nut (5) as far as it will go onto draw spindle.
Screw reducer (2) on gear and union (7) on installation
tool and tighten.
Connect H.P. line (3) for expansion and H.P. hose (8) for
installation and tighten.
Fill oil pressure hand pumps with engine oil SAE 10.
Vent oil pressure hand pumps and pipework until
bubble-free oil emerges. Close shut-off valves.
Actuate oil pressure hand pumps to increase installation
pressure and expansion pressure alternately, starting
with installation pressure, until gear (7) is in contact with
lip (1) shaft.
The max. expansion pressure = 1900 bar is stamped on
gear and must not be exceeded.
After completion of installation procedure, relieve ex-
pansion pressure and maintain installation pressure on
gear for a further approx. 60 minutes.
Release installation pressure and remove oil pressure
hand pumps and H.P. lines (2) and (5).
Unscrew hex nut (4) and remove installation tool (3) and
thrust pad (6).
Again measure distance between surface of shaft and gear.
Compare measured push-on distance with specified push-on distance 5.0 mm - 1.3 mm.
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 10
Note
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 11
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 12
20046/20 E –10.96–
Task Description Section 3.20.1b.5
Page 13
20046/20 E –10.96–
Task Description Section 3.20.1b.6
Page 1
3.20.1b.6 Installation
Installing housing
Insert O-rings (8) into grooves on coolant line (9) and
coat with ”petroleum jelly”.
Insert coolant line into bore on housing (10).
Mount housing with rope and lifting gear on bearing re-
taining plate of crankcase.
Insert coolant line into bore on elbow of oil pan.
Mount dead-center indicator (7) with hex bolts (5) and
spring washers (6) on housing (10).
Insert studs (13) in housing.
Mount cover (3) and gasket (4) with nuts (1) and spring
washers (2) on housing.
Coat O-rings (11) and (12) with ”petroleum jelly” and in-
sert into grooves on housing (10).
Securing housing
Coat thread of screws with engine oil.
Mount housing (4) with screws (1), (3) and spring
washers (2) on bearing retaining plate (5) of crankcase
and tighten with torque wrench to tightening specifica-
tion 1.3.
20046/20 E –10.96–
Task Description Section 3.20.1b.6
Page 2
20046/20 E –10.96–
Task Description Section 3.20.1b.6
Page 3
20046/20 E –10.96–
Task Description Section 3.20.1b.6
Page 4
Caution
Danger
Hydraulic installation must be carried out only by trained personnel.
Use only specified tools.
The installation pressure stamped on the tool and the expansion pressure stamped on the gear (10) must not be ex-
ceeded.
During the installation procedure, make sure that nobody is standing behind the tool.
Check the equipment annually (draw spindle crack test).
Clean taper surfaces on coupling shaft (1) and gear (10)
with denaturated ethanol and coat with engine oil SAE
10.
Install gear on shaft and measure distance between sur-
face of shaft and gear hub.
Screw draw spindle (5) as far as it will go into shaft.
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.6
Page 5
Fill oil pressure hand pump with engine oil SAE 10.
Vent oil pressure hand pumps and pipework until
bubble-free oil emerges.
Close shut-off valves.
Actuate oil pressure hand pumps to increase installation
pressure and expansion pressure alternately, starting
with installation pressure, until gear (5) is in contact with
shaft bearing.
The max. expansion pressure = 1800 bar is stamped on
gear and must not be exceeded.
After completion of installation procedure, relieve ex-
pansion pressure and maintain installation pressure on
gear for a further approx. 60 minutes.
Release installation pressure, disconnect oil pressure
hand pump, H.P. lines (1) and (4) and unscrew hex nut
(3).
Remove installation tool (2).
Again measure distance between front surfaces of shaft
and flange.
Compare measured push-on distance with specified
push-on distance 5.0 mm - 1.6 mm.
Installing bearing inner race on coupling shaft
Heat bearing inner race (2) of cylindrical roller bearing
to 80 °C and install up to gear (1) on coupling shaft.
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.6
Page 6
Note
20046/20 E –10.96–
Task Description Section 3.20.1b.6
Page 7
2
4
3
1
SG200001a0
20046/20 E –10.96–
Task Description Section 3.20.3
Page 1
20046/20 E –10.96–
Task Description Section 3.20.3
Page 2
1 Housing 15 Cover
2 Sleeve 16 Spring washer
3 O-ring 17 Screw
4 Thermal element 18 Sealing ring
5 O-ring 19 Sealing ring
6 Snap ring 20 Plug
7 Control piston 21 Plug
8 Nut 22 Sealing ring
9 Threaded pin 23 Plug for access port to secure control piston when locking
10 Pressure spring
11 Pressure spring (1) Oil supply from engine
12 Control piston (2) Oil supply to hydraulic fan drive
13 Nozzle needle (3) Leak-off oil
14 Seal
20046/20 E –10.96–
Task Description Section 3.20.3.1
Page 1
1 2 3 Operations See
20046/20 E –10.96–
Task Description Section 3.20.3.2
Page 1
3.20.3.2 Removal
Remove nuts (1).
Remove spring washers (2), control unit (3) and gasket
(4).
Remove studs (5) from elbow if necessary.
20046/20 E –10.96–
Task Description Section 3.20.3.3
Page 1
3.20.3.3 Disassembly
Removing cover from housing
Release screws (3) and spring washers (2) from cover
(10).
Remove cover and gasket (11) from housing (1).
Unscrew plugs (5) and (8) on cover and remove with
sealing rings (4) and (9).
Only if necessary, unscrew plug (7) and sealing ring (6)
from plug (5).
20046/20 E –10.96–
Task Description Section 3.20.3.3
Page 2
20046/20 E –10.96–
Task Description Section 3.20.3.4
Page 1
20046/20 E –10.96–
Task Description Section 3.20.3.5
Page 1
3.20.3.5 Assembly
Preassembling control piston
Insert threaded pin (2) into control piston (1).
Preset threaded pin projection to dimension ”A” =
±
3.5 mm 0.2 mm; final setting takes place on engine.
Lock threaded pin (2) with nut (3).
20046/20 E –10.96–
Task Description Section 3.20.3.5
Page 2
20046/20 E –10.96–
Task Description Section 3.20.3.5
Page 3
20046/20 E –10.96–
Task Description Section 3.20.3.6
Page 1
3.20.3.6 Installation
Clean and smooth sealing surfaces on control unit (3)
and elbow.
Insert studs (5) into elbow.
Fit gasket (4) and mount control unit with spring washers
(2) and nuts (1) on elbow and tighten.
20046/20 E –10.96–
Task Description Section 3.20.3.7
Page 1
20046/20 E –10.96–
Task Description Section 3.20.3a
Page 1
3.20.3a Control Unit for Hydraulic Fan Drive with Supplementary Piston
20046/20 E –10.96–
Task Description Section 3.20.3a
Page 2
Arrangement of control unit for hydraulic fan drive with supplementary piston
20046/20 E –10.96–
Task Description Section 3.20.3a.1
Page 1
1 2 3 Operations See
20046/20 E –10.96–
Task Description Section 3.20.3a.2
Page 1
3.20.3a.2 Removal
Remove nut (6).
Remove spring washers (5), control unit (2) with sole-
noid valve (1) and gasket (3).
Remove stud (4) from elbow if necessary.
20046/20 E –10.96–
Task Description Section 3.20.3a.3
Page 1
3.20.3a.3 Disassembly
Removing solenoid valve and return line
Unscrew locknut (10) from union (7).
Remove return line (2) from cover and remove with seal-
ing rings (8).
Remove banjo union (9) from return line and remove O-
ring (1) from return line.
Remove union (7) from solenoid valve (4).
Remove socket-head screws (6) from solenoid valve.
Remove solenoid valve from cover of control unit (5).
Note
20046/20 E –10.96–
Task Description Section 3.20.3a.3
Page 2
20046/20 E –10.96–
Task Description Section 3.20.3a.3
Page 3
20046/20 E –10.96–
Task Description Section 3.20.3a.4
Page 1
20046/20 E –10.96–
Task Description Section 3.20.3a.5
Page 1
3.20.3a.5 Assembly
Preassembling control piston
Insert threaded pin (2) into control piston (1).
Preset threaded pin projection to dimension ”A” =
±
3.5 mm 0.2 mm; final setting takes place on engine.
Lock threaded pin (2) with nut (3).
20046/20 E –10.96–
Task Description Section 3.20.3a.5
Page 2
20046/20 E –10.96–
Task Description Section 3.20.3a.5
Page 3
Note
Pressure difference
Engine/control unit approx. 2.5 bar.
20046/20 E –10.96–
Task Description Section 3.20.3a.5
Page 4
20046/20 E –10.96–
Task Description Section 3.20.3a.6
Page 1
3.20.3a.6 Installation
Clean and smooth sealing surfaces on housing and
elbow.
Insert studs (4) on housing.
Mount gasket (3).
Mount control unit (2) and solenoid valve (1) with nuts (6)
and spring washer (5) on housing and tighten.
20046/20 E –10.96–
Task Description Section 3.20.3a.7
Page 1
20046/20 E –10.96–
Task Description Section 3.20.4
Page 1
20046/20 E –10.96–
Task Description Section 3.20.4
Page 2
20046/20 E –10.96–
Task Description Section 3.20.4
Page 3
1 2 3 Operations See
3.20.4.2 Removal
Perform removal as shown in illustration, page 1 and 2.
3.20.4.6 Installation
Prior to installation, check mating faces on fan wheel shaft and fan wheel for flatness; smooth with oilstone if necessary.
Perform installation as shown in illustration, page 1 and 2.
20046/20 E –10.96–
Task Description Section 3.27
Page 1
20046/20 E –11.96–
Task Description Section 3.27
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –11.96–
Task Description Section 3.27.1a
Page 1
20046/20 E –11.96–
Task Description Section 3.27.1a
Page 2
20046/20 E –11.96–
Task Description Section 3.27.1a
Page 3
1 2 3 Operations See
3.27.1a.2 Removal
Prior to removing compressed air lines, it is advisable to take photographs of all sides of the engine or to identify lines
with metal tags.
After removing lines, seal all connections with suitable plugs.
Remove solenoid valve and distributor as shown in illustration, Page 1 and 2.
For actuating cylinder removal, see 3.10.8a.2
3.27.1a.6 Installation
Mount distributor and solenoid valve as shown in illustration, Page 1 and 2.
Prior to installation, blow out all compressed air lines with dry compressed air.
Mount free of tension with attachments as shown in illustration 3.27.1 and photographs or markings.
For actuating cylinder installation, see 3.10.8a.6.
Note
Before mounting air lines on distributor and actuating cylinder, check function of exhaust flow control flap and air flow
control flap – see Description and Operating Instructions.
20046/20 E –11.96–
Task Description Section 3.27.1b
Page 1
20046/20 E –11.96–
Task Description Section 3.27.1b
Page 2
20046/20 E –11.96–
Task Description Section 3.27.1b
Page 3
1 2 3 Operations See
3.27.1b.2 Removal
Prior to removing compressed air lines, it is advisable to take photographs of all sides of the engine or to identify lines
with metal tags.
After removing lines, seal all connections with suitable plugs.
Remove solenoids and valve as shown in illustration, Page 1 and 2.
For actuating cylinder removal, see 3.10.8a.2.
3.27.1b6 Installation
Remove valve and solenoid valves as shown in illustration, Page 1 and 2.
Prior to installation, blow out all compressed air lines with dry compressed air.
Mount free of tension with attachments as shown in illustration 3.27.1 and photographs or markings.
For actuating cylinder installation, see 3.10.8a.6.
Note
Before mounting air lines on distributor and actuating cylinder, check function of exhaust flow control flap and air flow
control flap – see Description and Operating Instructions.
20046/20 E –11.96–
Task Description Section 3.84
Page 1
20046/20 E –11.96–
Task Description Section 3.84
Page 2
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –11.96–
Task Description Section 3.84.1a
Page 1
1 Float
2 Flange
3 Housing with switch
20062/00 E –03.95–
Task Description Section 3.84.1a
Page 2
20062/00 E –03.95–
Task Description Section 3.84.1a1
Page 1
1 2 3 Operations See
20046/20 E –10.96–
Task Description Section 3.84.1a2
Page 1
3.84.1a2 Removal
Release securing screws (1) at level switch (2) and re-
move together with washers.
Note
When removing the level switch, make sure that the float
is not damaged.
20062/00 E –10.96–
Task Description Section 3.84.1a4
Page 1
20062/00 E –03.95–
Task Description Section 3.84.1a.6
Page 1
3.84.1a.6 Installation
Install level switch (2) with gasket in cooler housing (1).
Note
20062/00 E –10.96–
Task Description Section 3.84.2
Page 1
1 Speed transmitter
2 O-ring
20038/10 E –11.92–
Task Description Section 3.84.2.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.84.2.2
Page 1
3.84.2.2 Removal
Release tightening bolt (2) at flange (1).
Withdraw speed transmitter (3) from flange.
20038/10 E –11.92–
Task Description Section 3.84.2.3
Page 1
3.84.2.3 Disassembly
Withdraw snap ring (1) with scriber (3) from groove at
speed transmitter.
Withdraw drive shaft (2) from gear teeth at speed trans-
mitter.
Remove O-rings (4) from groove at speed transmitter.
20038/10 E –11.92–
Task Description Section 3.84.2.4
Page 1
20038/10 E –11.92–
Task Description Section 3.84.2.5
Page 1
3.84.2.5 Assembly
Insert O-ring (4) into speed transmitter groove and coat
with petroleum jelly.
Coat gear teeth of drive shaft (2) with engine oil.
Insert drive shaft in gear teeth at speed transmitter.
Secure drive shaft with snap ring (1).
Using a scriber (3), press snap ring into retaining groove
at speed transmitter.
20038/10 E –11.96–
Task Description Section 3.84.2.6
Page 1
3.84.2.6 Installation
Coat speed transmitter at the fit with assembly paste.
Insert speed transmitter (3) in the flange (1) at crank-
case upper section.
Insert the shaft in the driver gear teeth at the camshaft
drive gear.
Secure tightening bolt (2) in flange.
20038/10 E –11.94–
Task Description Section 3.84.3
Page 1
20038/10 E –11.93–
Task Description Section 3.84.3.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.84.3.2
Page 1
3.84.3.2 Removal
Removing speed transmitter (left engine side)
Release screw (1) on speed transmitter drive housing.
20054/00 E –10.93–
Task Description Section 3.84.3.3
Page 1
3.84.3.3 Disassembly
Withdraw snap ring (1) with scriber (3) from groove at
speed transmitter.
Withdraw drive shaft (2) from gear teeth.
Remove O-ring (4) from groove at speed transmitter.
20038/10 E –11.92–
Task Description Section 3.84.3.4
Page 1
20054/00 E –10.93–
Task Description Section 3.84.3.5
Page 1
3.84.3.5 Assembly
Insert O-ring (4) into speed transmitter groove and coat
with petroleum jelly.
Coat gear teeth of drive shaft (2) with engine oil.
Insert drive shaft in gear teeth at speed transmitter.
Secure drive shaft with snap ring (1).
Using a scriber (3), press snap ring into retaining groove
at speed transmitter.
20038/10 E –11.96–
Task Description Section 3.84.3.6
Page 1
3.84.3.6 Installation
Installing speed transmitter (left engine side)
Insert speed transmitter in speed transmitter drive hous-
ing.
Insert shaft in driver gear teeth.
20054/00 E –10.93–
Task Description Section 3.84.4
Page 1
20038/10 E –11.92–
Task Description Section 3.84.4.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.84.4.2
Page 1
3.84.4.2 Removal
Removing speed sensor
Unscrew speed sensor (1) from crankcase.
Remove O-ring (2).
20038/10 E –11.96–
Task Description Section 3.84.4.4
Page 1
a Voltage stabilisation
b Voltage protection
20038/10 E –11.96–
Task Description Section 3.84.4.6
Page 1
3.84.4.6 Installation
Installing speed sensor
Insert new O-ring (2) in groove in speed sensor (1).
Coat O-ring with petroleum jelly.
Screw speed sensor into crankcase.
20038/10 E –11.96–
Task Description Section 3.84.4a
Page 1
20062/00 E –03.95–
Task Description Section 3.84.4a
Page 2
Speed transmitter
20062/00 E –03.95–
Task Description Section 3.84.4a1
Page 1
1 2 3 Operations See
20062/00 E –03.95–
Task Description Section 3.84.4a.2
Page 1
3.84.4a.2 Removal
Removing speed sensor
Unscrew speed sensor (1) from crankcase.
Remove O-ring (2).
20062/00 E –11.96–
Task Description Section 3.84.4a.4
Page 1
Block diagram
A Winding 1
approx. 700 Ohm
B Winding 1
C (NC) jacket
D Winding 2
approx. 1000 Ohm
E Winding 2
20062/00 E –11.96–
Task Description Section 3.84.4a.6
Page 1
3.84.4a.6 Installation
Installing speed sensor
Insert new O-ring (2) in groove in speed sensor (1).
Coat O-ring with petroleum jelly.
Screw speed sensor into crankcase.
20062/00 E –11.96–
Task Description Section 3.84.5
Page 1
20038/10 E –11.92–
Task Description Section 3.84.5.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.84.5.2
Page 1
3.84.5.2 Removal
Removing float solenoid switch
Release single-ended union (2) on cover of leak-off fuel
tank.
Remove float solenoid switch (1) with sealing ring (3).
20038/10 E –11.92–
Task Description Section 3.84.5.4
Page 1
Switch setting:
1 Float element, bottom
2 Float element, top
20038/10 E –11.92–
Task Description Section 3.84.5.6
Page 1
3.84.5.6 Installation
Installing float solenoid switch
Install float solenoid switch (1) with new sealing ring (3)
into housing of leak-off fuel tank.
Tighten screw fitting (2).
20038/10 E –11.92–
Task Description Section 3.84.6(.)
Page 1
1 Miltac microswitch
2 Cable entry
3 Sealing ring
1 2 3 Operations See
3.84.6.2 Removal
For removal of Miltac miniature switch – see 3.10.4a.2
20046/20 E –11.96–
Task Description Section 3.84.6(.)
Page 2
3.84.6.6 Installation
For installation of Miltac miniature switch – see 3.10.4a.6
20046/20 E –11.96–
Task Description Section 3.84.6a
Page 1
1 Proximity switch
2 Housing
3 Cable entry
1 2 3 Operations See
3.84.6a.2 Removal
For removal of proximity switch – see 3.10.4a.2
20046/20 E –11.96–
Task Description Section 3.84.6a
Page 2
3.84.6a.6 Installation
For installation of proximity switch – see 3.10.4a.6
20046/20 E –11.96–
Task Description Section 3.86
Page 1
3.86.1 Generator
3.86.1.1 Before-removal operations
3.86.1.2 Removal
3.86.1.4 Inspection and repair
3.86.1.6 Installation
3.86.7 Solenoid
3.86.7.1 Before-removal operations (see 3.86.7)
3.86.7.2 Removal (see 3.10.4.2)
3.86.7.4 Inspection and repair (3.86.7)
3.86.7.6 Installation (see 3.10.4.6)
20046/20 E –11.96–
Task Description Section 3.86
Page 2
3.86.10a 4/2-way solenoid valve (air and exhaust flow control flap control)
3.86.10a.1 Before-removal operations
3.86.10a.2 Before-removal operations (see 3.86.10a.1)
3.86.10a.4 Inspection and repair (see 3.86.10a.1)
3.86.10a.6 Installation (see 3.86.10a.1)
20046/20 E –11.96–
Task Description Section 3.86
Page 3
The following is a list of tools and miscellaneous materials required for the operations:
Caution
When using these miscellaneous materials, it is essential to observe the manufacturer’s instructions for use, safety
instructions and waste disposal specifications.
20046/20 E –11.96–
Task Description Section 3.86.1
Page 1
3.86.1 Generator
ET 86 69 1
1 A/C generator
20038/10 E –11.92–
Task Description Section 3.86.1
Page 2
Generator mounting
ET 86 72 1
20038/10 E –11.92–
Task Description Section 3.86.1.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.86.1.2
Page 1
3.86.1.2 Removal
Remove protective guard (2) and flange (1) from gener-
ator.
20038/10 E –11.92–
Task Description Section 3.86.1.4
Page 1
20038/10 E –11.92–
Task Description Section 3.86.1.6
Page 1
3.86.1.6 Installation
Mount left mounting bracket (1) with screws and
washers to retain generator on crankcase.
Drive generator with coupling element into left mounting
bracket and then mount right mounting bracket with
screws and washers.
Move generator in direction of free end.
Turn resilient coupling and insert screws (2) into coupl-
ing element, drive side.
Coat thread of bolts with engine oil.
Fit spring washers and tighten nuts with torque wrench
in accordance with tightening specification 1.3.
Remove band clamp (3) from resilient coupling.
Note
20038/10 E –11.92–
Task Description Section 3.86.2
Page 1
20038/10 E –11.92–
Task Description Section 3.86.2
Page 2
Generator coupling
20038/10 E –11.92–
Task Description Section 3.86.2.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.86.2.2
Page 1
3.86.2.2 Removal
Removing resilient coupling
Remove screws (1) from resilient coupling.
Remove coupling from coupling element (2).
Note
20038/10 E –11.92–
Task Description Section 3.86.2.2
Page 2
Caution
Danger
20038/10 E –11.92–
Task Description Section 3.86.2.4
Page 1
20038/10 E –11.92–
Task Description Section 3.86.2.6
Page 1
3.86.2.6 Installation
Installing coupling element
Clean press-fit surface of coupling element (1) and drive
shaft with acetone and coat with engine oil SAE 10.
Push coupling element onto drive shaft taper.
Measure distance of drive shaft end to coupling element
end with depth gauge.
Caution
Danger
Hydraulic installation may only be carried out by trained personnel.
Use only those tools and equipment stipulated for hydraulic installation.
Check the equipment annually (draw spindle crack test).
The maximum permissible expansion pressure of Pmax = 2000 bar must not be exceeded.
It is not permitted for personnel to remain within the danger area behind the equipment during the installation operations.
Insert draw spindle (1) of installation device (2) into
threaded bore of drive shaft and tighten.
20038/10 E –11.92–
Task Description Section 3.86.2.6
Page 2
20038/10 E –11.92–
Task Description Section 3.86.2.6
Page 3
Note
20038/10 E –11.92–
Task Description Section 3.86.3
Page 1
20046/20 E –11.96–
Task Description Section 3.86.3
Page 2
20046/20 E –11.96–
Task Description Section 3.86.3
Page 3
20046/20 E –11.96–
Task Description Section 3.86.3.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.86.3.2
Page 1
3.86.3.2 Removal
Removing cover
Removing securing screw (1) with spring washer (2).
Remove cover (3).
Remove O-ring (4) from bearing flange (5).
Caution
Danger
20038/10 E –11.92–
Task Description Section 3.86.3.2
Page 2
20038/10 E –11.92–
Task Description Section 3.86.3.3
Page 1
3.86.3.3 Disassembly
Removing cylindrical roller bearing
Use circlip pliers to remove circlip (1) from bearing
flange.
20038/10 E –11.92–
Task Description Section 3.86.3.3
Page 2
20038/10 E –11.92–
Task Description Section 3.86.3.4
Page 1
20038/10 E –11.92–
Task Description Section 3.86.3.5
Page 1
3.86.3.5 Assembly
Installing cylindrical roller bearing
Using press-in mandrel (1), insert cylindrical roller bear-
ing (2) (without inner race) into bearing flange (3).
Note
Caution
20038/10 E –11.96–
Task Description Section 3.86.3.5
Page 2
Note
20038/10 E –11.96–
Task Description Section 3.86.3.6
Page 1
3.86.3.6 Installation
Installing drive shaft
Insert drive shaft with bearing flange on generator side
into crankcase.
Installing sleeve
Check taper in sleeve (1) and taper on drive shaft (2) for
damage.
Check for burrs at transition areas between contact and
lateral surfaces, and oil distribution and discharge
grooves.
Machining scores and transition radii must be polished
smooth if necessary.
Degrease press-fit surface with acetone, blow dry with
compressed air and coat with engine oil SAE 10.
Fit sleeve onto drive shaft taper.
Measure distance from shaft end to sleeve end.
20038/10 E –11.92–
Task Description Section 3.86.3.6
Page 2
Caution
Danger
20038/10 E –11.92–
Task Description Section 3.86.3.6
Page 3
Installing cover
Insert sealing ring (4) into groove on bearing flange (5)
and coat with ”petroleum jelly”.
Mount end cover (3) on free end with screw (1) and
spring washer (2) on bearing flange and tighten.
20038/10 E –11.96–
Task Description Section 3.86.3a
Page 1
20046/20 E –11.96–
Task Description Section 3.86.3a
Page 2
1 Crankcase 9 Carrier
2 Output shaft 10 Centring element
3 Bearing flange 11 Bracket with clamp
4 Drive flange 12 Generator
5 V-belt 13 Shaft seal
6 Belt pulley 14 Grooved ball bearing
7 Threaded pin 15 Snap ring
8 Setting bush
20046/20 E –11.96–
Task Description Section 3.86.3a.1
Page 1
1 2 3 Operations See
20046/20 E –11.96–
Task Description Section 3.86.3a.2
Page 1
3.86.3a.2 Removal
Removing accidental-contact protection
Remove screws (4) on bracket (2).
Remove guard plate (3) and bracket (5).
Remove screws (1).
Remove bracket (2).
Caution
Spring tension
Remove nuts on threaded pin (1).
Remove nuts (5) from threaded rod and remove spring
retainer (3), spring (2) and threaded rod (4).
20046/20 E –11.96–
Task Description Section 3.86.3a.2
Page 2
20046/20 E –11.96–
Task Description Section 3.86.3a.4
Page 1
20046/20 E –11.96–
Task Description Section 3.86.3a.6
Page 1
3.86.3a.6 Installation
Installing carrier
Fit centring elements (2) on dowel pins (5) on carrier (4).
Tighten screws (1) with torque wrench to tightening
specification 1.3.
Install carrier with screws (3) on crankcase and tighten
with torque wrench to tightening specification 1.3.
Caution
20046/20 E –11.96–
Task Description Section 3.86.3a.6
Page 2
Coat threaded pin (4) and setting bushes (5) with en-
gine oil.
Insert three-phase alternator (8) into carrier; in doing so,
insert threaded pins at same time.
Insert setting bushes into carrier (6).
Fit bushes (3) on threaded pin and tighten nuts (2) to
tightening specification 1.3.
Using straightedge, check that both V-belt pulleys (1)
and (9) are aligned.
Axially adjust V-belt by means of threaded pins and set-
ting bushes.
Install spacer sleeves and fit nuts (7).
Push three-phase alternator in initial position and fit V-
belt on V-belt pulleys.
Note
Caution
Spring tension
For initial assembly dimension X = 26 mm
Tighten nut on threaded pin with torque wrench to
tightening specification 1.3 and lock locknuts on
threaded pin (3) and threaded rod (5).
Tighten nuts of spacer sleeves on carrier with torque
wrench to tightening specification 1.3.
20046/20 E –11.96–
Task Description Section 3.86.3a.6
Page 3
20046/20 E –11.96–
Task Description Section 3.86.3a.7
Page 1
1 Adjusting nut
2 Locknut
3 Threaded rod
4 Compression spring
x Setting dimension
20046/20 E –11.96–
Task Description Section 3.86.4
Page 1
20038/10 E –11.92–
Task Description Section 3.86.4
Page 2
20038/10 E –11.96–
Task Description Section 3.86.4
Page 3
20038/10 E –11.96–
Task Description Section 3.86.4.1
Page 1
1 2 3 Operations See
20038/10 E –11.92–
Task Description Section 3.86.4.2
Page 1
3.86.4.2 Removal
Removing air compressor
Remove securing screws (2) and spring washers (3)
from air compressor (1).
Pull air compressor from fit on bearing flange (4) and re-
move.
20038/10 E –11.92–
Task Description Section 3.86.4.2
Page 2
Caution
Danger
20038/10 E –11.92–
Task Description Section 3.86.4.2
Page 3
20038/10 E –11.92–
Task Description Section 3.86.4.4
Page 1
20038/10 E –11.92–
Task Description Section 3.86.4.6
Page 1
3.86.4.6 Installation
Hydraulically installing coupling element
Clean press-fit surfaces with acetone.
Coat press-fit surfaces with engine oil SAE 10.
Fit coupling element (1) onto taper of coolant pump shaft
(2).
Caution
Danger
20038/10 E –11.92–
Task Description Section 3.86.4.6
Page 2
20038/10 E –11.92–
Task Description Section 3.86.4.6
Page 3
20038/10 E –11.96–
Task Description Section 3.86.4a
Page 1
20046/20 E –11.96–
Task Description Section 3.86.4a
Page 2
20046/20 E –11.96–
Task Description Section 3.86.4a
Page 3
20046/20 E –11.96–
Task Description Section 3.86.4a.1
Page 1
1 2 3 Operations See
20046/20 E –11.96–
Task Description Section 3.86.4a.2
Page 1
3.86.4a.2 Removal
Removing air compressor
Remove securing screws (1) and spring washers from
air compressor (3).
Remove air compressor from fit on intermediate flange.
Remove O-ring from air compressor flange.
20046/20 E –11.96–
Task Description Section 3.86.4a.2
Page 2
Caution
20046/20 E –11.96–
Task Description Section 3.86.4a.2
Page 3
20046/20 E –11.96–
Task Description Section 3.86.4a.4
Page 1
20046/20 E –11.96–
Task Description Section 3.86.4a.6
Page 1
3.86.4a.6 Installation
Hydraulically installing coupling element
Clean and degrease press-fit surfaces with acetone.
Coat press-fit surfaces with engine oil SAE 10.
Fit coupling element (1) onto taper of coolant pump shaft
(2).
Caution
Danger
Hydraulic installation may only be carried out by trained personnel.
Use only those tools and equipment stipulated for hydraulic installation.
Check the equipment annually (draw spindle crack test).
The maximum permissible expansion pressure (Pmax = 1500) bar must not be exceeded.
It is not permitted for personnel to remain within the danger area behind the equipment during the installation oper-
ations.
Fit installation tool with draw spindle (1) to pump shaft
and secure.
1 Draw spindle
2 Hex nut
3 Spherical washer
4 Ball socket
5 Thrust washer
6 Grub screw
20046/20 E –11.96–
Task Description Section 3.86.4a.6
Page 2
20046/20 E –11.96–
Task Description Section 3.86.4a.6
Page 3
20046/20 E –11.96–
Task Description Section 3.86.6a
Page 1
20047/10 E –12.95–
Task Description Section 3.86.6a
Page 2
20047/10 E –12.95–
Task Description Section 3.86.6a
Page 3
1 2 3 Operations See
3.86.6a.2 Removal
For removal of 4/2-way solenoid valve – see 3.11.8b.2
3.86.6a.4 Inspection and Repair
Check condition of 4/2-way solenoid valve, replace O-rings.
For functional check, see operating instructions.
3.86.6a.6 Installation
For installation of 4/2-way solenoid valve – see 3.11.8b.6
20047/10 E –12.95–
Task Description Section 3.86.7
Page 1
3.86.7 Solenoid
1 Solenoid
2 Pull rod
3 Nut
20038/10 E –03.95–
Task Description Section 3.86.7
Page 2
Solenoid arrangement
1 Solenoid
2 Guide rod
3 Terminal box
Solenoid diagram
Voltage: 24 VDC
Rated current: 1.42 A
Protection: IP 65
Pulling force: 59 N
20038/10 E –11.92–
Task Description Section 3.86.7
Page 3
1 2 3 Operations See
3.86.7.2 Removal
For solenoid removal, see 3.10.4.2.
3.86.7.6 Installation
Installing solenoid, see 3.10.4.6.
20038/10 E –11.92–
Task Description Section 3.86.9
Page 1
1 Actuating cylinder
2 Connector
20038/10 E –11.96–
Task Description Section 3.86.9
Page 2
20038/10 E –12.95–
Task Description Section 3.86.9
Page 3
1 2 3 Operations See
3.86.9.2 Removal
Removing actuating cylinder, see 3.10.8.2.
20038/10 E –12.95–
Task Description Section 3.86.9.3
Page 1
3.86.9.3 Disassembly
Prior to disassembly, remove boot from actuating cylin-
der – see 3.10.8.3
Remove nut (1) from piston rod (19).
Remove collar nuts (3) and washers (4) from tie bolts
(12).
Remove cylinder head cover (5) and cylinder crown (13)
from cylinder pipe (7) and/or from piston rod.
Withdraw piston rod from cylinder pipe.
In order to be able to disassemble piston rod, the nut
(14) secured with high-strength thread-locking agent
must be removed.
Then individual components (15, 16, 17, 18) can be re-
moved from piston rod.
Remove gasket (11) from cylinder head cover and cylin-
der crown.
Remove snap ring (2) from cylinder head cover.
Press scraper (8), bush (9) and grooved ring (10) out of
cylinder head cover.
20038/10 E –11.92–
Task Description Section 3.86.9.4
Page 1
20038/10 E –11.92–
Task Description Section 3.86.9.5
Page 1
3.86.9.5 Assembly
Prior to assembly, coat all sliding-contact surfaces and
rubber components with ”petroleum jelly”.
Insert grooved ring (10), bush (9), scraper (8) and snap
ring (2) in specified sequence into cylinder head cover
(5).
Apply a few drops of high-strength thread-locking agent
to mating face on retaining ring (15) and to lip of piston
rod (19).
Fit individual components (15, 16, 17, 18) on piston rod
in correct sequence in accordance with illustration.
Coat thread of nut (14) with high-strength thread-locking
agent and tighten to Tightening Specification 1.3.
Insert gasket (11) into annular groove of cylinder head
cover (5) and cylinder crown (13).
Fit cylinder (7) on cylinder crown.
Insert readily-assembled piston rod into cylinder pipe.
Ensure that sealing lips of pot sleeve are not damaged.
Fit cylinder head cover on piston rod.
Four tie bolts (12) hold cylinder together.
Tighten collar nuts (3) of tie bolt diagonally and evenly
with torque wrench.
After assembly, check actuating cylinder for leaks and
check function.
For boot and connector installation – see 3.10.8.5
3.86.9.6 Installation
Installing actuating cylinder, see 3.10.8.6.
20038/10 E –12.95–
Task Description Section 3.86.9b
Page 1
20046/20 E –11.96–
Task Description Section 3.86.9b
Page 2
1 2 3 Operations See
3.86.9b.2 Removal
For actuating cylinder removal, see 3.10.8a.2
20046/20 E –11.96–
Task Description Section 3.86.9b.3
Page 1
3.86.9b.3 Disassembly
Remove scalloped rings (1) of adjustable end-position
dampings.
Remove adjusting screws (2).
Remove O-ring from adjusting screw.
Caution
Spring tension
Remove collar screws (1), (4) for bearing cap (5) and
end cover (3).
Note
Note
20046/20 E –11.96–
Task Description Section 3.86.9b.3
Page 2
20046/20 E –11.96–
Task Description Section 3.86.9b.4
Page 1
20046/20 E –11.96–
Task Description Section 3.86.9b.5
Page 1
3.86.9b.5 Assembly
Note
Insert rod gasket (2) into bearing cap (3) as far as it will
go and secure with snap ring (1).
Coat sliding surfaces of gaskets with assembly grease.
20046/20 E –11.96–
Task Description Section 3.86.9b.5
Page 2
Caution
Spring tension
Insert tie bolt (6).
Mount collar screws (1), (4) on tie bolt and tighten diag-
onally and evenly to specified tightening torque – see
1.3.
Coat O-ring with assembly grease and install on adjust-
ing screws (2) twist-free.
Insert adjusting screws into bearing cap and end cover
as far as it will go.
Back-off adjusting screw in bearing cap by one rotation
and adjusting screw in end cover by three rotations.
Secure adjusting screws with thread locking varnish.
Insert scalloped rings (1).
Check function of actuating cylinder and check for leaks.
3.86.9b.6 Installation
For actuating cylinder installation, see 3.10.8a.6
20046/20 E –11.96–
Task Description Section 3.86.10
Page 1
20046/20 E –11.96–
Task Description Section 3.86.10
Page 2
1 2 3 Operations See
3.86.10.2 Removal
For solenoid valve removal – see 3.20.3a.2
3.86.10.6 Installation
For solenoid valve installation – see 3.20.3a.5
20046/20 E –11.96–
Task Description Section 3.86.10a
Page 1
3.86.10a 4/2-Way Solenoid Valve (Air and Exhaust Flow Control Flap Control)
10
7 6 5
20058/0 E –03.93–
Task Description Section 3.86.10a
Page 2
1 2 3 Operations See
3.86.10a.2 Removal
For solenoid valve removal – see 3.10.8a.
3.86.10a.6 Installation
For solenoid valve installation – see 3.10.8a.
20058/0 E –03.93–
Task Description Section 3.87
Page 1
20046/20 E –11.96–
Task Description Section 3.88
Page 1
20038/10 E –11.92–