Instructions for Exchange of Sub-

assemblies
Diesel Engine
12 V 1163 Mx4
16 V 1163 Mx4
20 V 1163 Mx4

MS22061/04E
 Engine model kW/cyl. Application group
12V1163M74 300 kW/cyl. 1B; Continuous operation, variable, high load
16V1163M74 300 kW/cyl. 1B; Continuous operation, variable, high load
20V1163M74 300 kW/cyl. 1B; Continuous operation, variable, high load
12V1163M84 325 kW/cyl. 1D; Continuous operation, variable, medium load
16V1163M84 325 kW/cyl. 1D; Continuous operation, variable, medium load
20V1163M84 325 kW/cyl. 1D; Continuous operation, variable, medium load
12V1163M94 370 kW/cyl. 1DS; Continuous operation, variable, low load
16V1163M94 370 kW/cyl. 1DS; Continuous operation, variable, low load
20V1163M94 370 kW/cyl. 1DS; Continuous operation, variable, low load

Table 1: Applicability

© 2015 Copyright MTU Friedrichshafen GmbH

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
 Table of Contents
1 Safety 3.2.12 Piston and conrod – Assembly 66
3.2.13 Piston and conrod – Installation 69
1.1 Important provisions for all products 6 3.2.14 Piston and conrod – Final steps 73
1.2 Correct use for all products 7
3.3 Cylinder Head 74
1.3 Personnel and organizational requirements 8
3.3.1 Cylinder head – Overview 74
1.4 Safety regulations for startup and operation 9 3.3.2 Cylinder head – Preparatory steps 76
1.5 Safety precautions when working on the 3.3.3 Cylinder head ‒ Removal 77
engine 11 3.3.4 Cylinder head – Cleaning 79
1.6 Fire prevention and environmental 3.3.5 Cylinder head – Installation 80
protection, fluids and lubricants, auxiliary 3.3.6 Cylinder head – Final steps 83
materials 14 3.4 Valve Gear 84
1.7 Standards for safety notices in the text 16 3.4.1 Valve drive – Overview 84
1.8 Transport 17 3.4.2 Valve gear – Preparatory steps 86
3.4.3 Valve drive – Removal 87
2 General Information 3.4.4 Valve drive – Cleaning 88
3.4.5 Valve gear ‒ Check 89
2.1 General information on fiber-reinforced 3.4.6 Valve drive – Installation 90
composites 18 3.4.7 Valve gear – Final steps 92
2.2 Engine side and cylinder designations 20
3.5 Fuel System (High Pressure) 93
3.5.1 HP pump – Overview 93
3 Task Description 3.5.2 HP pump – Preparatory steps 94
3.5.3 HP pump – Removal 95
3.1 Crankcase and Attachments 21 3.5.4 HP pump – Cleaning 97
3.1.1 Inspection port cover – Overview 21
3.5.5 HP pump – Installation 98
3.1.2 Inspection port cover – Preparatory steps 22
3.5.6 HP pump – Final steps 100
3.1.3 Inspection port cover ‒ Removal 23
3.5.7 HP fuel accumulator – Overview 101
3.1.4 Inspection port cover – Cleaning sealing
3.5.8 HP fuel accumulator – Preparatory steps 103
surfaces 24
3.5.9 HP fuel accumulator – Removal 104
3.1.5 Inspection port cover – Check 25
3.5.10 HP fuel accumulator – Installation 105
3.1.6 Inspection port cover – Installation 26
3.5.11 HP fuel accumulator – Final steps 107
3.1.7 Inspection port cover – Final steps 27
3.5.12 HP fuel lines – Overview 108
3.1.8 Cylinder liner – Overview 28
3.5.13 High-pressure line – Preparatory steps 110
3.1.9 Cylinder liner – Preparatory steps 29
3.5.14 HP line – Removal 111
3.1.10 Cylinder liner ‒ Removal 30
3.5.15 HP fuel lines – Installation 112
3.1.11 Cylinder liner – Cleaning 33
3.5.16 HP fuel line – Final steps 116
3.1.12 Cylinder liner ‒ Check 34
3.1.13 Cylinder liner – Tolerances 35 3.6 Fuel System (Low Pressure) 117
3.1.14 Cylinder liner – Installation 36 3.6.1 Pressure limiting valve – Overview 117
3.1.15 Cylinder liner – Final steps 39 3.6.2 Pressure limiting valve – Preparatory steps 118
3.6.3 Pressure limiting valve – Removal 119
3.2 Running Gear 40 3.6.4 Pressure limiting valve – Cleaning 120
3.2.1 Vibration damper on PTO, free end – Overview 40
3.6.5 Pressure limiting valve – Check 121
3.2.2 Vibration damper on free end – Preparatory
3.6.6 Pressure limiting valve – Installation 122
steps 43
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3.6.7 Pressure limiting valve – Final steps 123

3.2.3 Vibration damper on PTO, free end – Removal 44
3.6.8 Fuel priming pump – Overview 124
3.2.4 Vibration damper on PTO, free end ‒
3.6.9 Fuel priming pump – Preparatory steps 125
Installation 47
3.6.10 Fuel priming pump – Removal 126
3.2.5 Vibration damper on free end – Final steps 52
3.6.11 Fuel priming pump – Cleaning 127
3.2.6 Piston and conrod – Overview 53
3.6.12 Fuel priming pump – Check 128
3.2.7 Piston and conrod – Preparatory steps 55
3.6.13 Fuel priming pump ‒ Installation 129
3.2.8 Piston and conrod – Removal 56
3.6.14 Fuel priming pump – Final steps 130
3.2.9 Piston – Cleaning 59
3.6.15 Leak fuel pipework – Overview 131
3.2.10 Piston ‒ Check 60
3.6.16 Leak-off fuel pipework – Preparatory steps 133
3.2.11 Piston – Tolerances 62

MS22061/04E 2015-11 | Table of Contents | 3

 3.6.17 Leak fuel line – Removal 134 3.11 Lube Oil System, Lube Oil Circuit 209
3.6.18 Leak-off fuel pipework ‒ Installation 135 3.11.1 Exhaust turbocharger oil supply, distributor
3.6.19 Leak-off fuel pipework – Final steps 136 and securing hardware 12V – Overview 209
3.11.2 Oil supply pipework for exhaust
3.7 Exhaust Turbocharger 137
turbochargers, distributor and fasteners 16V –
3.7.1 Exhaust turbocharger – Overview and
Overview 210
diagram 137
3.11.3 Exhaust turbocharger oil supply, distributor
3.7.2 Exhaust turbocharger – Preparatory steps 139
and securing hardware 20V – Overview 211
3.7.3 Exhaust turbocharger – Removal 140
3.11.4 Exhaust turbocharger oil supply, distributor
3.7.4 Exhaust turbocharger – Cleaning 141
and fasteners – Removal 212
3.7.5 Exhaust turbocharger – Check 142
3.11.5 Exhaust turbocharger oil supply pipework,
3.7.6 Exhaust turbocharger – Installation 143
distributor and fasteners – Installation 213
3.7.7 Exhaust turbocharger – Final steps 146
3.11.6 Vent line for oil supply pipework of exhaust
3.8 Air Intake / Air Supply 147 turbochargers – Overview 214
3.8.1 Air and exhaust flap control – Overview 147 3.11.7 Vent line for oil supply pipework of exhaust
3.8.2 Air and exhaust flap control – Removal 149 turbochargers – Removal 215
3.8.3 Air and exhaust flap control – Installation 151 3.11.8 Vent line for oil supply pipework of exhaust
3.8.4 Intake housing with air flap – Overview 153 turbocharger – Installation 216
3.8.5 Intake housing with air flap – Preparatory
3.12 Coolant System 217
steps 155
3.12.1 Engine coolant pump – Overview 217
3.8.6 Intake housing with air flap ‒ Removal 156
3.12.2 Engine coolant pump – Preparatory steps 219
3.8.7 Intake housing with air flap – Cleaning 157
3.12.3 Engine coolant pump – Removal 220
3.8.8 Intake housing with air flap – Check 158
3.12.4 Engine coolant pump – Cleaning 221
3.8.9 Intake housing with air flap – Installation 159
3.12.5 Engine coolant pump – Check 222
3.8.10 Intake housing with air flap – Final steps 161
3.12.6 Engine coolant pump ‒ Installation 223
3.8.11 Air pipework to the cylinder heads, right side
3.12.7 Engine coolant pump – Final steps 224
– Overview 162
3.12.8 Coolant cooler and fuel cooler – Overview 225
3.8.12 Air pipework to cylinders – Preparatory steps 163
3.12.9 Engine coolant cooler and fuel cooler –
3.8.13 Air supply pipework to cylinders – Removal 164
Preparatory steps 226
3.8.14 Air pipework to cylinders ‒ Installation 167
3.12.10 Engine coolant cooler and fuel cooler ‒
3.8.15 Air pipework to cylinders – Final steps 168
Removal 227
3.9 Exhaust Pipework 169 3.12.11 Coolant cooler and fuel cooler – Cleaning 228
3.9.1 Constant-pressure manifold / manifold housing 3.12.12 Engine coolant cooler and fuel cooler – Check 231
– Overview 169 3.12.13 Engine coolant cooler and fuel cooler –
3.9.2 Constant-pressure manifold ‒ Preparatory Leakage test 232
steps 172 3.12.14 Engine coolant cooler and fuel cooler –
3.9.3 Constant-pressure manifold housing ‒ Installation 233
Removal 173 3.12.15 Engine coolant cooler and fuel cooler – Final
3.9.4 Constant-pressure manifold ‒ Cleaning 176 steps 234
3.9.5 Constant-pressure manifold ‒ Check 177 3.12.16 Engine coolant thermostat – Overview 235
3.9.6 Constant-pressure manifold – Assembly 178 3.12.17 Engine coolant thermostat – Preparatory steps 237
3.9.7 Constant-pressure manifold – Final steps 192 3.12.18 Engine coolant thermostat ‒ Removal 238
3.9.8 Carrier housing – Overview 193 3.12.19 Engine coolant thermostat ‒ Cleaning 239
3.9.9 Carrier housing – Preparatory steps 194 3.12.20 Engine coolant thermostat – Check 240
3.9.10 Carrier housing upper section – Removal and 3.12.21 Engine coolant thermostat – Installation 241
installation 195 3.12.22 Engine coolant thermostat – Final steps 242
3.9.11 Carrier housing – Final steps 198 3.12.23 Raw-water pump – Overview 243
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3.12.24 Raw water pump – Preparatory steps 245

3.10 Starting Equipment 199 3.12.25 Raw water pump – Removal 246
3.10.1 Compressed-air distributor – Overview 199
3.12.26 Raw water pump – Cleaning 247
3.10.2 Compressed-air distributor – Preparatory steps 201
3.12.27 Raw-water pump ‒ Check 248
3.10.3 Compressed-air distributor – Removal 202
3.12.28 Raw water pump – Installation 249
3.10.4 Starting-air distributor ‒ Cleaning 203
3.12.29 Raw water pump – Final steps 250
3.10.5 Compressed-air distributor – Check 204
3.10.6 Compressed-air distributor – Adjustment and 3.13 Monitoring, Control and Regulation
Installation 205 Equipment 251
3.10.7 Compressed-air distributor – Final steps 208

4 | Table of Contents | MS22061/04E 2015-11

 3.13.1 Engine wiring harnesses and brackets – 4.2 Conversion tables 289
Overview 251 4.3 Tolerances and wear limits list – General
3.13.2 Sensors and actuators – Overview 257 information 293
3.13.3 Sensors and actuators – Preparatory steps 261
4.4 Abbreviations 294
3.13.4 Sensors and actuators – Removal 262
4.5 MTU Contact/Service Partners 296
3.13.5 Sensors and actuators – Check 268
3.13.6 Sensors and actuators – Installation 269
3.13.7 Sensors, actuators and injectors – Final steps 275 5 Appendix B
5.1 Special Tools 297
4 Appendix A 5.2 Consumables 318
5.3 Index 325
4.1 Tightening specifications for screws, nuts
and bolts 276
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MS22061/04E 2015-11 | Table of Contents | 5

 1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.

General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices

Emission regulations and emission labels

Responsibility for compliance with emission regulations
Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes that might affect the emission characteristics of the
product are prohibited by emission regulations. Emission control units/systems may only be maintained, ex-
changed or repaired if the components used for this purpose are approved by the manufacturer.
Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.

Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.
Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.
Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Do not transfer the emission labels from the replaced part to the spare part.
• Remove the emission labels from the replaced part and destroy them.
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6 | Safety | MS22061/04E 2015-11

 1.2 Correct use for all products
Correct use
The product is intended for use in accordance with its contractually-defined purpose as described in the rele-
vant technical documents only.
Intended use entails operation:
• Within the permissible operating parameters in accordance with the (→ Technical data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubricants
Specifications of the manufacturer)
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva-
tion Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con-
tact/Service partner)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in-
cluding engine control/parameters)
• In compliance with all safety regulations and in adherence with all warning notices in this manual
• In compliance with the maintenance work and intervals specified in the (→ Maintenance Schedule)
throughout the useful life of the product
• In compliance with the maintenance and repair instructions contained in this manual, in particular with
regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and re-
pair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
The product shall not be operated in explosive atmospheres unless the necessary approval has been grant-
ed.
Any other use, particularly misuse, is considered as being contrary to the intended purpose. Such improper
use increases the risk of injury and damage when working with the product. The manufacturer shall not be
held liable for any damage resulting from improper, non-intended use.
The specifications of the manufacturer will be amended or supplemented as necessary. Prior to operation,
make sure that the latest version is used. The latest version can be found on the websites:
• For drive systems: http://www.mtu-online.com
• For power generation: http://www.mtuonsiteenergy.com

Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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MS22061/04E 2015-11 | Safety | 7

 1.3 Personnel and organizational requirements
Organizational measures of the user/manufacturer
This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.
Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.
This is important in the case of personnel who only occasionally perform work on or around the product.
These personnel must be instructed repeatedly.

Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.

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8 | Safety | MS22061/04E 2015-11

 1.4 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications
before putting the product into service. All necessary approvals must be granted by the relevant authorities
and all requirements for initial startup must be fulfilled.
Whenever the product is subsequently taken into operation ensure that:
• All personnel is clear of the danger zone surrounding moving parts of the machine.
Electrically-actuated linkages may be set in motion when the Engine Control Unit (governor) is switched
on.
• All maintenance and repair work has been completed.
• All loose parts have been removed from rotating machine components.
• All safety equipment is in place.
• No persons wearing pacemakers or any other technical body aids are present.
• The service room is adequately ventilated.
• In the first few hours of operation, the product emits gases as a result of smoldering e.g. lacquers or oil.
These gases may be hazardous to health. Always wear respiratory protection in the operating room during
this period.
• The exhaust system is leak-tight and that the gases are vented to atmosphere.
• Protect battery terminals, generator terminals or cables against accidental contact.
• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).
Immediately after putting the product into operation, make sure that all control and display instruments as
well as the signaling and alarm systems work properly.
Smoking is prohibited in the area of the product.

Safety regulations during operation

The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with regard to
present operating status, violation of limit values and warning or alarm messages.

Malfunctions and emergency stop

Practice emergency procedures, especially emergency stopping, at regular intervals.
The following steps must be taken if a malfunction of the system is detected or reported by the system:
• Inform supervisor(s) in charge.
• Analyze the message.
• Respond by taking any necessary emergency action, e.g. emergency stop.

Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
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to do so following a written procedure.

Do not inhale the exhaust gases of the product.
The following requirements must be fulfilled before the product is started:
• Wear ear protection.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder agent.

Operation of electrical equipment

Parts of the electrical equipment are live, i.e. under voltage/high tension, during operation.

MS22061/04E 2015-11 | Safety | 9

 Follow the applicable warning instructions pertaining to such devices.

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10 | Safety | MS22061/04E 2015-11

 1.5 Safety precautions when working on the engine
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk
of burning).
Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suita-
ble collecting vessels of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated.
Never carry out maintenance and repair work with the product in operation, unless:
• It is expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely necessary.
Lock-out the product to preclude undesired starting, e.g.
• Start interlock
• Key switch
• With hydraulic starting system: shut off supply line.
Attach “Do not operate” sign in the operating area or to control equipment.
Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock out circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic start-
ers are fitted.
Disconnect the control equipment from the product.
Use the recommended special tools or suitable equivalents when instructed to do so.
Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted.
They may only be installed after painting the engine or must be covered before painting work is carried out.
The following applies to starters with copper-beryllium alloy pinions:
• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter
with compressed air. Clean the flywheel housing inside with a class H dust extraction device.
• Observe the safety data sheet.

Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product.
Release residual pressure before removing or replacing a component in the supply line. To depressurize pres-
surized lines, shut off the lines first, then release the residual pressure.
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassem-
bly.
Carry out work only on assemblies or plants which are properly secured.
Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that
components/tools fall down. Use the specified lifting equipment for all components.
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Never use the product as a climbing aid.

When working high on the equipment, always use suitable ladders and work platforms. Never work on en-
gines or components that are held in place by lifting equipment.
Keep fuel injection lines and connections clean.
Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g.
components carrying oil, fuel, or air).
Always seal connections with caps or covers if a line is removed or opened.
Fit new seals when re-installing lines.

MS22061/04E 2015-11 | Safety | 11

 Never bend lines and avoid damaging lines, particularly the fuel lines.
Ensure that all retainers and dampers are installed correctly.
Ensure that O-rings are not installed in a slanted/twisted condition.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact
with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or
resinous appearance.
Note cooling time for components which are heated for installation or removal (risk of burning).
Pay particular attention to cleanliness at all times.
Remove any condensate from components which were chilled before assembly. If necessary, coat the com-
ponents with a suitable corrosion inhibitor.

Safety regulations following maintenance and repair work

Before barring the engine, make sure that nobody is standing in the danger zone of the product.
Check that all access ports/apertures which have been opened to facilitate working are closed again.
Check that all safety equipment has been installed and that all tools and loose parts have been removed
(especially the barring gear).
Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).
Ensure that the grounding system is properly connected.

Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing cabling harnesses of the product. The
welding current may otherwise induce an interference voltage in the cabling harnesses which could conceiv-
ably damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.

Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the
specified jigs and fixtures for hydraulic removal/installation procedures.
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Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on H.P. lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.

12 | Safety | MS22061/04E 2015-11

 During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the
component being pressed.

Working with batteries

Observe the safety instructions of the battery manufacturer when working with batteries.
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 clothing, goggles and protective gloves.
Do not place objects on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to in-
jury through the sudden discharge of acid or bursting of the battery body.

Working on electrical and electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair work or
switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged
during operation by:
• Contact with sharp edges
• Chafing on components
• Contact with hot surfaces.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a functional testing on completion of all repair work. Check cor-
rect execution of the emergency stop function in particular.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package
faulty electronic components or assemblies properly before dispatching for repair:
• Moisture-proof
• Shock-proof
• Wrapped in antistatic foil if necessary.

Work with laser devices

Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety in-
structions in the manufacturer's user manual when working with laser equipment.
Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation).
Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensur-
ing safe operation.
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Measuring component dimensions

Workpieces, components and measuring equipment lie in the specified tolerance range at a reference tem-
perature of 20 °C.

MS22061/04E 2015-11 | Safety | 13

 1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Flames, naked light and smoking are prohibited.
When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The
resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere.
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always
keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product.
Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a
nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first. To
avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the
ground lead of the engine or to the ground terminal of the starter.
Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with its
handling.

Noise
Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating dan-
ger are drowned.
Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposal

Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recy-
cled.

Auxiliary materials
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.

Used oil
Used oil contains combustion residues that are harmful to health.
Wear protective gloves!
Wash relevant areas after contact with used oil.
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Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash relevant areas after contact with lead or lead-containing substances.

14 | Safety | MS22061/04E 2015-11

 Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con-
tainers, risks causing an explosion.
• Wear goggles when blowing dirt off workpieces or blowing away swarf.
• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass)
for drying purposes or to check for leaks risks bursting them.
• Pay special attention to the pressure in the compressed air system or pressure vessel.
• Assemblies or products which are to be connected must be designed to withstand this pressure. Install
pressure-reducing or safety valves set to the admissible pressure if this is not the case.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• Release residual pressure before removing or replacing pneumatic equipment in the supply line. To de-
pressurize compressed-air lines, shut off the lines first, then release the residual pressure.
• Carry out leak test in accordance with the specifications.

Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

Acids/alkaline solutions/urea (AdBlue®, DEF)

• Observe the relevant safety data sheet for all materials.
• When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective cloth-
ing.
• Do not inhale vapors.
• If urea solution is swallowed, rinse out mouth and drink plenty of water.
• Remove any wet clothing immediately.
• After contact skin, wash body areas with plenty of water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible.
TIM-ID: 0000040536 - 010

MS22061/04E 2015-11 | Safety | 15

 1.7 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.

Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.

TIM-ID: 0000040578 - 005

16 | Safety | MS22061/04E 2015-11

 1.8 Transport
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
The engine/genset must only be transported in installation position: maximum permissible diagonal pull 6°.
Remove any loose parts on the genset.
Raise the engine/genset slowly. The lifting ropes or chains must not make contact with the engine or its
components. Readjust lifting device if necessary.
Pay attention to the center of gravity of the engine/genset.
For special packaging with aluminum foil: Suspend the engine/genset by the lifting eyes on the bearing ped-
estal or transport by means of handling equipment (forklift truck) capable of bearing the load.
Prior to transport, install the crankshaft transportation lock on the engine and fit the engine mount locking
devices.
Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slipping
and tipping when driving up or down inclines and ramps.

Placement after transport

Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-case
basis.
TIM-ID: 0000042956 - 002

MS22061/04E 2015-11 | Safety | 17

 2 General Information
2.1 General information on fiber-reinforced composites
Safety regulations for operation and assembly
WARNING
Incorrect assembly of a coupling with components made of fiber-reinforced composites containing e.g.
carbon or glass fibers.
Overload.
Risk of destruction of the coupling and of flying parts!
Risks due to exposure to fibers and dusts!
• Ensure tension-free assembly.
• Do not use damaged couplings.
• Ensure correct installation position of components.
• Carry out assembly work in accordance with the instructions, do not use tools such as assembly lev-
er or hammer.

WARNING
Discharged fibers or dusts from a damaged coupling with components made of fiber-reinforced compo-
sites containing e.g. carbon or glass fibers.
Risk of injury to respiratory tract or irritation of skin!
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Wear breathing mask of protective class FFP2 or higher.
• Avoid contact with skin.

The abrasion of fiber-reinforced components produces very fine particles which can be respirable depending
on the type of fiber. The following instructions must be followed in such cases:
• Ensure proper room ventilation;
• Wear breathing mask of protective class FFP2 or higher;
• Wear protective clothing, protective gloves, and safety glasses / facial protection;
• Avoid contact with skin.

General information on fiber-reinforced composites

A fiber-reinforced composite basically consists two main components (an embedding matrix and reinforcing
fibers) which together form a multi-layer or mixed material.
The interaction of the constituent materials provides better material properties than each of the individual
materials.
The superior material properties of the fiber-reinforced composite are achieved by the combination of the
two components.
Thus, the two components form three effective phases in the material: Fibers of high tensile strength, a com-
paratively smooth embedding matrix and a boundary layer which connects the two components.
TIM-ID: 0000060670 - 001

18 | General Information | MS22061/04E 2015-11

 Constituents
Constituent Task
Matrix The matrix gives the fiber-reinforced composite its
appearance. There are no limits in variation both
with regard to color and to surface structure. The
matrix has the mechanical function to keep the rein-
forcing fibers in position and to transfer and to dis-
tribute stresses between them. In terms of durabili-
ty, the matrix must protect the fibers from external
mechanical and chemical impact.
Fibers The fibers give the fiber-reinforced composite its
strength. This may refer, apart from tensile strength,
also to bending strength, if the material shall be ex-
posed to pressure loads.
Boundary layer The boundary layer transfers the tension between
the two components. It transfers exclusively thrust
and may occur in very abstract shapes, e.g. if thrust
is exerted solely by friction. In other cases, e.g. in
the event of thrust acting through adhesion, the lay-
er is intended as a part of the production technology
and exists physically. In the latter case, the fibers
are coated with a coupling agent before they get into
first contact with the matrix. This substance is able
to react with both components and to provide con-
tinuous transfer to the greatest possible extent.
TIM-ID: 0000060670 - 001

MS22061/04E 2015-11 | General Information | 19

 2.2 Engine side and cylinder designations

1 Left engine side (A-side) 3 Right engine side (B-side)

2 Engine free end in accord- 4 Engine driving end in ac-
ance with DIN ISO 1204 cordance with
(KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup-
seite) plungsseite)
Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).
For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the left-
hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of
each bank are numbered consecutively, starting with x=1 at driving end (4).
The numbering of other engine components also starts with 1 at driving end (4).
TIM-ID: 0000002185 - 013

20 | General Information | MS22061/04E 2015-11

 3 Task Description
3.1 Crankcase and Attachments
3.1.1 Inspection port cover – Overview

1 Rubber ring 5 Screw 9 Washer

2 Inspection port cover 6 Washer 10 O-ring
3 Sealing ring 7 Safety valve 11 Inspection port cover
4 Union 8 Screw 12 Inspection port cover
TIM-ID: 0000003263 - 003

MS22061/04E 2015-11 | Task Description | 21

 3.1.2 Inspection port cover – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Remove vent lines from crankcase.
2. Remove oil return line from air distributor.

TIM-ID: 0000011363 - 001

22 | Task Description | MS22061/04E 2015-11

 3.1.3 Inspection port cover ‒ Removal
Preconditions
☑ Preparatory steps are completed.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Inspection port cover ‒ Removal

1. Remove screws with washers on inspection
port cover/safety valve.
2. Remove inspection port cover/safety valve.
TIM-ID: 0000003274 - 002

MS22061/04E 2015-11 | Task Description | 23

 3.1.4 Inspection port cover – Cleaning sealing surfaces
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Hakupur 50/136) X00056700 1

WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Inspection port cover – Cleaning sealing surfaces

1. Remove all deposits from the sealing surfaces.
2. Clean all sealing surfaces with cleaning agent.
3. Rub all sealing surfaces dry with a clean, lint-free cloth.

TIM-ID: 0000011343 - 013

24 | Task Description | MS22061/04E 2015-11

 3.1.5 Inspection port cover – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Checking inspection port cover

Item Findings Action
Check all mating and sealing sur- Signs of wear • Rework: Smooth with oilstone.
faces. • Replace
Check valve and spring seating Signs of wear • Replace
surfaces for stress marks.
Check if wire mesh is complete. Damaged • Replace
Check all threads for damage. Damaged Recut threads.
TIM-ID: 0000003269 - 002

MS22061/04E 2015-11 | Task Description | 25

 3.1.6 Inspection port cover – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
O-ring (→ Spare Parts Catalog)

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Installing inspection port cover

1. Coat O-ring with assembly compound and in-
sert in groove on housing.
2. Install safety valves on crankcase with
screws and washers on cylinders A4, B3 and
B7 and tighten.
3. Install inspection port cover on crankcase in
same way.

TIM-ID: 0000011371 - 005

26 | Task Description | MS22061/04E 2015-11

 3.1.7 Inspection port cover – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 22).
2. Enable engine start.
TIM-ID: 0000011381 - 001

MS22061/04E 2015-11 | Task Description | 27

 3.1.8 Cylinder liner – Overview

1 Carbon scraper ring 3 Sealing ring

2 Cylinder liner 4 Sealing ring

TIM-ID: 0000003287 - 004

28 | Task Description | MS22061/04E 2015-11

 3.1.9 Cylinder liner – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Remove cylinder head (→ Page 77).
2. Remove piston and conrod (if necessary) (→ Page 56).
TIM-ID: 0000011418 - 002

MS22061/04E 2015-11 | Task Description | 29

 3.1.10 Cylinder liner ‒ Removal
Preconditions
☑ Preparatory steps completed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Extraction device F6557114 1
Extraction device F6795766 1
Lifting gear T80092853 1
Tong arms T80090507
Tool kit Series 956/1163 5845890999/00 1
Tool kit Series 956/1163 5845891199/00 1
Torque wrench, 300–800 Nm F30047798 1
Hydraulic hand pump, 0–700 bar B80147075 1
Ratchet adapter F30027341 1

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Removing carbon scraper ring

1. Install extraction device (3) on cylinder lin-
er (1).
2. Remove carbon scraper ring (2) with extrac-
tion device (3) from cylinder liner fit (1).
3. Remove extraction device (3).
TIM-ID: 0000011416 - 005

30 | Task Description | MS22061/04E 2015-11

 Removing cylinder liner with
piston removed
Note: When inserting extraction device (2), do not
damage spray nozzle.
1. Install extraction device (2) and hydraulic
hand pump (3).
2. Make sure that extraction device (2) fits cor-
rectly in cylinder liner (1).
3. Actuate hydraulic hand pump until cylinder
liner (1) is released from crankcase bore.
4. Remove extraction device (2) and hydraulic
hand pump (3).

5. Attach lifting device (1) to cylinder liner (2).

6. Use lifting gear to extract cylinder liner (2).
7. Remove lifting device (1).

Removing cylinder liner with

piston installed
1. Set piston to TDC.
2. Use lifting gear (1) to remove piston crown.
TIM-ID: 0000011416 - 005

MS22061/04E 2015-11 | Task Description | 31

 3. Move piston (1) to BDC position.
4. Remove oil control ring.
5. Degrease liner.
6. Attach extraction device (2) for cylinder lin-
er (5).

7. Tighten nut (3) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Nut M30 Tightening torque 340 Nm

Result: If tightening is performed beyond this torque or up to a maximum of 500 Nm, measure cylinder liner and
perform crack test.
8. Extract cylinder liner (5) above jackscrews (4).
9. Install support plates under cylinder liner collar.
10. Hold extraction device (2) firmly in position and release nut (3).
11. Release clamping taper (6) by giving the spindle a knock.
12. Remove extraction device (2).
13. Use retaining jig to fasten conrod.
14. Attach retaining jig for piston (1).
15. Attach tongs device for cylinder liner (5).
16. Hold piston firmly in position and remove cylinder liner (5).

TIM-ID: 0000011416 - 005

32 | Task Description | MS22061/04E 2015-11

 3.1.11 Cylinder liner – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Hakupur 50/136) X00056700 1

WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Cylinder liner – Cleaning

1. Remove all deposits from functional and sealing surfaces.
2. Clean all functional and sealing surfaces with cleaning agent.
3. Wipe all functional and sealing surfaces dry with a clean, lint-free cloth.
4. Remove corrosion inhibitor from new component using cleaning agent.
TIM-ID: 0000011388 - 013

MS22061/04E 2015-11 | Task Description | 33

 3.1.12 Cylinder liner ‒ Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Bore gage, 160–290 mm Y20091483 1
Micrometer, 225–250 mm Y20001746 1
Dial gage Y20011268 1
Oilstone 8205893261/00 1
Cylinder liner (→ Spare Parts Catalog)
Carbon scraper ring (→ Spare Parts Catalog)

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Cylinder liner ‒ Check

Item Findings Action
Check outer wall for corrosive pit- Corrosive pitting visible. Replace
ting.
Check sealing and mating faces • Wear • Rework: Smooth with oilstone.
for wear and damage. • Damage • Replace
visible
Check carbon scraper ring for • Scoring Replace
scoring and pitting. • Pitting
visible
Check floating mount of carbon Seizure marks • Measure cylinder liner.
scraper ring in cylinder liner. • Replace carbon scraper ring.
Check cylinder liner running sur- • Scoring Replace
face for scoring and corrosive pit- • Corrosive pitting
ting. visible
Check reversal point of first piston Wear visible. Replace cylinder liner.
ring for wear.
Measure cylinder liner bore with Values exceeded. Replace
bore gage and dial gage. Measure-
ment plane and values
(→ Page 35)
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34 | Task Description | MS22061/04E 2015-11

 3.1.13 Cylinder liner – Tolerances

Item Designation Re- Toleranced Deviation Clearance Interference Wear limit

pair size Lower Upper Min. Max. Min. Max.
size Basic size
1 Cylinder liner bore - 237.000 H7 0 +0.046 0.015 0.107 - - -
Carbon scraper ring OD - 237.000 g7 -0.061 -0.015
2 Carbon scraper ring bore - 229.000 H8 0 +0.072 - - - - -
3 Cylinder liner bore - 230.000 H7 0 +0.046 - - - - 230.150*
Out-of-
round max.
0.030

Table 2: Cylinder liner – Tolerances

Notes:
Re 1 and 2: Check outer and inner diameters of carbon scraper ring in installed condition.
* This wear limit can only be achieved by re-honing, i.e. the hone structure must exist (no polished areas).
TIM-ID: 0000003297 - 003

MS22061/04E 2015-11 | Task Description | 35

 3.1.14 Cylinder liner – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Tool kit BR 956/1163 5845890999/00 1
Tool kit BR 956/1163 5845891199/00 1
Adjusting ring, 230 mm Y20004315 1
Bore gage, 160–290 mm Y20091483 1
Hydraulic hand pump, 0–700 bar B80147075 1
Torque wrench, 10–60 Nm F30510423 1
Ratchet adapter F30027340 1
Assembly sleeve F6557120 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Sealing compound (Molyduval Ciric A) X00065696 1
Assembly compound (Molykote G-N Plus) 40041 1
Engine oil
Sealing ring (→ Spare Parts Catalog) 1
Gaskets (→ Spare Parts Catalog) 2

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
TIM-ID: 0000011425 - 006

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

36 | Task Description | MS22061/04E 2015-11

 Preparing cylinder liner for in-
stallation
1. Coat sealing ring (1) and gaskets (2) with as-
sembly compound (Kluthe Hakuform 30-11C)
and fit on cylinder liner (3).
2. Move sealing ring (1) and gaskets (2) back
and forth several times in the grooves to
eliminate any tension.
3. Check projection of sealing ring (1) and gas-
kets (2) with a ruler.
4. Use a spotting ring to check mating face of
cylinder liner (3) on crankcase for any surface
irregularities.
5. Clean cylinder liner fit and coat with assem-
bly compound (Kluthe Hakuform 30-11C).

Installing cylinder liner with pis-

ton removed
1. Mount lifting clamp (1) on cylinder liner (2).
2. Install cylinder liner (2) with corrosive pitting
rotated by 90°.
3. Insert cylinder liner (2) in crankcase with lift-
ing gear.
4. Remove lifting clamp (1).

5. Install pressing jig (2) with pressure plate and

hydraulic press (at pos. 3).
6. Connect hydraulic hand pump to hydraulic
press with high-pressure hose.
7. Actuate pump plunger until cylinder liner (1)
is seated on crankcase.
8. Remove pressing jig (2) and hydraulic press.
TIM-ID: 0000011425 - 006

MS22061/04E 2015-11 | Task Description | 37

 Installing cylinder liner with piston installed
1. Install cylinder liner using retaining jig.
2. Remove retaining jig.
3. Use pressing jig to install cylinder liner (→ Step 5).
4. Set piston to TDC.
5. Install oil control ring.
6. Screw both adjusting mandrels into piston skirt.
7. Install assembly sleeve on crankcase.
8. Place piston crown on piston skirt using assembly sleeve.
9. Remove both adjusting mandrels.
10. Coat screw head mating faces with sealing compound.
11. Coat threads of screws with assembly compound.
12. Tighten screws crosswise to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw M10-4 h Preload torque (Assembly compound 20 Nm +2 Nm
(Molykote G-N Plus))
Screw M10-4 h Residual torque release
Screw M10-4 h Residual torque 10 Nm +1 Nm
Screw M10-4 h Residual angle of rotation 90° +5°
Screw M10-4 h Control torque 25 Nm +2.5 Nm

13. Install carbon scraper ring.

Measuring cylinder liner bore

1. Set bore gage (1) with adjusting ring to basic
dimension of cylinder liner bore. Value and
measurement planes (→ Page 35).
Note: Cylinder liner (2) must be seated firmly on
balcony seat.
2. Measure cylinder liner bore with bore
gage (1) at the corresponding measuring
plane twice, rotated through 90°.
3. Record measured values in data sheet.
4. If out-of-roundness is measured:
a) Remove cylinder liner.
b) Remeasure cylinder liner bore and out-
side diameter.
TIM-ID: 0000011425 - 006

38 | Task Description | MS22061/04E 2015-11

 3.1.15 Cylinder liner – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 29).
2. Enable engine start.
TIM-ID: 0000011432 - 006

MS22061/04E 2015-11 | Task Description | 39

 3.2 Running Gear
3.2.1 Vibration damper on PTO, free end – Overview
Vibration damper 20 V

1 Vibration damper

TIM-ID: 0000011777 - 004

40 | Task Description | MS22061/04E 2015-11

 Vibration damper 16 V

1 Vibration damper
Applies analogously to 12 V.
TIM-ID: 0000011777 - 004

MS22061/04E 2015-11 | Task Description | 41

 1 Sealing ring 6 Shim 11 Screw
2 Clamping ring 7 Spacer 12 Side plate
3 Eyebolt (transport protec- 8 Flange 13 Sealing ring
tion) 9 Inner star
4 Spring pack 10 Belleville washer
5 Shim

TIM-ID: 0000011777 - 004

42 | Task Description | MS22061/04E 2015-11

 3.2.2 Vibration damper on free end – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Observe safety regulations.
2. Disable engine start.
TIM-ID: 0000011807 - 002

MS22061/04E 2015-11 | Task Description | 43

 3.2.3 Vibration damper on PTO, free end – Removal
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Removal/installation jig F0141110 1
Hydraulic hand pump, 0–3000 bar B80144839 1
Hydraulic hand pump, 0–1000 bar B80146898 1
Plug-in coupling nipple B80144866 1
Eyebolt 070612020000 1
Shackle 082101000107 1
Wire rope F6271443 1
Lifting bracket T80092874

DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

WARNING
Equipment can drop off.
Liquid is highly pressurized.
Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Removing end cover

1. Install lifting bracket (2) on end cover.
2. Undo screws (1) and remove.
3. Attach shackle to lifting bracket (2) and re-
move end cover.
TIM-ID: 0000051630 - 001

44 | Task Description | MS22061/04E 2015-11

 Removing vibration damper
(with pulse generating ring)
1. Insert puller spindle on hydraulic removal jig
into bore on crankshaft, free end, and tight-
en.
2. Push force-off bushing (5) and hydraulic
nut (1) on to puller spindle and screw on pull
nut.
3. Connect high-pressure line for expansion of
vibration damper to hydraulic nut (2) and fix-
ture (2) and tighten.
4. Fill hydraulic hand pump with SAE10 engine
oil.
Note: Do not exceed expansion pressure of max.
800 bar.
5. To catch the vibration damper (4), operate
the pump plunger of the hydraulic hand pump
until there is strong resistance.
6. The pressurized expansion fluid penetrates
the connection and loosens the press fitting
after a few minutes, re-pump if necessary.
7. Remove high-pressure line from vibration
damper (4).
8. Remove high-pressure hose from removal jig.
9. Remove removal jig with puller spindle and
force-off bushing.
10. Screw eyebolts into threaded holes (3) on vi-
bration damper as far as they will go.
11. Lift vibration damper (4) off crankshaft with
lifting gear.
TIM-ID: 0000051630 - 001

MS22061/04E 2015-11 | Task Description | 45

 Removing vibration damper
1. Insert puller spindle on hydraulic removal jig
into bore on crankshaft, free end, and tight-
en.
2. Push force-off bushing (5) hydraulic nut (1)
and spacer disk (1) on to puller spindle and
screw on pull nut.
3. Connect high-pressure line for expansion of
vibration damper to hydraulic nut (3) and fix-
ture (3) and tighten.
4. Fill hydraulic hand pump with SAE10 engine
oil.
Note: Do not exceed expansion pressure of max.
800 bar.
5. To catch the vibration damper (4), operate
the pump plunger of the hydraulic hand pump
until there is strong resistance.
6. The pressurized expansion fluid penetrates
the connection and loosens the press fitting
after a few minutes, re-pump if necessary.
7. Remove high-pressure line from vibration
damper (4).
8. Remove high-pressure hose from removal jig.
9. Remove removal jig with puller spindle and
force-off bushing.
10. Screw eyebolts into threaded holes (1) on vi-
bration damper as far as they will go.
11. Attach lifting gear to both eyebolts and lift vi-
bration damper off crankshaft.

TIM-ID: 0000051630 - 001

46 | Task Description | MS22061/04E 2015-11

 3.2.4 Vibration damper on PTO, free end ‒ Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Removal/installation jig F0141110 1
Hydraulic hand pump, 0–3000 bar B80144839 1
Hydraulic hand pump, 0–1000 bar B80146898 1
Plug-in coupling nipple B80144866 1
Eyebolt 070612020000 1
Shackle 082101000107 1
Wire rope F6271443 1
Engine oil

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Equipment can drop off.
Liquid is highly pressurized.
Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
TIM-ID: 0000051631 - 002

MS22061/04E 2015-11 | Task Description | 47

 Installing vibration damper
1. Check tapers in vibration damper and on
crankshaft for cleanness.
2. Degrease all press-fit surfaces and coat with
engine oil.
3. Screw in eyebolt (1) up to the stop in the vi-
bration damper.
4. Attach vibration damper to lifting gear and
push on to crankshaft taper.
5. Use depth gage to measure distance from vi-
bration damper end face to crankshaft end
face and write it down.

6. Specified push-on dimension (vibration damp-

er (1) onto crankshaft (2)): 11.0 mm to
14.5 mm.
• Example (also applies similarly to vibration
damper with pulse generating ring):
• Dimension (a) before press-fitting =
208.5 mm
• Push-on dimension (c) = 12 mm
• Dimension b after press-fit-
ting = 220.5 mm

TIM-ID: 0000051631 - 002

48 | Task Description | MS22061/04E 2015-11

 7. Insert puller spindle on hydraulic press-fit de-
vice into bore on crankshaft, free end, and
tighten.
8. Push press-fit bushing (5) hydraulic nut (2)
and spacer disk (1) on to puller spindle and
screw on pull nut.
9. Connect high-pressure line for expansion of
vibration damper to hydraulic nut (3) and fix-
ture (3) and tighten.
10. Fill hydraulic hand pump with SAE10 engine
oil.
11. Connect high-pressure hose to press-fit de-
vice.
12. Fill hydraulic hand pumps with SAE10 engine
oil.
Note: At the beginning of the press-fitting process,
do not exceed an expansion pressure of max.
800 bar.
13. Increase force-on pressure and expansion
pressure, beginning with the force-on pres-
sure, using the pump plunger alternately, un-
til the push-on dimension is established in
the driver.
14. After completing the press-fitting process, re-
lease the expansion pressure and allow the
force-on pressure to take effect on the vibra-
tion damper (1) for about another 30 mi-
nutes.
15. Release force-on pressure.
16. Remove hydraulic hand pump and press-fit
device.
17. Use depth gage to check push-on dimen-
sion (see previous illustration).
TIM-ID: 0000051631 - 002

MS22061/04E 2015-11 | Task Description | 49

 Installing vibration damper
(with pulse generating ring)
1. Check tapers in vibration damper and on
crankshaft for cleanness.
2. Degrease all press-fit surfaces and coat with
engine oil.
3. Screw eyebolts into threaded holes (3) on vi-
bration damper (4) as far as they will go.
4. Attach vibration damper (4) to lifting gear and
push on to crankshaft taper.
5. Use depth gage to measure distance from vi-
bration damper end face to crankshaft end
face and write it down.
6. Insert puller spindle on hydraulic press-fit de-
vice into bore on crankshaft, free end, and
tighten.
7. Push press-fit bushing (5) and hydraulic
nut (1) on to puller spindle and screw on pull
nut.
8. Connect high-pressure line for expansion of
vibration damper to bore in hydraulic nut (2)
and fixture (2) and tighten.
9. Fill hydraulic hand pump with SAE10 engine
oil.
10. Connect high-pressure hose to press-fit de-
vice.
11. Fill hydraulic hand pumps with SAE10 engine
oil.
Note: At the beginning of the press-fitting process,
do not exceed an expansion pressure of max.
800 bar.
12. Increase force-on pressure and expansion
pressure, beginning with the force-on pres-
sure, using the pump plunger alternately, un-
til the push-on dimension is established in
the driver.
13. After completing the press-fitting process, re-
lease the expansion pressure and allow the
force-on pressure to take effect on the vibra-
tion damper (1) for about another 30 mi-
nutes.
14. Release force-on pressure.
15. Remove hydraulic hand pump and press-fit
device.
16. Use depth gage to check push-on dimen-
sion (see previous illustration).
TIM-ID: 0000051631 - 002

50 | Task Description | MS22061/04E 2015-11

 Installing end cover
1. Install lifting bracket (2) on end cover.
2. Attach shackle to lifting bracket (2) and fit
end cover.
3. Install screws (1) and tighten (→ Page 276).
TIM-ID: 0000051631 - 002

MS22061/04E 2015-11 | Task Description | 51

 3.2.5 Vibration damper on free end – Final steps

Final steps
1. Assemble in reverse order to disassembly.
2. Enable engine start.

TIM-ID: 0000011829 - 002

52 | Task Description | MS22061/04E 2015-11

 3.2.6 Piston and conrod – Overview
Piston – Overview drawing

1 Rectangular-section ring 4 Screw 7 Piston pin

2 Rectangular-section ring 5 Piston crown 8 Support washer
3 Oil-control ring with coiled- 6 Piston skirt 9 Snap ring
spring expander
TIM-ID: 0000004015 - 003

MS22061/04E 2015-11 | Task Description | 53

 Conrod – Overview drawing

1 Conrod bushing 3 Conrod bearing 5 Conrod cap

2 Conrod 4 Locating pin 6 Conrod screw

TIM-ID: 0000004015 - 003

54 | Task Description | MS22061/04E 2015-11

 3.2.7 Piston and conrod – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Remove cylinder head (→ Page 77).
2. Remove inspection port cover of respective cylinder (→ Page 23).
TIM-ID: 0000011916 - 009

MS22061/04E 2015-11 | Task Description | 55

 3.2.8 Piston and conrod – Removal
Preconditions
☑ Preparatory steps completed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Barring device 5805890259/00 1
Index plate F6270942 1
Pointer for setting TDC point (16V and 20V) Y4275569 1
Pointer for setting TDC point (12V) Y4275535 1
Retaining device for piston F6277794 1
Removal device (carbon scraper ring) F6559641 1
Support bracket for piston and conrod T80090232 1
Installation jig for piston and conrod F6348802 1
Sliding block F6348804 1
Sliding block F6348805 1

DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Removal with oil pan installed

1. Use removal device to remove carbon scra-
per ring from cylinder liner.
2. Clean and remove combustion residue from
cylinder liner at piston's TDC point.
3. Fit pointer (1) on axial bearing housing and
tighten.
4. Use force amplifier (3) to fit graduated
disk (2) on crankshaft end at driving end and
tighten.
5. Insert ratchet wrench in square of force am-
TIM-ID: 0000011907 - 006

plifier (3).
6. Turn crankshaft crankpin of relevant cylinder
on
• left-hand engine side to 35° past TDC, and
on
• right-hand engine side to 35° before TDC.

56 | Task Description | MS22061/04E 2015-11

 7. Release conrod screws (2) using socket and
ratchet lever.
8. Remove three conrod screws from conrod
and conrod bearing cap (1).

9. Use lever (2) to hold conrod bearing cap (1)

up.
10. Remove fourth conrod screw from conrod
and conrod bearing cap (1).
11. Use lever (2) to lower conrod bearing cap (1)
and remove from crankshaft space.
12. Screw sliding block on to conrod.
13. Rotate piston on A side to 41° after TDC and
on B-side to 41° before TDC and remove
from cylinder liner with lifting device.

14. For reassembly, use felt pen to mark upper

conrod bearing shell (1) with “U” and lower
bearing shell (2) with “L”.
TIM-ID: 0000011907 - 006

MS22061/04E 2015-11 | Task Description | 57

 15. Press clips of strap (1) down, pull bearing
shells on crankpin apart and remove.

TIM-ID: 0000011907 - 006

58 | Task Description | MS22061/04E 2015-11

 3.2.9 Piston – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Hakupur 312) 30390 1

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Piston – Cleaning
Note: The graphite layer on the piston skirt must not come into contact with strong cleaning agents or be removed
mechanically.
1. Remove all deposits from functional and sealing surfaces.
2. Clean piston ring groove area using rotating plastic roller brush.
3. Clean all functional and sealing surfaces with cleaning agent.
4. Wipe all functional and sealing surfaces dry with a clean, lint-free cloth.
5. Remove corrosion inhibitor from new component using cleaning agent.
TIM-ID: 0000011873 - 013

MS22061/04E 2015-11 | Task Description | 59

 3.2.10 Piston ‒ Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Feeler gage Y4341964 1
Gage block kit 0005891619/00 1
Depth gage, 300 mm Y20002777 1
Bore gage, 18–100 mm Y20091481 1
Bore gage, 160–290 mm Y20091483 1
Micrometer, 75–100 mm Y20000169 1
Micrometer, 225–250 mm Y20001746 1
Oilstone 8205893261/00 1
Piston (→ Spare Parts Catalog)
Piston pin (→ Spare Parts Catalog)
Oil-control ring (→ Spare Parts Catalog)
Rectangular-section ring (→ Spare Parts Catalog)

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Piston ‒ Check
Item Findings Action
Check piston crown for signs of • Wear • Recondition: Smooth with oil-
wear and damage. • Damage stone.
visible • Replace piston crown.
TIM-ID: 0000011884 - 003

Check piston crown for contact Contact erosion visible Replace piston crown.
erosion at piston edge.
Check piston for wear. • Large area of polish wear on Replace piston.
piston skirt (appears matt)
• Concentrated occurrence of
scores
• Seizure marks
Measure piston pin boss. Values Values exceeded Replace piston.
(→ Page 62)

60 | Task Description | MS22061/04E 2015-11

 Item Findings Action
Check outside diameter of piston Values not attained. Replace piston.
skirt at non-phosphated measur-
ing points. Values (→ Page 62).
Check sliding surface on bushing • Wear Replace piston.
for signs of wear and scoring. • Scoring
visible
Check groove width with gage Values exceeded. Replace piston.
blocks. If no gage block is availa-
ble, alternatively a new piston ring
can be inserted in the groove and
the thrust distance checked with a
feeler gage. Values (→ Page 62)
Check condition of piston pin. • Signs of wear Replace piston.
• Scoring
• Points of impact
visible
Measure piston pin outside diame- Values exceeded. Replace piston.
ter with micrometer. Values
(→ Page 62)
Check piston rings. • Piston rings burred, chipped or Replace
sharp-edged
• If chrome layer shows scores,
cracks or burn marks.
Check piston crown screws for • Damage Replace
wear and damage. Values • Wear
(→ Page 62). visible

Checking piston rings

1. Place piston ring (1) in ring gage (3) to meas-
ure piston ring end clearance. Make sure that
piston ring lies evenly in ring gage (3).
2. Check ring end clearance with feeler
gage (2). Values (→ Page 62)
3. Values exceeded: Replace piston rings. Only
replace piston rings in sets.
4. After installation of new piston rings, replace
cylinder liners. (→ Page 30)
TIM-ID: 0000011884 - 003

MS22061/04E 2015-11 | Task Description | 61

 3.2.11 Piston – Tolerances

Item Designation Re- Toleranced Deviation Clearance Interference Wear limit

pair size Lower Upper Min. Max. Min. Max.
size Basic size
1 Groove width 4.000 +0.120 +0.150 0.180 0.225 max. 0.300
Rectangular-section ring 3.950 −0.025 −0.010
2 Ring end clearance * *
Rectangular-section ring 0.800 1.050
Rectangular-section ring 1.600 2.100
Oil-control ring 0.900 1.150
3 Groove width 10.000 +0.070 +0.110 0.083 0.145 max. 0.180
Oil-control ring 10.000 −0.035 −0.013
4 Groove width 5.000 +0.075 +0.100 0.165 0.205 max. 0.240
Rectangular-section ring 4.920 −0.025 −0.010
Permissible weight difference of pistons within an engine is 300 g
TIM-ID: 0000004026 - 004

Reconditioning notes:
Re 1 and 2: Wear limit exceeded: replace rectangular-section rings. Limit values exceeded for new rectangu-
lar-section ring: Replace piston crown.
Re 3: Wear limit exceeded: replace oil-control ring. Limit value exceeded for new oil-control ring: recondition
piston skirt.
Re 4: Wear limit exceeded: replace piston rings.
* measured in adjusting ring, accuracy depends on ring gauge tolerance.

62 | Task Description | MS22061/04E 2015-11

 Piston crown mounting

Item Designation Re- Toleranced Deviation Clearance Interference Wear limit

pair size Lower Upper Min. Max. Min. Max.
size Basic size
1 Screw length, 60.000 −0.300 0 max. 61.00
- removed 0

Reconditioning notes:
Re 1: Wear limit exceeded: Replace screw.
TIM-ID: 0000004026 - 004

MS22061/04E 2015-11 | Task Description | 63

 Piston pin bearing

Item Designation Re- Toleranced Deviation Clearance Interference Wear limit

pair size Lower Upper Min. Max. Min. Max.
size Basic size
1 Conrod bore 0 94.000 H6 0 +0.022 0.124 0.168 Interfer-
1 94.500 H6 ence min.
2 95.000 H6 0.100
Test load
Bushing 0 94.000 v6 +0.146 +0.168
min.
outer Ø 1 94.500 v6 35000 N
2 95.000 v6
2 Bushing bore 85.000 E5 +0.072 +0.087 0.072 0.092 Clearance
- installed max. 0.150
Piston pin 85.000 −0.005 0
outer Ø
3 Piston bore 85.000 +0.017 +0.027 0.017 0.032 Clearance
Piston pin 85.000 −0.005 0 max. 0.070
outer Ø
TIM-ID: 0000004026 - 004

Reconditioning notes:
Re 1: Limit value not reached: enlarge conrod bore to stage and press-fit step bushing. Enlarge bushing to
85 E5.
Re 2: Wear limit exceeded: replace bushing and piston pin, enlarge bushing to 85 E5 .
Re 3: Wear limit exceeded: replace piston pin or piston skirt.

64 | Task Description | MS22061/04E 2015-11

 Piston clearance

Item Designation Re- Toleranced Deviation Clearance Interference Wear limit

pair size Lower Upper Min. Max. Min. Max.
size Basic size
1 Carbon scraper ring 229,000 H8 0 +0,072 0,906 1,008 Clearance
max. 1,100
Piston crown Ø 228,094* −0,030 0
2 Carbon scraper ring 229,000 H8 0 +0,072 0,570 0,672 Clearance
max. 0,750
Piston crown Ø 228,430* −0,030 0
3 Liner bore 230,000 H7 0 +0,046 0,300 0,376 Clearance
max. 0,450
Piston crown Ø 229,700* -0,030 0
4 Liner bore 230,000 H7 0 +0,046 0,355 0,431 Clearance
max. 0,550
Piston skirt Ø 229,630* −0,015 +0,015
5 Liner bore 230,000 H7 0 +0,046 0,215 0,291 Clearance
max. 0,480
Piston skirt Ø 229,770* −0,015 +0,015

Notice:
TIM-ID: 0000004026 - 004

* measured in direction of pressure/back pressure (90° to the pin axis).

MS22061/04E 2015-11 | Task Description | 65

 3.2.12 Piston and conrod – Assembly
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Piston-ring pliers for rectangular-section ring F30378005 1
Piston-ring pliers for oil control ring F30378006 1
Snap ring pliers F30002760 1
Retaining device for piston F6277794 1
Torque wrench, 6–50 Nm F30027336 1
Ratchet adapter F30027340 1
Assembly compound (Molykote G-N Plus) 40041 1
Sealing compound (Led-Plate 250F) 40134 1
Engine oil
Snap ring (→ Spare Parts Catalog)
Support plate (→ Spare Parts Catalog)
Screw (→ Spare Parts Catalog)

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

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

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

NOTICE
Incorrect installation of components and lines.
TIM-ID: 0000004062 - 006

Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

66 | Task Description | MS22061/04E 2015-11

 Assembling piston
1. Check inlet and outlet of piston coolant oil for
obstructions.
2. Insert piston skirt in retaining device.
3. Set down piston crown (3) on piston skirt.
4. Coat thread of screws (1) with assembly
compound.
5. Coat head mating faces of screws (1) with
sealing compound.

6. Tighten screws (1) diagonally to specified torque using a torque wrench (2).
Name Size Type Lubricant Value/Standard
Screw M10-4 h Preload torque 20 Nm +2 Nm
Screw M10-4 h Residual torque release
Screw M10-4 h Residual torque 10 Nm +1 Nm
Screw M10-4 h Residual angle of rotation 90° +5°
Screw M10-4 h Control torque 25 Nm +2.5 Nm

Installing piston rings

1. Turn coiled-spring expander (2) in oil-control
ring (1) in order to offset ring spring butting
face (arrowed) to oil-control ring butt by
180°.
2. Prepare piston rings as per installation se-
quence. Note that new piston rings always
need to be replaced in sets.
TIM-ID: 0000004062 - 006

MS22061/04E 2015-11 | Task Description | 67

 Note: Only install piston with new piston rings in
new or re-honed cylinder liners.
3. Use piston-ring pliers (1) to stretch piston
rings until they can be pushed over the pis-
ton.
4. Insert piston rings in sequence from bottom
to top in annular grooves on piston in such a
way, that TOP mark on piston rings faces pis-
ton crown.
5. Check piston rings for easy movement.

Installing conrod in piston

1. Wipe down piston pin (3), conrod bushing and
piston pin bore with chamois leather and coat
with engine oil.
2. Insert support plate into piston pin bore.
3. Insert snap ring.
4. Install conrod (1) in piston in such a way that
the broad collar of the main conrod bore is in
alignment with the main piston cooling oil
bore with nozzle (2).
5. Insert piston pin until it lies on installed sup-
port plate.

6. Install second support plate with snap ring.

7. Check piston pin for easy movement.
8. Check that both snap rings (arrowed) fit well
and are in correct position.
TIM-ID: 0000004062 - 006

68 | Task Description | MS22061/04E 2015-11

 3.2.13 Piston and conrod – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Assembly sleeve F6557120 1
Support bracket for piston and conrod T80090232 1
Installation jig for piston and conrod F6348802 1
Sliding block F6348804 1
Sliding block F6348805 1
Assembly jig for lifting conrod F6375369 1
Assembly jig for conrod bearing F6456288 1
Spacer for assembling conrod F6375336 1
Socket for conrod screw F30378301 1
Barring device 5805890259/00 1
Torque wrench, 80 to 400 Nm F30027338 1
Ratchet adapter F30027341 1
Assembly compound (Molykote G-N Plus) 40041 1
Engine oil

DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.
TIM-ID: 0000011939 - 005

Installation with oil pan installed

1. Turn crankshaft crank pin of relevant cylinder on:
• left-hand side to 35° past TDC, and on
• right-hand side to 35° before TDC
2. Prior to installation of conrod bearing, check stage and bearing clearance.

MS22061/04E 2015-11 | Task Description | 69

 3. Bearing shells are marked on the back to de-
termine positions as follows:
4. Bearing shell (3) in conrod: O
5. Bearing shell (2) in conrod cap: U
6. The arrows (1) must be opposite each other
at the shell joint and face the crank web.
7. The cross (A) indicates the position of the
serration.

8. Clean bearing shells (1) and (2) with a leather

cloth.
Note: During the following operations, the crank-
shaft may not be rotated any further, until the
assembly of the respective conrod is com-
pleted.
9. After numbering, apply conrod bearing shell
(1) with clips to crankpin.
10. Press corresponding bearing shell (2) without
clips against shell joint until clips lock into
place.

1 No expansion in the vicinity of the

joint faces
2 Clip expanded here
TIM-ID: 0000011939 - 005

11. Clean bearing shells with leather cloth.

70 | Task Description | MS22061/04E 2015-11

 12. Install sliding blocks on serration of joints
and tighten.
13. Coat threads and mating faces of conrod
screws with assembly compound.

14. Attach lifting device (1) to piston and tighten.

15. Set assembly jig down on cylinder liner.
16. Attach piston to lifting device with rope.
17. Move joints of rectangular-section rings and
oil-control ring together evenly.
18. Coat piston and piston rings with engine oil.
19. Push piston with conrod into oiled cylinder
liner until sliding blocks can be removed
through inspection port.

Note: Do not use brute force to press lever (2)

down, otherwise bearing shell will be dam-
aged.
20. Insert conrod bearing cap (1) through inspec-
tion port and use lever (2) to carefully push it
up against crankpin.
21. Turn bearing shells on crankpin until dowel
pin on conrod bearing cap (1) is in alignment
with recess on bearing shell.
22. Carefully press lever (2) on down until dowel
TIM-ID: 0000011939 - 005

pin locks into place in bearing shell on con-

rod bearing cap (1).
23. Seating of bearing shells in conrod bearing
cap (1) can be checked through cylinder liner
bore.
24. Push in piston completely until conrod mesh-
ing lies on conrod cap.

MS22061/04E 2015-11 | Task Description | 71

 1 Conrod number
2 Notch marks on conrod screw and
conrod cap
3 Conrod screw numbers 1, 2, 3, 4

25. Insert conrod screws (3) into conrod according to numbers and hand-tighten.
26. Tighten conrod screws (3) 1 and 2 on short arm of conrod to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Conrod screw M22 Preload torque (Assembly compound 100 Nm
(Molykote G-N Plus))

27. Tighten conrod screws (3) 3 and 4 on long arm of conrod to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Conrod screw M22 Preload torque (Assembly compound 100 Nm
(Molykote G-N Plus))

28. Check interval of 120° between notch mark on conrod screw and notch mark on conrod.
Result: If deviation from angular dimension exceeds 30°, remove conrod screws and check screw elongation. Value
(→ Page 62)
29. Check lateral easy movement of mounted conrod on crank pin by hand.
30. Tighten conrod screws (3) in any order in one go, individually or together, to notch mark.
31. Check specified torque of conrod screws using a torque wrench.
Name Size Type Lubricant Value/Standard
Conrod screw M22 Control torque (Assembly compound 300 Nm +30 Nm
(Molykote G-N Plus))

32. After fitting the second conrod of the same crankpin, check max. clearance of 0.6 mm of conrod to crank-
shaft.
33. If the maximum clearance is not attained, remove conrod and remount with new bearings.
TIM-ID: 0000011939 - 005

72 | Task Description | MS22061/04E 2015-11

 3.2.14 Piston and conrod – Final steps

Final steps
1. Observe safety instructions.
2. Assemble in reverse order of disassembly (→ Page 55).
TIM-ID: 0000011945 - 008

MS22061/04E 2015-11 | Task Description | 73

 3.3 Cylinder Head
3.3.1 Cylinder head – Overview

1 Sleeve 7 O-ring 13 Sealing ring

2 Sealing ring 8 Thrust washer 14 Plug screw
3 Seal carrier 9 Stress bolt 15 Sealing ring
4 Sealing ring 10 Screw 16 Cylinder head, complete
5 Sealing ring 11 Plug screw 17 Sealing ring
6 Seal carrier 12 Sealing ring

TIM-ID: 0000004143 - 004

74 | Task Description | MS22061/04E 2015-11

 Overview drawing

1 Valve cone 9 Exhaust valve 17 O-ring

2 Spring plate 10 Cylinder head 18 Valve guide, exhaust
3 Valve spring, outer 11 Plug rod 19 End cover
4 Valve spring, inner 12 End cover 20 Plug screw
5 Valve rotator 13 End cover 21 Plug rod
6 End cover 14 Plug 22 Valve guide, inlet
7 Inlet valve 15 Coiled spring pin
8 End cover 16 Plug rod
TIM-ID: 0000004143 - 004

MS22061/04E 2015-11 | Task Description | 75

 3.3.2 Cylinder head – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Remove cylinder head covers (→ Operating Instructions).
2. Drain engine coolant (→ Operating Instructions).
3. Remove valve drive (→ Page 87).
4. Remove air pipework to cylinders (→ Page 164).

TIM-ID: 0000012034 - 001

76 | Task Description | MS22061/04E 2015-11

 3.3.3 Cylinder head ‒ Removal
Preconditions
☑ Preparatory steps are completed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Socket insert F30013228 1
Support bracket T80092856 1
Guide tube F6271448 1

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Removing cylinder head

1. Remove two stress bolts (1) diagonally.
2. Insert two guide tubes into crankcase.
3. Remove remaining stress bolts (1) from cylin-
der head (2).
4. Remove thrust washers from stress bolts (1).
TIM-ID: 0000050449 - 001

MS22061/04E 2015-11 | Task Description | 77

 5. Attach cylinder head (2) with support brack-
et (1) and rope to crane, ensuring that the
rope is lightly tensioned.
6. Lift off cylinder head (2) and place on a firm
surface.
7. Remove guide tubes (3).

8. Take off sealing ring (1).

9. Remove seal carrier (2), sleeves and rings (3).

TIM-ID: 0000050449 - 001

78 | Task Description | MS22061/04E 2015-11

 3.3.4 Cylinder head – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Hakupur 312) 30390 1

WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Cleaning sealing surfaces

1. Remove all deposits from functional and sealing surfaces.
2. Clean all functional and sealing surfaces with cleaning agent.
3. Wipe all functional and sealing surfaces dry with a clean, lint-free cloth.
4. Remove corrosion inhibitor from new component using cleaning agent.
TIM-ID: 0000011994 - 013

MS22061/04E 2015-11 | Task Description | 79

 3.3.5 Cylinder head – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Guide tube F6271448 2
Force amplifying wrench F30030459 1
Socket insert F30013228 1
Support bracket T80092856 1
Torque wrench, 10–60 Nm F30510423 1
Ratchet adapter F30027340 1
Torque wrench, 40–200 Nm F30027337 1
Ratchet adapter F30027341 1
Tightening tool F6794031 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Assembly compound (Molykote G-N Plus) 40041 1
Corrosion inhibitor (Tectyl 846-K-19) X00057275 1
Engine oil
Sleeve (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)
Seal carrier (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

NOTICE
Contamination in blind holes.
Damage to component!
• Check and clean blind hole.

NOTICE
TIM-ID: 0000050450 - 002

Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

80 | Task Description | MS22061/04E 2015-11

 Cylinder head – Installation
1. Coat sealing rings (2) with assembly com-
pound (Kluthe Hakuform 30-11C) and wind
on to sleeves (3).

2. Place sealing ring (1) on sealing surface on

cylinder liner collar in accordance with the
measured thickness or marking.
3. Place seal carrier (3) with sealing rings on
crankcase.
4. Check coiled spring pins (2) for locking cylin-
der head for damage.
Result: Replace if damaged.
5. Ensure that all sleeves (4) and sealing
rings (1) are present.
6. Install support bracket on cylinder head.
7. Screw guide tubes for attaching cylinder
head into crankcase.
8. Use rope and lifting gear to set cylinder head
down on crankcase. In doing so, make sure
that it engages in the coiled spring pins.
9. Remove support bracket from cylinder head.
10. Remove guide tubes.
11. Coat mating faces of thrust washers and
stress bolt thread with corrosion inhibitor.
12. Coat stress bolt mating face with engine oil.
13. Screw in stress bolts using thrust washers.
TIM-ID: 0000050450 - 002

MS22061/04E 2015-11 | Task Description | 81

 14. Use a torque wrench (1) to tighten stress bolts crosswise to specified tightening torque.
Name Size Type Lubricant Value/Standard
Stress bolt M24 Preload torque 20 Nm +10 Nm
Stress bolt M24 Residual torque 110 Nm +11 Nm

15. Fit rotation angle tightening tool to stress

bolts on cylinder head.

16. Use ratchet wrench to tighten stress bolts crosswise to specified angle of further rotation.
Name Size Type Lubricant Value/Standard
Stress bolt M24 Residual angle of rotation 90° +5°

17. Remove rotation angle tightening tool.

TIM-ID: 0000050450 - 002

82 | Task Description | MS22061/04E 2015-11

 3.3.6 Cylinder head – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 76).
2. Fill with engine coolant (→ Operating Instructions).
3. Fill fuel system (→ Operating Instructions).
4. Enable engine start.
TIM-ID: 0000012071 - 004

MS22061/04E 2015-11 | Task Description | 83

 3.4 Valve Gear
3.4.1 Valve drive – Overview

1 Rocker arm, exhaust 5 Rocker shaft 9 Rocker shaft support

2 Rocker arm, inlet 6 Rocker shaft support 10 Screw
3 Screw 7 Pushrod, inlet
4 Spring washer 8 Pushrod, exhaust

TIM-ID: 0000004342 - 003

84 | Task Description | MS22061/04E 2015-11

 1 Ball 3 Rocker arm, inlet 5 Ball seat
2 Nut 4 Bearing bushing 6 Adjusting screw
TIM-ID: 0000004342 - 003

1 Ball 3 Rocker arm, exhaust 5 Ball seat

2 Nut 4 Bearing bushing 6 Adjusting screw

MS22061/04E 2015-11 | Task Description | 85

 3.4.2 Valve gear – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Drain engine coolant (→ Operating Instructions).
2. Remove cylinder head cover (→ Operating Instructions).

TIM-ID: 0000012251 - 002

86 | Task Description | MS22061/04E 2015-11

 3.4.3 Valve drive – Removal
Preconditions
☑ Preparatory steps are completed.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Removing rocker arm

1. Set the piston of the relevant cylinder to fir-
ing TDC.
2. Remove screws (2) on rocker arm (1).

Note: Press the rocker shaft supports (1) with the

rocker arm (2) together with both hands oth-
erwise the parts will fall apart.
3. Remove rocker shaft supports (1) with rocker
arm (1) from cylinder head.
4. Remove pushrods.
TIM-ID: 0000004390 - 004

MS22061/04E 2015-11 | Task Description | 87

 3.4.4 Valve drive – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaner (Snow-White 11-0) X00054118 1
Cleaner (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
• Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Valve drive – Cleaning

1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Blow off all parts with compressed air.

TIM-ID: 0000012218 - 013

88 | Task Description | MS22061/04E 2015-11

 3.4.5 Valve gear ‒ Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Rocker arm (→ Spare Parts Catalog)
Bearing bushing (→ Spare Parts Catalog)
Rocker shaft (→ Spare Parts Catalog)
Adjusting screw (→ Spare Parts Catalog)
Ball seat (→ Spare Parts Catalog)

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Valve gear ‒ Check

Item Findings Action
Check bearing bushing, ball seat • Wear • Rework: Smooth with oilstone.
and rocker shaft support for signs • Damage • Replace
of wear and damage. visible
Check screws, nuts and adjusting Damaged Replace
screws for damage.
TIM-ID: 0000012234 - 002

MS22061/04E 2015-11 | Task Description | 89

 3.4.6 Valve drive – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 60–320 Nm F30047446 1
Ratchet adapter F30027341 1
Engine oil

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Valve drive – Installation

1. Check mating faces on cylinder head and
rocker shaft support (1) for flatness, smooth-
en with oilstone as necessary.
2. Set relevant cylinder to firing TDC.
3. Coat push rod head with engine oil.
4. Install push rods.
5. Install rocker (2) with rocker shaft and rocker
shaft support on cylinder head.

TIM-ID: 0000012265 - 003

90 | Task Description | MS22061/04E 2015-11

 6. Coat threads and mating faces of stress
bolts (2) with engine oil.

7. Insert stress bolts (2) and tighten to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 230 Nm +20 Nm

8. Adjust valve clearance (→ Operating Instructions).

TIM-ID: 0000012265 - 003

MS22061/04E 2015-11 | Task Description | 91

 3.4.7 Valve gear – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 86).
2. Enable engine start.

TIM-ID: 0000012273 - 002

92 | Task Description | MS22061/04E 2015-11

 3.5 Fuel System (High Pressure)
3.5.1 HP pump – Overview

1 HP connection 4 Fuel return 7 O-ring

2 Lube oil connection 5 Leak-off fuel
3 Fuel inlet 6 Lifting groove
TIM-ID: 0000043798 - 001

MS22061/04E 2015-11 | Task Description | 93

 3.5.2 HP pump – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Observe safety regulations.
2. Remove HP line (→ Page 111).
3. Remove leak-fuel line (→ Page 134).
4. Provide a suitable container to catch residual fuel.

TIM-ID: 0000043915 - 001

94 | Task Description | MS22061/04E 2015-11

 3.5.3 HP pump – Removal
Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Force amplifying wrench F30030459 1
Ratchet F30006211 1
Support bracket T80092979 1

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.
TIM-ID: 0000043799 - 003

MS22061/04E 2015-11 | Task Description | 95

 HP pump – Removal
1. Turn crankshaft until double cam on cam-
shaft is in base circle for HP pump con-
cerned.
2. Remove screws (4) from HP pump (2).
3. Remove screws (4) and washers (3).
4. Lever HP pump (2) up and out with previously
installed support bracket (1).
5. Remove O-ring from groove in injection pump
flange and dispose appropriately.

TIM-ID: 0000043799 - 003

96 | Task Description | MS22061/04E 2015-11

 3.5.4 HP pump – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaner (Hakupur 312) 30390 1

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

HP pump – Cleaning
1. Remove all deposits from functional and sealing surfaces.
2. Use cleaner to clean all functional and sealing surfaces.
3. Use a clean, lint-free cloth to wipe all functional and sealing faces dry.
4. Use cleaner to remove any corrosion inhibitor from new component.
TIM-ID: 0000031201 - 005

MS22061/04E 2015-11 | Task Description | 97

 3.5.5 HP pump – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Force amplifying wrench F30030459 1
Ratchet F30006211 1
Torque wrench, 60–320 Nm F30047446 1
Ratchet adapter F30027340 1
Ratchet adapter F30027341 1
Support bracket T80092979 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Engine oil
O-ring (→ Spare Parts Catalog)

Installing HP pump
1. Turn crankshaft in direction of engine rota-
tion until double cam on camshaft is in base
circle for HP pump concerned before assem-
bling HP pump (1).
2. Coat new O-ring (2) with assembly compound
(Kluthe Hakuform 30-11C) and insert in
groove in flange of HP pump (1).

3. Install HP pump (4) on crankcase with han-

dle (1) installed.
4. Coat threads on screws (2) with engine oil
and screw into crankcase with washers (3).
TIM-ID: 0000043800 - 003

98 | Task Description | MS22061/04E 2015-11

 5. Tighten screws (2) on HP pump (4) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm

6. Remove support bracket (1).

TIM-ID: 0000043800 - 003

MS22061/04E 2015-11 | Task Description | 99

 3.5.6 HP pump – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 94).
2. Fill and vent fuel system (→ Operating Instructions).
3. Enable engine start.

TIM-ID: 0000024548 - 004

100 | Task Description | MS22061/04E 2015-11

 3.5.7 HP fuel accumulator – Overview

1 HP fuel accumulator 2 HP fuel lines

TIM-ID: 0000043801 - 001

MS22061/04E 2015-11 | Task Description | 101

 1 HP fuel accumulator 5 Limiting valve 9 Temperature sensor
2 HP fuel line of HP pump 6 Shim washer 10 Leak-off fuel
3 HP fuel line 7 O-ring 11 HP fuel line to the injector
4 HP fuel line 8 Retaining screw

TIM-ID: 0000043801 - 001

102 | Task Description | MS22061/04E 2015-11

 3.5.8 HP fuel accumulator – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Observe safety regulations.
2. Remove HP line to HP accumulator (→ Page 111).
3. Remove leak fuel line to HP accumulator (→ Page 134).
4. Provide a suitable container to catch residual fuel.
TIM-ID: 0000043802 - 002

MS22061/04E 2015-11 | Task Description | 103

 3.5.9 HP fuel accumulator – Removal
Preconditions
☑ Preparatory steps have been carried out.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Support bracket T80091150 1

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

HP fuel accumulator – Removal

1. Remove screws (4) from HP fuel accumula-
tor.
2. Remove screws (4) and washers (3).
3. Install support bracket (1) in transport
threads (2) with two hand screws.
4. Lift HP fuel accumulator out of the mount
with the crane.
TIM-ID: 0000043803 - 003

5. Set down HP fuel accumulator and remove

support bracket (1).

104 | Task Description | MS22061/04E 2015-11

 3.5.10 HP fuel accumulator – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Support bracket T80091150 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Engine oil
O-ring (→ Spare Parts Catalog)

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Installing HP fuel accumulator

1. Coat O-rings with assembly compound.
2. Install handle (1) in transport threads (2) on
HP fuel accumulator with two hand screws.
3. Attach HP fuel accumulator to the crane and
lift into the mount with the crane.
4. Coat threads on screws (4) with engine oil
and screw into crankcase with washers (3).
TIM-ID: 0000043804 - 003

5. Tighten screws (4) of HP fuel accumulator to specified torque.

Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm

MS22061/04E 2015-11 | Task Description | 105

 6. Install HP fuel lines (→ Page 112).
7. Install leak fuel lines (→ Page 135).

TIM-ID: 0000043804 - 003

106 | Task Description | MS22061/04E 2015-11

 3.5.11 HP fuel accumulator – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 103).
2. Install HP line (→ Page 112).
3. Install leak fuel line(→ Page 135)
4. Enable engine start.
TIM-ID: 0000043805 - 001

MS22061/04E 2015-11 | Task Description | 107

 3.5.12 HP fuel lines – Overview

1 Pressure sensor 4 HP fuel line (HP accumula- 7 HP fuel line (HP accumula-
2 Pressure sensor tor/HP accumulator) tor/HP pump)
3 Pressure relief valve 5 HP fuel line (HP accumula- 8 Pressure relief valve
tor/injector)
6 HP fuel line (HP accumula-
tor/injector)

TIM-ID: 0000043806 - 002

108 | Task Description | MS22061/04E 2015-11

 1 Grommet 4 Washer 7 Screw
2 Pipe half-clamp 5 Washer 8 Washer
3 Screw 6 Holder 9 Screw
TIM-ID: 0000043806 - 002

MS22061/04E 2015-11 | Task Description | 109

 3.5.13 High-pressure line – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

1. Observe safety regulations.

2. Provide a suitable container to catch residual fuel.
3. Shut off fuel supply line.

TIM-ID: 0000043807 - 001

110 | Task Description | MS22061/04E 2015-11

 3.5.14 HP line – Removal
Preconditions
☑ Preparatory steps have been carried out.

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Internal tension and residual pressure in the HP fuel system.Parts can be ejected when loosening them.
Risk of injury by ejected parts!
• Only use specified tools and devices.
• Wear goggles/facial protection.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

HP line – Removal
1. Prior to removal of the lines, take photos or
mark externally mounted components and
lines.
2. Remove retainer (3) with concentric camlock
grommets (4).
3. Loosen union nuts (2) on HP pump (1) and HP
accumulator (1).
4. Remove HP line.
5. Close off openings on HP accumulator (1), HP
pump (5) and HP line with suitable plugs.
TIM-ID: 0000043912 - 003

MS22061/04E 2015-11 | Task Description | 111

 3.5.15 HP fuel lines – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 40–200 Nm F30027337 1
Torque wrench, 20–100 Nm F30026582 1
Torque wrench, 4–20 Nm F30044239 1
Ratchet adapter F30027340 1
Ratchet adapter F30027341 1
Assembly paste(Optimoly Paste White T) 40477 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Engine oil

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Installing injector line (limiting

valve installed)
1. Remove all covers prior to installation.
Note: Ensure special cleanness.
2. Lubricate O-rings (3), (4) and (5) on injector
TIM-ID: 0000043913 - 004

line with assembly paste.

3. Coat thread and sealing cone of injector line
as well as thrust pad seat with engine oil.
4. Fit injector line on injector (1) first, then on
HP accumulator (6). Tighten both retaining
screws by hand.

112 | Task Description | MS22061/04E 2015-11

 5. Tighten injector line on injector (1) first, then on HP accumulator (6) to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Retaining screw M32 Preload torque (Engine oil) 100 Nm +10 Nm

6. Undo injector line and re-tighten on injector (1) first, then on HP accumulator (6) to specified torque using a
torque wrench.
Name Size Type Lubricant Value/Standard
Retaining screw M32 Tightening torque (Engine oil) 100 Nm +10 Nm

Installing injector line (limiting

valve not installed)
1. Remove all covers prior to installation.
Note: Minimize contamination!
• Lubricate O-rings (3, 4, 5, 7) and compen-
sating washer (8) with assembly paste.
• Lubricate sealing ball, sealing cone,
thread (2, 6) and thrust pad seat with en-
gine oil.
2. Insert limiting valve (9) with shim washer (8)
in HP accumulator (10).
3. Fit retaining screw (6) on HP accumula-
tor (10) and tighten by hand.

4. Tighten retaining screw (6) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Retaining screw M62 Tightening torque (Engine oil) 150 Nm +10 Nm

5. Fit injector line on injector (1) first, then on HP accumulator (10). Tighten retaining screws by hand.
6. Tighten injector line on injector (1) first, then on HP accumulator (10) to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Retaining screw M32 Preload torque (Engine oil) 100 Nm +10 Nm

7. Undo injector line and re-tighten on injector (1) first, then on HP accumulator (10) to specified torque using a
torque wrench.
Name Size Type Lubricant Value/Standard
TIM-ID: 0000043913 - 004

Retaining screw M32 Tightening torque (Engine oil) 100 Nm +10 Nm

MS22061/04E 2015-11 | Task Description | 113

 Installing HP fuel lines
1. Install retainer (11) for HP lines on charge-air
pipe.
2. Lubricate screw head mating faces and
threads of screws (4) with engine oil.
Note: Ensure special cleanness.
3. Lubricate O-rings of HP line with assembly
paste.
4. Lubricate thread and sealing cone of injector
line as well as thrust pad seat with engine oil.
5. Tighten both ends of HP line (9) on HP accu-
mulators (1).
6. Tighten both ends of HP line (2) on HP
pump (10) and HP accumulator (1).
7. Install pipe half-clamps (4) and camlock
grommets (7) on HP line without tensioning,
tighten by hand with screws (5) and wash-
ers (6).
8. Tighten HP line to specified torque.
Name Size Type Lubricant Value/Standard
Retaining screw M22 Preload torque (Engine oil) 120 Nm +10 Nm

9. Undo HP lines by a 45° angle of rotation.

10. Tighten HP lines to specified torque.
Name Size Type Lubricant Value/Standard
Retaining screw M22 Tightening torque (Engine oil) 120 Nm +10 Nm

11. Tighten pipe half-clamps (4) with screws (5) to specified torque.

Installing pressure limiting

valve and HP sensor
1. Install screws (3) and (5) for adapters (4)
and (7) of pressure limiting valve (6) and HP
sensor (2) by hand. TIM-ID: 0000043913 - 004

114 | Task Description | MS22061/04E 2015-11

 2. Install screws (3) and (5) for adapters (4) and (7) of pressure limiting valve (6) and HP sensor (2) gradually
and alternately.
Name Size Type Lubricant Value/Standard
Cap screw M10 Preload torque (Engine oil) 10 Nm +1 Nm
Cap screw M10 Residual torque 20 Nm + 2 Nm
Cap screw M10 Tightening torque 40 Nm + 5 Nm

3. Coat O-rings on pressure limiting valve (6) and HP sensor (2) with assembly compound (Kluthe Hakuform
30-11C).
4. Coat sealing cone on pressure limiting valve (6) and HP sensor (2) with engine oil.
5. Tighten pressure limiting valve (6) to specified torque.
Name Size Type Lubricant Value/Standard
Pressure limiting M36 Tightening torque (Engine oil) 150 Nm +5 Nm
valve

6. Tighten HP sensor (2) to specified torque.

Name Size Type Lubricant Value/Standard
High-pressure sen- M10 Tightening torque (Engine oil) 30 Nm +3 Nm
sor
TIM-ID: 0000043913 - 004

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 3.5.16 HP fuel line – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 110).
2. Fill and vent fuel system (→ Operating Instructions).
3. Enable engine start.

TIM-ID: 0000043914 - 002

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 3.6 Fuel System (Low Pressure)
3.6.1 Pressure limiting valve – Overview

1 Plug screw 6 Union 11 Valve guide

2 Sealing ring 7 Sealing ring 12 Snap ring
3 Compression spring 8 Valve housing 13 Sealing ring
4 Sealing ring 9 Internal valve parts 14 Plug screw
5 Internal valve parts 10 Sealing ring
TIM-ID: 0000004778 - 003

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 3.6.2 Pressure limiting valve – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Observe safety regulations.
2. Provide a suitable container to catch residual fuel.
3. Shut off fuel supply line.
4. Remove fuel priming pump (→ Page 126).

TIM-ID: 0000043916 - 001

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 3.6.3 Pressure limiting valve – Removal
Preconditions
☑ Preparatory steps are completed.

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Pressure limiting valve – Re-

moval
1. Remove pressure limiting valve (1) from fuel
delivery pump (3).
2. Remove gasket (2).
TIM-ID: 0000004787 - 004

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 3.6.4 Pressure limiting valve – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Snow-White 11-0) X00054118 1
Cleaning agent (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
• Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Pressure limiting valve – Cleaning

1. Clean all metallic parts with cleaning agent (Snow-White 11-0), then rinse parts with cleaning agent (Hakupur
312).
2. Blow off all parts with compressed air.

TIM-ID: 0000012602 - 003

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 3.6.5 Pressure limiting valve – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Valve housing (→ Spare Parts Catalog)
Internal valve parts (→ Spare Parts Catalog)

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Checking pressure limiting valve

Item Findings Action
Check internal valve parts. Damaged Replace
Check sealing cone mating faces Damaged Replace
in valve housing.
Check mating faces for uneven- • Uneven • Rework: Smooth with oilstone.
ness and damage. • Damaged • Replace
Check threads for damage. Damaged • Rework: Recut threads
• Replace
TIM-ID: 0000012603 - 002

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 3.6.6 Pressure limiting valve – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Engine oil
Gasket (→ Spare Parts Catalog)

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Pressure limiting valve – Instal-

lation
1. Place gasket (2) on fuel delivery pump (3).
2. Push pressure limiting valve (1) onto stud on
fuel delivery pump (3).

TIM-ID: 0000004796 - 003

122 | Task Description | MS22061/04E 2015-11

 3.6.7 Pressure limiting valve – Final steps

Final steps
1. Install fuel priming pump (→ Page 129).
2. Fill fuel system (→ Operating Instructions).
3. Enable engine start.
4. Visually inspect fuel lines for leaks after engine start.
TIM-ID: 0000012608 - 003

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 3.6.8 Fuel priming pump – Overview

1 Screw 7 Diaphragm 13 Pump housing

2 Spring washer 8 Gasket 14 Tension spring
3 Coiled spring pin 9 Screw 15 Pin
4 Pump cover 10 Snap ring 16 Lever
5 Retainer 11 Valve guide
6 Washer 12 Internal valve parts

TIM-ID: 0000004798 - 003

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 3.6.9 Fuel priming pump – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Observe safety regulations.
2. Shut off fuel supply line.
TIM-ID: 0000012616 - 002

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 3.6.10 Fuel priming pump – Removal
Preconditions
☑ Preparatory steps are completed.

WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Removing fuel priming pump

1. Remove securing nuts (2) with conical spring
washers from fuel priming pump (1).
2. Remove fuel priming pump (1) with gasket
from pressure limiting valve (3).

TIM-ID: 0000004802 - 003

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 3.6.11 Fuel priming pump – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaner (Snow-White 11-0) X00054118 1
Cleaner (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
• Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Fuel priming pump – Cleaning

1. Clean all parts with cleaner.
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse parts with cleaner (Hakupur 312).
3. Blow off all components thoroughly with compressed air.
TIM-ID: 0000012609 - 004

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 3.6.12 Fuel priming pump – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Pump housing (→ Spare Parts Catalog)
Internal valve parts (→ Spare Parts Catalog)

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Checking fuel priming pump

Item Findings Action
Check sealing cone mating faces Damaged Replace
in pump housing.
Check internal valve parts. Damaged Replace
Check mating faces for uneven- • Uneven • Rework: Smooth with oilstone.
ness and damage. • Damaged • Replace
Check threads for damage. Damaged • Rework: Recut threads
• Replace

TIM-ID: 0000012611 - 003

128 | Task Description | MS22061/04E 2015-11

 3.6.13 Fuel priming pump ‒ Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Engine oil
Gasket (→ Spare Parts Catalog)

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Fuel priming pump ‒ Installation

1. Place gasket (2) on pressure limiting
valve (3).
2. Install fuel priming pump (1) on pressure lim-
iting valve (3) with nuts and spring washers.
TIM-ID: 0000004806 - 004

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 3.6.14 Fuel priming pump – Final steps

Final steps
1. Fill fuel system (→ Operating Instructions).
2. Enable engine start.
3. Visually inspect fuel lines for leaks after engine start.

TIM-ID: 0000012620 - 003

130 | Task Description | MS22061/04E 2015-11

 3.6.15 Leak fuel pipework – Overview
Leak fuel pipework

1 Fuel line 6 Grommet 11 Grommet

2 Fuel line 7 Fuel line 12 Fuel line
3 Screw 8 Screw 13 Plug screw
4 Washer 9 Washer 14 Fuel line
5 Pipe half-clamp 10 Pipe half-clamp
TIM-ID: 0000043917 - 001

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 Leak fuel monitoring

1 Nut 7 Adapter 13 Sealing ring

2 Washer 8 Sealing ring 14 Plug screw
3 Sealing ring 9 Housing 15 Sealing ring
4 Cover 10 Screw 16 Stud
5 Gasket 11 Washer
6 Fuel line 12 Plug screw

TIM-ID: 0000043917 - 001

132 | Task Description | MS22061/04E 2015-11

 3.6.16 Leak-off fuel pipework – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Observe safety instructions.
2. Remove charge-air manifold (if necessary) (→ Page 164).
TIM-ID: 0000012808 - 004

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 3.6.17 Leak fuel line – Removal
Preconditions
☑ Preparatory steps have been carried out.
☑ Provide a suitable container to collect the residual fuel.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Removing leak fuel line

1. Prior to removal of the lines take photos or mark externally mounted components and lines.
2. Release threaded union on fuel line and catch fuel as it escapes.
3. Remove fuel lines with mounting parts as shown in overview drawing (→ Page 131).
4. Seal openings with suitable covers.

TIM-ID: 0000005013 - 006

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 3.6.18 Leak-off fuel pipework ‒ Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Sealing ring (→ Spare Parts Catalog)
Grommet (→ Spare Parts Catalog)

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Leak-off fuel pipework ‒ Installation

1. Remove all covers before installation.
2. Blow out leak-off fuel lines with compressed air.
Note: Always use new sealing rings when doing this.
3. Install the leak-off fuel lines as shown in overview drawing or according to photos or markings (→ Page 131).
TIM-ID: 0000005018 - 006

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 3.6.19 Leak-off fuel pipework – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 133).
2. Enable engine start.

TIM-ID: 0000012810 - 002

136 | Task Description | MS22061/04E 2015-11

 3.7 Exhaust Turbocharger
3.7.1 Exhaust turbocharger – Overview and diagram

1 Exhaust turbocharger (high 4 Protective pipe 7 Sealing ring

pressure) 5 Burst protection (LP turbo-
2 Burst protection (HP turbo- charger)
charger) 6 Exhaust turbocharger (low-
3 Threaded sleeve pressure charger)
TIM-ID: 0000043918 - 001

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 1 Turbocharger group A1 4 Turbocharger group B2 N Exhaust turbocharger (L.P.
2 Turbocharger group A2 5 Turbocharger group B1 turbocharger)
3 Turbocharger group B3 H Exhaust turbocharger (H.P.
turbocharger)

TIM-ID: 0000043918 - 001

138 | Task Description | MS22061/04E 2015-11

 3.7.2 Exhaust turbocharger – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Observe safety instructions.
2. Remove carrier housing upper section (→ Page 195).
TIM-ID: 0000013104 - 002

MS22061/04E 2015-11 | Task Description | 139

 3.7.3 Exhaust turbocharger – Removal
Preconditions
☑ Preparatory steps have been carried out.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Lifting gear T80092852 1
Assembly jig F6794057 1

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Removing exhaust turbocharger

1. Install lifting gear (2) on HP turbocharger (1)
and LP turbocharger (2).
2. Attach exhaust turbochargers (1) and (3) on
lifting gear (2) to crane and lift out of lower
carrier housing.

3. Place exhaust turbochargers (1) and (2) in as-

sembly jig (3) and bolt down.
4. Remove lifting gear.
5. Remove HP turbocharger (1) and LP turbo-
charger (2) separately from assembly jig.
TIM-ID: 0000043920 - 001

140 | Task Description | MS22061/04E 2015-11

 3.7.4 Exhaust turbocharger – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Hakupur 312) 30390 1

WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Exhaust turbocharger – Cleaning

1. Remove all deposits from functional and sealing surfaces.
2. Clean all functional and sealing surfaces with cleaning agent.
3. Wipe all functional and sealing surfaces dry with a clean, lint-free cloth.
4. Remove corrosion inhibitor from new component using cleaning agent.
TIM-ID: 0000013048 - 012

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 3.7.5 Exhaust turbocharger – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Exhaust turbocharger ZR 170 (→ Spare Parts Catalog) 1
Exhaust turbocharger ZR 210 (→ Spare Parts Catalog) 1

Checking exhaust turbocharger

Item Findings Action
Check turbine housing, bearing • Grinding • Rework: Smooth with oilstone.
housing and compressor housing • Scoring • Replace
for scoring and grinding. visible
Check threads of securing screws. Damaged Replace

TIM-ID: 0000043921 - 001

142 | Task Description | MS22061/04E 2015-11

 3.7.6 Exhaust turbocharger – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Lifting gear T80092852 1
Assembly jig F6794057 1
Guide plate F6795525 4
Assembly compound (Ultra-Therm MTU) 50547 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Engine oil
Sealing ring (→ Spare Parts Catalog)

DANGER
Missing protective devices after working on the engine.
Risk of severe injuries and danger to life due to ejected parts!
• Disable engine start.
• After working on the engine, check that all protective devices have been reinstalled.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Installing exhaust turbocharger

1. Coat protection tube (1) on sealing faces with
assembly compound (Ultra-Therm MTU).
2. Install protection tube (1) in LP turbocharger
housing (2).
TIM-ID: 0000043989 - 004

MS22061/04E 2015-11 | Task Description | 143

 3. Place LP turbocharger (2) in assembly jig (3)
and bolt down.
4. Place HP turbocharger (1) in assembly jig (3)
and bolt down.

5. Install lifting gear (2) on HP turbocharger (1)

and LP turbocharger (2).

6. Coat sealing ring (2) with assembly com-

pound (Kluthe Hakuform 30-11C) and mount
along with sleeve (3) on lower carrier hous-
ing (1).
7. Install screws (4) and washers (5) in lower
carrier housing (1).
TIM-ID: 0000043989 - 004

144 | Task Description | MS22061/04E 2015-11

 8. Install guide plate (1) on lower carrier hous-
ing.
9. Attach exhaust turbocharger to lifting gear on
crane and lift into lower carrier housing by
crane.
10. Remove guide plate (1).
11. Tighten screws securing exhaust turbocharg-
ers by hand.
12. Remove lifting gear.

13. Tighten screws securing LP turbocharger to specified torque after installing upper carrier housing.
Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque (Engine oil) 70 Nm +7 Nm

14. Tighten screws securing HP turbocharger to specified torque after installing upper carrier housing.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 42 Nm +4 Nm

15. Re-install all guards.

TIM-ID: 0000043989 - 004

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 3.7.7 Exhaust turbocharger – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 139).
2. Enable engine start.

TIM-ID: 0000013146 - 002

146 | Task Description | MS22061/04E 2015-11

 3.8 Air Intake / Air Supply
3.8.1 Air and exhaust flap control – Overview

1 Screw 17 Nut 33 Retainer

2 Spring washer 18 Clevis head 34 Nut
3 Lever 19 Screw 35 Spring washer
4 Washer 20 Screw 36 Plate
5 Nut 21 Strap 37 Retainer
6 Spring washer 22 Lever 38 Screw
7 Screw 23 Washer 39 Actuating cylinder
8 Sealing ring 24 Nut 40 Retainer
9 Threaded adapter 25 Washer 41 Spring washer
10 Screw 26 Screw 42 Screw
11 Spring washer 27 Screw 43 Nut
12 Spring washer 28 Washer 44 Washer
13 Screw 29 Screw 45 Clevis head
14 Nut 30 Actuating cylinder 46 Screw
15 Washer 31 Sealing ring 47 Rod
16 Spring washer 32 Threaded adapter 48 Screw
TIM-ID: 0000005477 - 003

MS22061/04E 2015-11 | Task Description | 147

 1 Nut 14 Washer 27 O-ring
2 Snap ring 15 Buffer seal 28 Magnet
3 Cylinder bearing 16 Sealing ring 29 Bearing ring
4 O-ring 17 Adjusting screw 30 Piston
5 Bearing cap, complete 18 End cover, complete 31 Buffer piston
6 Adjusting screw 19 Toothed ring 32 Lip ring
7 Toothed ring 20 O-ring 33 Piston rod
8 Washer 21 Magnet 34 Buffer seal
9 O-ring 22 End cover 35 Sealing ring
10 O-ring 23 Threaded fitting 36 Bearing cap
11 O-ring 24 Lip ring 37 Collar screw
12 Rating plate 25 Buffer piston 38 Rod seal
13 Cylinder pipe 26 Piston TIM-ID: 0000005477 - 003

148 | Task Description | MS22061/04E 2015-11

 3.8.2 Air and exhaust flap control – Removal
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.

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

Removing actuating cylinder for

air flap
1. Remove control line (1) and (4) from actuat-
ing cylinder (2).
2. Unscrew nut (6) and remove with washer.
3. Remove screws (5) with spring washers from
actuating cylinder (2) and push screw out of
clevis head and strap.
4. Remove actuating cylinder (2) from retain-
er (3).
5. Heat up clevis head to approx. 200°C.
6. Remove clevis head from actuating cylin-
der (2).

7. Unscrew screw (3) with washer (2) from

shaft.
8. Press lever (1) with screw M 16 out of the
shaft.
TIM-ID: 0000005507 - 003

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 Removing actuating cylinder for
exhaust flap
1. Remove control line on actuating cylinder (3).
2. Unscrew nut from screw (1) and remove with
washer.
3. Pull screw off clevis head (1) and rod.
4. Remove actuating cylinder (3) from retain-
er (2).
5. Heat up clevis head to approx. 200°C.
6. Remove clevis head from actuating cylin-
der (3).

TIM-ID: 0000005507 - 003

150 | Task Description | MS22061/04E 2015-11

 3.8.3 Air and exhaust flap control – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Pipe thread sealant (Loctite 586) 40033 1
Engine oil

WARNING
Exhaust flaps close automatically.
Danger of crushing hands!
• Keep clear of the danger zone around the exhaust flaps when calibrating.
• Switch off the Engine Control Unit operating voltage when performing mechanical tests.
• Wear protective gloves.

WARNING
Component is hot.
Risk of burning!
• Wear protective gloves.

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

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Installing and adjusting lever

1. Rub tapered connection between shaft and
lever (1) dry and grease-free.
2. Push lever (1) onto the shaft and connect
with strap.
3. Slightly insert screw (2) with washer.
4. Flap (7) closed, piston rod (6) of actuating
cylinder (5) engaged at top stop as well as
pin (3) on retainer (4).
5. Fix lever (1) with screw (2) and washer.
TIM-ID: 0000005525 - 005

MS22061/04E 2015-11 | Task Description | 151

 6. Align retainer (2) to middle of pin (3) of lev-
er (1)and tighten with nuts (4).

7. Insert key into the shaft and push lever (4)

flush up to the end of the shaft.
8. Tighten screw of lever (4).
9. Screw nuts onto swivel heads.
10. Coat threaded parts of swivel heads and
rod (3) with pipe thread sealant and assem-
ble to 260 mm (middle to middle of swivel
head bore) and lock.
11. Fasten rod (3) to lever (4) and clevis head of
actuating cylinder (2) with screws, washers
and nuts.
12. Apply load to actuating cylinder (2) and check
that the exhaust flap (1) opens completely
and closes.

TIM-ID: 0000005525 - 005

152 | Task Description | MS22061/04E 2015-11

 3.8.4 Intake housing with air flap – Overview

1 Flap 12 Cover 23 Adjusting shim

2 Tab washer 13 Washer 24 Snap ring
3 Washer 14 Screw 25 O-ring
4 Screw 15 Screw 26 Spring washer
5 Sealing ring 16 Tab washer 27 Screw
6 Plug screw 17 Cover 28 Stop cover
7 Intake housing 18 Gasket 29 Intake housing
8 Sealing ring 19 Pin 30 O-ring
9 Plug screw 20 Screw 31 Shaft seal
10 Plug 21 Cover 32 Shaft
11 Gasket 22 Gasket
TIM-ID: 0000005532 - 002

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 1 O-ring 7 Gasket retainer 13 Washer
2 O-ring 8 Gasket 14 Stud
3 Stud 9 Screw 15 Washer
4 Gasket 10 Washer 16 Nut
5 Spacer plate 11 Intake housing
6 Gasket 12 Nut

TIM-ID: 0000005532 - 002

154 | Task Description | MS22061/04E 2015-11

 3.8.5 Intake housing with air flap – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Observe safety instructions.
2. Disable engine start (→ Page 11).
TIM-ID: 0000013469 - 004

MS22061/04E 2015-11 | Task Description | 155

 3.8.6 Intake housing with air flap ‒ Removal
Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Air flaps close abruptly.
Risk of injury!
• Before actuating, ensure that nobody is in the danger zone.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Intake housing with air flap ‒

Removal
1. Attach markings (e.g. A1) before removing
the intake housing.
2. Unscrew nuts on intake housing and remove
intake housing from exhaust turbocharger.

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 3.8.7 Intake housing with air flap – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaner (Snow-White 11-0) X00054118 1
Cleaner (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
• Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Intake housing with air flap – Cleaning

1. Clean all parts with cleaner.
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse parts with cleaner (Hakupur 312).
3. Thoroughly blow out all parts with compressed air.
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 3.8.8 Intake housing with air flap – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Intake housing (→ Spare Parts Catalog)
Flap (→ Spare Parts Catalog)
Shaft seal (→ Spare Parts Catalog)
Shaft (→ Spare Parts Catalog)
O-ring (→ Spare Parts Catalog)

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Checking intake housing with air flap

Item Findings Measure
Check intake housing sealing, • Damaged • Rework: Smooth with oilstone.
mating and contact surfaces for • Uneven • Replace
damage and unevenness.
Check bore in intake housing for Damaged • Rework: Smooth with oilstone.
wear. • Replace
Check serration on shaft and flap. Damaged Replace
Check thread inserts and screws Sluggish • Rework
for easy movement. • Replace

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 3.8.9 Intake housing with air flap – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
O-ring (→ Spare Parts Catalog)

WARNING
Air flaps close abruptly.
Risk of injury!
• Before actuating, ensure that nobody is in the danger zone.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Installing intake housing with

air flap
1. Coat O-ring (1) with assembly compound and
insert in groove on intake housing.
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 2. Install intake housing on low-pressure ex-
haust turbocharger with nuts and spring
washers and fasten.

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 3.8.10 Intake housing with air flap – Final steps

Final steps
1. Assemble in reverse order of disassembly.
2. Enable engine start.
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 3.8.11 Air pipework to the cylinder heads, right side – Overview

1 Sealing ring 15 Washer 29 Charge-air manifold

2 Plug screw 16 Screw 30 Cover
3 Metal collar 17 Plug screw 31 Sealing ring
4 Rubber sleeve 18 Sealing ring 32 Plug screw
5 Screw 19 Condensate drain line 33 Sealing ring
6 Washer 20 Adapter 34 Adapter
7 Gasket 21 Sealing ring 35 Blanking cone
8 Elbow 22 Screw 36 Nut
9 Rubber sleeve 23 Plug screw 37 Plug screw
10 Clamp 24 Sealing ring 38 Sealing ring
11 Metal collar 25 Charge-air manifold 39 Screw
12 Charge-air manifold 26 Washer 40 Washer
13 Gasket 27 Screw
14 Elbow 28 Screw
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 3.8.12 Air pipework to cylinders – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
u Remove intake housing (→ Page 149).
TIM-ID: 0000013530 - 004

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 3.8.13 Air supply pipework to cylinders – Removal
Preconditions
☑ Preparatory steps are completed.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Removing air supply pipe from

cylinder head
1. Remove clamps (6) with metal collars (2).
2. Remove screws (13) with washers (14) on el-
bow (12).
3. Remove elbow (12) gasket (1) and air pipe
with rubber sleeves (5).
4. Remove plug screw (11) with sealing
ring (10).
5. Remove drain line (9) and adapter (8) with
washer (7).
6. Remove locknut (4) and remove sealing
cone (3).

7. Remove metal collar (1).

8. Unscrew screws (2) and remove cover (3)
from air pipe using a crow bar.

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164 | Task Description | MS22061/04E 2015-11

 9. Unscrew clamp with metal collar (5).
10. Remove screws (4) with washers (3) on el-
bow (2).
11. Remove elbow (2) with gasket (1) and rubber
sleeve.
12. Unscrew screws (7) with washers (6) on air
pipe (8).
13. Remove air pipe (8).

Removing air pipes

1. Remove screws (1, 4) with washers (2).
2. Remove elbow (7) from retainer (3).
3. Remove plug-in pipe (8) and sleeve (6) with
O-rings (5).
4. Remove snap ring from air pipe.

5. Unscrew screws (1, 4) with washers (2) on re-

tainer (3).
6. Pull air pipe (9) out of sleeve (8) and remove
snap ring.
7. Pull sleeve (8) out of air pipe (5) and remove
O-rings (6).
8. Remove plug-in sleeve (7) on compressor
housing of exhaust turbocharger and remove
O-rings (6) from grooves.
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MS22061/04E 2015-11 | Task Description | 165

 9. Unscrew screws (1, 7) with washers (2) on re-
tainer (3).
10. Remove retainer (6), intermediate section (5)
and O-rings (4).

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 3.8.14 Air pipework to cylinders ‒ Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Grease Kluthe Hakuform 30-11C X00059351 1
Engine oil
Metal collar (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
Rubber sleeve (→ Spare Parts Catalog)

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Air pipework to cylinders ‒ Installation

1. Remove all covers before installation.
2. Fit gaskets on cylinder heads.
3. Install air pipework to cylinders as shown in overview drawing (→ Page 162).
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 3.8.15 Air pipework to cylinders – Final steps

Final steps
1. Assemble in reverse order to disassembly (→ Page 163).
2. Enable engine start.

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 3.9 Exhaust Pipework
3.9.1 Constant-pressure manifold / manifold housing – Overview
Constant-pressure manifold

1 Locating pin 10 Shim 19 Support

2 Screw 11 Constant-pressure manifold 20 Pipe support
3 Nut 12 Constant-pressure manifold 21 Support
4 Screw 13 Constant-pressure manifold 22 Exhaust heat shield pan
5 Washer 14 Constant-pressure manifold 23 Constant-pressure manifold
6 Screw 15 Constant-pressure manifold 24 Constant-pressure manifold
7 Shim 16 Constant-pressure manifold 25 Constant-pressure manifold
8 Cover upper section 17 Constant-pressure manifold 26 Cover lower section
9 Cover lower section 18 Pipe support 27 Cover upper section
TIM-ID: 0000013719 - 003

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 Constant-pressure manifold housing

1 Constant-pressure manifold 4 Spring washer 7 Spring washer

housing 5 Blind flange 8 Screw
2 Sealing ring 6 Spacer tube 9 Sealing ring
3 Screw

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 1 Sealing ring 7 Plug screw 13 Spring washer
2 Threaded bushing 8 Sealing ring 14 Screw
3 Sealing ring 9 Threaded bushing 15 Dowel pin
4 Plug screw 10 Sealing ring 16 O-ring
5 Plug screw 11 Screw 17 O-ring
6 Sealing ring 12 Washer 18 Dowel pin
TIM-ID: 0000013719 - 003

MS22061/04E 2015-11 | Task Description | 171

 3.9.2 Constant-pressure manifold ‒ Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Observe safety regulations.
2. Drain engine coolant (→ Operating Instructions).

TIM-ID: 0000013739 - 002

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 3.9.3 Constant-pressure manifold housing ‒ Removal
Preconditions
☑ Preparatory steps are completed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Eyebolt for constant-pressure manifold housing B80099952 4
Socket insert F30013228 1
Power amplifying wrench F30030459 1

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Constant-pressure manifold
housing ‒ Removal
1. Use socket, torque multiplier (2) and extend-
ed ratchet wrench (1) to remove screws from
constant-pressure manifold housing, driving
end.
2. Remove spring washers.

3. Attach washers separately with wire to lifting

eyes and mark engine side.
4. Place fixture (3) on lifting eyes (4).
5. Use torque multiplier (2) and extended ratch-
et wrench (1) to remove lifting eye from con-
stant-pressure manifold housing.
6. Remove studs with thrust nut from crank-
case.
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MS22061/04E 2015-11 | Task Description | 173

 7. Remove screws (3) from elbow (2).
8. Remove elbow (2) with plug-in pipe (1) from
cylinder head and constant-pressure manifold
housing.
9. Remove gasket with O-rings.

10. Release nut (1) on band clamp (2).

11. Use crow bar to remove bellows and band
clamp between constant-pressure manifold
housing (3) and cylinder head.

12. Remove screws (1) from constant-pressure

manifold housing and take off spring wash-
ers.
TIM-ID: 0000005741 - 005

174 | Task Description | MS22061/04E 2015-11

 13. Insert lifting eyes (2) into constant-pressure
manifold housing at free end.
14. Use rope (3) to attach constant-pressure
manifold housing to lifting yoke (1) and lifting
eyes (2) on driving end.
15. Use lifting gear to lift constant-pressure
manifold housing off crankcase.
TIM-ID: 0000005741 - 005

MS22061/04E 2015-11 | Task Description | 175

 3.9.4 Constant-pressure manifold ‒ Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Snow-White 11-0) X00054118 1
Cleaning agent (Hakupur 312) 30390 1
Synthetic blasting abrasive 20098 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
• Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Constant-pressure manifold ‒ Cleaning

1. Clean all metallic parts using cleaning agent (Snow-White 11-0), then rinse with cleaning agent ((Hakupur
312).
2. Place parts with soot deposits in a container with decarbonizer. Dwell time in the cleaning bath depends on
layer thickness of deposits.
3. After cleaning with decarbonizer, rinse components in water until no further residues are washed off.
4. If deposits are stubborn, use synthetic blasting abrasive (nominal grain size 16 to 20) to help cleaning.
5. Remove cleaning agent.
6. Thoroughly blow out constant-pressure manifold with compressed air.
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176 | Task Description | MS22061/04E 2015-11

 3.9.5 Constant-pressure manifold ‒ Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Exhaust manifold (→ Spare Parts Catalog)
Exhaust line (→ Spare Parts Catalog)
Cover (→ Spare Parts Catalog)
Exhaust crossover (→ Spare Parts Catalog)
Plug-in pipe (→ Spare Parts Catalog)
Exhaust elbow (→ Spare Parts Catalog)
Connection housing (→ Spare Parts Catalog)

WARNING
Compressed air is pressurized.
Risk of injury!
• Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Constant-pressure manifold ‒ Check

Item Findings Action
Check exhaust pipes for deforma- Deformation Replace
tion.
Check sealing and contact surfa- Damaged • Rework: Smooth with oilstone.
ces for damage. • Replace
Check threads for easy move- Sluggish • Rework: Recut threads.
ment. • Replace
Check screws for damage. Damaged Replace
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 3.9.6 Constant-pressure manifold – Assembly
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Eyebolt for constant-pressure manifold housing B80099952 4
Support device for shroud F6450512 3
Locating device for exhaust pipes F6553614 2
Tightening device for lifting eye F6271439 1
Socket wrench F30450844 1
Torque wrench, 4–20 Nm F30044239 1
Torque wrench, 20–100 Nm F30026582 1
Torque wrench, 40–200 Nm F30027337 1
Oilstone 8205893261/00 1
Assembly compound (Ultra-Therm MTU) 50547 1
Engine oil
Sealing paste(Optid) 50136 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Screw (→ Spare Parts Catalog)

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Assembling constant-pressure
manifold
1. The designation of the individual constant-
pressure manifolds is applied, 5 mm high (ar-
rowed), by electrolysis.
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178 | Task Description | MS22061/04E 2015-11

 2. The upper parts (a) and lower parts (b) are as-
sembled in sequence according to the illus-
tration and are installed.

3. Bolt on support devices at positions 1, 2 and 3 on shroud and tighten.

Name Size Type Lubricant Value/Standard
Screw M12 Tightening torque (Engine oil) 74 Nm +5 Nm

4. Place constant-pressure manifold lower sec-

tion (3) and upper section (1) in jig (4) and
secure with locating pin (2).
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MS22061/04E 2015-11 | Task Description | 179

 Note: Pay attention to marking 'SB' on screws and
nuts (2).
5. Bolt constant-pressure manifold halves to-
gether with new screws and nuts (2).

6. Tighten nuts with torque wrench (1) to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut M10 Tightening torque (Assembly compound 26 Nm +2 Nm
(Ultra-Therm MTU))

7. Screw locating pins (3) into shroud (2) and tighten to specified torque using torque wrench (1).
Name Size Type Lubricant Value/Standard
Locating pin - Tightening torque (Engine oil) 74 Nm +5 Nm
TIM-ID: 0000005752 - 006

180 | Task Description | MS22061/04E 2015-11

 8. Fit washers (1) on shroud (2).

9. Mount support (2) on shroud (3) and locating

pin (1).

10. Coat mating face of support (1) with assem-

bly compound (Ultra-Therm MTU).
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MS22061/04E 2015-11 | Task Description | 181

 11. Install preassembled constant-pressure mani-
fold (1) in correct sequence on shroud (2).

12. Coat mating face of pipe support (1) with as-

sembly compound (Ultra-Therm MTU).
13. Place pipe support (1) on locating pin (2).

14. Coat thread and head mating faces of

screws (1) with assembly compound (Ultra-
Therm MTU) and screw into shroud (2) by
hand.
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182 | Task Description | MS22061/04E 2015-11

 15. Install locating device (2) (for placing sup-
ports and pipe supports on constant-pressure
manifolds) with screws (1) on shroud (3).

16. Place supports and pipe supports on con-

stant-pressure manifold with jig (2).

17. Use torque wrench (1) to tighten screws (3) diagonally and evenly to specified tightening torque (pretighten-
ing).
Name Size Type Lubricant Value/Standard
Screw M14 X 1.5 Preload torque (Assembly compound 95 Nm +10 Nm
(Ultra-Therm MTU))

18. After all screws have been pretightened, unscrew individually (adjacent screw remains pretensioned).
19. Coat threads and head mating faces once again with assembly compound (Ultra-Therm MTU) and tighten to
specified torque using torque wrench (1).
TIM-ID: 0000005752 - 006

Name Size Type Lubricant Value/Standard

Screw M14 X 1.5 Tightening torque (Assembly compound 95 Nm +10 Nm
(Ultra-Therm MTU))

MS22061/04E 2015-11 | Task Description | 183

 20. Make sure gap is (2 ±1)mm over entire shell
circumference (arrowed).

21. Place shim (1) on shroud (2) on driving and

free end.

22. Place end cover lower part (1) (driving and

free ends) on shim (2). TIM-ID: 0000005752 - 006

184 | Task Description | MS22061/04E 2015-11

 23. Install end cover upper part (1) at driving and
free ends.
24. Place shim (3) in position and tighten
screws (2) with torque wrench to specified
tightening torque as with the constant-pres-
sure manifold.

25. Use a setting gage (1) to check that center

gap is (2 ±1) mm.
26. Make sure gap is (3 ±2) mm (arrowed)
around entire cover circumference.

27. Smooth surface of shroud (1) with oil-

stone (2).
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MS22061/04E 2015-11 | Task Description | 185

 28. Apply sealing paste (1) evenly at bolt-on sur-
face (2).

29. Coat O-rings (1) with assembly compound

(Kluthe Hakuform 30-11C) and insert into
coolant transfer bores.
30. Coat sealing face on constant-pressure mani-
fold housing with sealing paste (2).

31. Use lifting device to place shroud (1) on con-

stant-pressure manifold housing. TIM-ID: 0000005752 - 006

186 | Task Description | MS22061/04E 2015-11

 32. Coat thread of screws (1) with assembly
compound (Ultra-Therm MTU).
33. Insert screws (1) with crinkled spring wash-
ers and spacer tubes (2) into constant-pres-
sure manifold housing and tighten with tor-
que wrench to specified tightening torque
(→ Page 276).
34. Insert screws (3) with crinkled spring wash-
ers on driving and free end and use torque
wrench to tighten to specified tightening tor-
que (→ Page 276).

35. Fit flange (3) on elbow (1).

36. Insert sealing ring (2).

37. Coat threads of screws with assembly com-

pound (Ultra-Therm MTU).
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MS22061/04E 2015-11 | Task Description | 187

 38. Tighten elbow with screws and crinkled spring washers on constant-pressure manifold housing.
Name Size Type Lubricant Value/Standard
Cap screw M8 X 16 Tightening torque (Assembly compound 21 Nm +2 Nm
(Ultra-Therm MTU))

39. Check dimension 'A' min. 1.5 mm over entire

pipe circumference.

Installing constant-pressure
manifold housing on crankcase
1. Coat O-rings (1) with assembly compound
(Kluthe Hakuform 30-11C) and insert in bores
on crankcase.
2. Coat sealing face on crankcase with sealing
paste.

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188 | Task Description | MS22061/04E 2015-11

 3. Attach lifting device to constant-pressure
manifold housing.
4. Use lifting gear to place constant-pressure
manifold housing on crankcase.
5. Remove lifting device.
6. Coat threads of studs for lifting eyes with en-
gine oil.
7. Insert studs into free end of crankcase with
thrust nuts.
8. Coat thread of screws (1) at driving end with
engine oil and screw into crankcase.

9. Coat threads of screws with assembly com-

pound (Ultra-Therm MTU) and screw into con-
stant-pressure manifold housing with spring
washers.
10. Position constant-pressure manifold housing
centrally between cylinder heads on left and
right engine sides.
11. Tighten screws to specified tightening torque
using offset socket (2) and torque wrench (1)
(→ Page 276).

Note: Note that the torque multiplier has fourfold

tightening power.
12. Use a torque wrench (1), torque multiplier (2)
and socket to tighten screws on driving end
to specified tightening torque (→ Page 276).
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MS22061/04E 2015-11 | Task Description | 189

 Installing lifting eyes at free end
Note: Washers of thicknesses (0.30, 0.56, 0.63 and
0.75) mm are available.
1. Fit washers and screw in lifting eye (4).
2. Mount tightening device (3) with torque mul-
tiplier (2) on lifting eye (4).
3. Use a torque wrench (1) to tighten lifting
eye (4) so that it is facing in engine longitudi-
nal direction.

Installing bellows between con-

stant-pressure manifold hous-
ing and cylinder head
1. Coat screw on band clamp with assembly
compound (Ultra-Therm MTU) and insert on
bellows (2).
2. Fit sealing rings on both sides of bellows (2)
with assembly compound (Ultra-Therm MTU).
3. Insert protective tube in bellows (2).
4. Insert assembled bellows (2) between cylin-
der head and constant-pressure manifold
housing (3) until it contacts projecting slotted
spring pins at elbow.

5. Tighten nut (1) on band clamp to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Nut M6 Tightening torque (Assembly compound 5 Nm +2 Nm
(Ultra-Therm MTU))
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190 | Task Description | MS22061/04E 2015-11

 Installing coolant outlet elbow
on constant-pressure manifold
housing
1. Coat O-rings with assembly compound
(Kluthe Hakuform 30-11C) and insert in
grooves on plug-in pipe (1).
2. Install elbow (2) with plug-in pipe (1) and gas-
ket.
3. Tighten elbow (2) with screws (3) and crin-
kled spring washers.
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MS22061/04E 2015-11 | Task Description | 191

 3.9.7 Constant-pressure manifold – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 172).
2. Fill with engine coolant (→ Operating Instructions).
3. Enable engine start.

TIM-ID: 0000013760 - 002

192 | Task Description | MS22061/04E 2015-11

 3.9.8 Carrier housing – Overview

1 Plug screw 6 Threaded bushing 11 Plug screw

2 Thread insert 7 Sealing ring 12 Dowel pin
3 Carrier housing, upper sec- 8 Thread insert 13 Sleeve
tion 9 Thread insert 14 Thread insert
4 Carrier housing, lower sec- 10 Thread insert
tion
5 Thread insert
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 3.9.9 Carrier housing – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Drain engine coolant (→ Operating Instructions).
2. Remove air and exhaust flap actuators (→ Page 149).
3. Remove intake housing with air flap (→ Page 156).
4. Remove oil supply pipework for exhaust turbochargers (→ Page 212).
5. Remove vent line for oil supply pipework for exhaust turbochargers (→ Page 215).

TIM-ID: 0000013790 - 001

194 | Task Description | MS22061/04E 2015-11

 3.9.10 Carrier housing upper section – Removal and installation
Preconditions
☑ Preparatory steps are completed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Shackle chain T80090289 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Engine oil

DANGER
Missing protective devices after working on the engine.
Risk of severe injuries and danger to life due to ejected parts!
• Disable engine start.
• After working on the engine, check that all protective devices have been reinstalled.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Removing carrier housing upper

section
1. Remove all screws (2) from carrier housing
upper section (1).
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MS22061/04E 2015-11 | Task Description | 195

 2. Remove all screws (1) for fastening exhaust
turbochargers on carrier housing upper sec-
tion (2).

3. Fasten shackle chain to bores (1) on carrier

housing upper section (2).
4. Remove carrier housing upper section (2).

Installing carrier housing upper

section
1. Check that sealing faces on carrier housings
are clean.
2. Coat sealing rings (2) with assembly com-
pound and insert in bores on carrier housing
lower section.
3. Insert sealing ring (1) into oil supply bore on
TIM-ID: 0000013825 - 002

exhaust turbocharger.

196 | Task Description | MS22061/04E 2015-11

 4. Attach shackle chain (1) to carrier housing
upper section (2).
5. Mount carrier housing upper section (2).
6. Insert screws with washers for fastening ex-
haust turbochargers in carrier housing upper
section (2) and hand-tighten.

7. Insert screws (2) for fastening carrier housing

upper section (1) along with washers and
tighten.
TIM-ID: 0000013825 - 002

MS22061/04E 2015-11 | Task Description | 197

 3.9.11 Carrier housing – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 194).
2. Fill up with engine coolant (→ Operating Instructions).
3. Enable engine start.

TIM-ID: 0000013817 - 001

198 | Task Description | MS22061/04E 2015-11

 3.10 Starting Equipment
3.10.1 Compressed-air distributor – Overview

1 Union 8 Adapter 15 Sealing ring

2 Union nut 9 Wire snap ring 16 Gasket
3 Cutting ring 10 Coupling piece 17 Washer
4 Screw-fitting union 11 Union nut 18 Screw
5 Sealing ring 12 Cutting ring 19 Compressed-air distributor
6 Coupling piece 13 Union 20 Sealing ring
7 Wire snap ring 14 Screw-fitting union
TIM-ID: 0000005935 - 003

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 1 Camshaft 7 Screw 13 Distributor shaft
2 Drive gear 8 Bushing 14 Adapter
3 Flange housing 9 Starting-air distributor 15 Gasket
4 Gearcase 10 Cover 16 Shaft seal
5 Gasket 11 Screw 17 Collared bushing
6 Washer 12 Washer

TIM-ID: 0000005935 - 003

200 | Task Description | MS22061/04E 2015-11

 3.10.2 Compressed-air distributor – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Shut off compressed air supply.
2. Disconnect starting and air lines form compress air distributor.
TIM-ID: 0000013935 - 003

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 3.10.3 Compressed-air distributor – Removal
Preconditions
☑ Preparatory steps are completed.

Compressed-air distributor – Re-

moval
1. Remove screws (2) with washers from cover.
2. Remove cover with gasket on distributor
body (1).
3. Remove distributor shaft with distributor
plate from the distributor body (1).
4. Remove distributor body (1) from flange
housing.

5. Remove screws (1) with washers from flange

housing (2).
6. Remove flange housing (2) with gasket from
gearcase.
7. Remove connection piece with coupling
piece.

TIM-ID: 0000005958 - 004

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 3.10.4 Starting-air distributor ‒ Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaner (Snow-White 11-0) X00054118 1
Cleaner (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
Cleaner is extremely caustic.
Risk of injury and suffocation!
• Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Starting-air distributor ‒ Cleaning

1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse parts with cleaner (Hakupur 312).
2. Blow out all parts with compressed air.
TIM-ID: 0000005943 - 003

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 3.10.5 Compressed-air distributor – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Abrasive paste
Adapter (→ Spare Parts Catalog)
Coupling piece (→ Spare Parts Catalog)
Wire snap ring (→ Spare Parts Catalog)
Spacer (→ Spare Parts Catalog)
Bushing (→ Spare Parts Catalog)
Guide tube (→ Spare Parts Catalog)
Distributor plate (→ Spare Parts Catalog)
Distributor body (→ Spare Parts Catalog)
Distributor shaft (→ Spare Parts Catalog)
Gasket (→ Spare Parts Catalog)
Pressure seal (→ Spare Parts Catalog)
Connector cover (→ Spare Parts Catalog)

Checking compressed-air distributor

Item Finding Action
Check coupling piece and adapter • Signs of wear Replace
for stress marks and damage. • Damage
visible
Check coating on friction washer Damaged Replace
for damage.
Check bushings and guide tube for • Wear Replace
wear and wear marks. • Wear marks
visible
Check end face on distributor Uneven Replace component.
plate and body for surface irregu-
larities.
Check taper face in distributor Traces of wear visible. • Grind distributor plate with fine
plate and on distributor shaft for abrasive paste.
stress marks. • Replace component.
Check bore in connector cover for Traces of wear visible. Replace
wear.
Check sealing and bolt-on faces Uneven • Corrective work: Smooth with
TIM-ID: 0000005954 - 001

for surface irregularities. oilstone.

• Replace
Check tapped holes. Threads damaged • Corrective work: Replace
thread inserts.
Replace component.

204 | Task Description | MS22061/04E 2015-11

 3.10.6 Compressed-air distributor – Adjustment and Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Engine oil
Assembly compound Molykote G-N Plus

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Compressed-air distributor – Adjustment

1. Set piston of cylinder 1 on starter side to 2° crankshaft past TDC (= start of firing stroke) by rotating in direc-
tion of engine rotation.
2. Fit distributor disc (1) on shaft cone. Fit
spacer disc (4) and tab washer (2) on shaft.
Ensure correct positioning of spacer disc.
Screw on nut (3) by hand, do not tighten.
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 3. Rotate distributor disc on shaft cone counter
to the rotating direction of the camshaft (2)
in direction (1).
Result: The opening of the distributor disc (4) touch-
es the control bore (3) of cylinder 1 (see illus-
tration) very slightly.

4. Use torque wrench to tighten nut on distributor shaft to specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut Preload torque 5 Nm

5. Remove distributor disc with shaft from compressed-air distributor.

Note: Ensure that the position of the distributor
disc on the shaft does not change.
6. Mount shaft with distributor disc (1) in bench
vise (soft jaws) and remove nut.
7. Coat thread on shaft and mating face of nut
with assembly compound.

8. Screw on nut by hand and use torque wrench to tighten nut to specified tightening torque.
Name Size Type Lubricant Value/Standard
Nut Tightening torque 32 to 35 Nm
TIM-ID: 0000056844 - 001

9. Secure nut with tab washer.

206 | Task Description | MS22061/04E 2015-11

 10. Install distributor disc (3) in compressed-air
distributor (4).
11. Recheck the setting.
12. Install cover (1) with gasket (2) on com-
pressed-air distributor (4).

Cover – Installation
1. Tighten cover with screws (2) and washers
crosswise.
2. Screw in union with sealing ring on com-
pressed-air distributor (1) and tighten.
TIM-ID: 0000056844 - 001

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 3.10.7 Compressed-air distributor – Final steps

Final steps
1. Assemble in reverse order to disassembly (→ Page 202).
2. Open compressed air supply.
3. Enable engine start.

TIM-ID: 0000013947 - 002

208 | Task Description | MS22061/04E 2015-11

 3.11 Lube Oil System, Lube Oil Circuit
3.11.1 Exhaust turbocharger oil supply, distributor and securing hardware 12V –
Overview

1340 Pressure reducing valve 1427 Sealing ring 1575 Union

1350 Screw 1430 Oil line 1580 Sealing ring
1355 Washer 1435 Elbow 1585 Elbow
1360 O-ring 1440 Hose 1590 Nut
1370 Elbow 1450 Pipe half-clamp 1595 Sealing cone
1375 Screw-fitting union 1455 Screw 1605 Adapter
1380 Sealing ring 1460 Spring washer 1610 Sealing ring
1385 Adapter 1475 Oil line, right side 1620 Oil line
1390 Sealing ring 1480 O-ring 1630 Plug screw
1395 Oil line 1490 Plug-in pipe 1635 Sealing ring
1400 O-ring 1495 Plug-in pipe 1645 O-ring
1405 Screw 1500 O-ring 1650 Plug-in pipe
1410 Washer 1505 Snap ring 1655 Plug-in pipe
1415 Union 1510 Oil line, right side 1665 Pipe half-clamp
1420 Sealing ring 1520 Threaded bushing 1675 Pipe half-clamp
TIM-ID: 0000019603 - 001

1422 Flange 1525 Sealing ring 1680 Spring washer

1423 Sealing ring 1530 Sealing ring 1685 Screw
1424 Screw 1535 Adapter 1695 Pipe half-clamp
1425 Spring washer 1550 Oil line 1700 Screw
1426 Union 1560 Threaded bushing 1705 Spring washer

MS22061/04E 2015-11 | Task Description | 209

 3.11.2 Oil supply pipework for exhaust turbochargers, distributor and fasteners 16V –
Overview

1330 Pressure reducing valve 1425 Hose 1570 Union

1340 Hex screw 1430 Pipe elbow 1575 Sealing ring
1345 Washer 1440 Pipe half-clamp 1580 Pipe elbow
1350 O-ring 1445 Hex screw 1585 Nut
1360 Elbow 1450 Spring washer 1590 Sealing cone
1365 Screw-fitting union 1465 Oil line 1600 Adapter
1370 Sealing ring 1470 O-ring 1605 Sealing ring
1375 Adapter 1480 Plug-in pipe 1615 Oil line
1380 Sealing ring 1485 Plug-in pipe 1620 Oil line
1385 Oil line 1490 O-ring 1630 Plug screw
1390 O-ring 1495 Snap ring 1635 Sealing ring
1395 Hex screw 1500 Oil line 1645 O-ring
1400 Washer 1510 Threaded bushing 1650 Plug-in pipe
1405 Union 1515 Sealing ring 1655 Plug-in pipe
1410 Sealing ring 1520 Sealing ring 1665 Pipe half-clamp
1412 Flange 1525 Adapter 1670 Spring washer
1413 Sealing ring 1530 Oil line 1675 Screw
TIM-ID: 0000019604 - 001

1414 Hex screw 1535 Oil line 1685 Pipe half-clamp

1415 Spring washer 1540 Plug screw 1690 Hex screw
1416 Union 1545 Sealing ring 1695 Spring washer
1417 Sealing ring 1555 Threaded bushing
1420 Oil line 1560 Sealing ring

210 | Task Description | MS22061/04E 2015-11

 3.11.3 Exhaust turbocharger oil supply, distributor and securing hardware 20V –
Overview

1400 Pressure reducing valve 1535 Oil line 1660 Nut

1410 Screw 1540 O-ring 1665 Sealing cone
1415 Washer 1550 Plug-in pipe 1675 Adapter
1420 O-ring 1555 Plug-in pipe 1680 Sealing ring
1430 Elbow 1560 O-ring 1690 Oil line
1435 Screw-fitting union 1565 Snap ring 1695 Oil line
1440 Sealing ring 1570 Oil line 1705 Plug screw
1445 Adapter 1580 Threaded bushing 1710 Sealing ring
1450 Sealing ring 1585 Sealing ring 1720 O-ring
1455 Oil line 1590 Sealing ring 1725 Plug-in pipe
1460 O-ring 1595 Adapter 1730 Plug-in pipe
1465 Screw 1600 Oil line 1740 Pipe half-clamp
1470 Washer 1605 Oil line 1745 Washer
1475 Union 1610 Oil line 1750 Screw
1480 Sealing ring 1615 Plug screw 1755 Screw
1490 Oil line 1620 Sealing ring 1760 Screw
1495 Hose 1630 Threaded bushing 1770 Pipe half-clamp
1500 Elbow 1635 Sealing ring 1775 Screw
TIM-ID: 0000014380 - 002

1510 Pipe half-clamp 1645 Union 1780 Washer

1515 Screw 1650 Sealing ring
1520 Washer 1655 Elbow

MS22061/04E 2015-11 | Task Description | 211

 3.11.4 Exhaust turbocharger oil supply, distributor and fasteners – Removal
Preconditions
☑ Preparatory steps have been completed.

Removing exhaust turbocharger oil supply, distributor and fasteners

1. Prior to removal of the lines take photos or mark add-on components and lines.
2. Remove distributor and fasteners as shown in overview drawing (→ Page 209).
3. Remove all sealing elements.
4. Seal openings with suitable covers.

TIM-ID: 0000014385 - 002

212 | Task Description | MS22061/04E 2015-11

 3.11.5 Exhaust turbocharger oil supply pipework, distributor and fasteners –
Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Engine oil
O-ring (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Installing exhaust turbocharger oil supply pipework, distributor and fasten-

ers
1. Remove all covers prior to installation.
2. Coat O-rings with assembly compound.
3. Insert O-rings in groove.
4. Install distributor and fasteners as shown in overview drawing (→ Page 209).
5. Visually inspect connections for leaks after engine start.
TIM-ID: 0000014389 - 004

MS22061/04E 2015-11 | Task Description | 213

 3.11.6 Vent line for oil supply pipework of exhaust turbochargers – Overview

1 Screw 17 Union 33 Pipe

2 Washer 18 Sealing ring 34 Screw
3 Pipe half-clamp 19 Adapter 35 Washer
4 Retainer 20 Sealing ring 36 Pipe half-clamp
5 Pipe 21 Screw 37 Grommet
6 Screw 22 Washer 38 Screw
7 Washer 23 Plug screw 39 Washer
8 Pipe half-clamp 24 Distributor piece 40 Pipe half-clamp
9 Grommet 25 Union 41 Grommet
10 Screw 26 Pipe half-clamp 42 Pipe half-clamp
11 Washer 27 Grommet 43 Grommet
12 Pipe half-clamp 28 Washer 44 Pipe
13 Grommet 29 Screw 45 Pipe
14 Retainer 30 Pipe 46 Pipe
15 Pipe 31 Sealing ring
16 Grommet 32 Union
TIM-ID: 0000014447 - 002

214 | Task Description | MS22061/04E 2015-11

 3.11.7 Vent line for oil supply pipework of exhaust turbochargers – Removal
Preconditions
☑ Engine shut down and starting disabled.

Vent line for oil supply pipework of exhaust turbochargers – Removal

1. Before removing the lines, take photos or label add-on components and lines.
2. Remove vent line for oil supply pipework of exhaust turbochargers as shown in overview drawing
(→ Page 214).
3. Remove all sealing elements.
4. Seal openings with suitable covers.
TIM-ID: 0000014449 - 001

MS22061/04E 2015-11 | Task Description | 215

 3.11.8 Vent line for oil supply pipework of exhaust turbocharger – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Engine oil
O-ring (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Installing vent line for oil supply pipework of exhaust turbocharger

1. Remove all covers prior to installation.
2. Coat O-rings with assembly compound.
3. Insert O-rings in groove.
4. Install distributor and fasteners as shown in overview drawing (→ Page 214).
5. Visually inspect connections for leaks after engine start.

TIM-ID: 0000014450 - 004

216 | Task Description | MS22061/04E 2015-11

 3.12 Coolant System
3.12.1 Engine coolant pump – Overview

1 Rotary seal 6 Angular-contact ball bearing 11 Cap nut

2 Volute 7 Nut 12 Intake connection
3 Seal carrier 8 Bearing housing for cylindri- 13 Impeller
4 Shaft seal cal roller bearing a Engine coolant inlet
5 Bearing housing 9 Drive gear b Engine coolant outlet
10 Pump shaft
TIM-ID: 0000006785 - 002

MS22061/04E 2015-11 | Task Description | 217

 1 Pump shaft 11 Screw 21 O-ring
2 Grub screw (M12) 12 O-ring 22 Nut
3 Spacer ring 13 Radial-lip shaft seal 23 Plate
4 Angular-contact ball bearing 14 Seal carrier 24 Volute
5 Nut 15 O-ring 25 O-ring
6 Bearing housing 16 Rotary seal 26 Intake connection
7 Spring washer 17 Counterring 27 Spring washer
8 Screw 18 O-ring 28 Screw
9 Cylindrical roller bearing 19 Spacer ring
10 Spring washer 20 Impeller

TIM-ID: 0000006785 - 002

218 | Task Description | MS22061/04E 2015-11

 3.12.2 Engine coolant pump – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Observe safety regulations.
2. Remove engine coolant thermostat (→ Page 238).
TIM-ID: 0000014642 - 002

MS22061/04E 2015-11 | Task Description | 219

 3.12.3 Engine coolant pump – Removal
Preconditions
☑ Preparatory steps are completed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Lifting device F6271437 1
Assembly lever 8205892161/00 1
Wrench F30378587 1

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Engine coolant pump – Removal

1. Attach lifting device (3) to engine coolant
pump (2).
2. Remove screws (1) for engine coolant
pump (2).
3. Use assembly lever to remove engine coolant
pump (2).

TIM-ID: 0000006819 - 002

220 | Task Description | MS22061/04E 2015-11

 3.12.4 Engine coolant pump – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Hakupur 312) 30390 1

WARNING
Chemical substances in cleaners.
Risk of irritation and chemical burns!
• Always obey manufacturer's instructions for use.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Cleaning engine coolant pump

1. Remove all deposits from functional and sealing surfaces.
2. Clean all functional and sealing surfaces with cleaning agent (Hakupur 312).
3. Wipe all functional and sealing surfaces dry with a clean, lint-free cloth.
4. Remove corrosion inhibitor from new component with cleaning agent (Hakupur 312).
TIM-ID: 0000014616 - 016

MS22061/04E 2015-11 | Task Description | 221

 3.12.5 Engine coolant pump – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Engine coolant pump (→ Spare Parts Catalog)

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Engine coolant pump – Check

Item Findings Measure
Check pump housing and impeller Cavitation visible Replace
for cavitation.
Visually inspect sealing surfaces • Signs of wear • Rework: Smooth with oilstone.
for signs of wear, impact marks • Impact marks • Replace
and cavitation. • Cavitation
visible
Check gear for indentations, signs • Signs of wear • Rework: Smooth with oilstone.
of wear and damage. • Indentations • Replace gear.
• Damage
visible
Check threads of securing screws. Damaged Replace

TIM-ID: 0000014618 - 008

222 | Task Description | MS22061/04E 2015-11

 3.12.6 Engine coolant pump ‒ Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Lifting device F6271437 1
Oilstone 8205893261/00 1
Engine oil
Gasket (→ Spare Parts Catalog)

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Engine coolant pump ‒ Installa-

tion
1. Remove all covers prior to installation.
2. Check mating faces for flatness. If necessary,
smoothen with oilstone and fit gasket.
3. Install lifting device (3) on engine coolant
pump (2).
4. Install engine coolant pump (2) on gearcase,
paying attention to gear engagement.
5. Coat screws (1) with engine oil.
6. Insert screws (1) with washers and tighten.
7. Remove lifting device (3).
TIM-ID: 0000014661 - 004

MS22061/04E 2015-11 | Task Description | 223

 3.12.7 Engine coolant pump – Final steps

Final steps
1. Fill with engine coolant (→ Operating Instructions).
2. Enable engine start.

TIM-ID: 0000014675 - 003

224 | Task Description | MS22061/04E 2015-11

 3.12.8 Coolant cooler and fuel cooler – Overview
Plate-core heat exchanger

1 Plate-core heat exchanger

TIM-ID: 0000033827 - 001

MS22061/04E 2015-11 | Task Description | 225

 3.12.9 Engine coolant cooler and fuel cooler – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Drain engine coolant (→ Operating Instructions).
2. Cut out fuel supply.
3. Close raw water supply.
4. Drain raw water.
5. Remove raw water lines.

TIM-ID: 0000014983 - 003

226 | Task Description | MS22061/04E 2015-11

 3.12.10 Engine coolant cooler and fuel cooler ‒ Removal
Preconditions
☑ Preparatory steps are completed.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Engine coolant cooler and fuel

cooler ‒ Removal
1. Mark cooler plates with numbers or identify
otherwise to ensure correct installation se-
quence of cooler plates during assembly.
2. Note initial dimension between baseplate and
cover plate.
3. Unscrew nuts evenly in stages.
4. Remove cover plate via guide sleeves.
5. Remove plates individually.
TIM-ID: 0000014977 - 004

MS22061/04E 2015-11 | Task Description | 227

 3.12.11 Coolant cooler and fuel cooler – Cleaning
Preconditions
☑ Confirmation from the cleaning agent manufacturer that the cleaning agent does not attack cooler plate
and sealing materials is available.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
High-pressure cleaning unit (→ Tools Catalog)
Smooth cleaning brush (→ Tools Catalog)
Caustic soda
Sodium carbonate
Hypochlorites
Nitric acid
Sulfamic acid
Citric acid
Phosphoric acid
Masking agent(EDTA, NTA)
Sodium polyphosphate
Solvent on paraffin or naphta basis

DANGER
Cleaner is an explosive and poisonous substance.
Danger to life, major material damage!
• Avoid open flames, electrical sparks and ignition sources.
• Wear goggles/facial protection.
• Only work in a well-ventilated room.
• Do not smoke.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
High-pressure water jet.
TIM-ID: 0000007115 - 004

Risk of injury!
• Do not direct water jet at persons, electric or electronic equipment.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

228 | Task Description | MS22061/04E 2015-11

 NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

NOTICE
Cleaning agents containing chlorine and hydrochloric acid attack metal surfaces.
Risk of damage due to corrosion!
• Do not use hydrochloric acid with stainless steel.
• Chlorine concentration in water solution must not exceed 300 ppm for cleaning purposes. If a higher
chlorine concentration is required, contact MTU..
• Protect aluminum components against chemicals.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

Note: Do NOT use the following solvents:

• Ketones (e. g.: Acetone, methyl-ethylene ketone, methylisobutyl ketone)
• Esters (e. g.: Ethyl acetate, butyl acetate)
• halogenized carbon hydrides (e. g.: chlorothenes, carbon tetrachlorides, freon)
• Aromatic compounds (e. g.: Benzine, toluene)

Preparatory steps
1. Remove cooler plates (→ Page 227).
2. Place cooler plates on a suitable surface for cleaning.

Coarse fouling
Note: With the device open, mechanical cleaning to remove:
• Algae
• Bits of wood/fabric
• Crustaceans
1. Clean plates under running water with a soft brush. Take care not to damage the seal.
2. Clean plates with high-pressure hose.

Biological fouling
Note: With the device open, mechanical or chemical cleaning to remove:
• Bacteria
• Nematodes
• Protozoa
1. Clean plates under running water with a soft brush. Take care not to damage the seal.
2. Clean plates with high-pressure hose.
TIM-ID: 0000007115 - 004

3. Clean plates with alkaline cleaning agents e.g.:

• Caustic soda
• Sodium carbonate
• The cleansing effect is considerably increased by adding small amounts of hypochlorite or complex gener-
ating agents and foaming agents.

Concentration Temperature
max. 4% max. 80°C

MS22061/04E 2015-11 | Task Description | 229

 Removing encrustation and scale
Note: With the device open, mechanical or chemical cleaning to remove:
• Calcium carbonate
• Calcium sulfate
• Silicate
1. Clean plates under running water with a soft brush. Take care not to damage the seal.
2. Clean plates with high-pressure hose.
3. Clean plates with acidic cleaning agents e.g.:
• Nitric acid
• Sulfamic acid
• Citric acid
• Phosphoric acid
• Masking agent(EDTA, NTA)
• Sodium polyphosphate

Concentration Temperature
max. 4% max. 60°C

Sediments (deposits)
Note: With the device open, mechanical or chemical cleaning to remove:
• Corrosion products
• Metal oxides
• Sludge
• Alumina clay
• Diatomic organisms
1. Clean plates under running water with a soft brush. Take care not to damage the seal.
2. Clean plates with high-pressure hose.
3. Clean plates with chemical cleaning agents e.g.:
• Nitric acid
• Sulfamic acid
• Citric acid
• Phosphoric acid
• Masking agent(EDTA, NTA)
• Sodium polyphosphate

Concentration Temperature
max. 4% max. 60°C

4. The cleansing effect is increased by adding foaming agents.

Oil residues, asphalts and fats

Note: With the device open, mechanical or chemical cleaning to remove:
• Oil residues
• Asphalts
TIM-ID: 0000007115 - 004

• Fats
1. Clean plates with a soft brush and paraffin- or naphta-based solvents. Contact time should not exceed half
an hour, as these agents cause rubber to swell.
2. Dry plates with a cloth or rinse with water.

Cleaning cover plate

Note: Protect aluminum parts from chemicals.
1. Clean cover plate with cold cleaner and a soft brush.
2. Remove cleaning agent.
3. Blow off cover plate with compressed air.

230 | Task Description | MS22061/04E 2015-11

 3.12.12 Engine coolant cooler and fuel cooler – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Clamping plate Z=4.128-668 1
Base plate Z=4.129-304 1
Threaded pin Z=4.406-185 8

Checking engine coolant cooler and fuel cooler

Item Findings Action
Check threads for easy move- Sluggish • Rework: Recut threads.
ment. • Replace
Check contact and sealing surfa- • Signs of wear • Rework: Smooth with oilstone.
ces of clamping plate for signs of • Damage • Replace
wear and damage. visible
TIM-ID: 0000040934 - 002

MS22061/04E 2015-11 | Task Description | 231

 3.12.13 Engine coolant cooler and fuel cooler – Leakage test

Engine coolant cooler and fuel cooler – Leakage test

1. Visually inspect engine coolant cooler and fuel cooler for leakage.
2. Contact Service before rectifying faults to preclude inexpert work being performed on the plate-core heat
exchanger and the consequences associated therewith. Some typical faults which may be encountered in the
course of plate-core heat exchanger operation are listed below.
Fault Findings Task
Sealing between cooler plates Plate-core heat exchanger preten- Check correct pretensioning di-
faulty. sioning dimension incorrect. mension data on rating plate.
Excessively high operating pres- Check operating pressure data on
sures. rating plate.
Excessively high/low operating Check operating temperature data
temperatures. on rating plate.
Gaskets incorrectly seated. Open plate-core heat exchanger
and correct gasket seating.
Gaskets dirty. Open plate-core heat exchanger
and clean gaskets.
Gaskets faulty. Open plate-core heat exchanger
and replace gaskets.
Poor sealing between cooler Seals and gaskets incorrectly Open plate-core heat exchanger,
plates and frame, intermediate seated. correct seal and gasket seating.
plates, spacers. Seals and gaskets dirty. Open plate-core heat exchanger,
clean seals and gaskets.
Seals and gaskets faulty. Open plate-core heat exchanger,
replace seals and gaskets.
Poor sealing between frame con- Pipeline exerts excessive load on Reduce connection loading to ad-
nection and pipeline. frame connection. missible values.
Seal incorrectly seated. Undo frame connection and cor-
rect seal seating.
Seal dirty. Undo frame connection and clean
seal.
Seal faulty. Undo frame connection and re-
place seal.
Flanged joint not tight enough. Check seal and tighten connection
evenly as necessary.
Cooler plates damaged. Plate package tightened exces- Replace faulty cooler plates.
sively (pretensioning dimension
below “a min”)
TIM-ID: 0000014976 - 002

Cooler plate material corroded. Check design of plate-core heat

exchanger in regard of flowing me-
dia, inform Service.
Initial or final cooler plates dam- Incorrect grounding when welding Replace faulty cooler plates.
aged. on special connections at open
connection pipes on plate-core
heat exchanger frame.

232 | Task Description | MS22061/04E 2015-11

 3.12.14 Engine coolant cooler and fuel cooler – Installation
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

NOTICE
Contamination of components.
Damage to component!
• Observe manufacturer's instructions.
• Check components for special cleanliness.

NOTICE
Incorrect installation of components and lines.
Damage to component!
• Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Engine coolant cooler and fuel cooler – Installation

1. Remove all covers.
2. Line up plates in a row according to marks made during disassembly.
Result: Stacking sequence of plates should form a web pattern.
3. Slide on cover plate.
4. Screw in diagonally opposing nuts and washers 2 turns each up to stop working from inside to outside.
5. Determine necessary initial dimension:
• The required initial dimension is the “a max” listed on the rating plate when the gasket is replaced com-
pletely.
• The initial dimension noted before opening the cooler plates applies if the cooler plates were only cleaned
and the gasket was not replaced.
6. Screw on cover plate tightening diagonally opposing nuts alternately to reach the necessary initial dimension
“a”.
7. Perform a leak test before restarting (→ Page 232).
TIM-ID: 0000014994 - 004

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 3.12.15 Engine coolant cooler and fuel cooler – Final steps

Final steps
1. Assemble in reverse order of disassembly (→ Page 226).
2. Fill with engine coolant (→ Operating Instructions).
3. Fill fuel system (→ Operating Instructions).
4. Open fuel supply.
5. Install raw water lines.
6. Prime raw water pump.
7. Open raw water supply.
8. Enable engine start.

TIM-ID: 0000015000 - 003

234 | Task Description | MS22061/04E 2015-11

 3.12.16 Engine coolant thermostat – Overview

11 Coolant controller 7 Spring washer 4 Nut

13 Plug screw 8 Screw 1 Screw
12 Sealing ring 6 Gasket 2 Washer
9 Cover 3 Retainer
10 Gasket 5 Washer
TIM-ID: 0000039730 - 002

MS22061/04E 2015-11 | Task Description | 235

 4 Cover 8 O-ring 19 Screw
5 O-ring 12 Spring 1 Locking bushing
3 Sealing ring 13 Washer 11 Pin
2 Threaded bushing 14 Thermal actuator 10 Compression spring
6 Slide valve 15 Snap ring 16 Scraper
7 Compression spring 17 Housing
9 Stop pin 18 Washer

TIM-ID: 0000039730 - 002

236 | Task Description | MS22061/04E 2015-11

 3.12.17 Engine coolant thermostat – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Observe safety regulations.
2. Drain engine coolant (→ Operating Instructions).
TIM-ID: 0000015104 - 001

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 3.12.18 Engine coolant thermostat ‒ Removal
Preconditions
☑ Preparatory steps are completed.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Removing engine coolant ther-

mostat
1. Remove crossbeams (2 + 3) with holder be-
tween engine coolant thermostat and end
cover for vibration damper.
2. Unscrew fastening nuts (1) from engine cool-
ant thermostat and remove engine coolant
thermostat with gasket from engine coolant
pump.

TIM-ID: 0000051636 - 001

238 | Task Description | MS22061/04E 2015-11

 3.12.19 Engine coolant thermostat ‒ Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Engine coolant thermostat ‒ Cleaning

1. Remove all deposits from functional and sealing surfaces.
2. Clean all functional and sealing surfaces with cleaning agent.
3. Wipe all functional and sealing faces dry with a clean, lint-free cloth.
4. Remove corrosion-protection agent from new component using cleaning agent.
TIM-ID: 0000015073 - 004

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 3.12.20 Engine coolant thermostat – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1

Engine coolant thermostat – Check

Item Findings Action
Check all components for damage Damaged • Recondition
(visual inspection). • Replace
Check all sealing, mating and sup- • Damaged • Rework:
port surfaces for damage and un- • Uneven Smooth with oilstone.
evenness. • Replace

TIM-ID: 0000015082 - 003

240 | Task Description | MS22061/04E 2015-11

 3.12.21 Engine coolant thermostat – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Engine oil
Gasket (→ Spare Parts Catalog)
Crossbeam (→ Spare Parts Catalog)

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Installing engine coolant ther-

mostat
1. Install engine coolant thermostat (3) with
nuts and washers and tighten.
2. Install crossbeams (1) and (2) and retainers
with nuts and washers between engine cool-
ant thermostat and end cover for vibration
damper and fasten.
TIM-ID: 0000053220 - 001

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 3.12.22 Engine coolant thermostat – Final steps

Final steps
1. Fill up with engine coolant (→ Operating Instructions).
2. Enable engine start.

TIM-ID: 0000015137 - 001

242 | Task Description | MS22061/04E 2015-11

 3.12.23 Raw-water pump – Overview

1 Volute 10 Spacer ring 19 Grub screw

2 Nut 11 Gear no. 11 20 Pump shaft
3 O-ring 12 Snap ring 21 Spring washer
4 Impeller 13 Cylindrical roller bearing 22 Screw
5 Boot, rotary seal 14 Screw 23 Sealing ring
6 O-ring 15 Spring washer 24 Plug screw
7 Seal carrier 16 Bearing housing 25 Screw
8 Radial-lip shaft seal 17 Nut 26 Screw
9 O-ring 18 Angular-contact ball bearing
TIM-ID: 0000007266 - 003

MS22061/04E 2015-11 | Task Description | 243

 1 Screw 9 O-ring 17 Nut
2 Bearing housing 10 Boot, rotary seal 18 Pump shaft
3 Seal carrier 11 Screw 19 O-ring
4 O-ring 12 Plug screw 20 Cylindrical roller bearing
5 Volute 13 Shaft seal 21 Snap ring
6 Screw 14 O-ring 22 Gear no. 11
7 Impeller 15 Spacer ring
8 Nut 16 Angular-contact ball bearing

TIM-ID: 0000007266 - 003

244 | Task Description | MS22061/04E 2015-11

 3.12.24 Raw water pump – Preparatory steps
Preconditions
☑ Engine is stopped and starting disabled.

Preparatory steps
1. Close raw water supply.
2. Drain raw water.
3. Remove elbow.
TIM-ID: 0000015197 - 001

MS22061/04E 2015-11 | Task Description | 245

 3.12.25 Raw water pump – Removal
Preconditions
☑ Preparatory steps are completed.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Lifting gear T80091986 1
Assembly lever 8205892161/00 1

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

Removing raw water pump

1. Install support beam (1) on raw water
pump (2).
2. Remove screws for raw water pump (2).
3. Use assembly lever to release raw water
pump (2) from centering unit and remove.
4. Seal openings with suitable covers.

TIM-ID: 0000007297 - 003

246 | Task Description | MS22061/04E 2015-11

 3.12.26 Raw water pump – Cleaning
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Cleaning agent (Hakupur 312) 30390 1

WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.

Raw water pump – Cleaning

1. Remove all deposits from functional and sealing surfaces.
2. Clean all functional and sealing surfaces with cleaner (Hakupur 312).
3. Wipe all functional and sealing faces dry with a clean, lint-free cloth.
4. Remove corrosion inhibitor from new component with cleaner (Hakupur 312).
TIM-ID: 0000015167 - 002

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 3.12.27 Raw-water pump ‒ Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Oilstone 8205893261/00 1
Raw-water pump (→ Spare Parts Catalog)

WARNING
Components have sharp edges.
Risk of injury!
• Wear protective gloves.

WARNING
The component is very heavy and may fall or tip over if unstable.
Risk of crushing injuries to persons or limbs!
• Use appropriate lifting gear and equipment.
• Wear safety footwear.

Raw-water pump ‒ Check

Item Findings Measure
Check volute and impeller for cavi- Cavitation visible. Replace
tation.
Visually inspect sealing surfaces • Signs of wear • Rework: Smoothen with oil-
for signs of wear, pitting and cavi- • Impact marks stone.
tation. • Cavitation • Replace
visible
Check gear for indentations, • Indentations • Rework: Smoothen with oil-
traces of wear and damage. • Wear traces stone.
• Damage • Replace.
visible

TIM-ID: 0000015180 - 002

248 | Task Description | MS22061/04E 2015-11

 3.12.28 Raw water pump – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Lifting gear T80091986 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
Engine oil
O-ring (→ Spare Parts Catalog)

DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Installing raw water pump

1. Remove all covers prior to installation.
2. Coat O-ring with assembly compound.
3. Insert O-ring in groove on bearing housing.
4. Install support beam (1) on raw water
pump (2).
5. Install raw water pump (2) on gearcase with
screws and washers.
6. Remove support beam (1).
TIM-ID: 0000007324 - 004

MS22061/04E 2015-11 | Task Description | 249

 3.12.29 Raw water pump – Final steps

Final steps
1. Install elbow.
2. Open raw water supply.
3. Fill raw water pump.
4. Enable engine start.

TIM-ID: 0000015220 - 001

250 | Task Description | MS22061/04E 2015-11

 3.13 Monitoring, Control and Regulation Equipment
3.13.1 Engine wiring harnesses and brackets – Overview
Overview of engine wiring harness and holders

1 EIM (X51, X52) 2 Pressure sensors 3 ECU with EMU (X2/X3/

X11/X12)
TIM-ID: 0000044230 - 001

MS22061/04E 2015-11 | Task Description | 251

 Engine wiring harness sensors ECU9 – X2

Desig- Pin assignment

nation
ECU9 - A19 EIL Engine ident label (EIL)
X2
B1 Camshaft speed
B10.1 Charge-air pressure A
B10.2 Charge-air pressure B
B13.1 Crankshaft speed
B13.2 Crankshaft speed EMU
B16 Coolant pressure HT
B3 Intake air temperature
B33.5 Rail fuel temperature A
B33.6 Rail fuel temperature B
B34.1 Fuel line pressure after filter
B34.2 Fuel line pressure before filter
TIM-ID: 0000044230 - 001

B34.4 Fuel line pressure before engine

B35 Leakage reservoir
B38 Fuel temperature
B4.25 Exhaust temperature
B4.26 Exhaust temperature
B44.1 Speed of ETC A
B44.2 Speed of ETC B
B44.3 Speed of ETC C

252 | Task Description | MS22061/04E 2015-11

 Desig- Pin assignment
nation
B44.4 Speed of ETC D
B48.1 High-pressure fuel A
B48.2 High-pressure fuel B
B5.1 Lube oil pressure after filter
B5.3 Lube oil pressure before filter
B5.5 Lube oil pressure before high pressure pump A
B5.6 Lube oil pressure before high pressure pump B
B5.8 Lube oil pressure ETC A
B5.9 Lube oil pressure ETC B
B50 Crankcase pressure
B54 Oil replenishment pump pressure
B6.1 Coolant temperature HAT
B7 Lube oil temperature
B7.3 Oil temperature before ETC
B8 Seawater temperature
B81.1 Intake air pressure after filter
B9.5 Charge-air temperature A
F33 Coolant level HAT
F46 Leak fuel level
F50 Oil level reservoir
M8.1 Fuel pump A
M8.2 Fuel pump B
M8.3 Fuel pump A
M8.4 Fuel pump B
M8.5 Fuel pump A
M8.6 Fuel pump B
S37 Start interlock
S37.1 Start interlock free end
S37.2 Start interlock driving end
X14 Adapation switching valves ETC
X2 Adaption governor ECU9 sensor
X2X11 Adaption sensor EIM
X2X12 Adaption sensor EMU
X37 Adaption barring device
TIM-ID: 0000044230 - 001

XF33 Adaption coolant level

XF50 Adaption oil level reservoir
XS37 Adaption start interlock
XS37.1 Adaption start interlock free end
XS37.2 Adaption start interlock driving end
XY1 Adaption starting air valve
Y1 Starting valve
Y45.1 Pressure regulating valve 3.3A

MS22061/04E 2015-11 | Task Description | 253

 Desig- Pin assignment
nation
Y45.2 Pressure regulating valve 3.3B
Y59 Valve
Y60 Valve

Table 3: Engine wiring harness sensors ECU9 – X2

Engine wiring harness injectors ECU9 – X3

Desig- Pin assignment

nation
ECU9 - X3 Adaption governor ECU9 injector
X3
Y39A1-A8 Injectors 1-8 A
Y39B1-B8 Injectors 1-8 B

Table 4: Engine wiring harness injectors ECU9 – X3

TIM-ID: 0000044230 - 001

254 | Task Description | MS22061/04E 2015-11

 Engine wiring harness sensors ECU9/EMU/EIM

Desig- Pin assignment

nation
ECU9/ B19 Starting-air pressure
EMU/E
IM -
X52
X1 Adaption ECU
X11 Adaption EMU
X2X11 Adaption control block
X37 Adaption start interlock
X52 Adaption EIM engine box
XD1 Adaption dialog
XY1 Adaption starting valve
XY61 Adaption priming support

Table 5: Engine wiring harness sensors ECU9/EMU/EIM- X1/ X11/ X52

TIM-ID: 0000044230 - 001

MS22061/04E 2015-11 | Task Description | 255

 Engine wiring harness sensors EMU8 – X12

Desig- Pin assignment

nation
EMU8 - B17 Control air pressure
X12
B21 Seawater pressure
B21.2 Seawater pressure before pump
B48.3 High-pressure fuel redundant A
B48.4 High-pressure fuel redundant B
B4A1-A8 Single exhaust temperature measurement 1-8 A
B4B1-B8 Single exhaust temperature measurement 1-8 B
B5.2 Lube oil pressure after filter, redundant
B5.4 Lube oil pressure last bearing
B5.7 Lube oil pressure piston cooling
B57.1-9 Main bearing temperature 1-9
B6.2 Coolant temperature HAT redundant
TIM-ID: 0000044230 - 001

B77B1-B8 Splash oil B1-B8

B9.6 Charge-air temperature B
X12 Adaption governor EMU
X2X12 Adaption ECU-EMU
XB41 Adaption exhaust back pressure

Table 6: Engine wiring harness sensors EMU8 – X12

256 | Task Description | MS22061/04E 2015-11

 3.13.2 Sensors and actuators – Overview

Item Designation Meaning

1 B4A1 - B4A10 / B4B1 - B4B10 Single exhaust temperature measurement
2 B4.25 Exhaust temperature
3 Y26 / Y30 / Y31 / Y45 Solenoid valves
4 A19 / B1 / Y45 Engine ident label / Camshaft speed / pres-
sure regulating valve
5 B48.1 / B48.3 High-pressure fuel A / high-pressure redun-
dant A
6 B50 Crankcase pressure
7 B9.5 Charge air temperature A
8 M8.1 / M8.3 / M8.5 / M8.7 Fuel pump A
9 B33.5 Rail fuel temperature rail A
10 B34.4 Rail fuel temperature B
11 B38 Fuel temperature
TIM-ID: 0000042599 - 001

12 B35 Leakage reservoir

13 B21.2 Seawater pressure before pump
14 B5.7 Lube oil pressure piston cooling
15 Y39A1 - Y39A10 Injectors 1-10 A
16 Y45.1 Pressure regulating valve 3.3A

MS22061/04E 2015-11 | Task Description | 257

 Item Designation Meaning
1 B10.2 Charge air pressure B
2 Y39B1 - Y39B10 Injectors 1-10 B
3 B81.1 Intake air pressure after filter
4 B3 Intake air temperature
5 B8 Seawater temperature
6 B1 Camshaft speed
7 B48.2 High-pressure fuel B
7 B48.4 High-pressure fuel redundant B
8 B33.6 Rail fuel temperature B
9 M8.2 / M8.4 / M8.6 / M8.8 Fuel pump B
10 B9.6 Charge air temperature B
11 B77B1 - B77B10 Splash oil B1 - B10
12 B57.1 - B57.11 Main bearing temperature 1-10
13 Y45.2 Pressure regulating valve 3.3B
TIM-ID: 0000042599 - 001

258 | Task Description | MS22061/04E 2015-11

 Item Designation Meaning
1 B5.4 / B5.5 / B5.6 / B16 / B17 / B21 Lube oil pressure last bearing
1 B5.5 Lube oil pressure before high pressure pump
A
1 B5.6 Lube oil pressure before high pressure pump
B
1 B16 Coolant pressure HT
1 B17 Control air pressure
1 B21 Seawater pressure
2 B54 Oil replenishment pump pressure
3 Start interlock, drive end
4 B13.1 Crankshaft speed
4 B13.2 Crankshaft speed, EMU
4 Y60 Control valve for charge-air preheater
5 B34.1 Fuel pressure after filter
TIM-ID: 0000042599 - 001

5 B34.2 Fuel pressure before filter

6 B5.1 Lube oil pressure after filter
6 B5.2 Lube oil pressure after filter redundant
6 B5.3 Lube oil pressure before filter
7 B7 Lube oil temperature
8 F46 Leak fuel level
9 Control air pressure
10 Cold-start system

MS22061/04E 2015-11 | Task Description | 259

 Item Designation Meaning
1 B5.9 Lube oil pressure ETC B
2 B5.8 Lube oil pressure ETC A
3 B44.1 Speed ETC A
3 B44.2 Speed ETC B
3 B44.3 Speed ETC C
3 B44.4 Speed ETC D
3 B44.5 Speed ETC E
4 B6.1 Coolant temperature HT
4 B6.2 Coolant temperature HT redundant
TIM-ID: 0000042599 - 001

260 | Task Description | MS22061/04E 2015-11

 3.13.3 Sensors and actuators – Preparatory steps
Preconditions
☑ Engine shut down and starting disabled.

Preparatory steps
1. Switch off operating voltage.
2. Drain engine coolant (only when removing coolant sensors) (→ Operating Instructions).
3. Drain raw water (only for removal of raw water sensors).
TIM-ID: 0000012977 - 005

MS22061/04E 2015-11 | Task Description | 261

 3.13.4 Sensors and actuators – Removal
WARNING
Escaping vapors of highly volatile media, e.g. fuel or ether. Contact with these substances causes irrita-
tion of eyes and skin.
Risk of poisoning and injury!
• Allow engine to cool down.
• Ventilate the workspace.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
• Do not inhale vapors and smoke.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Removing temperature sensors

(B3, B6.1, B6.2, B7, B7.3, B8,
B9.5, B9.6, B33.5, B33.6)
1. Observe the following general information:
• The temperature sensors are identical with
regard to design and electrical function.
Their removal is also identical.
• Arrangement and position of temperature
sensors (→ Page 257).
2. Observe the following before removing:
TIM-ID: 0000044231 - 003

Sensor
B6.1 and B6.2 (coolant tem- Procedure and safety notes (→ Operating Instructions).
perature)
B7; B7.3 (lube oil tempera- Small amounts of engine oil may emerge during removal Catch engine oil in a
ture) suitable container.
B33 .5 and B33.6 (fuel tem- Small amounts of fuel may emerge during removal. Catch fuel in a suitable
perature) container.

262 | Task Description | MS22061/04E 2015-11

 3. Loosen bayonet lock (2) and remove connector (1).
4. Remove sensor via nut (3).

Removing temperature sensors

(B38, B4.25, B4.26, B4A1-A8,
B4B1-B8)

1. Observe the following general information:

• The temperature sensors are identical with regard to design and electrical function. Their removal is also
identical.
• Arrangement and position of temperature sensors (→ Page 257).
Sensor
B38 (fuel temperature) Small amounts of fuel may emerge during removal. Catch fuel in a suitable
container.

2. Remove union nut (1) from temperature sensor and, at the same time, counterhold nut (2) of threaded adapt-
er (3).
3. Extract temperature sensor from threaded adapter (3).

Removing temperature sensor for main bearing temperature (B57.1-9)

1. Observe the following general information:
• Arrangement and position of temperature sensor (→ Page 257).
2. Loosen plug connection on crankcase and remove.
3. Remove temperature sensor from crankcase.
TIM-ID: 0000044231 - 003

MS22061/04E 2015-11 | Task Description | 263

 Removing pressure sensors
(B17, B34.1, B34.2, B34.4, B5.1
- B5.9, B54, B21.2)
1. Observe the following general information:
• The pressure sensors are identical with re-
gard to design and electrical function.
Their removal is also identical.
• Arrangement and position of pressure sen-
sors (→ Page 257).
• Small amounts of engine oil may emerge
during removal of the pressure sensor (oil
pressure). Catch engine oil in a suitable
container.
• Small amounts of fuel may emerge during
removal of the pressure sensor (fuel pres-
sure after filter). Catch fuel in a suitable
container.
2. Loosen bayonet lock (2) and remove connec-
tor (1).
3. Remove sensor via nut (3).

Removing pressure sensor

(B21)
1. Observe the following general information:
• Arrangement and position of pressure sen-
sor (→ Page 257).
2. Loosen bayonet lock (2) and remove connec-
tor (1).
3. Remove sensor (3) via nut.

TIM-ID: 0000044231 - 003

264 | Task Description | MS22061/04E 2015-11

 Removing pressure sensors
(B48.1, B48.2)
1. Observe the following general information:
• Arrangement and position of pressure sen-
sor (→ Page 257).
• Small amounts of fuel may emerge during
removal of the pressure sensor (fuel high
pressure). Catch fuel in a suitable contain-
er.
2. Loosen bayonet lock (2) and remove connec-
tor (1).
3. Remove sensor (3) via nut.

Removing pressure sensors

(B50, B81.1)
1. Observe the following general information:
• Arrangement and position of pressure sen-
sor (→ Page 257).
2. Loosen bayonet lock (2) and remove connec-
tor (1).
3. Remove sensor via nut (3).

Removing speed sensors (B1,

B13.1, B13.2)
1. Observe the following general information:
• The speed sensors are identical with re-
gard to design and electrical function.
Their removal is also identical.
• Arrangement and position of speed sen-
TIM-ID: 0000044231 - 003

sors (→ Page 257).

2. Loosen bayonet lock (4) of speed sensor (1)
and remove connector (3) from engine wiring
system.
3. Remove screw (2).
4. Extract speed sensor (1).

MS22061/04E 2015-11 | Task Description | 265

 Removing speed transmitters
(B44.1 - B44.4)
1. Observe the following general information:
• The speed transmitters are identical with
regard to design and electrical function.
Their removal is also identical.
• Arrangement and position of speed trans-
mitters (→ Page 257).
2. Loosen bayonet lock (2) of speed transmitter
and remove connector from engine wiring
system.
3. Extract speed transmitter (1) at turbocharger.

Removing level monitors (F46,

F50)
1. Observe the following general information:
• Arrangement and position of level monitor
(→ Page 257).
2. Loosen bayonet lock (1) and remove connec-
tor.
3. Remove level monitor via nut (2).

Removing level sensors (XF33)

1. Observe the following general information:
• The level sensors are identical with regard
to design and electrical function. Their re-
moval is also identical.
• Arrangement and position of level sensors
(→ Page 257).
2. Loosen bayonet lock (2) and remove connec-
TIM-ID: 0000044231 - 003

tor (1).
3. Remove level sensors (3) via nut.

266 | Task Description | MS22061/04E 2015-11

 Removing actuators (M8) on fuel pump
1. Observe the following general information:
• Arrangement and position of actuator (→ Page 257).
2. Loosen connector on fuel pump and remove.
TIM-ID: 0000044231 - 003

MS22061/04E 2015-11 | Task Description | 267

 3.13.5 Sensors and actuators – Check
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Solvent (isopropyl alcohol) X00058037 1
Pressure sensor (→ Spare Parts Catalog)
Pressure sensors (→ Spare Parts Catalog)
Speed sensors (→ Spare Parts Catalog)
Temperature sensors (→ Spare Parts Catalog)
Level sensors (→ Spare Parts Catalog)

Sensors and actuators – Check

1. Always note:
• The engine management control unit detects faulty electrical equipment, wiring breaks, short circuits and
abnormal sensor readings.
2. Carry out the following checks:

Item Findings Measure

Check that sensors and actuators Sensors and actuators loose. Retighten securing screws.
are firmly seated.
Check electrical connectors are Electrical connectors loose. Properly connect and tighten elec-
securely connected. trical connectors.
Check sensors, actuators and Damaged Replace
electrical connectors for mechani-
cal damage.
Check sensors, actuators and Contamination visible. Clean affected assembly with iso-
electrical connectors for contami- propyl alcohol.
nation (e.g. by oil sludge).

TIM-ID: 0000012955 - 012

268 | Task Description | MS22061/04E 2015-11

 3.13.6 Sensors and actuators – Installation
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 6–50 Nm F30027336 1
Ratchet adapter F30027340 1
Connector pliers 0135315483 1
Assembly compound (Kluthe Hakuform 30-11C) X00059351 1
O-ring 735221011000 2
Sealing ring 007603014103 2
Sealing ring 007603018101 2

Installing temperature sensors

(B3, B6.1, B6.2, B7, B7.3, B8,
B9.5, B9.6, B33.5, B33.6)
1. Observe the following general information:
• The temperature sensors are identical with
regard to design and electrical function.
Their installation is also identical.
• Arrangement and position of temperature
sensors (→ Page 257).
2. Coat O-ring of temperature sensor with as-
sembly compound.
3. Screw temperature sensor into bore by hand.

4. Tighten nut (3) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Temperature sensor M14 x 1.5 Tightening torque 15 Nm - 30 Nm

5. Fit connector (1) and tighten bayonet lock (2).

TIM-ID: 0000044232 - 003

MS22061/04E 2015-11 | Task Description | 269

 Installing temperature sensors
(B38, B4.25, B4.26, B4A1-A8,
B4B1-B8)
1. Observe the following general information:
• The temperature sensors are identical with
regard to design and electrical function.
Their installation is also identical.
• Arrangement and position of temperature
sensors (→ Page 257).
2. Screw in threaded adapter (3) by hand.

3. Tighten threaded adapter (3) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Threaded adapter M14 x 1.5 Tightening torque 40 Nm ±5 Nm

4. Insert temperature sensor into threaded adapter (3).

5. Tighten union nut (1) of temperature sensor with torque wrench to specified tightening torque and, at the
same time, counterhold nut (2) of threaded adapter (3).
Name Size Type Lubricant Value/Standard
Union nut M10 Tightening torque 35 Nm ±5 Nm

Installing temperature sensor for main bearing temperature (B57.1-9)

1. Observe the following general information:
• Arrangement and position of temperature sensor (→ Page 257).
2. Install temperature sensor on crankcase.

Installing pressure sensors

(B17, B34.1, B34.2, B34.4, B5.1
- B5.9, B54, B21.2)
1. Observe the following general information:
• The pressure sensors are identical with re-
gard to design and electrical function.
Their installation is also identical.
• Arrangement and position of pressure sen-
sors (→ Page 257).
TIM-ID: 0000044232 - 003

2. Coat O-ring of pressure sensor with assembly

compound.
3. Screw pressure sensor into bore by hand.

270 | Task Description | MS22061/04E 2015-11

 4. Tighten nut (3) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Pressure sensor M14 x 1.5 Tightening torque 25 Nm ±3 Nm

5. Fit connector (1) and tighten bayonet lock (2).

Installing pressure sensor (B21)

1. Observe the following general information:
• Arrangement and position of pressure sen-
sor (→ Page 257).
2. Coat O-ring of pressure sensor with assembly
compound.
3. Screw pressure sensor (3) into bore by hand.

4. Tighten nut to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Pressure sensor G ¼” Tightening torque 20 Nm ±3 Nm

5. Fit connector (1) and tighten bayonet lock (2).

Installing pressure sensors

(B48.1, B48.2)
1. Observe the following general information:
• Arrangement and position of pressure sen-
sor (→ Page 257).
2. Coat O-ring of pressure sensor with assembly
compound.
3. Screw pressure sensor (3) into bore by hand.
TIM-ID: 0000044232 - 003

4. Tighten nut to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Pressure sensor M18 x 1.5 Tightening torque 30 Nm ±3 Nm

5. Fit connector (1) and tighten bayonet lock (2).

MS22061/04E 2015-11 | Task Description | 271

 Installing pressure sensors
(B50, B81.1)
1. Observe the following general information:
• Arrangement and position of pressure sen-
sor (→ Page 257).
2. Coat O-ring of pressure sensor with assembly
compound.
3. Screw pressure sensor into bore by hand.

4. Tighten nut (3) to specified torque using a torque wrench.

Name Size Type Lubricant Value/Standard
Pressure sensor M14 x 1.5 Tightening torque 25 Nm ±3 Nm

5. Fit connector (1) and tighten bayonet lock (2).

Installing speed sensors (B1,

B13.1, B13.2)
1. Observe the following general information:
• Arrangement and position of speed sen-
sors (→ Page 257).
2. Coat O-ring of speed sensor with assembly
compound.
3. Insert speed sensor in bore and press in.
4. Tighten speed sensor (1) with screw (2).
5. Insert connector for speed sensor (1) in sock-
et (3) of engine wiring system. Tighten bayo-
net lock (4).
6. If necessary, roll up sensor cable to correct
length and secure with cable ties.
TIM-ID: 0000044232 - 003

272 | Task Description | MS22061/04E 2015-11

 Installing speed transmitters
(B44.1 - B44.4)
1. Observe the following general information:
• The speed transmitters are identical with
regard to design and electrical function.
Their installation is also identical.
• Arrangement and position of speed trans-
mitters (→ Page 257).
2. Coat O-ring with assembly compound and
pull on.
3. Insert speed transmitter (1) into bore at tur-
bocharger and press in.

4. Tighten speed transmitter (1) to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Nut M12 Tightening torque 12 Nm ±3 Nm

5. Fit connector and tighten bayonet lock (2).

Installing level monitors (F46,

F50)
1. Observe the following general information:
• Arrangement and position of level monitor
(→ Page 257).
2. Coat O-ring with assembly compound.
3. Screw level monitor into bore by hand.

4. Tighten nut (2) to specified tightening torque using a torque wrench.

Name Size Type Lubricant Value/Standard
TIM-ID: 0000044232 - 003

Level monitor M18 x 1.5 Tightening torque 22 Nm ±3 Nm

5. Fit connector and tighten bayonet lock (1).

MS22061/04E 2015-11 | Task Description | 273

 Installing level sensor (XF33)
1. Observe the following general information:
• The sensors are identical with regard to
design and electrical function. Their instal-
lation is also identical.
• Arrangement and position of sensors
(→ Page 257).
2. Coat O-ring with assembly compound.
3. Screw sensor into bore by hand.

4. Tighten nut of sensor (3) with torque wrench to specified tightening torque.
Name Size Type Lubricant Value/Standard
Level sensor M18 x 1.5 Tightening torque 25 Nm ±3 Nm

5. Fit connector (1) and tighten bayonet lock (2).

Installing plug connection for actuators (M8) on fuel pump

1. Observe the following general information:
• Arrangement and position of actuator (→ Page 257).
2. Plug in connector (2) until it engages.

TIM-ID: 0000044232 - 003

274 | Task Description | MS22061/04E 2015-11

 3.13.7 Sensors, actuators and injectors – Final steps

Final steps
1. Fill with engine coolant (→ Operating Instructions).
2. Check firm and precise seating of all plug connections.
3. Enable engine start.
TIM-ID: 0000012997 - 005

MS22061/04E 2015-11 | Task Description | 275

 4 Appendix A
4.1 Tightening specifications for screws, nuts and bolts
Tightening torques for setscrew and stud joints to MTN 5008 standard
This standard applies to setscrews not subject to dynamic loads and the associated nuts according to:
• MMN 384
• ISO 4762 (DIN 912)
• ISO 4014 (DIN 931-1)
• ISO 4017 (DIN 933)
• DIN EN ISO 8765 (EN 28765; DIN 960)
• DIN EN ISO 8676 (EN 28676; DIN 961)
• DIN 6912
This standard applies to studs not subject to dynamic loads and the associated nuts according to:
• DIN 833
• DIN 835
• DIN EN ISO 5395 (DIN 836)
• DIN 938
• DIN 939
This standard applies to screws with hexalobular heads according to:
• DIN 34800
• DIN 34801
The standard does not apply to heat-resistant screws in the hot component zone.
Tightening torques MA are specified for screws of strength class 8.8 (surface finish bare metal, phosphatized
or galvanized) and 10.9 (surface finish bare metal or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
When hand-tightening (defined torque), an assembly tolerance of +10% of the figures in the table is permit-
ted.
When machine-tightening, the permissible assembly tolerance is ±15%.

Tightening torques for setscrews

Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M6 9 12 8 11
M8 21 31 20 28
M8 x 1 23 32 21 30
M10 42 60 40 57
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M10 x 1.25 45 63 42 60
M12 74 100 70 92
M12 x 1.25 80 110 75 105
M12 x 1.5 76 105 72 100
M14 115 160 110 150
M14 x 1.5 125 180 120 170
M16 180 250 170 235
M16 x 1.5 190 270 180 255

276 | Appendix A | MS22061/04E 2015-11

 Hand-tightening Machine-tightening
Thread
8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)
M18 250 350 240 330
M18 x 1.5 280 400 270 380
M20 350 500 330 475
M20 x 1.5 390 550 350 520
M22 480 680 450 650
M22 x 1.5 520 730 490 700
M24 600 850 570 810
M24 x 1.5 680 950 640 900
M24 x 2 660 900 620 850
M27 900 1250 850 1175
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA= tightening torques

Tightening torques for studs

Screwed into
Thread Steel M A Gray cast iron MA Al alloy MA
(Nm) (Nm) (Nm)
M6 9 6 6
M8 11 9 10
M10 17 13 13
M12 27 23 18
M14 37 33 33
M16 55 45 –
MA= tightening torques

Tightening torques for setscrews and nuts made of stainless steel

The values in the table are based on a friction coefficient µtot = 0.12, lubricated with Molykote on the thread
and under the screw head.

Strength class
70 80
Basic size Material
MA MA
TIM-ID: 0000002333 - 017

(Nm) (Nm)
M5 3.7 4.9 A2 / A4
M6 6.4 8.5 A2 / A4
M8 15,3 20,4 A2 / A4
M10 31 41 A2 / A4
M12 52 70 A2 / A4
M16 126 167 A2 / A4

MS22061/04E 2015-11 | Appendix A | 277

 Strength class
70 80
Basic size Material
MA MA
(Nm) (Nm)
M20 254 326 A2 / A4
MA= tightening torques

Tightening torque for self-locking hex nuts

Thread MA (Nm) Lubricant
M6 7,5 +1 –
M8 17 +2 –
M10 35 +4 –
M12 59 +6 –
M14 100 +10 –
M16 140 +14 –
M20 290 +29 –
MA= tightening torques

Tightening torques for stress bolt connections to MTN 5007 standard

This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of
strength class 10.9 as well as to the associated nuts.
Shank and junction dimensions to MMN 209 standard and material and manufacture to MMN 389 standard
(bare metal or phosphatized).
The values in the table are based on a friction coefficient µtot = 0.125.
Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.
The figures in the table are for hand-tightening using a torque wrench.

Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)

M6 9 12
M8 21 28
M8 x 1 24 30
M10 42 55
M10 x 1.25 46 60
M12 75 93
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M12 x 1.5 78 99
M14 120 150
M14 x 1.5 135 160
M16 180 225
M16 x 1.5 200 245
M18 250 315
M18 x 1.5 300 360
M20 350 450

278 | Appendix A | MS22061/04E 2015-11

 Thread Not torsion-protected MA(Nm) Torsion-protected MA (Nm)
M20 x 1.5 430 495
M22 500 620
M22 x 1.5 560 675
M24 640 790
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*Protect screw shaft from torsion when tightening.
MA= tightening torques

Tightening torques for plug screws to MTN 5183-1 standard

This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852
Form A (sealed with sealing ring to DIN 7603-Cu).
TIM-ID: 0000002333 - 017

MS22061/04E 2015-11 | Appendix A | 279

 Tightening torques MA are given for screw plugs made of steel (St) with surface protected by a phosphate
coating and oiled or galvanized.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.
Tightening torques for plug screws to DIN 908, DIN 910 and DIN 7604A (with short threaded end).

Screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 15 15
M12 x 1.5 25 25
M14 x 1.5 35 30
M16 x 1.5 40 35
M18 x 1.5 50 40
M20 x 1.5 60 50
M22 x 1.5 70 70
M24 x 1.5 85 80
M26 x 1.5 100 100
M27 x 2 100 100
M30 x 1.5 110 110
M30 x 2 120 120
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M33 x 2 160 160

M36 x 1.5 190 180
M38 x 1.5 220 200
M42 x 1.5 260 240
M45 x 1.5 290 270
M48 x 1.5 310 300
M52 x 1.5 325 320
M56 x 2 380 360

280 | Appendix A | MS22061/04E 2015-11

 Screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M64 x 2 400 400
MA= tightening torques

Tightening torques for plug screws to DIN 7604C (with long threaded end)
Screwed into
Thread Steel/gray cast iron M A Al alloy MA
(Nm) (Nm)
M8 x 1 10 10
M22 x 1.5 80 65
M26 x 1.5 105 90
M30 x 1.5 130 130
M38 x 1.5 140 120
M45 x 1.5 160 140
MA= tightening torques

Tightening torques for banjo screws to MTN 5183-2 standard

This standard applies to banjo screws to MMN 223 and N 15011 sealed with sealing ring to DIN 7603-Cu.
TIM-ID: 0000002333 - 017

MS22061/04E 2015-11 | Appendix A | 281

 The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface coating and
oiled, or galvanized, and to banjo screws made of copper/aluminum alloys.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.

Tightening torques for steel banjo screws

inserted in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M8 x 1 10
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 25
M16 x 1.5 25
M18 x 1.5 30
M22 x 1.5 60
M26 x 1.5 90
M30 x 1.5 130
M38 x 1.5 140
M45 x 1.5 160
MA= tightening torques
TIM-ID: 0000002333 - 017

Tightening torques for banjo screws made of copper-aluminum alloy

inserted in steel/gray cast iron/aluminum alloy
Thread MA
(Nm)
M10 x 1 15
M16 x 1.5 30
MA= tightening torques

282 | Appendix A | MS22061/04E 2015-11

 Tightening torques for male unions to MTN 5183-3 standard
This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by
sealing ring to DIN 7603-Cu).

Tightening torques MA are given for male unions made of steel (St) with phosphatized surface coating and
oiled, or galvanized.
Threads and mating faces beneath heads must be coated with engine oil prior to assembly.
An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during
the tightening process.
inserted in steel/gray cast iron MA
Thread
(Nm)
M10 x 1 15
M12 x 1.5 20
M14 x 1.5 35
M16 x 1.5 50
M18 x 1.5 60
M22 x 1.5 70
M26 x 1.5 100
M32 x 2 160
M42 x 2 260
M48 x 2 320
MA= tightening torques
TIM-ID: 0000002333 - 017

MS22061/04E 2015-11 | Appendix A | 283

 Tightening torques for union nuts to DIN 3859-2
1 Union nut
2 Union body
3 O-ring
4 Ferrule

Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase
in force), it should be tightened another 1/4 turn (90°) past this point.

Tightening torques for spigot unions with O-ring to ISO 6149-2

Thread Torque (Nm) +10%

TIM-ID: 0000002333 - 017

M8 x 1 10
M10 x 1 20
M12 x 1.5 35
M14 x 1.5 45
M16 x 1.5 55
M18 x 1.5 70
M20 x 1.5 1) 80
M22 x 1.5 100

284 | Appendix A | MS22061/04E 2015-11

 Thread Torque (Nm) +10%
M27 x 2 170
M33 x 2 310
M42 x 2 330
M48 x 2 420
M60 x 2 500
1)
Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789)

Tightening torques for spigot unions with O-ring to ISO 6149-3

Thread Torque (Nm) +10%

M8 x 1 8
M10 x 1 15
M12 x 1.5 25
M14 x 1.5 35
M16 x 1.5 40
M18 x 1.5 45
M22 x 1.5 60
M27 x 2 100
M33 x 2 160
M42 x 2 210
M48 x 2 260
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M60 x 2 315

MS22061/04E 2015-11 | Appendix A | 285

 Tightening torques for plug screws to MTN 5183-6

Screwed into
Thread Steel/gray cast iron MA AI alloy MA
(Nm) (Nm)
M10 x 1 20 10 +2
M12 x 1.5 35 14 +2
M14 x 1.5 45 15 +3
M16 x 1.5 55 18 +3
M18 x 1.5 70 23 +3
M22 x 1.5 100 33 +4
M27 x 2 170 57 +5
M33 x 2 310 103 +10
M42 x 2 330 110 +11
M48 x 2 420 140 +14
M60 x 2 – 200 +20
MA= tightening torques

Assembly instructions and tightening torques for hose fittings with union nuts
These instructions do not apply to ORFS fittings. In contrast to the instructions for pipe unions, hose fittings
with sealing heads and the matching adapters must be fitted and connected as follows.
Hose fitting forming metallic seal with union nut: tighten union nut by hand then tighten a further
TIM-ID: 0000002333 - 017

max. 1/4 of a turn with a wrench.

Hose fitting with O-ring and union nut: tighten union nut by hand then tighten a further max. 1/2 of a turn
with a wrench.
Hoses must be properly aligned before tightening the union nuts.

Sealing head/sealing cone with metric union nut

Metric thread Pipe outer dia. Torque (Nm)
M12 x 1.5 6 20
M14 x 1.5 8 38

286 | Appendix A | MS22061/04E 2015-11

 Sealing head/sealing cone with metric union nut
Metric thread Pipe outer dia. Torque (Nm)
M16 x 1.5 8 45
10
M18 x 1.5 10 51
12
M20 x 1.5 12 58
M22 x 1.5 14 74
15
M24 x 1.5 16 74
M26 x 1.5 18 105
M30 x 2 20 135
22
M36 x 2 25 166
28
M42 x 2 30 240
M45 x 2 35 290
M52 x 2 38 330
42

Sealing head with BSP union nut

BSPP thread Torque (Nm)
G1/4 20
G3/8 34
G1/2 60
G5/8 69
G3/4 115
G1 140
G1.1/4 210
G1.1/2 290
G2 400

SAE sealing cone with union nut JIC 37°

UNF thread Size Torque (Nm)
7/16–20 –4 15
1/2–20 –5 20
9/16–18 –6 30
3/4–16 –8 50
TIM-ID: 0000002333 - 017

7/8–14 –10 69
1.1/16–12 –12 98
1.3/16–12 –14 118
1.5/16–12 –16 140
1.5/8–12 –20 210
1.7/8–12 –24 290
2.1/2–12 –32 450

MS22061/04E 2015-11 | Appendix A | 287

 ORFS – flat sealing with union nut
UNF thread Size Torque (Nm)
9/16–18 –4 14 +2
11/16–16 –6 24 +3
13/16–16 –8 43 +4
1–14 –10 60 +8
1.3/16–12 –12 90 +5
1.3/16–12 –14 90 +5
1.7/16–12 –16 125 +10
1.11/16–12 –20 170 +20
2–12 –24 200 +25
2–1/2–20 –32 460 +30

TIM-ID: 0000002333 - 017

288 | Appendix A | MS22061/04E 2015-11

 4.2 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km
Nm 1.852 = km
yd 3 = ft
yd 36 = in

Unit B multiplied by factor = Unit A

mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile

Area
Unit A multiplied by factor = Unit B
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.59 = km2

Unit B multiplied by factor Unit A

mm 2 0.00155 = in2
m2 10.764 = ft2
m2 1.1960 = yd2
km2 0.3861 = stat. mile2

Volume
Unit A multiplied by factor = Unit B
in 3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
gallon (U.S.) 3.785 = dm3
TIM-ID: 0000002173 - 016

gallon (UK) 4.546 = dm3

Unit B multiplied by factor = Unit A

cm 3 0.06102 = in3
m3 35.31 = ft3
dm3 0.2642 = gallon (U.S.)
dm3 0.22 = gallon (UK)

MS22061/04E 2015-11 | Appendix A | 289

 Volumetric flow
Unit A multiplied by factor = Unit B
gal/min (GPM, U.S.) 3.79 = l/min
gal/min (GPM, U.S.) 0.134 = ft3/min (cfm)
ft3/min (cfm) 1.70 = m3/h

Unit B multiplied by factor = Unit A

l/min 0.264 = gal/min (U.S.)
3
ft /min (cfm) 7.48 = gal/min (U.S.)
m3/h 0.589 = ft3/min (cfm)

Velocity
Unit A multiplied by factor = Unit B
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (UK) 1.852 = km/h

Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s
km/h 0.6214 = stat. mile/h (mph)
km/h 0.54 = knot (UK)

Mass
Unit A multiplied by factor = Unit B
lb 0.4536 = kg
oz 28.35 =g
ton (imp.) 1.016 =t

Unit B multiplied by factor = Unit A

g 0.03527 = oz
kg 2.205 = lb
t 0.9842 = ton (imp.)

Force
Unit A multiplied by factor = Unit B
lbf 0.4536 = kp
lbf 4.4482 =N
TIM-ID: 0000002173 - 016

kp 9.80665 =N

Unit B multiplied by factor = Unit A

kp 2.205 = lbf
N 0.10197 = kp
N 0.2248 = lbf

290 | Appendix A | MS22061/04E 2015-11

 Density
Unit A multiplied by factor = Unit B
slug/ft 3 515.4 = kg/m3

Unit B multiplied by factor = Unit A

kg/m 3 0.00194 = slug/ft3

Torque
Unit A multiplied by factor = Unit B
lbf ft 1.3558 = Nm

Unit B multiplied by factor = Unit A

Nm 0.7376 = lbf ft

Pressure
Unit A multiplied by factor = Unit B
2
lbf/in (psi) 703.1 = kp/m2 (mmH2O)
lbf/in2 (psi) 0.06895 = bar
2
lbf/ft (psf) 47.88 = Pa
inHg 0.03386 = bar
inHg 345.3 = kp/m2 (mmH2O)

Unit B multiplied by factor = Unit A

atm 760 = mmHg
atm 1.0133 = bar
atm 10332 = kp/m2 (mmH2O)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lbf/in2 (psi)
bar 14.504 = lbf/in2 (psi)
Pa 0.0209 = lbf/ft2 (psf)

2nd moment of mass

Unit A multiplied by factor = Unit B
slug ft 2 1.3558 = kg m2

Unit B multiplied by factor = Unit A

kg m 2 0.7376 = slug ft2
TIM-ID: 0000002173 - 016

Energy
Unit A multiplied by factor = Unit B
lbf ft 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J

MS22061/04E 2015-11 | Appendix A | 291

 Unit B multiplied by factor = Unit A
J 0.7376 = lbf ft
J 0.0002388 = kcal
J 0.0009478 = BTU
J 0.00052656 = CHU

Power
Unit A multiplied by factor = Unit B
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.054 = kW
kcal/h 1.163 =W
HP 550 = lbf ft/s

Unit B multiplied by factor = Unit A

kW 1.36 = PS
kW 1.341 = HP
kW 0.9487 = BTU/s
W 0.8598 = kcal/h
lbf ft/s 0.0018 = HP

Temperature
Celsius Kelvin
x °C - = x + 273.15 K
xK = x − 273.15 °C -
x °F = 5/9(x − 32) °C = 5/9(x − 32) + 273.15 K
x °R = 5/4x °C = (5/4x) + 273.15 K

Fahrenheit Réaumur
x °C = 9/5x + 32 °F = (4/5x) °R
xK = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15) °R
x °F - = 4/9(x − 32) °R
x °R = (9/4x) + 32 °F -

Fuel consumption
Unit A multiplied by factor = Unit B
mile/gal (US) 0.4251 = km/l
TIM-ID: 0000002173 - 016

gal/mile (US) 2.3527 = l/km

Unit B multiplied by factor = Unit A

km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)

292 | Appendix A | MS22061/04E 2015-11

 4.3 Tolerances and wear limits list – General information
The tolerances and wear limits are helpful clues when inspecting components and making repairs.
Explanation of terms for dimensions of new components
Toleranced size Designed size followed by a fits symbol (e.g. 24 H6) or by the permissible dimen-
sional deviation (e.g. 24 +0.013)
Basic size Designed size without fit symbol or permissible dimensional deviation
Deviation Permissible tolerance of toleranced/basic size. Deviation determines the upper
and lower limit of the toleranced/basic size
Clearance Difference between bore and shaft diameter when bore diameter is greater than
shaft diameter
Interference Difference between bore and shaft diameter when bore diameter is smaller than
shaft diameter

Explanation of terms for the dimension to be observed when overhauling components

Wear limit The wear limits do not denote the max. permissible wear for satisfactory function-
ing of the component. They are to be regarded as indications that the next required
major overhaul will be reached safely. A component must be replaced when its
wear limit is exceeded.
Reconditioning in- If a wear limit is exceeded or not reached, the parts in question must be repaired
struction or replaced in accordance with the reconditioning instructions.

Deviations from roundness, cylindrical form, parallelism and concentricity must be within specified limits un-
less otherwise indicated. All dimensions are given in "mm" unless otherwise specified.
TIM-ID: 0000002848 - 013

MS22061/04E 2015-11 | Appendix A | 293

 4.4 Abbreviations
Abbre- Meaning Explanation
viation
ADEC Advanced Diesel Engine Controller Engine management system
EGR Exhaust Gas Recirculation
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ETC Exhaust turbocharger
BDM Backup Data Module Data backup module
BR (Baureihe) Series
BV (Betriebsstoffvorschrift) Fluids and Lubri- MTU Publication No. A001061/..
cants Specifications
CAN Controller Area Network Data bus system, bus standard
CPP Controllable Pitch Propeller
CR Common Rail
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards
(DIN = “Deutsche Industrie-Norm”)
DIS Display Unit Display panel
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EIL Engine Ident Label
EMU Engine Monitoring Unit
SPC Spare Parts Catalog
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
value
HT High Temperature
ICFN ISO – Continuous rating – Fuel stop power Power specifications acc. to DIN-ISO 3046-7
TIM-ID: 0000002045 - 019

– Net
IDM Interface Data Module Memory module for interface data
IMO International Maritime Organization
ISO International Organization for Standardiza- International umbrella organization of all standards
tion institutes
KGS Engine free end Engine free end in accordance with DIN ISO 1204
KS Engine driving end Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal Device

294 | Appendix A | MS22061/04E 2015-11

 Abbre- Meaning Explanation
viation
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
value
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it value
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
LPU Lubricating Oil Pump Control Unit Lube oil pump control
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing Unit
TDC Top Dead Center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Control panel
PAU Power Automation Unit Module for monitoring, control and plant-related sys-
tem integration of peripheral components
PCU Propeller Control Unit
PIM Peripheral Interface Module
UPS Unit Pump System
POM Power Output Module Module to control starter and battery-charging gen-
erator
PPC Priming Pump Control Oil priming pump
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)
SS Safety System Safety system alarm
SSK Emergency-air shutoff flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Sensor comparison fault
BDC Bottom Dead Center
VS Voith Schneider Voith Schneider drive
TIM-ID: 0000002045 - 019

WJ Water jet Water jet drive

TC Tool Catalog

MS22061/04E 2015-11 | Appendix A | 295

 4.5 MTU Contact/Service Partners
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure the high availability of our products.

Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com

24h Hotline
With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000

Spare Parts Service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at
headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778

TIM-ID: 0000000873 - 016

296 | Appendix A | MS22061/04E 2015-11

 5 Appendix B
5.1 Special Tools
Adjusting ring, 230 mm
Part No.: Y20004315
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)

Assembly jig
Part No.: F6794057
Qty.: 1
Used in: 3.7.3 Exhaust turbocharger – Removal (→ Page 140)
Qty.: 1
Used in: 3.7.6 Exhaust turbocharger – Installation (→ Page 143)

Assembly jig for conrod bearing

Part No.: F6456288
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 297

 Assembly jig for lifting conrod
Part No.: F6375369
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

Assembly lever
Part No.: 8205892161/00
Qty.: 1
Used in: 3.12.3 Engine coolant pump – Removal (→ Page 220)
Qty.: 1
Used in: 3.12.25 Raw water pump – Removal (→ Page 246)

Assembly sleeve
Part No.: F6557120
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

Barring device
Part No.: 5805890259/00
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)
DCL-ID: 0000027862 - 006

298 | Appendix B | MS22061/04E 2015-11

 Bore gage, 160–290 mm
Part No.: Y20091483
Qty.: 1
Used in: 3.1.12 Cylinder liner ‒ Check (→ Page 34)
Qty.: 1
Used in: 3.2.10 Piston ‒ Check (→ Page 60)

Bore gage, 160–290 mm

Part No.: Y20091483
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)

Bore gage, 18–100 mm

Part No.: Y20091481
Qty.: 1
Used in: 3.2.10 Piston ‒ Check (→ Page 60)

Connector pliers
Part No.: 0135315483
Qty.: 1
Used in: 3.13.6 Sensors and actuators – Installation (→ Page 269)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 299

 Depth gage, 300 mm
Part No.: Y20002777
Qty.: 1
Used in: 3.2.10 Piston ‒ Check (→ Page 60)

Dial gage
Part No.: Y20011268
Qty.: 1
Used in: 3.1.12 Cylinder liner ‒ Check (→ Page 34)

Extraction device
Part No.: F6557114
Qty.: 1
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)

Extraction device
Part No.: F6795766
Qty.: 1
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)
DCL-ID: 0000027862 - 006

300 | Appendix B | MS22061/04E 2015-11

 Eyebolt
Part No.: 070612020000
Qty.: 1
Used in: 3.2.3 Vibration damper on PTO, free end – Removal
(→ Page 44)
Qty.: 1
Used in: 3.2.4 Vibration damper on PTO, free end ‒ Installation
(→ Page 47)

Eyebolt for constant-pressure manifold housing

Part No.: B80099952
Qty.: 4
Used in: 3.9.3 Constant-pressure manifold housing ‒ Removal
(→ Page 173)
Qty.: 4
Used in: 3.9.6 Constant-pressure manifold – Assembly
(→ Page 178)

Feeler gage
Part No.: Y4341964
Qty.: 1
Used in: 3.2.10 Piston ‒ Check (→ Page 60)

Force amplifying wrench

Part No.: F30030459
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)
Qty.: 1
Used in: 3.5.3 HP pump – Removal (→ Page 95)
Qty.: 1
Used in: 3.5.5 HP pump – Installation (→ Page 98)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 301

 Gage block kit
Part No.: 0005891619/00
Qty.: 1
Used in: 3.2.10 Piston ‒ Check (→ Page 60)

Guide plate
Part No.: F6795525
Qty.: 4
Used in: 3.7.6 Exhaust turbocharger – Installation (→ Page 143)

Guide tube
Part No.: F6271448
Qty.: 1
Used in: 3.3.3 Cylinder head ‒ Removal (→ Page 77)
Qty.: 2
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)

High-pressure cleaning unit

Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning
(→ Page 228)
DCL-ID: 0000027862 - 006

302 | Appendix B | MS22061/04E 2015-11

 Hydraulic hand pump, 0–1000 bar
Part No.: B80146898
Qty.: 1
Used in: 3.2.3 Vibration damper on PTO, free end – Removal
(→ Page 44)
Qty.: 1
Used in: 3.2.4 Vibration damper on PTO, free end ‒ Installation
(→ Page 47)

Hydraulic hand pump, 0–3000 bar

Part No.: B80144839
Qty.: 1
Used in: 3.2.3 Vibration damper on PTO, free end – Removal
(→ Page 44)
Qty.: 1
Used in: 3.2.4 Vibration damper on PTO, free end ‒ Installation
(→ Page 47)

Hydraulic hand pump, 0–700 bar

Part No.: B80147075
Qty.: 1
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)

Index plate
Part No.: F6270942
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 303

 Installation jig for piston and conrod
Part No.: F6348802
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

Lifting bracket
Part No.: T80092874
Qty.:
Used in: 3.2.3 Vibration damper on PTO, free end – Removal
(→ Page 44)

Lifting device
Part No.: F6271437
Qty.: 1
Used in: 3.12.3 Engine coolant pump – Removal (→ Page 220)
Qty.: 1
Used in: 3.12.6 Engine coolant pump ‒ Installation (→ Page 223)

Lifting gear
Part No.: T80092853
Qty.: 1
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)
DCL-ID: 0000027862 - 006

304 | Appendix B | MS22061/04E 2015-11

 Lifting gear
Part No.: T80092852
Qty.: 1
Used in: 3.7.3 Exhaust turbocharger – Removal (→ Page 140)
Qty.: 1
Used in: 3.7.6 Exhaust turbocharger – Installation (→ Page 143)

Lifting gear
Part No.: T80091986
Qty.: 1
Used in: 3.12.25 Raw water pump – Removal (→ Page 246)
Qty.: 1
Used in: 3.12.28 Raw water pump – Installation (→ Page 249)

Locating device for exhaust pipes

Part No.: F6553614
Qty.: 2
Used in: 3.9.6 Constant-pressure manifold – Assembly
(→ Page 178)

Micrometer, 225–250 mm
Part No.: Y20001746
Qty.: 1
Used in: 3.1.12 Cylinder liner ‒ Check (→ Page 34)
Qty.: 1
Used in: 3.2.10 Piston ‒ Check (→ Page 60)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 305

 Micrometer, 75–100 mm
Part No.: Y20000169
Qty.: 1
Used in: 3.2.10 Piston ‒ Check (→ Page 60)

Oilstone
Part No.: 8205893261/00
Qty.: 1
Used in: 3.1.5 Inspection port cover – Check (→ Page 25)
Qty.: 1
Used in: 3.1.12 Cylinder liner ‒ Check (→ Page 34)
Qty.: 1
Used in: 3.2.10 Piston ‒ Check (→ Page 60)
Qty.: 1
Used in: 3.4.5 Valve gear ‒ Check (→ Page 89)
Qty.: 1
Used in: 3.6.5 Pressure limiting valve – Check (→ Page 121)
Qty.: 1
Used in: 3.6.12 Fuel priming pump – Check (→ Page 128)
Qty.: 1
Used in: 3.7.5 Exhaust turbocharger – Check (→ Page 142)
Qty.: 1
Used in: 3.8.8 Intake housing with air flap – Check (→ Page 158)
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly
(→ Page 178)
Qty.: 1
Used in: 3.10.5 Compressed-air distributor – Check (→ Page 204)
Qty.: 1
Used in: 3.12.5 Engine coolant pump – Check (→ Page 222)
Qty.: 1
Used in: 3.12.6 Engine coolant pump ‒ Installation (→ Page 223)
Qty.: 1
Used in: 3.12.12 Engine coolant cooler and fuel cooler – Check
DCL-ID: 0000027862 - 006

(→ Page 231)
Qty.: 1
Used in: 3.12.20 Engine coolant thermostat – Check (→ Page 240)
Qty.: 1
Used in: 3.12.27 Raw-water pump ‒ Check (→ Page 248)

306 | Appendix B | MS22061/04E 2015-11

 Piston-ring pliers for oil control ring
Part No.: F30378006
Qty.: 1
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)

Piston-ring pliers for rectangular-section ring

Part No.: F30378005
Qty.: 1
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)

Plug-in coupling nipple

Part No.: B80144866
Qty.: 1
Used in: 3.2.3 Vibration damper on PTO, free end – Removal
(→ Page 44)
Qty.: 1
Used in: 3.2.4 Vibration damper on PTO, free end ‒ Installation
(→ Page 47)

Pointer for setting TDC point (12V)

Part No.: Y4275535
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 307

 Pointer for setting TDC point (16V and 20V)
Part No.: Y4275569
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)

Power amplifying wrench

Part No.: F30030459
Qty.: 1
Used in: 3.9.3 Constant-pressure manifold housing ‒ Removal
(→ Page 173)

Ratchet
Part No.: F30006211
Qty.: 1
Used in: 3.5.3 HP pump – Removal (→ Page 95)
Qty.: 1
Used in: 3.5.5 HP pump – Installation (→ Page 98)

Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)
DCL-ID: 0000027862 - 006

Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)
Qty.: 1
Used in: 3.4.6 Valve drive – Installation (→ Page 90)
Qty.: 1
Used in: 3.5.5 HP pump – Installation (→ Page 98)
Qty.: 1
Used in: 3.5.15 HP fuel lines – Installation (→ Page 112)

308 | Appendix B | MS22061/04E 2015-11

 Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)
Qty.: 1
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)
Qty.: 1
Used in: 3.5.5 HP pump – Installation (→ Page 98)
Qty.: 1
Used in: 3.5.15 HP fuel lines – Installation (→ Page 112)
Qty.: 1
Used in: 3.13.6 Sensors and actuators – Installation (→ Page 269)

Removal device (carbon scraper ring)

Part No.: F6559641
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)

Removal/installation jig
Part No.: F0141110
Qty.: 1
Used in: 3.2.3 Vibration damper on PTO, free end – Removal
(→ Page 44)
Qty.: 1
Used in: 3.2.4 Vibration damper on PTO, free end ‒ Installation
(→ Page 47)

Retaining device for piston

Part No.: F6277794
DCL-ID: 0000027862 - 006

Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)
Qty.: 1
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)

MS22061/04E 2015-11 | Appendix B | 309

 Shackle
Part No.: 082101000107
Qty.: 1
Used in: 3.2.3 Vibration damper on PTO, free end – Removal
(→ Page 44)
Qty.: 1
Used in: 3.2.4 Vibration damper on PTO, free end ‒ Installation
(→ Page 47)

Shackle chain
Part No.: T80090289
Qty.: 1
Used in: 3.9.10 Carrier housing upper section – Removal and in-
stallation (→ Page 195)

Sliding block
Part No.: F6348804
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

Sliding block
Part No.: F6348805
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)
DCL-ID: 0000027862 - 006

310 | Appendix B | MS22061/04E 2015-11

 Smooth cleaning brush
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning
(→ Page 228)

Snap ring pliers

Part No.: F30002760
Qty.: 1
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)

Socket for conrod screw

Part No.: F30378301
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

Socket insert
Part No.: F30013228
Qty.: 1
Used in: 3.3.3 Cylinder head ‒ Removal (→ Page 77)
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)
Qty.: 1
Used in: 3.9.3 Constant-pressure manifold housing ‒ Removal
(→ Page 173)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 311

 Socket wrench
Part No.: F30450844
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly
(→ Page 178)

Spacer for assembling conrod

Part No.: F6375336
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

Support bracket
Part No.: T80092856
Qty.: 1
Used in: 3.3.3 Cylinder head ‒ Removal (→ Page 77)
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)

Support bracket
Part No.: T80092979
Qty.: 1
Used in: 3.5.3 HP pump – Removal (→ Page 95)
Qty.: 1
Used in: 3.5.5 HP pump – Installation (→ Page 98)
DCL-ID: 0000027862 - 006

312 | Appendix B | MS22061/04E 2015-11

 Support bracket
Part No.: T80091150
Qty.: 1
Used in: 3.5.9 HP fuel accumulator – Removal (→ Page 104)
Qty.: 1
Used in: 3.5.10 HP fuel accumulator – Installation (→ Page 105)

Support bracket for piston and conrod

Part No.: T80090232
Qty.: 1
Used in: 3.2.8 Piston and conrod – Removal (→ Page 56)
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

Support device for shroud

Part No.: F6450512
Qty.: 3
Used in: 3.9.6 Constant-pressure manifold – Assembly
(→ Page 178)

Tightening device for lifting eye

Part No.: F6271439
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly
(→ Page 178)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 313

 Tightening tool
Part No.: F6794031
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)

Tong arms
Part No.: T80090507
Qty.:
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)

Tool kit BR 956/1163

Part No.: 5845890999/00
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)

Tool kit BR 956/1163

Part No.: 5845891199/00
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)
DCL-ID: 0000027862 - 006

314 | Appendix B | MS22061/04E 2015-11

 Tool kit Series 956/1163
Part No.: 5845890999/00
Qty.: 1
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)

Tool kit Series 956/1163

Part No.: 5845891199/00
Qty.: 1
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)

Torque wrench, 10–60 Nm

Part No.: F30510423
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)

Torque wrench, 20–100 Nm

Part No.: F30026582
Qty.: 1
Used in: 3.5.15 HP fuel lines – Installation (→ Page 112)
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly
DCL-ID: 0000027862 - 006

(→ Page 178)

MS22061/04E 2015-11 | Appendix B | 315

 Torque wrench, 300–800 Nm
Part No.: F30047798
Qty.: 1
Used in: 3.1.10 Cylinder liner ‒ Removal (→ Page 30)

Torque wrench, 40–200 Nm

Part No.: F30027337
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)
Qty.: 1
Used in: 3.5.15 HP fuel lines – Installation (→ Page 112)
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly
(→ Page 178)

Torque wrench, 4–20 Nm

Part No.: F30044239
Qty.: 1
Used in: 3.5.15 HP fuel lines – Installation (→ Page 112)
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly
(→ Page 178)

Torque wrench, 60–320 Nm

Part No.: F30047446
Qty.: 1
Used in: 3.4.6 Valve drive – Installation (→ Page 90)
Qty.: 1
Used in: 3.5.5 HP pump – Installation (→ Page 98)
DCL-ID: 0000027862 - 006

316 | Appendix B | MS22061/04E 2015-11

 Torque wrench, 6–50 Nm
Part No.: F30027336
Qty.: 1
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)
Qty.: 1
Used in: 3.13.6 Sensors and actuators – Installation (→ Page 269)

Torque wrench, 80 to 400 Nm

Part No.: F30027338
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

Wire rope
Part No.: F6271443
Qty.: 1
Used in: 3.2.3 Vibration damper on PTO, free end – Removal
(→ Page 44)
Qty.: 1
Used in: 3.2.4 Vibration damper on PTO, free end ‒ Installation
(→ Page 47)

Wrench
Part No.: F30378587
Qty.: 1
Used in: 3.12.3 Engine coolant pump – Removal (→ Page 220)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 317

 5.2 Consumables
Abrasive paste
Part No.:
Qty.:
Used in: 3.10.5 Compressed-air distributor – Check (→ Page 204)

Assembly compound (Kluthe Hakuform 30-11C)

Part No.: X00059351
Qty.: 1
Used in: 3.1.6 Inspection port cover – Installation (→ Page 26)
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)
Qty.: 1
Used in: 3.5.5 HP pump – Installation (→ Page 98)
Qty.: 1
Used in: 3.5.10 HP fuel accumulator – Installation (→ Page 105)
Qty.: 1
Used in: 3.5.15 HP fuel lines – Installation (→ Page 112)
Qty.: 1
Used in: 3.7.6 Exhaust turbocharger – Installation (→ Page 143)
Qty.: 1
Used in: 3.8.9 Intake housing with air flap – Installation (→ Page 159)
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly (→ Page 178)
Qty.: 1
Used in: 3.9.10 Carrier housing upper section – Removal and installation (→ Page 195)
Qty.: 1
Used in: 3.11.5 Exhaust turbocharger oil supply pipework, distributor and fasteners – Installation
(→ Page 213)
Qty.: 1
Used in: 3.11.8 Vent line for oil supply pipework of exhaust turbocharger – Installation
(→ Page 216)
Qty.: 1
Used in: 3.12.28 Raw water pump – Installation (→ Page 249)
Qty.: 1
Used in: 3.13.6 Sensors and actuators – Installation (→ Page 269)
DCL-ID: 0000027862 - 006

Assembly compound (Molykote G-N Plus)

Part No.: 40041
Qty.: 1
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)
Qty.: 1
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)

318 | Appendix B | MS22061/04E 2015-11

 Assembly compound (Molykote G-N Plus)
Part No.: 40041
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)

Assembly compound (Ultra-Therm MTU)

Part No.: 50547
Qty.: 1
Used in: 3.7.6 Exhaust turbocharger – Installation (→ Page 143)
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly (→ Page 178)

Assembly compound Molykote G-N Plus

Part No.:
Qty.:
Used in: 3.10.6 Compressed-air distributor – Adjustment and Installation (→ Page 205)

Assembly paste(Optimoly Paste White T)

Part No.: 40477
Qty.: 1
Used in: 3.5.15 HP fuel lines – Installation (→ Page 112)

Caustic soda
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Citric acid
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Cleaner (Snow-White 11-0)

Part No.: X00054118
Qty.: 1
Used in: 3.6.11 Fuel priming pump – Cleaning (→ Page 127)
DCL-ID: 0000027862 - 006

Cleaner (Hakupur 312)

Part No.: 30390
Qty.: 1
Used in: 3.5.4 HP pump – Cleaning (→ Page 97)

MS22061/04E 2015-11 | Appendix B | 319

 Cleaner (Hakupur 312)
Part No.: 30390
Qty.: 1
Used in: 3.4.4 Valve drive – Cleaning (→ Page 88)
Qty.: 1
Used in: 3.6.11 Fuel priming pump – Cleaning (→ Page 127)
Qty.: 1
Used in: 3.8.7 Intake housing with air flap – Cleaning (→ Page 157)
Qty.: 1
Used in: 3.10.4 Starting-air distributor ‒ Cleaning (→ Page 203)

Cleaner (Snow-White 11-0)

Part No.: X00054118
Qty.: 1
Used in: 3.4.4 Valve drive – Cleaning (→ Page 88)
Qty.: 1
Used in: 3.8.7 Intake housing with air flap – Cleaning (→ Page 157)
Qty.: 1
Used in: 3.10.4 Starting-air distributor ‒ Cleaning (→ Page 203)

Cleaning agent (Hakupur 312)

Part No.: 30390
Qty.: 1
Used in: 3.12.19 Engine coolant thermostat ‒ Cleaning (→ Page 239)
Qty.: 1
Used in: 3.12.26 Raw water pump – Cleaning (→ Page 247)

Cleaning agent (Hakupur 312)

Part No.: 30390
Qty.: 1
Used in: 3.2.9 Piston – Cleaning (→ Page 59)
Qty.: 1
Used in: 3.3.4 Cylinder head – Cleaning (→ Page 79)
Qty.: 1
Used in: 3.6.4 Pressure limiting valve – Cleaning (→ Page 120)
Qty.: 1
Used in: 3.7.4 Exhaust turbocharger – Cleaning (→ Page 141)
Qty.: 1
Used in: 3.9.4 Constant-pressure manifold ‒ Cleaning (→ Page 176)
DCL-ID: 0000027862 - 006

Qty.: 1
Used in: 3.12.4 Engine coolant pump – Cleaning (→ Page 221)

Cleaning agent (Hakupur 50/136)

Part No.: X00056700
Qty.: 1
Used in: 3.1.4 Inspection port cover – Cleaning sealing surfaces (→ Page 24)
Qty.: 1
Used in: 3.1.11 Cylinder liner – Cleaning (→ Page 33)

320 | Appendix B | MS22061/04E 2015-11

 Cleaning agent (Snow-White 11-0)
Part No.: X00054118
Qty.: 1
Used in: 3.6.4 Pressure limiting valve – Cleaning (→ Page 120)
Qty.: 1
Used in: 3.9.4 Constant-pressure manifold ‒ Cleaning (→ Page 176)

Corrosion inhibitor (Tectyl 846-K-19)

Part No.: X00057275
Qty.: 1
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)
DCL-ID: 0000027862 - 006

MS22061/04E 2015-11 | Appendix B | 321

 Engine oil
Part No.:
Qty.:
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)
Qty.:
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)
Qty.:
Used in: 3.2.13 Piston and conrod – Installation (→ Page 69)
Qty.:
Used in: 3.3.5 Cylinder head – Installation (→ Page 80)
Qty.:
Used in: 3.4.6 Valve drive – Installation (→ Page 90)
Qty.:
Used in: 3.5.5 HP pump – Installation (→ Page 98)
Qty.:
Used in: 3.5.10 HP fuel accumulator – Installation (→ Page 105)
Qty.:
Used in: 3.5.15 HP fuel lines – Installation (→ Page 112)
Qty.:
Used in: 3.6.6 Pressure limiting valve – Installation (→ Page 122)
Qty.:
Used in: 3.6.13 Fuel priming pump ‒ Installation (→ Page 129)
Qty.:
Used in: 3.7.6 Exhaust turbocharger – Installation (→ Page 143)
Qty.:
Used in: 3.8.3 Air and exhaust flap control – Installation (→ Page 151)
Qty.:
Used in: 3.8.14 Air pipework to cylinders ‒ Installation (→ Page 167)
Qty.:
Used in: 3.9.6 Constant-pressure manifold – Assembly (→ Page 178)
Qty.:
Used in: 3.9.10 Carrier housing upper section – Removal and installation (→ Page 195)
Qty.:
Used in: 3.10.6 Compressed-air distributor – Adjustment and Installation (→ Page 205)
Qty.:
Used in: 3.11.5 Exhaust turbocharger oil supply pipework, distributor and fasteners – Installation
(→ Page 213)
Qty.:
Used in: 3.11.8 Vent line for oil supply pipework of exhaust turbocharger – Installation
(→ Page 216)
DCL-ID: 0000027862 - 006

Qty.:
Used in: 3.12.6 Engine coolant pump ‒ Installation (→ Page 223)
Qty.:
Used in: 3.12.21 Engine coolant thermostat – Installation (→ Page 241)
Qty.:
Used in: 3.12.28 Raw water pump – Installation (→ Page 249)

322 | Appendix B | MS22061/04E 2015-11

 Engine oil
Part No.:
Qty.:
Used in: 3.2.4 Vibration damper on PTO, free end ‒ Installation (→ Page 47)

Grease Kluthe Hakuform 30-11C

Part No.: X00059351
Qty.: 1
Used in: 3.8.14 Air pipework to cylinders ‒ Installation (→ Page 167)

Hypochlorites
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Masking agent(EDTA, NTA)

Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Nitric acid
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Oilstone
Part No.: 8205893261/00
Qty.: 1
Used in: 3.9.5 Constant-pressure manifold ‒ Check (→ Page 177)

Phosphoric acid
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Pipe thread sealant (Loctite 586)

Part No.: 40033
Qty.: 1
DCL-ID: 0000027862 - 006

Used in: 3.8.3 Air and exhaust flap control – Installation (→ Page 151)

Sealing compound (Led-Plate 250F)

Part No.: 40134
Qty.: 1
Used in: 3.2.12 Piston and conrod – Assembly (→ Page 66)

MS22061/04E 2015-11 | Appendix B | 323

 Sealing compound (Molyduval Ciric A)
Part No.: X00065696
Qty.: 1
Used in: 3.1.14 Cylinder liner – Installation (→ Page 36)

Sealing paste(Optid)
Part No.: 50136
Qty.: 1
Used in: 3.9.6 Constant-pressure manifold – Assembly (→ Page 178)

Sodium carbonate
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Sodium polyphosphate
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Solvent (isopropyl alcohol)

Part No.: X00058037
Qty.: 1
Used in: 3.13.5 Sensors and actuators – Check (→ Page 268)

Solvent on paraffin or naphta basis

Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Sulfamic acid
Part No.:
Qty.:
Used in: 3.12.11 Coolant cooler and fuel cooler – Cleaning (→ Page 228)

Synthetic blasting abrasive

Part No.: 20098
Qty.: 1
DCL-ID: 0000027862 - 006

Used in: 3.9.4 Constant-pressure manifold ‒ Cleaning (→ Page 176)

324 | Appendix B | MS22061/04E 2015-11

 5.3 Index
Constant-pressure manifold  Coolant cooler and fuel cooler 
– Overview  169 – Overview  225
Cylinder head  Coolant cooler and fuel cooler – Cleaning 228
– Overview  74 Cylinder 
Vibration damper on PTO, free end  – Designation  20
– Overview  40 Cylinder head 
– Cleaning  79
A – Final steps  83
Actuators  – Installation  80
– Check  268 – Removal  77
– Final steps  275 Cylinder head – Preparatory steps 76
– Preparatory steps  261 Cylinder liner 
– Removal  262 – Check  34
Air and exhaust flap control  – Cleaning  33
– Installation  151 – Final steps  39
– Overview  147 – Installation  36
– Removal  149 – Overview  28
Air pipework to cylinders  – Preparatory steps  29
– Installation  167 – Removal  30
– Preparatory steps  163 – Tolerances  35
Air pipework to cylinders – Final steps 168
E
Air pipework to the cylinder heads, right side 
– Overview  162 Engine coolant cooler 
Air supply pipework to cylinders  – Check  231
– Removal  164 – Fuel cooler  
– Final steps  234
C – Preparatory steps  226
Carrier housing  Engine coolant cooler and fuel cooler 
– Overview  193 – Final steps  234
– Upper section removal and installation  195 – Installation  233
Carrier housing – Final steps 198 – Preparatory steps  226
Carrier housing – Preparatory steps 194 Engine coolant cooler and fuel cooler – Leakage test  232
Compressed-air distributor  Engine coolant cooler and fuel cooler ‒ Removal 227
– Adjustment  205 Engine coolant pump 
– Installation  205 – Check  222
– Overview  199 – Cleaning  221
– Removal  202 – Final steps  224
Compressed-air distributor – Check 204 – Installation  223
Compressed-air distributor – Final steps 208 – Overview  217
Compressed-air distributor – Preparatory steps 201 – Preparatory steps  219
Conrod  – Removal  220
– Assembly  66 Engine coolant thermostat 
– Final steps  73 – Check  240
– Preparatory steps  55 – Cleaning  239
– Installation  241
DCL-ID: 0000027862 - 006

Constant-pressure manifold 
– Assembly  178 – Overview  235
– Check  177 – Removal  238
– Cleaning  176 Engine coolant thermostat – Final steps 242
– Final steps  192 Engine coolant thermostat – Preparatory steps 237
– Preparatory steps  172 Engine driving end 
Constant-pressure manifold housing  – Definition  20
– Overview  169 Engine free end 
– Removal  173 – Definition  20
Contact persons 296 Engine sides 
Conversion tables 289 – Designation  20

MS22061/04E 2015-11 | Appendix B | 325

 Engine wiring harness and brackets  I
– Overview  251 Inspection port cover 
Exhaust turbocharger  – Cleaning sealing surfaces  24
– Check  142 – Installation  26
– Cleaning  141 – Overview  21
– Final steps  146 – Removal  23
– Installation  143 Inspection port cover – Check 25
– Removal  140 Inspection port cover – Final steps 27
Exhaust turbocharger oil supply, distributor and securing Inspection port cover – Preparatory steps 22
hardware 12V – Overview 209, 211 Intake housing with air flap 
Exhaust turbocharger – Preparatory steps 139 – Check  158
– Cleaning  157
F
– Installation  159
Fiber-reinforced composites  – Overview  153
– General information  18 – Preparatory steps  155
Fuel cooler  – Removal  156
– Check  231 Intake housing with air flap – Final steps 161
Fuel pipework 
– Leak-off fuel   L
– Installation  135 Leak fuel line 
Fuel priming pump  – Removal  134
– Cleaning  127 Leak-off fuel line - Overview 131
– Final steps  130 Leak-off fuel pipework 
– Installation  129 – Final steps  136
– Overview  124 – Installation  135
– Preparatory steps  125 – Preparatory steps  133
– Removal  126 List of abbreviations 294
Fuel priming pump – Check 128
M
H
MTU contact persons 296
High-pressure line 
– Preparatory steps  110 O
Hotline 296 Oil supply 
HP fuel accumulator  – Exhaust turbochargers, distributor and fasteners  
– Final steps  107 – Installation  213
– Installation  105 Oil supply  
– Overview  101 – Exhaust turbocharger oil supply, distributor and fas-
– Preparatory steps  103 teners  
– Removal  104 – Removal  212
HP fuel line  Oil supply pipework for exhaust turbochargers, distribu-
– Final steps  116 tor and fasteners – Overview 210
HP fuel lines 
– Installation  112 P
– Overview  108 Piston 
HP line  – Assembly  66
– Removal  111 – Check  60
HP pump  – Cleaning  59
DCL-ID: 0000027862 - 006

– Cleaning  97 – Final steps  73

– Final steps  100 – Preparatory steps  55
– Installation  98 – Tolerances  62
– Overview  93 Piston and conrod 
– Preparatory steps  94 – Installation  69
– Removal  95 – Overview  53
– Removal  56

326 | Appendix B | MS22061/04E 2015-11

 Pressure limiting valve  Tolerance List 
– Cleaning  120 – General information  293
– Final steps  123 Transport 17
– Installation  122
– Overview  117 V
– Preparatory steps  118 Valve drive 
– Removal  119 – Cleaning  88
Pressure limiting valve – Check 121 – Installation  90
Pump  – Overview  84
– Engine coolant   – Removal  87
– Cleaning  221 Valve gear 
– Final steps  92
R – Preparatory steps  86
Raw water pump  Valve gear ‒ Check 89
– Cleaning  247 Vent line for oil supply pipework of exhaust turbocharger
– Installation  249 – Installation 216
– Removal  246 Vent line for oil supply pipework of exhaust turbocharg-
Raw water pump – Final steps 250 ers 
Raw water pump – Preparatory steps 245 – Overview  214
Raw-water pump  Vent line for oil supply pipework of exhaust turbocharg-
– Check  248 ers – Removal  215
– Overview  243 Vibration damper on free end – Final steps 52
Vibration damper on free end – Preparatory steps 43
S Vibration damper on PTO, free end 
Safety notices, standards 16 – Installation  47
Safety regulations  – Removal  44
– Auxiliary materials  14
– Environmental protection  14 W
– Fire prevention  14 Wear Limits List 
– Fluids and lubricants  14 – General information  293
– Important provisions  6, 7
– Maintenance work  11
– Operation  9
– Organizational requirements  8
– Personnel requirements  8
– Repair work  11
– Startup  9
Safety requirements 
– Safety notices, standards  16
Sensors 
– Check  268
– Final steps  275
– Installation  269
– Preparatory steps  261
– Removal  262
Sensors and actuators 
– Installation  269
DCL-ID: 0000027862 - 006

– Removal  262
Sensors and actuators – Overview 257
Service partners 296
Spare parts service 296
Starting-air distributor  
– Cleaning  203

T
Tightening specifications 
– Nuts  276
– Screws and bolts  276
– Screws, nuts and bolts  276

MS22061/04E 2015-11 | Appendix B | 327