MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD

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MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD

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MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD

Language : English
Pages :820
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD

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

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MTU Diesel Engine 12 V 4000 Gx1 16 V 4000 Gx1 Maintenance Manual M020108-00E PDF DOWNLOAD

• Compliance with maintenance and repair specifications is an important safety factor.
• Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. Secure the engine against inadvertent starting. With an electric starter, disconnect the battery. With a pneumatic starter, close the main shut-off valve of the compressed-air system and release pressure from the compressed-air supply line. Attach a sign “Do not operate” in the operating area or to control equipment. Persons not involved must keep clear.
• Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required. Maintenance and repair work must only be carried out by authorized, qualified personnel.
• Use only proper, calibrated tools.
• Do not work on engines or components which are only held by lifting equipment or crane. Always support these components in accordance with regulations on suitable frames or stands before beginning any maintenance or repair work.
• Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check that all guards have been installed and that all tools and loose components have been removed from the engine.
• Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before starting work, relieve pressure in systems and H.P. lines which are to be opened.
• Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean. Always seal connections with caps or covers if a line is removed or opened.
• During maintenance and repair work, take care not to damage the fuel lines. To tighten the connections when installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
• Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other components to avoid contact with them. Do not place fuel or oil lines near hot components, except when necessary for design reasons during installation.
• Elastomers (e.g. “Viton” sealing rings) are stable under normal operating conditions. When subjected to fire or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals if they have a carbonized or resinous appearance. Wear protective gloves!
• Take care with hot fluids in lines, pipes, and chambers. Risk of injury!
• Note cooling period for components which are heated for installation or removal. Risk of injury!
• Do not touch hot components of the compressor and the exhaust system. Risk of injury!
• Take special care when removing ventilation or plugs from the engine. In order to avoid discharge of highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has recently been shut down, as the liquids can still be hot.
• Take special care when draining hot fluids. Risk of injury!
• When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or soak them with a suitable bonding agent.
• When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
• When working high on the engine, always use suitable ladders and work platforms. Make sure components are placed on stable surfaces.
• In order to prevent back injuries when lifting heavy components, adults, depending on age and sex, should only lift weights between max. 10 kg and 30 kg, therefore: Use lifting gear or seek assistance

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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