MTU 12 V 2000 G25 Operating Instructions Manual
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MTU 12 V 2000 G25 Operating Instructions Manual

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Operating Instructions

Diesel engine
12 V 2000 G25, G25 TB
12 V 2000 G45, G45 TB
12 V 2000 G65, G65 TB
12 V 2000 G85, G85 TB
16 V 2000 G25, G25 TB
16 V 2000 G45, G45 TB
16 V 2000 G65, G65 TB
16 V 2000 G85, G85 TB
18 V 2000 G25, G25 TB
18 V 2000 G45, G45 TB
18 V 2000 G65, G65 TB
18 V 2000 G85, G85 TB
Application group 3A
MS15018/02E

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Mohammed Ibrahim
February 20, 2025

Is the alternator belt for the model 16V 2000 G85 TB is same as of 16V 4000 G83

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Summary of Contents for MTU 12 V 2000 G25

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 2000 G25, G25 TB 12 V 2000 G45, G45 TB 12 V 2000 G65, G65 TB 12 V 2000 G85, G85 TB 16 V 2000 G25, G25 TB 16 V 2000 G45, G45 TB...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi- crofilming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 6 Troubleshooting 1.1 Important provisions for all products 6.1 Fault indication on SAM display – Genset 1.2 Personnel and organizational requirements applications 1.3 Transport 6.2 Troubleshooting 1.4 Safety regulations for startup and operation 1.5 Safety regulations for maintenance and 7 Task Description repair work 7.1 Engine...
  • Page 4 7.15.5 Coolant pump – Relief bore check 7.16 Low-Temperature Circuit 8.1 Abbreviations 7.16.1 Charge-air coolant – Filling 8.2 MTU contact persons/service partners 7.16.2 Charge-air coolant – Draining 7.16.3 Charge-air coolant – Change 9 Appendix B 7.16.4 Charge-air coolant – Level check 9.1 Special Tools...

  • Page 5: Safety

    1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product. General information This product may pose a risk of injury or damage in the following cases: •...

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 7: Transport

    Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis .

  • Page 8: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met.

  • Page 9: Safety Regulations For Maintenance And Repair Work

    1.5 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
  • Page 10 When working high on the equipment, always use suitable ladders and work platforms. Make sure com- ponents or assemblies are placed on stable surfaces. Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and cable ties).
  • Page 11 Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so.

  • Page 12: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The latest version can be found on the website on the "Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply to the product.

  • Page 13: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 14: Standards For Safety Notices In The Text

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

  • Page 15: General Information

    2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4). For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on the left-hand side of the engine and the letter "B"...

  • Page 16: Engine - Overview

    2.2 Engine – Overview Illustration is applicable to 12/16/18 V 2000 Gxy engines (with water-cooled intercooler TB) 010 Crankcase and add-on 7 Oil heat exchanger 14 Charge-air manifold components 8 Oil filter 15 Cylinder head 1 Air filter 9 Coolant pump 16 Flywheel housing 2 Oil separator 10 Fuel priming pump...
  • Page 17 Illustration is applicable to 12/16/18 V 2000 Gxy engines (with air-cooled intercooler TD) 1 Air filter 7 Oil heat exchanger 13 Exhaust elbow 2 Oil separator 8 Oil filter 14 Charge-air manifold 3 Air outlet 9 Coolant pump 15 Cylinder head 4 Engine governor 10 Fuel priming pump 16 Flywheel housing...

  • Page 18: Sensors And Actuators - Overview

    2.3 Sensors and actuators – Overview Engines with water-cooled intercooler TB Item Name Monitoring of Lube oil temperature Lube oil pressure Charge-air coolant temperature Charge-air pressure Camshaft speed Crankshaft speed Coolant temperature Fuel temperature The coolant level sensor F33 is located in the coolant expansion tank at the cooler 18 | General Information | MS15018/02E 2013-09...
  • Page 19 Engine with air-cooled intercooler TD Item Name Monitoring of Lube oil temperature Lube oil pressure Charge-air coolant temperature Charge-air pressure Camshaft speed Crankshaft speed Coolant temperature Fuel temperature The coolant level sensor F33 is located in the coolant expansion tank at the cooler MS15018/02E 2013-09 | General Information | 19...

  • Page 20: Technical Data

    3 Technical Data 3.1 12/16/18 V 2000 Gx5 engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 21 Number of cylinders Combustion method: Direct fuel injection Cooling system: conditioned water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder configuration: V angle Degrees Bore Stroke Displacement per cylinder liters 1.99 1.99 1.99 1.99 Displacement, total liters 23.88 23.88 31.84...
  • Page 22 Number of cylinders Lube-oil operating pressure before engine, from Lube-oil operating pressure before engine, Lube-oil pressure before engine, alarm Lube-oil pressure before engine, shut- down FUEL SYSTEM Number of cylinders Fuel pressure at engine supply connec- -0.3 -0.3 -0.3 -0.3 tion, min.
  • Page 23 WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configu- 2490 2490 3100 3500 ration acc. to scope of supply specifica- tion) ACOUSTICS Number of cylinders Exhaust noise, unsilenced - DL (sound dB(A) power level LW, ISO 6798) Engine surface noise with attenuated in- dB(A) take noise filter) - DL (sound power level...

  • Page 24: 12/16/18 V 2000 Gx5-Tb Engine Data, Optimized Fuel Consumption

    3.2 12/16/18 V 2000 Gx5-TB engine data, optimized fuel consumption Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power settings). N Not yet defined value - Not applicable X Applicable...
  • Page 25 Number of cylinders Cooling system: conditioned water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder configuration: V angle Degrees Bore Stroke Displacement per cylinder liters 1.99 1.99 1.99 1.99 Displacement, total liters 23.88 23.88 31.84 35.82 Compression ratio Cylinder heads: single-cylinder Cylinder liners: wet, replaceable Inlet valves per cylinder...
  • Page 26 LUBE-OIL SYSTEM Number of cylinders Lube oil operating temperature before en- °C gine, from Lube-oil operating temperature before en- °C gine, to Lube-oil temperature before engine, alarm R °C Lube-oil temperature before engine, shut- °C down Lube-oil operating pressure before engine, from Lube-oil operating pressure before engine, Lube-oil pressure before engine, alarm...
  • Page 27 Number of cylinders Oil pan capacity at dipstick mark "min." liters (standard oil system) (Option: max. oper- ating inclinations) Oil pan capacity at dipstick mark "max." liters (standard oil system) (Option: max. oper- ating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configu- 2570 2570...

  • Page 28: Firing Order

    3.3 Firing order Firing order 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 18 V A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8 28 | Technical Data | MS15018/02E 2013-09...

  • Page 29: Engine - Main Dimensions

    3.4 Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 12 V 2000 Gxy approx. 1885 mm approx. 1580 mm approx. 1585 mm 16 V 2000 Gxy approx. 2230 mm approx. 1580 mm approx. 1585 mm 18 V 2000 Gxy approx.

  • Page 30: Operation

    4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the PowerPack into operation after extended out-of-service-periods (>3 months) Item Action Engine Depreserve (→...

  • Page 31: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 109); Cooling system Check engine coolant level (→ Page 112); Check charge-air coolant level (→...

  • Page 32: Engine - Starting In Manual Mode (Test Run)

    4.3 Engine – Starting in manual mode (test run) Preconditions ☑Generator (if fitted) is not connected to network. ☑External start interlock is not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 33: Safety System - Override

    4.4 Safety system – Override NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. NOTICE Inadmissible operating status. Severe damage to property! • Use override function only in hazardous situations to ensure full capability in the event of engine faults.

  • Page 34: Operational Checks

    4.5 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 35: Engine - Stopping In Manual Mode (Test Run)

    4.6 Engine – Stopping in manual mode (test run) Preconditions ☑Generator (if fitted) is not connected to network ☑Engine in manual mode NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses.

  • Page 36: Engine - Emergency Stop

    4.7 Engine – Emergency stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Action Emergency stop pushbutton Press pushbutton. •...

  • Page 37: After Stopping The Engine - Engine Remains Ready For Operation

    4.8 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control MS15018/02E 2013-09 | Operation | 37...

  • Page 38: After Stopping The Engine - Putting The Engine Out Of Operation

    4.9 After stopping the engine – Putting the engine out of operation Preconditions ☑MTU Preservation and Represervation Specifications (A001070/..) are available. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 114); Drain charge-air coolant (→ Page 120) if: •...

  • Page 39: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 40: Fault Indication On Sam Display - Genset Applications

    6 Troubleshooting 6.1 Fault indication on SAM display – Genset applications SAM fault messages 1 2-line LC display 3 Fault type 2 Time indicator for alarms 4 Node number The structure of the display is as follows: • First line –...
  • Page 41 Fault type – fault message text SE no. Error message text Sensor Temperatur Defect Temperature failure Sensor Voltage Defect Voltage failure CAN Bus- 1 Error/Bus Defec CAN Bus- 1 Overrun CAN Bus- 2 Error/Bus Defec CAN Bus- 2 Overrun Temperatur Compensation Error I/O-Module Slot2 Defect I/O-Module Slot3 Defect I/O-Module Slot4 Defect...
  • Page 42 The fault code (1) comprises three digits. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/ actuators checked and replaced as necessary if the troubleshooting measures listed in the table below prove unsuccessful. IMPORTANT NOTE: The information provided in the columns “Meaning”...
  • Page 43 Fault Setting parame- code no. Full designation Meaning Action ter no. SS T-Charge Air Main warning: Charge-air Check cooler, check 2.0121.932 temperature too high (limit intercooler, contact value 2, alarm configuration Service if no fault parameter, see PR detected. 2.8008.100 for explanation). HI T-Coolant Intercool- Prewarning: Coolant temper- Check cooler, con-...
  • Page 44 Fault Setting parame- code no. Full designation Meaning Action ter no. LO P-Fuel Fuel inlet pressure too low Check filter, check 2.0102.921 (limit value 1, alarm configu- genset fuel supply. ration parameter, see PR 2.8008.100 for explanation). Warning. SS P-Fuel Fuel inlet pressure too low Check filter, check 2.0102.922...
  • Page 45 Fault Setting parame- code no. Full designation Meaning Action ter no. SS Release Speed Not Runup speed not reached Check for additional 2.1090.924 Reached (alarm configuration parame- messages. Recharge ter, see PR 2.8008.100 for battery. Engine un- explanation). Start terminat- der load: Check fuel supply;...
  • Page 46 Fault Setting parame- code no. Full designation Meaning Action ter no. HI ECU Power Supply Supply voltage too high (limit Check batteries and 2.0140.931 Voltage value 1, alarm configuration generator. parameter, see PR 2.8008.100 for explanation). Warning. HIHI ECU Power Sup- Supply voltage too high (limit Check batteries and 2.0140.932...
  • Page 47 Fault Setting parame- code no. Full designation Meaning Action ter no. AL CAN No PU-Data The selected CAN mode initi- Check devices con- 2.0500.683 alizes communication by nected to CAN. means of the PU data mod- ule. However, the required PU data module is unavaila- ble or invalid (alarm configu- ration parameter, see PR...
  • Page 48 Fault Setting parame- code no. Full designation Meaning Action ter no. SD T-Charge Air SD alarm configuration, Check sensor and 1.8004.571 charge-air temperature sen- wiring (B9), replace sor faulty, short circuit or as necessary. wire break. SD T-Coolant Intercool- SD alarm configuration, cool- Check sensor and 1.8004.574 ant temperature sensor of in-...
  • Page 49 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Stop Camshaft Sen- Engine stop due to camshaft Check connector 1.8004.562 sor Defect sensor fault (and a previous and wiring to sensor crankshaft sensor fault in the B1, replace as nec- same operating cycle).
  • Page 50 Fault Setting parame- code no. Full designation Meaning Action ter no. SD Frequency Input SD alarm configuration, fre- Contact Service. 2.8006.590 quency input faulty, short cir- cuit or wiring damage. AL Timing Cylinder A1 Time-of-flight measuring fault Replace plug-in 1.8004.500 injector cylinder A1: Time-of- pump if this occurs flight value measured ex-...
  • Page 51 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Timing Cylinder A8 Time-of-flight measuring fault Replace plug-in 1.8004.507 injector cylinder A8 Time-of- pump if this occurs flight value measured ex- frequently. tremely small or large (alarm configuration parameter, see PR 2.8008.100 for explana- tion).
  • Page 52 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Timing Cylinder B5 Time-of-flight measuring fault Replace plug-in 1.8004.514 injector cylinder B5: Time-of- pump if this occurs flight value measured ex- frequently. tremely small or large (alarm configuration parameter, see PR 2.8008.100 for explana- tion).
  • Page 53 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Wiring Cylinder A2 Wiring fault in injector wiring Check injector wir- 1.8004.521 cylinder A2. Result: Misfiring ing, rectify injector (alarm configuration parame- solenoid valve short ter, see PR 2.8008.100 for circuit (positive to explanation).
  • Page 54 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Wiring Cylinder A8 Wiring fault in injector wiring Check injector wir- 1.8004.527 cylinder A8. Result: Misfiring ing, rectify injector (alarm configuration parame- solenoid valve short ter, see PR 2.8008.100 for circuit (positive to explanation).
  • Page 55 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Wiring Cylinder B4 Wiring fault in injector wiring Check injector wir- 1.8004.533 cylinder B4. Result: Misfiring ing, rectify injector (alarm configuration parame- solenoid valve short ter, see PR 2.8008.100 for circuit (positive to explanation).
  • Page 56 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Wiring Cylinder B10 Wiring fault in injector wiring Check injector wir- 1.8004539 cylinder B10. Result: Misfir- ing, rectify injector ing (alarm configuration pa- solenoid valve short rameter, see PR 2.8008.100 circuit (positive to for explanation).
  • Page 57 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Open Load Cylinder Disruption fault in injector Check injector wir- 1.8004.545 wiring cylinder A6. Result: ing, exclude disrup- Misfiring (alarm configuration tion in solenoid parameter, see PR valve (e.g. by injec- 2.8008.100 for explanation).
  • Page 58 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Open Load Cylinder Disruption fault in injector Check injector wir- 1.8004.551 wiring cylinder B2. Result: ing, exclude disrup- Misfiring (alarm configuration tion in solenoid parameter, see PR valve (e.g. by injec- 2.8008.100 for explanation).
  • Page 59 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Open Load Cylinder Disruption fault in injector Check injector wir- 1.8004.557 wiring cylinder B8. Result: ing, exclude disrup- Misfiring (alarm configuration tion in solenoid parameter, see PR valve (e.g. by injec- 2.8008.100 for explanation).
  • Page 60 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Stop MV-Wiring Injector wiring fault. Engine Check wiring, re- 1.8004.561 Ground stop configurable (alarm con- place wiring harness figuration parameter, see PR as necessary. 2.8008.100 for explanation). Possible causes: 1. Short cir- cuit of injector positive con- nection to ground of one or more injectors.
  • Page 61 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Open Load Digital Line disruption at digital in- Check wiring. 2.8006627 Input 3 put 3, wiring faulty or no re- sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for explana- tion).
  • Page 62 Fault Setting parame- code no. Full designation Meaning Action ter no. HIHI U-PDU Injector voltage too high (lim- Execute engine gov- 2.0141.932 it value 2, alarm configura- ernor self-test, re- tion parameter, see PR place engine gover- 2.8008.100 for explanation). nor in case of fault.
  • Page 63 External engine protection Contact Service. 2.0291.921 tion function active (alarm config- uration parameter, see PR 2.8008.100 for explanation). AL Call MTU Field Serv- Power reduction caused by Contact Service. 2.0555.001 maintenance function (main- tenance concept, alarm con- figuration parameter, see PR 2.8008.100 for explanation).

  • Page 64: Troubleshooting

    6.2 Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are properly secured (see manufacturer's documen- tation). Starter Engine wiring or starter defective Check if cable connections are properly secured, contact Service.
  • Page 65 Defective Contact Service. Charge-air temperature too high Component Probable Cause Task Coolant Incorrect coolant concentration Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge-air pressure too low...
  • Page 66 Exhaust gas white Component Probable Cause Task Engine Not at operating temperature Run engine to reach operating tempera- ture. Fuel system Water in fuel Check fuel system on fuel prefilter. Drain fuel prefilter (→ Page 98). Intercooler Leaking Contact Service. 66 | Troubleshooting | MS15018/02E 2013-09...

  • Page 67: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device for 12V engines F6558556 Barring device for 16V, 18V engines F6558557 DANGER Rotating and moving engine parts.

  • Page 68: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Preconditions ☑External pushbutton “Bar engine without starting” is provided. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 69: Engine - Test Run

    7.1.3 Engine – Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 70: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 80). Remove injector (→ Page 86). Positioning crankshaft at BDC Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
  • Page 71 Final steps Install injector (→ Page 86). Install cylinder head cover (→ Page 80). MS15018/02E 2013-09 | Task Description | 71...

  • Page 72: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex- amination report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 73 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 74: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet F30027340 Engine oil Filter element (→...
  • Page 75 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia- phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 76: Crankcase Breather - Wire Mesh Cleaning

    7.3.2 Crankcase breather – Wire mesh cleaning Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner Diesel fuel Petroleum jelly Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 77: Valve Drive

    7.4 Valve Drive 7.4.1 Valve clearance – Check and adjustment Preconditions ☑Engine is stopped and starting disabled. ☑Engine coolant temperature is max. 40 °C. ☑Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y4342013 Torque wrench, 20-100 Nm F30026582...
  • Page 78 Diagram for 16V engines (two crankshaft positions) Diagram for 18V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. •...

  • Page 79: Adjusting Valve Clearance

    Adjusting valve clearance Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm. Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. Tighten locknut (1) with torque wrench to the specified tightening torque while holding adjusting screw (2) firmly with screw driver.

  • Page 80: Cylinder Head Cover - Removal And Installation

    7.4.2 Cylinder head cover – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F30043446 Ratchet F30027340 Gasket (→ Spare Parts Catalog) Preparatory steps On cylinder head covers with crankcase breather: Loosen clamps.

  • Page 81: Injection Pump / Hp Pump

    7.5 Injection Pump / HP Pump 7.5.1 Injection pump – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injection pump (→ Spare Parts Catalog) Injection pump – Replacement Remove injection pump and install new one (→ Page 82). MS15018/02E 2013-09 | Task Description | 81...

  • Page 82: Injection Pump - Removal And Installation

    7.5.2 Injection pump – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet F30027340 Adapter F30006234 Crowfoot wrench, 19 mm F30027424 Crowfoot box wrench, 22 mm F30027425 Torque wrench, 0.5-5 Nm 0015384230...
  • Page 83 Removing injection pump Mark installation position of injection pump. Disconnect wiring (1) from injection pump. Disconnect fuel line (2). Unscrew securing screws of injection pump by approx. 6 mm. Result: The preloaded compression spring presses the injection pump out of the crankcase. If not: •...
  • Page 84 Install injection pump, observing marked installation position. Install securing screws of injection pump and tighten with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 60 Nm +12 Nm Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (3) with engine oil.

  • Page 85: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 86). MS15018/02E 2013-09 | Task Description | 85...

  • Page 86: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Impact extractor F30377999 Fuel suction device F30378207 Torque wrench, 20-100 Nm F30026582 Ratchet F30027340 Adapter F30006234 Plug-in open-end wrench, 19 mm F30025897 Crowfoot wrench, 19 mm...
  • Page 87 Removing injector Disconnect leak-off fuel line from cylinder head. Disconnect fuel line (1). Remove thrust screw (2). Pull off pressure pipe neck (3). Extract fuel from the exposed bores using the suction device. Remove screw (2). Take off clamp (1). Screw impact extractor into injector.
  • Page 88 Blow out fuel line (2) and pressure pipe neck (5) with compressed air. Coat sealing ring with grease and fit onto pressure pipe neck (5). Coat the tape of the pressure pipe neck (5) with engine oil. Insert pressure pipe neck (5) into cylinder head until the sealing ring is in contact with cylinder head.

  • Page 89: Fuel System

    7.7 Fuel System 7.7.1 Fuel injection line – Pressure pipe neck replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet F30027340 Adapter F30006234 Plug-in open-end wrench, 19 mm F30025897 Crowfoot wrench, 19 mm F30027424...
  • Page 90 Replacing pressure pipe neck Disconnect fuel line (2). Blow out fuel line (2) with compressed air. Remove thrust screw (4). Withdraw pressure pipe neck (5). Coat sealing ring with grease and fit on new pressure pipe neck (5). Coat the tape of the pressure pipe neck (5) with engine oil.

  • Page 91: Fuel - Draining

    7.7.2 Fuel – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F30043446 Box wrench, 17 mm F30028341 Engine oil WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 92 If fuel no longer emerges, install non-return valve and tighten with torque wrench to the specified tight- ening torque. Name Size Type Lubricant Value/Standard Non-return valve Tightening torque (Engine oil) 10 Nm +1 Nm Connect fuel line. Tighten nut on banjo union. 92 | Task Description | MS15018/02E 2013-09...

  • Page 93: Fuel Pressure Maintaining Valve - Removal And Installation

    7.7.3 Fuel pressure maintaining valve – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Pressure relief valve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→...

  • Page 94: Fuel System - Venting

    7.7.4 Fuel system – Venting Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...
  • Page 95 Loosen banjo screw (arrow). Operate the pump with the handle until bubble-free fuel emerges. Tighten banjo screw. Loosen union nut of fuel return line. Loosen non-return valve (arrow). Operate the pump with the handle until bubble-free fuel emerges. Use torque wrench to non-return valve to the specified tightening torque. Name Size Type...

  • Page 96: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 97: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

    7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 98: Fuel Prefilter - Draining

    7.8.3 Fuel prefilter – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 99: Fuel Prefilter - Flushing

    7.8.4 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Seal (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 100 Open vent plug (5) of the filter to be flush- Unlock drain cock (6) by pressing toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un- filtered side, flushing the filter deposits downwards out of the filter. Close vent plug (5) and drain cock (6).

  • Page 101: Fuel Prefilter - Cleaning

    7.8.5 Fuel prefilter – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 102: Fuel Prefilter - Filter Element Replacement

    7.8.6 Fuel prefilter – Filter element replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 103 Open threaded vent plug (5) of contaminat- ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele- ment (3).

  • Page 104: Charge-Air Cooling General, Left-Hand Side

    7.9 Charge-Air Cooling General, Left-Hand Side 7.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Compressed air gun ejects a jet of pressurized air.

  • Page 105: Air Filter

    7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Filter insert (→ Spare Parts Catalog) Filter element (→ Spare Parts Catalog) Air filter – Replacement Remove air filter(s) and install new one(s) (→...

  • Page 106: Air Filter – Removal And Installation

    7.10.2 Air filter – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Variant A Loosen clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3). Verify that there are no objects in the flange of the intake housing (3) and clean Fit air filter (1) and clamp (2) on connecting flange of intake housing (3).

  • Page 107: Air Intake

    7.11 Air Intake 7.11.1 Service indicator – Signal ring position check Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position Replace air filter, if the signal ring (2) is completely visible in the red area of the service indicator control window (3) (→...

  • Page 108: Starting Equipment

    7.12 Starting Equipment 7.12.1 Air starter – Manual operation DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 109: Lube Oil System, Lube Oil Circuit

    7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil – Level check Preconditions ☑Engine is stopped and starting disabled. Oil level check prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx.

  • Page 110: Engine Oil – Change

    7.13.2 Engine oil – Change Preconditions ☑Engine is stopped and starting disabled. ☑Engine is at operating temperature. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring (→...

  • Page 111: Oil Filtration / Cooling

    7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 112: Circuit

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Engine coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 113: Engine Coolant – Change

    7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Engine coolant – Change Drain engine coolant (→ Page 114). Fill with engine coolant (→ Page 115). MS15018/02E 2013-09 | Task Description | 113...

  • Page 114: Engine Coolant – Draining

    7.15.3 Engine coolant – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 115: Engine Coolant – Filling

    7.15.4 Engine coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 116 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 112), top up with coolant if required. 116 | Task Description | MS15018/02E 2013-09...

  • Page 117: Coolant Pump – Relief Bore Check

    7.15.5 Coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 118: Low-Temperature Circuit

    7.16 Low-Temperature Circuit 7.16.1 Charge-air coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure.
  • Page 119 Charge-air coolant – Filling Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level reaches marking plate. Install plug screws of filling points with new sealing rings. Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it.

  • Page 120: Charge-Air Coolant – Draining

    7.16.2 Charge-air coolant – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 121: Charge-Air Coolant – Change

    7.16.3 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 120). Fill with charge-air coolant (→ Page 118). MS15018/02E 2013-09 | Task Description | 121...

  • Page 122: Charge-Air Coolant – Level Check

    7.16.4 Charge-air coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask.

  • Page 123: Coolant System

    7.17 Coolant System 7.17.1 Cooler – Checking cooler elements externally for dirt Preconditions ☑Engine is stopped and starting disabled. Check cooler elements externally for dirt Inspect cooler elements visually for dirt. Clean badly soiled cooler elements (→ Page 124). MS15018/02E 2013-09 | Task Description | 123...

  • Page 124: Cooler – Cleaning Cooler Elements

    7.17.2 Cooler – Cleaning cooler elements Preconditions ☑Engine is stopped and starting disabled. WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. WARNING Chemical substances in cleaners. Risk of irritation and chemical burns! •...

  • Page 125: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Drive-belt check and adjustment Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Pre-tension gauge Y20097429 Torque wrench, 20-100 Nm F30026582 Ratchet F30027340 Engine oil Drive belt –...
  • Page 126 Install protective cover. Setting (new drive belt) 450 N - 50 N Setting (used drive belt) 350 N - 50 N Drive belt – Tension adjustment Release screws (2, 3). Tension drive belt with tensioning nut (1) and check belt tension. Tighten screw (2) to specified torque using a torque wrench.

  • Page 127: Battery-Charging Generator Drive – Drive Belt Replacement

    7.18.2 Battery-charging generator drive – Drive belt replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet F30027340 Engine oil Drive belt (→ Spare Parts Catalog) Battery-charging generator drive –...

  • Page 128: Fan Drive

    7.19 Fan Drive 7.19.1 Fan drive – Drive-belt check and adjustment Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Belt tension tester 5505890119/00 Torque wrench, 20-100 Nm F30026582 Ratchet F30027340 Engine oil Preparatory steps Remove screws from protective cover.
  • Page 129 Drive belt – Tension check, var- iant B Place belt-tension tester onto drive midway between the belt pulleys (arrow). Press button uniformly against drive belt surface until spring disengagement can be heard and felt. Do not press any further, otherwise the dis- play value will be falsified.
  • Page 130 Drive belt – Tension adjustment, variant B Release screws (1, 4). Note: Bolt (3) is in position A for variant 50 Hz, and in position B for variant 60 Hz. Screw in screw (2) to tension drive belt. Check drive belt tension. Tighten screws (1, 4) with torque wrench to the specified tightening torque.

  • Page 131: Fan Drive – Belt Replacement

    7.19.2 Fan drive – Belt replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Preparatory steps Remove protective cover from radiator. Remove fan. Drive belt replacement, variant Loosen securing screwsBelt replace- ment (3).
  • Page 132 Final steps Install fan. Install protective cover. 132 | Task Description | MS15018/02E 2013-09...

  • Page 133: Wiring (General) For Engine/Gearbox/Unit

    7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Checking engine wiring Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 134: Accessories For (Electronic) Engine Governor / Control System

    7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine governor and connectors – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose. Otherwise the contacts could be bent.

  • Page 135: Engine Governor Plug Connections – Check

    7.21.2 Engine governor plug connections – Check Preconditions ☑Engine stopped and starting disabled. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.

  • Page 136: Installation

    7.21.3 ECU 7 engine governor – Removal and installation Preconditions ☑Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 137: Abbreviations

    Abgasturbolader/Abgasturboaufladung Exhaust turbocharger/exhaust turbocharging Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting of drift compensation in engine governor with DiaSys...
  • Page 138 Abbre- Meaning Explanation viation Engine Data Module Memory module for engine data Electrically Erasable Programmable Read Electrically Erasable Programmable Read Only Mem- PROM Only Memory EFPA Electronic Foot Pedal Assembly Electronic Foot Pedal Assembly Exhaust Gas Recirculation Exhaust gas recirculation Engine Ident Label Engine Monitoring Unit Engine monitoring unit...
  • Page 139 Abbre- Meaning Explanation viation Normal Null Reference surface for height above sea level Niedertemperatur Original Equipment Manufacturer Optimized Idle Oil Level Sensor Monitors oil level Oil pressure sensor Monitors oil pressure Oil Temperature Sensor Monitors oil temperature Oberer Totpunkt Top Dead Center Panel Control panel Peripheral Interface Module...

  • Page 140: Mtu Contact Persons/Service Partners

    Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 141: Special Tools

    9 Appendix B 9.1 Special Tools Adapter Part No.: F30006234 Qty.: Used in: 7.5.2 Injection pump – Removal and installation (→ Page 82) Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 86) Qty.: Used in: 7.7.1 Fuel injection line – Pressure pipe neck replace- ment (→...
  • Page 142 Belt tension tester Part No.: 5505890119/00 Qty.: Used in: 7.19.1 Fan drive – Drive-belt check and adjustment (→ Page 128) Box wrench, 17 mm Part No.: F30028341 Qty.: Used in: 7.7.2 Fuel – Draining (→ Page 91) Crowfoot box wrench, 22 mm Part No.: F30027425 Qty.:...
  • Page 143 Double-head box wrench Part No.: F30011450 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 86) Qty.: Used in: 7.7.1 Fuel injection line – Pressure pipe neck replace- ment (→ Page 89) Feeler gauge Part No.: Y4342013 Qty.: Used in: 7.4.1 Valve clearance –...
  • Page 144 Impact extractor Part No.: F30377999 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 86) Plug-in open-end wrench, 19 mm Part No.: F30025897 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 86) Qty.: Used in: 7.7.1 Fuel injection line –...
  • Page 145 Ratchet Part No.: F30027340 Qty.: Used in: 7.3.1 Crankcase breather – Oil separator element re- placement, diaphragm check and replacement (→ Page 74) Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 77) Qty.: Used in: 7.4.2 Cylinder head cover – Removal and installation (→...
  • Page 146 Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in: 7.5.2 Injection pump – Removal and installation (→ Page 82) Torque wrench, 20-100 Nm Part No.: F30026582 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 77) Qty.: Used in: 7.5.2 Injection pump –...
  • Page 147 Torque wrench, 8-40 Nm Part No.: F30043446 Qty.: Used in: 7.4.2 Cylinder head cover – Removal and installation (→ Page 80) Qty.: Used in: 7.7.2 Fuel – Draining (→ Page 91) MS15018/02E 2013-09 | Appendix B | 147...

  • Page 148: Consumables

    9.2 Consumables Cleaner Part No.: Qty.: Used in: 7.3.2 Crankcase breather – Wire mesh cleaning (→ Page 76) Coolant Part No.: Qty.: Used in: 7.15.4 Engine coolant – Filling (→ Page 115) Qty.: Used in: 7.16.1 Charge-air coolant – Filling (→ Page 118) Qty.: Used in: 7.16.3 Charge-air coolant –...
  • Page 149 Engine oil Part No.: Qty.: Used in: 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement (→ Page 74) Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 77) Qty.: Used in: 7.5.2 Injection pump – Removal and installation (→ Page 82) Qty.: Used in: 7.6.2 Injector –...
  • Page 150 Petroleum jelly Part No.: Qty.: Used in: 7.3.2 Crankcase breather – Wire mesh cleaning (→ Page 76) 150 | Appendix B | MS15018/02E 2013-09...

  • Page 151: Spare Parts

    9.3 Spare Parts Air filter Part No.: Qty.: Used in: 7.10.1 Air filter – Replacement (→ Page 105) Diaphragm Part No.: Qty.: Used in: 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement (→ Page 74) Drive belt Part No.: Qty.: Used in:...
  • Page 152 Gasket Part No.: Qty.: Used in: 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement (→ Page 74) Qty.: Used in: 7.4.2 Cylinder head cover – Removal and installation (→ Page 80) Qty.: Used in: 7.5.2 Injection pump – Removal and installation (→ Page 82) Qty.: Used in: 7.6.2 Injector –...
  • Page 153 Sealing ring Part No.: Qty.: Used in: 7.3.2 Crankcase breather – Wire mesh cleaning (→ Page 76) Qty.: Used in: 7.5.2 Injection pump – Removal and installation (→ Page 82) Qty.: Used in: 7.5.2 Injection pump – Removal and installation (→ Page 82) Qty.: Used in: 7.6.2 Injector –...

  • Page 154: Index

    9.4 Index Numerics 12/16/18 V 2000 Gx5 engine data, optimized fuel con- Designations  sumption 20 – Engine sides and cylinders  15 12/16/18 V 2000 Gx5-TB engine data, optimized fuel con- Drive belt  sumption 24 – Check and adjustment  125, 128 – Replacement  127 Abbreviations 137 After stopping the engine ...
  • Page 155 – Check  77 – Check  104 – Condensate drain for obstructions   – Check  104 MTU contact persons 140 Operational checks 34 Putting the engine into operation after extended out-of- service periods (>3 months) 30 Putting the engine into operation after scheduled out-of- service-period  31...

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