8V-12V-16v 4000 G M070040_00E.1109

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Technical Publication

Diesel Engine8V 4000 G

12V 4000 G

16V 4000 G

Tolerances andWear Limits ListM070040/00E

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Printed in Germany 2002 Copyright MTU Friedrichshafen GmbHDiese Veröffentlichung einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigenschriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung,Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbankenund Online-Diensten.Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligenWartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten.

Printed in Germany 2002 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission ofMTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing onelectronic systems including data bases and online services.This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.Subject to alterations and amendments.

Imprimé en Allemagne 2002 Copyright MTU Friedrichshafen GmbHTout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTUFriedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches,

la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous àl’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.Modifications réservées.

Impreso en Alemania 2002 Copyright MTU Friedrichshafen GmbHEsta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como sureproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que seincluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición delpersonal de mantenimiento y de servicio.Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania

2002 Copyright MTU Friedrichshafen GmbHQuesta pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo allariproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm ed alla memorizzazione od all’elaborazione in sistemielettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’ utente al personale addettoalla manutenzione e alla condotta.Con riserva di modifiche.

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Amendment Service! Any changes in contents will be sent to you in the form of an amendment,

provided you complete the reverse of this receipt card and return it to us.

Postcard

MTU Friedrichshafen GmbH

Department SCT

88040 Friedrichshafen

GERMANY

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Receipt Amendment No.

Publication number: M070040/00E

Name ..........................................................

Manufacturer .......................................................

Department .........................................................

Fax ....................Telephone.....................

Street ..........................................................

Postal box number ..............................................

(Postal code) City ................................................

Country ..........................................................

1. 02-07

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

No. Date Name

1. 02-07

2.

3. 4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

Please mark all filed amendments here.

Please use block capitals!

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Contents Page 1

M070040/00E 02-07 © MTU

Contents

General Information

010 Crankcase

020 Gear train

030 Running gear

040 Cylinder head

050 Valve gear

200 Coolant system

Preliminary Note

Data Sheets

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Page 2 Contents

M070040/00E 00-01 © MTU

General Information

The tolerances and wear limits indicated in this publication are intended as a guide for the examination of engine componentsduring inspection and repair.

Explanation of terms for dimensions of new componentsTol. size Designed size followed by a letter/number symbol (e.g. 24

H6) or by the permissible dimensional

deviation (e.g.24

+0.013)

Basic size Designed size without fit symbol or quotation of dimensional deviation

Deviation Permissible deviation from the basic or toleranced size,indicated by the upper and lower limits

Clearance Difference between bore and shaft diameterswhen bore diameter is greater than shaft diameter

Interference Difference between bore and shaft diameterswhen bore diameter is smaller than shaft diameter

Explanation of terms for reconditioning and operational limits

Wear limit The limit dimensions specified do not represent the absolute maximum values permissible forsatisfactory engine operation.

They indicate that the next basic overhaul can be reached safely.

If a limit value is exceeded, the component must be replaced.

Reconditioninginstructions

If values exceed or drop below limit values, the components must be reconditioned inaccordance with the relevant reconditioning instructions or replaced.

Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limit values, unless exceptions arespecifically indicated.

All dimensions are given in "mm", unless alternative units of measurement are specifically indicated.

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Crankcase Group 010Page 1

M070040/00E 00-01 © MTU

Cylinder Liner

No. Designation Stage Tol. size Deviation Clearance Interference Wear limit

Basic size lower upper min. max. min. max.

1 Housing bore 0 196.000H7

0 + 0.046 0.059 0.016

- upper fit 1 196.500H7

Cylinder liner 0 196.000 j6 - 0.013 + 0.016

- upper fit 1 196.500 j6

2 Housing bore 0 189.000H7

0 + 0.046 0.050 0.125

- lower fit 1 189.500H7

Cylinder liner 0 189.000 f6 - 0.079 - 0.050

- lower fit 1 189.500 f6

3 Bush bore 170.000H7

0 + 0.040 0.014 0.094

Scraper ringOD

170.000 g7 - 0.054 - 0.014

4 Scraper ring bore 164.000H8

0 + 0.063

5 Bush bore 165.000H7

0 + 0.040

- installed

6 Marking for stage

Reconditioning instructions:

Re 1 and 2: In event of cavitation at upper and/or lower fit of crankcase bore:Introduce next repair stage and install cylinder liner of corresponding stage

Re 3 and 4: Check scraper ring OD and ID when fitted

Re 6: Stamp markings with 6 mm high numeral punches- at stage 1 + 0.5

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Group 010 CrankcasePage 2

M070040/00E 00-01 © MTU

Crankshaft Bearing Cap



1 Bearing cap bed 298.000E9

+ 0.110 + 0.240 0.022 0.184

Bearing cap width 298.000 p6 + 0.056 + 0.0882 Bearing cap bed 298.000

H7 0 + 0.052 0.004 0.088

Bearing cap width 298.000 p6 + 0.056 + 0.088

3 Screw length 348.000 - 0.500 + 0.500

Note:

Re 1: Install bearing cap as specified and tighten screws as per tightening specification.

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M070040/00E 00-01 © MTU

Crankshaft Bearing Bore

Insert crankshaft bearing cap in crankcase as per installation instructions and tighten screws as per tightening specification.

Measure main bearing bores:

- Determine diameters a, b1 and b2 each in 2 measuring planes and from the results determine the mean values of a, b1 andb2.

- Check roundness of bores:Possible deviations from roundness result from the mean values of a, b1 and b2in accordance with the equation 0.5 (b1+b2)-a

Vertical ovality - a greater than 0.5 (b1+b2) - is not permissible.

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M070040/00E 00-01 © MTU

Coaxiality of Crankcase Bores for Crankshaft Bearings

Max. permissible deviation from coaxiality New condition Wear limit

a in each case, adjacent left and right bearings dia. 0.040 dia. 0.050

b 8 V from crankshaft bearing 1 to 5 dia. 0.060 dia. 0.100

c 12 V from crankshaft bearing 1 to 7 dia. 0.080 dia. 0.120

d 16 V from main bearing 1 to 9 dia. 0.120 dia. 0.140

e applicable for all bearings 0.100 0.120

f applicable for all bearings O 0.010 O 0.035

g applicable for all bearings, not concave - 0.010 - 0.012

h applicable for all bearings // 0.015 // 0.018

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M070040/00E 00-01 © MTU

Coaxiality of Crankcase Bores for Camshaft Bearings


a in each case, adjacent left and right bearings dia. 0.040 dia. 0.050

b 8 V from camshaft bearing 1 to 5 dia. 0.060 dia. 0.100

c 12 V from camshaft bearing 1 to 7 dia. 0.080 dia. 0.120

d 16 V from camshaft bearing 1 to 9 dia. 0.120 dia. 0.140

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M070040/00E 00-01 © MTU

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Gear Train Group 020Page 1

M070040/00E 00-01 © MTU

Idler Gear, Free End



1 Equipment carrierbore

81.000H7

0 + 0.035 0 0.070 Clearancemax. 0.080

Axle OD 81.000 h7 - 0.035 0

2 Gear bore 80.000H7

0 + 0.030 0.029 0.078

Bush OD 80.000 s6 + 0.059 + 0.078

3 Bush bore

- installed 75.000H8

0 + 0.046 0.060 0.136

- removed 75.000E6

+ 0.060 + 0.079

Axle OD 75.000 e7 - 0.090 - 0.060


75.000P7

- 0.051 - 0.021 0.009 0.069 Clearancemax. 0.080

Axle OD 75.000 e7 - 0.090 - 0.060

5 Equipment carrierwidth

41.200 0 + 0.200 0.050 0.800 Clearancemax.

Gear width 40.700 - 0.100 0 0.090

6 Crankcase

Note:

Re 5: Measure equipment carrier width when it is free of tension.

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Group 020 Gear TrainPage 2

M070040/00E 00-01 © MTU

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Running Gear Group 030Page 1

M070040/00E 00-01 © MTU

Crankshaft Bearing Arrangement, Free End




193.000H6

0 + 0.029 0.175 0.233 Interferencemin. 0.150

Bearing OD 193.204 0 + 0.029

- not installed

2 Bearing bush bore 180.121 0 + 0.069 0.321 0.430 Clearancemax. 0.450

- bearing fitted

Driver flange OD 179.800 h7 - 0.040 0

- not press-fitted

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Group 030 Running GearPage 2

M070040/00E 00-01 © MTU

Crankshaft Seal, Free End



1 Inner star bore 198.000H7

0 + 0.046 0.059 0.016

Driver flange OD 198.000 j6 - 0.013 + 0.016- not press-fitted

2 Seal carrier bore 230.000H8

0 + 0.072 0.278 0.590

Shaft seal OD 230.470 - 0.120 + 0.120

3 Running surfaceOD

199.800 h9 - 0.115 0

4 Radial-lip oil seal fitted flush


Re 3:Running surface worn: Metal-spray running surface and grind using feed-in method

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M070040/00E 00-01 © MTU

Crankshaft Bearing Arrangement, Alignment Bearing



1 Housing bore 0 - 0

0 - 10 - 2

0 - 3

1 - 0

1 - 1

1 - 2

1 - 3

171.000H6

171.000

H6

171.000H6

171.000H6

171.500H6

171.500H6

171.500H6

171.500H6

0

0

+ 0.025

+ 0.025

171.035

Transverseovality

max. 0.050

171.535

Transverseovality

max. 0.050

2 Alignment bearingdiameter

- installed

0 - 0

0 - 1

0 - 2

0 - 3

1 - 0

1 - 11 - 2

1 - 3

160.120

159.620

159.120

158.620

160.120

159.620159.120

158.620

0

0

+ 0.054

+ 0.054

0.120 0.199 Transverseovality max.0.050

Main bearing journalOD

0 - 0

0 - 1

0 - 2

0 - 3

1 - 0

1 - 1

1 - 2

1 - 3

160.000 h6

159.500 h6

159.000 h6

158.500 h6

160.000 h6

159.500 h6

159.000 h6

158.500 h6

- 0.025

- 0.025

0

0

159.970

159.470

158.970

158.470

159.970

159.470

158.970

158.470

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M070040/00E 00-01 © MTU

Crankshaft Mounting, Alignment Bearing Spreading Dimension



1 Alignment bearing, upper half

2 Alignment bearing, lower half3 Spreading

dimension

- Alignmentbearing, upperand lower halves

0 - 0

0 - 1

0 - 2

0 - 3

1 - 0

1 - 1

1 - 2

1 - 3

171.200

171.200

171.200

171.200

171.700

171.700

171.700

171.700

0

0

+ 0.500

+ 0.500

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M070040/00E 00-01 © MTU

Crankshaft Bearing Arrangement




0 - 10 - 2

0 - 3

1 - 0

1 - 1

1 - 2

1 - 3

171.000H6

171.000

H6

171.000H6

171.000H6

171.500H6

171.500H6

171.500H6

171.500H6

0

0

+ 0.025

+ 0.025

171.035

Transverseovality

max. 0.050

171.535

Transverseovality max.0.050

2 Crankshaft bearingdiameter

- installed

0 - 0

0 - 1

0 - 2

0 - 3

1 - 0

1 - 11 - 2

1 - 3

160.120

159.620

159.120

158.620

160.120

159.620159.120

158.620

0

0

+ 0.054

+ 0.054

0.120 0.199 Transverseovality max.0.050

Main bearing journaldia.

0 - 0

0 - 1

0 - 2

0 - 3

1 - 0

1 - 1

1 - 2

1 - 3

160.000 h6

159.500 h6

159.000 h6

158.500 h6

160.000 h6

159.500 h6

159.000 h6

158.500 h6

- 0.025

- 0.025

0

0

159.970

159.470

158.970

158.470

159.970

159.470

158.970

158.470

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M070040/00E 00-01 © MTU

Crankshaft Bearing Arrangement



1 Main bearing, upper half

2 Main bearing, lower half3 Spreading

dimension

- Main bearing,upper and lowerhalves

0 - 0

0 - 1

0 - 2

0 - 3

1 - 0

1 - 1

1 - 2

1 - 3

171.400

171.400

171.400

171.400

171.900

171.900

171.900

171.900

0

0

+ 1.000

+ 1.000

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M070040/00E 00-01 © MTU

Axial Clearance - Crankshaft



1 Axial clearance

- crankshaft

0.200 0.600 Clearance

min. 0.100max. 0.700

2 Flywheel fitted flush

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M070040/00E 00-01 © MTU

Crankshaft Seal, Driving End

No.

Designation Stage Tol. size Clearance Interference Wear limit

lower upper min. max. min. max.

1 Flywheel bore

- not shrink-fitted

707.030 707.290 0.700 1.150

Flywheel OD 673.990 708.180

2 Flywheel bore 673.050 673.130 0.065 0.075

Adapter OD 673.075 673.125

3 Flywheel housing bore 240.000 240.072 0.278 0.590

Radial-lip shaft seal OD 240.350 240.590

4 Running surface OD 209.585 209.700

5 Radial-lip shaft seal flush-fitted

6 Flywheel fitted flush


Re 4:Running surface worn: Metal-spray running surface and grind using feed-in method

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M070040/00E 00-01 © MTU

Crankshaft Bearing Shells

Install bearing shells and tighten bearing cap according to tightening specifications.

Measure crankshaft bearing bores:

- Determine diameters, a, b1 and b2 in measuring planes 1 and 2 and in each case calculate mean values of a, b1 and b2.- Check roundness of bores:

Possible deviations from roundness result from the mean values of a, b1 and b2 in accordance with the equation 0.5 (b1+b2)-a

Replace bearing shells

- If deviation from roundness 0.040

- If b1 to b2 greater than / less than 0.040

- With vertical ovality - a 0.5 (b1+b2) - is not permissible.

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M070040/00E 00-01 © MTU

Counterweight Fixture



1 Screw length

- removed

130.000 - 0.400 0 max. length

132.000


Re 1: If wear limit has been exceeded: replace screw

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M070040/00E 00-01 © MTU

Crankshaft Gear, Free End



1 Gear press-fitted 145.500 - 0.300 + 0.300

- Crankshaft end togear face

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M070040/00E 00-01 © MTU

Crankshaft, Coaxiality of Main Bearing Journal 8 V 4000


From main bearing journal 1 to main bearing journal 5 0.100

From main bearing journal to main bearing journal 0.050

Note:

The crankshaft must be supported in main bearings 1 and 5.

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M070040/00E 00-01 © MTU

Crankshaft, Concentricity of Main Bearing Journal 12 V 4000




Note:The crankshaft must be supported in main bearings 2 and 6.

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M070040/00E 00-01 © MTU

Crankshaft, Concentricity of Main Bearing Journal 16 V 4000




Note:The crankshaft must be supported in main bearings 2 and 8.

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M070040/00E 00-01 © MTU

Crankshaft, Dynamic Balancing 8 V 4000

Balancing specification New condition Wear limit

Max. operating speed: 1900 rpm

Mass of balancing group: 463 kg


Balancing speed: 150 rpm

Permissible residual imbalance for each balancing plane during initial balancing:

Permissible residual imbalance for each balancing plane for comparable balancingin other clamping or balancing machinery

135 gcm

400 gcm


It will only be necessary to rebalance the crankshaft if the counterweights have been replaced.

If a crankshaft has been reworked to the next repair stage, rebalancing will not be necessary provided that the counterweightshave not been replaced.

Mark the counterweights and reassemble them according to marking.

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M070040/00E 00-01 © MTU









200 gcm

600 gcm





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M070040/00E 00-01 © MTU









200 gcm

300 gcm





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M070040/00E 00-01 © MTU

Conrod Bearing



1 Conrod bore 126.000H6

0 + 0.025

2 Conrod bearingbore

- Conrod bearinginstalled

0 - 00 - 1

0 - 2

0 - 3

117.082116.882

116.682

116.482

0 + 0.048 0.082 0.152

Crankpin journaldia.

0 - 0

0 - 1

0 - 2

0 - 3

117.000 h6

116.800 h6

116.600 h6

116.400 h6

- 0.022 0

3 Crankpin length 97.500 - 0.100 + 0.100 0.200 0.600

Conrod width 48.600 - 0.100 0

4 Spreadingdimension

- Conrod bearingshell, upper andlower halves

0 - 0

0 - 1

0 - 20 - 3

126.400

126.400

126.400126.400

0 + 1.000

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M070040/00E 00-01 © MTU

Conrod Bearing, Locating Pin



1 Locating pin bore 7.000H7

0 + 0.015 0.004 0.028

Locating pin OD 7.000 r6 + 0.019 + 0.028

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M070040/00E 00-01 © MTU

Conrod Bearing Bore



1 Screw length 103.000 - 0.400 + 0.200 104.500

- removed

Note:

Tighten conrod - conrod cap as per tightening specifications.

Conrod bearing - measure bearing bore in a, b and c. Min. dimension must be in direction a.


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M070040/00E 00-01 © MTU

Conrod Bearing Shells



1 Screw length 103.000 - 0.400 + 0.200 104.500

- removed

Note:

Tighten conrod bearing - conrod - conrod cap as per tightening specifications.

Conrod bearing - measure bearing bore in a, b and c. Min. dimension must be in direction a.


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M070040/00E 00-01 © MTU

Parallellity of Conrod Bores



1 Conrod length 354.000 - 0.100 + 0.100

- with bush andwithout bearingshells

Conrod length 354.000 - 0.100 + 0.100

- without bush andwithout bearingshells

2 Parallellity of axles 0.070 measured at 100 mm distance Inclinationmax. 0.100

- Inclination

3 Parallellity of axles 0.250 measured at 100 mm distance Twist max.0.350

- twist

Conrod weight 9.530 kg - 0.060 kg + 0.060 kg

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M070040/00E 00-01 © MTU

Piston Bearing



1 Conrod bore 0

12

75.000H6

75.200

H6

75.400H6

0 + 0.019 0.101 0.139 Axial testload forbushinstalled

Bush OD 0

1

2

75.000 v6

75.200 v6

75.400 v6

+ 0.120 + 0.139 min.17000 N

2 Bush ID

- finished-machined

68.000 + 0.070 + 0.080 0.070 0.085 Clearancemax. 0.090

Piston pin OD 68.000 - 0.005 0

3 Bush ID

- finished-machined

68.000 + 0.008 + 0.018 0.008 0.023 Clearancemax. 0.025

Piston pin OD 68.000 - 0.005 04 MTU part number and stage stamped on


Re 1: Bush loose at 17000 N test load: replace bush and introduce next repair stage if necessary.

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M070040/00E 00-01 © MTU

Piston Rings



1 Groove width 4.000 + 0.170 + 0.190 0.170 0.225 Clearance

Rectangular-sectionring 4.000 - 0.035 0 max. 0.300


Rectangular-sectionring

4.000 - 0.035 0 max. 0.200


Oil control ring 5.000 - 0.035 0 max. 0.200

4 Ring end clearance



Oil control ring

0.400

1.000

0.450

0.700

1.300

0.800

Max. play:

0.900

1.500

1.000

Note:

Re 4: Measure ring end clearance in ring gauge 165.0H6

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M070040/00E 00-01 © MTU

Piston Clearance in Cylinder Liner



1 Cylinder liner bore 165.000H7

0 + 0.040 0.184 0.246

Piston skirt OD 164.805 - 0.011 + 0.0112 Cylinder liner bore 165.000

H7 0 + 0.040 0.270 0.330

Piston skirt OD 164.720 - 0.010 + 0.010


0 + 0.040 0.400 0.840

Piston crown OD 164.580 - 0.020 + 0.020


0 + 0.040 0.315 0.355

Piston crown OD 164.665 - 0.020 + 0.020


0 + 0.063 0.585 0.698

Piston crown OD 163.390 - 0.025 + 0.025


0 + 0.063 0.720 0.833

Piston crown OD 163.255 - 0.025 + 0.025

7 Piston skirt, crowned-oval


Re 1 to 5: Measure piston crown dia. and piston skirt dia. vertically to piston pin axis

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M070040/00E 00-01 © MTU

Piston Crown Fixture



1 Screw length

- removed

49.000 - 0.100 + 0.100 max. length

49.8002 Screw length

- removed

50.000 - 0.100 + 0.100 max. length

50.800

3 Designation

- ZB Kolben

- Piston uppersection

Note:

Re 1 and 2: If wear limit has been exceeded: replace screw

Re 3: Marking XXXX, last four digits of piston assembly applied here.

Marking YYYY, last four digits of piston upper section applied here.

(See table for piston 524 030 20 17)

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Cylinder Head Group 040Page 1

M070040/00E 00-01 © MTU

Valve Guides, Inlet, Exhaust



1 Cylinder head bore 19.000H7

0 + 0.021 0.007 0.041

Valve guide OD 19.000 r6 + 0.028 + 0.0412 Valve guide bore

- installed

11.000H7

0 + 0.018 0.055 0.093

Valve stem dia. 10.935 - 0.010 + 0.010

Note:Re 2: Finish-machine valve guide bore after pressing into cylinder head.

Pushing slightly, it must be possible to insert the go-end of the plug gauge on the valve guide length.The no-go end of the plug gauge must not make contactMax. clearance exceeded: Install manufactured valve guide.

Manufactured valve guide for repair version



1 Cylinder head bore 01

2

19.000H7

19.100

H7

19.300H7

0 + 0.021 0.007 0.041

Valve guide OD 0

1

2

19.000 r6

19.100 r6

19.300 r6

+ 0.028 + 0.041

2 Valve guide bore

- installed

11.000H9

0 + 0.043 0.055 0.108

Valve stem dia. 10.935 - 0.010 + 0.100

Reconditioning instructions:Re 1: Cylinder head bore max. dimension exceeded: Ream to next stageRe 2: Max. clearance exceeded: Install new manufactured valve guide

Pushing slightly, it must be possible to insert the go-end of the plug gauge on the valve guide length.No-go side plug gauge contact max. 5 mm

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Group 040 Cylinder HeadPage 2

M070040/00E 00-01 © MTU

Valve Clearance



1 Valve clearance

- Exhaust

0.400 max. 2.400

2 Valve clearance

- Inlet

0.500 max. 2.500

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M070040/00E 00-01 © MTU

Valve Seats, Exhaust



1 Plug gaugediameter

73.200 0 0

2 Valve seat surface

Check dimension

- Plug gauge

4.800 - 0.100 + 0.100 min. 2.300

3 Cylinder headdepth

- Combustionchambers sealingring surface

13.800 0 + 0.100


Re 2: Recondition valve seat surface only until good support is achieved.

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M070040/00E 00-01 © MTU

Valve Seats, Inlet



1 Plug gaugediameter

87.130 0 0

2 Valve seat surface

Check dimension

- Plug gauge

4.800 - 0.100 + 0.100 min. 2.300

3 Cylinder headdepth

- Combustionchambers sealingring surface

13.800 0 + 0.100


Re 2: Recondition valve seat surface only until good support is achieved.

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M070040/00E 00-01 © MTU

Exhaust Valve



1 Valve headOD

56.000 - 0.200 + 0.200

2 Check dimension

- with ring gauge

- Valve seat dia. 54.000

- Valve seat height 4.180 - 0.200 + 0.100 min. 3.480

3 Check dimension

- without ringgauge

- Valve seat height3.200 - 0.200 + 0.100 min. 2.500


Re 2 and 3: Recondition valve seat height only until good support is achieved.

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M070040/00E 00-01 © MTU

Inlet Valve



1 Valve headOD

57.000 - 0.200 + 0.200

2 Check dimension

- with ring gauge

- Valve seat dia. 54.000

- Valve seat height 4.050 - 0.200 + 0.100 min. 3.350

3 Check dimension

- without ringgauge

- Valve seat height3.200 - 0.200 + 0.100 min. 2.500


Re 2 and 3: Recondition valve seat height only until good support is achieved.

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M070040/00E 00-01 © MTU

Outer Valve Springs



1 Spring length

- Unloaded

83.900

2 Spring length

- Loaded

66.000

2.1 Spring force withspring length 66.00

530.000 N

3 Spring length

- Loaded

51.750


952.000 N - 39 N + 39 N Springpower min.897.000 N

4 Spring length

- Block dimension

47.700 Blockdimensionmax.

47.7005 Coil dia. 34.400

6 Wire dia. 5.300

e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.500

e2 Spring support permissible deviation from parallelism max 0.600

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M070040/00E 00-01 © MTU

Inner Valve Springs



1 Spring length

- Unloaded

78.400

2 Spring length

- Loaded

61.000


256.000 N

3 Spring length

- Loaded

46.750


466.000 N - 19 N + 19 N Springpower min.420.000 N

4 Spring length

- Block dimension

42.500 Blockdimensionmax.

42.5005 Coil dia. 23.000

6 Wire dia. 3.600

e1 Permissible deviation of surface line from vertical with unloaded spring max. 2.300

e2 Spring support permissible deviation from parallelism max 0.400

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M070040/00E 00-01 © MTU

Cylinder Head - Mating Face - Protective Sleeve - Valve Bridge



1 Cylinder headheight

184.000 - 0.100 + 0.100

2 Protective sleevesupport

124.000 0 + 0.200

3 Protective sleevebore

44.200 0 + 0.100 0.100 0.300

Protective sleeveOD

44.100 - 0.100 0

4 Cylinder headthread

M 24x1.5

Protective sleevethread

M 24x1.5

5 Cylinder head bore 14.000N7

- 0.023 - 0.005 0.012 0.041

Sliding pin dia. 14.000m6 + 0.007 + 0.018

6 Valve bridge bore 14.000D7

+ 0.050 + 0.068 0.032 0.061Sliding pin dia. 14.000m6 + 0.007 + 0.018

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M070040/00E 00-01 © MTU

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Group 050 Valve GearPage 2

M070040/00E 00-01 © MTU

Camshaft Bearing




1 - 0

97.000H6

97.500

H6

0 + 0.022 0.058 0.130

Bush OD

- not installed

0 - 0

1 - 0

97.080

97.580

0 + 0.050

2 Bush bore

- installed

92.012 0 + 0.052 0.084 0.171

Camshaft OD 92.000 e7 - 0.107 - 0.072

a in each case, adjacent left and right bearings

b from camshaft bearing 1 to 2

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Valve Gear Group 050Page 3

M070040/00E 00-01 © MTU

Axial Clearance - Camshaft




0 + 0.025 0 0.050

Camshaft OD 32.000 h7 - 0.025 02 Axial play

- Camshaft

0.100 0.178

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M070040/00E 00-01 © MTU

Rocker Arm Bearing, Inlet and Exhaust



1 Rocker arm bore 50.000 H7

0 + 0.025

Bush OD 50.000 s6 + 0.043 + 0.0592 Bush bore

- installed

- not installed

45.000

45.000E6

0

+ 0.050

+ 0.050

+ 0.006

0.025 0.091

Clearancemax. 0.100

Rocker shaft OD 45.000 f6 - 0.041 - 0.025

3 Bearing pedestalbore

45.000U7

- 0.086 - 0.061 0.020 0.061

Rocker shaft OD 45.000 f6 - 0.041 - 0.025

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Valve Gear Group 050Page 5

M070040/00E 00-01 © MTU

Rocker Arm Bearing, Inlet and Exhaust



1 Rocker arm bore 36.000H7

0 + 0.025 0.018 0.059

Bush OD 36.000 s6 + 0.043 + 0.0592 Bush bore

- installed

- not installed

32.000

32.000E6

0

+ 0.050

+ 0.050

+ 0.066

0.025 0.091

Clearancemax. 0.100

Shaft OD 32.000 f6 - 0.041 - 0.025

3 Roller bore 21.000E7

+ 0.040 + 0.061 0.040 0.082 Clearance

Bush OD 21.000 h7 - 0.021 0 max. 0.090

4 Bush bore 14.000E7

+ 0.032 + 0.050 0.032 0.058 Clearance

Pin OD 14.000 h5 - 0.008 0 max. 0.065

5 Rocker arm bore 14.000P6

- 0.026 - 0.015 0.007 0.026

Pin OD 14.000 h5 - 0.008 0

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Coolant System Group 200Page 1

M070040/00E 00-01 © MTU

Engine Coolant Pump for H.P. Temperature System



1 Seal carrier bore 90.000K7

- 0.025 + 0.010 0.025 0.025

Bearing OD 90.000 - 0.015 02 Housing bore 90.000

K7 - 0.025 + 0.010 0.025 0.025

Bearing OD 90.000 - 0.015 0

3 Bearing bore 40.000 - 0.012 0 0.002 0.025

Shaft OD 40.000 k5 + 0.002 + 0.013

4 Spacer sleeve bore 40.000N7

- 0.033 - 0.008 0.010 0.046

Shaft OD 40.000 k5 + 0.002 + 0.013

5 Housing bore 80.000K7

- 0.021 + 0.009 0.022 0.021

Bearing OD 80.000 - 0.013 0

6 Bearing bore 40.000 - 0.012 0 0.002 0.025

Shaft OD 40.000 k5 + 0.002 + 0.013


0 + 0.025 0.018 0.059

Shaft OD 39.000 s6 + 0.043 + 0.059

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Group 200 Coolant SystemPage 2

M070040/00E 00-01 © MTU

Engine Coolant Pump for H.P. Temperature System



1 Seal carrier bore 72.000 H8

0 + 0.046 0.084 0.230

Shaft seal OD 72.000 + 0.130 + 0.2302 Shaft OD 48.000 - 0.100 0


0 + 0.030 0.040 0.100

Rotary seal OD 78.200 - 0.030 0

4 Impeller bore 30.000H5

0 + 0.009 0.032 0.050

Shaft OD 30.000 t5 + 0.041 + 0.050

5 Rotary seal

Counter ring

Note:

Re 2:Running surface worn: Metal-spray pump shaft and grind using feed-in method

Re 5:In the event of wear marks, replace parts together

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Coolant System Group 200Page 3

M070040/00E 00-01 © MTU

Engine Coolant Pump for L.P. Temperature System



1 Seal carrier bore 90.000K7

- 0.025 + 0.010 0.025 0.025

Bearing OD 90.000 - 0.015 02 Housing bore 90.000

K7 - 0.025 + 0.010 0.025 0.025

Bearing OD 90.000 - 0.015 0

3 Bearing bore 40.000 - 0.012 0 0.002 0.025

Shaft OD 40.000 k5 + 0.002 + 0.013

4 Spacer sleeve bore 40.000N7

- 0.033 - 0.008 0.010 0.046

Shaft OD 40.000 k5 + 0.002 + 0.013

5 Housing bore 80.000K7

- 0.021 + 0.009 0.022 0.021

Bearing OD 80.000 - 0.013 0

6 Bearing bore 40.000 - 0.012 0 0.002 0.025

Shaft OD 40.000 k5 + 0.002 + 0.013


0 + 0.025 0.018 0.059

Shaft OD 39.000 s6 + 0.043 + 0.059

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Group 200 Coolant SystemPage 4

M070040/00E 00-01 © MTU

Engine Coolant Pump for L.P. Temperature System



1 Seal carrier bore 72.000 H8

0 + 0.046 0.084 0.230

Shaft seal OD 72.000 + 0.130 + 0.2302 Shaft OD 48.000 - 0.100 0


0 + 0.030 0.040 0.100

Rotary seal OD 78.200 - 0.030 0

4 Impeller bore 30.000H5

0 + 0.009 0.032 0.050

Shaft OD 30.000 t5 + 0.041 + 0.050

5 Rotary seal

Counter ring


Re 2:Running surface worn: Metal-spray pump shaft and grind using feed-in method

Re 5:In the event of wear marks, Replace parts together

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Preliminary Note 00

M070040/00E 02-07 © MTU

Data Sheets

To ensure that unusable components are not installed or components which can still be used are not discarded allinspection work should only be carried out by qualified personnel using the necessary measuring instruments. All measuring and testing equipment is naturally subject to wear.To determine resulting tolerance deviations in good time, the measuring and test equipment must be inspectedannually at a location equipped with appropriate technical facilities. Alternatively, equipment can be inspected by our Product Support Service and MTU, Friedrichshafen, or DDC, orby an external product support service. Adherence to the limits specified in this Tolerances and Wear Limits List is mandatory.The following data sheets should be used to record the individual examination results:- Cylinder liner, installed- Cylinder liner, upper fit- Cylinder liner, lower fit- Main bearing (bearing installed)- Conrod bearing (bearing shells installed)- Timing

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Data Sheet 01

M070040/00E 02-07 © MTU

Cylinder Liner, Installed

Engine model:

Engine No.:

Order No.:

Crankcase No.:

Cylinder liner

Part No.:

Specified bore dimension:

To measure: In measurement direction a (direction of travel) and b(transverse).

Measurement plane 1 - 2

Actual dimensions Actual dimensionsCyl.No. Measur-ementdirec-tion

Basicdimen-sion

Measuring planesCyl.No. Measur-ement

direc-tion

Basicdimen-sion

Measuring planes

1 2 1 2

a a A1

bB1

b

a a A2

bB2

b

a a A3

bB3

b

a a A4

bB4

b

a a A5

bB5

b

a a A6

bB6

b

a a A7

bB7

b

a a A8

bB8

b

a a A9

bB9

b

a a A10

bB10

b

Remarks:

Date: .......................... Checked by: ........................................................

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Data Sheet 02

M070040/00E 02-07 © MTU

Cylinder Liner, Upper Fit

Engine model:

Engine No.:

Order No.:

Crankcase No.:

Cylinder liner

Part No.:

Specified dimension,upper fit: mm

- Crankcase bore mm

- Cylinder liner OD mm

Specified clearance: mm

Actual dimensionsCylinder No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

Crankcase bore

1Cylinder liner OD

Clearance/overlap

Actual dimensions

Cylinder No. B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Crankcase bore

1Cylinder liner OD

Clearance/overlap

Remarks:

Date: ......................... Checked by: ........................................................

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Data Sheet 03

M070040/00E 02-07 © MTU

Cylinder Liner, Lower Fit

Engine model:

Engine No.:

Order No.:

Crankcase No.:

Cylinder liner

Part No.:

Specified dimension,lower fit: mm

- Crankcase bore mm

- Cylinder liner OD mm

Specified clearance: mm

Actual dimensionsCylinder No. A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

Crankcase bore

1Cylinder liner OD

Clearance/overlap

Actual dimensions

Cylinder No. B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Crankcase bore

1Cylinder liner OD

Clearance/overlap

Remarks:

Date: ......................... Checked by: ........................................................

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Data Sheet 04

M070040/00E 02-07 © MTU

Main Bearing (Bearing Installed)

Engine model:

Engine No.:

Order No.:

Crankcase No.:

Crankshaft No.:

Measurement and Entry:

Diameter a, b1 and b2Measuring planes 1 and 2

Determining bearing

clearance:One-part bearing:Min. dimension a, b1 or b2

Standard:Min. dimension a

Free end: Crankshaftbearing Specified dia.: mm

Driveflange Specified dia.: mm

Driving end: Crankshaftbearing Specified dia.: mm

Driveflange Specified dia.: mm

Main bearing: Specified dia.: mm

Crankshafts Specified dia.: mm

Radialclearance: Free end: mm (min.) mm (max.)

Driving end: mm (min.) mm (max.)

Main bearing: mm (min.) mm (max.)

Crankshaftaxial clearance: mm (min.) mm (max.)

Actualdimension: mm

Actual dimensions

Bearing No. 1 2 3 4 5 6 7 8 9 10

1

Bearing dia. b1 2

1Bearing dia. b2 2

1

Bearing dia. a 2

Crankshaft dia.(actual dimension)

Bearing clearance(radial)

Remarks:

Date: .......................... Checked by: ........................................................

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Data Sheet 05

M070040/00E 02-07 © MTU

Conrod Bearing (Bearing Shells Installed)

Engine model: Specified dimensions:

Engine No.: - Conrod bearing bore mm

Order No.:

Crankcase No.: - Radial clearance min.: mm

Crankshaft No.: max.: mm

Conrod, A bank

Actual dimensions, dia.To measure:Diameter a, b, c

Cyl.No.

Rod No. Batch Basicdimen-

sion

Crankshaft Radialclearance

To determine clearanceMin. dimension a, b or c

a b c

1

2

3

4

5

6

7

8

9

10

Conrod, B bank

Actual dimensions, dia.

Cyl.No.

Rod No. Batch Basicdimen-

sion

Crankshaft Radialclearance

a b c

1

2

3

4

5

6

7

8

9

10

Remarks:

Date: .......................... Checked by: ........................................................

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Data sheet 06

M070040/00E 02-07 © MTU

Timing

Engine model:

Engine No.:

Order No.:

1. Timing Diagram:

Actual

Cylinder No.

Spec-ifiedin °

Toler-ance

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

Exhaust valveopens beforeBDC

±

Inlet valveopens before TDC

±

Exhaust valvecloses after TDC

±

Inlet valvecloses after BDC

±

Actual

Cylinder No.

Spec-ifiedin °

Toler-ance

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Exhaust valveopens beforeBDC

±

Inlet valveopens before TDC

±

Exhaust valve

closes after TDC

±

Inlet valvecloses after BDC

±

Settings for valve timing correspond to the adjustment diagram

2. Cam Lift/Valve Lift:

Actual

Cylinder No.

Spec-ified

in mm

Toler-ance

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

Exhaust ±

Inlet ±

Actual

Cylinder No.

Spec-ified

in mm

Toler-ance

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

Exhaust ±

Inlet ±

3. Injection Timing:

For start of delivery, see engine master card

Remarks:

Date: .......................... Checked by: ........................................................

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Data Sheet 06

Documents

8V-12V-16v 4000 G M070040_00E.1109