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Operating InstructionsDiesel engine16 V 4000 E20

M015241/03E

Printed in Germany© 2011 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 priorwritten permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐filming and storage or processing on electronic systems including data bases and online services.This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damageduring operation.Subject to alterations and amendments.

Commissioning NoteImportantPlease complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH.The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐ranty, spare parts, etc.).

Table of Contents1 Safety

1.1 General conditions 71.2 Personnel and organizational requirements 81.3 Transport 91.4 Crankshaft transport locking device 101.5 Safety regulations for startup and operation 121.6 Explosion hazard when removing

inspection port cover on engine 131.7 Safety regulations for maintenance and

repair work 141.8 Fluids and lubricants, fire prevention and

environmental protection 171.9 Engine – Barring with starting system 19

1.10 Conventions for safety instructions in thetext 20

2 General Information

2.1 Engine layout 212.2 Engine side and cylinder designations 252.3 Sensors and actuators – Overview 26

3 Technical Data

3.1 16V 4000 E20 engine data 283.2 Firing order 32

4 Operation

4.1 Putting the engine into operation afterextended out-of-service periods (>3months) 33

4.2 Putting the engine into operation afterscheduled out-of-service-period 34

4.3 Engine – Start in manual mode 354.4 Operational checks 364.5 Engine – Shutdown in manual mode 374.6 After stopping the engine 384.7 Plant – Cleaning 39

5 Maintenance

5.1 Maintenance task reference table [QL1] 40

6 Troubleshooting

6.1 Troubleshooting 416.2 DDEC alarms 44

7 Task Description

7.1 Engine 647.1.1 Engine – Barring manually 647.1.2 Engine – Barring with starting system 66

7.2 Cylinder Liner 677.2.1 Cylinder liner – Endoscopic examination 677.2.2 Instructions and comments on endoscopic

and visual examination of cylinder liners 69

7.3 Crankcase Breather 717.3.1 Crankcase breather – Oil separator check 717.3.2 Crankcase breather – Filter element

replacement 727.3.3 Crankcase breather (open-circuit crankcase

ventilation) – Filter element cleaning 74

7.4 Valve Drive 757.4.1 Valve gear – Lubrication 757.4.2 Valve clearance – Check and adjustment 767.4.3 Cylinder head cover – Removal and

installation 80

7.5 Injection Pump / HP Pump 817.5.1 HP pump – Relief bore check 81

7.6 Injection Valve / Injector 827.6.1 Injector – Replacement 827.6.2 Injector – Removal and installation 83

7.7 Fuel System 887.7.1 Fuel system – Venting 88

7.8 Fuel Filter 897.8.1 Fuel filter – Replacement 897.8.2 Fuel prefilter – Draining 907.8.3 Edge-type fuel filter – Draining 91

7.9 Charge-Air Cooling 927.9.1 Intercooler – Check drain for coolant leakage

and obstruction 92

7.10 Air Intake 937.10.1 Service indicator – Check 93

7.11 Starting Equipment 947.11.1 Starter – Condition check 947.11.2 Cold start system with ether injection – Check 95

7.12 Lube Oil System, Lube Oil Circuit 96

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7.12.1 Engine oil level – Check 967.12.2 Engine oil – Change 977.12.3 Engine oil – Sample extraction and analysis 99

7.13 Oil Filtration / Cooling 1007.13.1 Engine oil filter – Replacement 1007.13.2 Centrifugal oil filter – Cleaning and filter

sleeve replacement 101

7.14 Coolant Circuit, General, High-Temperature Circuit 103

7.14.1 Coolant level - Check 1037.14.2 Engine coolant – Change 1047.14.3 Engine coolant – Draining 1057.14.4 Engine coolant – Filling 1067.14.5 Engine coolant pump – Relief bore check 1087.14.6 Coolant – Sample extraction and analysis 109

7.15 Low-Temperature Circuit 1107.15.1 Charge-air coolant – Level check 1107.15.2 Charge-air coolant – Change 1117.15.3 Charge-air coolant – Draining 1127.15.4 Charge-air coolant – Filling 1137.15.5 Charge-air coolant pump – Relief bore check 116

7.16 Belt Drive 1177.16.1 Drive belt – Condition check 117

7.17 Battery-Charging Generator 1187.17.1 Battery-charging generator – Condition check 1187.17.2 Battery-charging generator – Check 1197.17.3 Battery-charging generator – Removal and

installation 120

7.17.4 Battery-charging generator drive – Drive beltand belt tensioner replacement 122

7.17.5 Battery-charging generator drive – Drive belttension adjustment 123

7.18 Fan Drive 1247.18.1 Fan drive belt– Tension check / adjustment 1247.18.2 Fan drive – Drive belt replacement 126

7.19 Wiring (General) for Engine/Gearbox/Unit 1277.19.1 Engine wiring – Check 127

7.20 Accessories for (Electronic) EngineGovernor / Control System 128

7.20.1 DDEC and connectors – Cleaning 1287.20.2 DDEC – Checking plug-in connections 130

8 Appendix A

8.1 Abbreviations 1318.2 MTU contacts/service partners 134

9 Appendix B

9.1 Special Tools 1359.2 Index 139

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1 Safety1.1 General conditions

GeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other com‐pulsory regulations regarding accident prevention and environmental protection must be observed. Thisstate-of-the-art engine has been designed to meet all applicable laws and regulations. The engine maynevertheless present a risk of injury or damage in the following cases:• Incorrect use• Operation, maintenance and repair by unqualified personnel• Modifications or conversions• Noncompliance with the Safety Instructions

Correct useThe engine is intended solely for use in accordance with contractual agreements and the purpose envis‐aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts noliability whatsoever for resultant damage or injury in such case. The responsibility is borne by the useralone.Correct use also includes observation of and compliance with the operating instructions and mainte‐nance and repair specifications.

Modifications or conversionsUnauthorized modifications to the engine represent a safety risk.MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications orconversions.

Spare partsOnly genuine MTU spare parts must be used to replace components or assemblies. MTU accepts noliability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shallbe voided in such case.

Reworking componentsRepair or engine overhaul must be carried out in workshops authorized by MTU.

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1.2 Personnel and organizational requirements

Personnel requirementsWork on the engine must only be carried out by appropriately qualified and instructed personnel.Observe the minimum legal age.Responsibilities of the operating, maintenance and repair personnel must be specified by the operatingcompany.

Organizational measuresThis publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐tion.Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair andtransport personnel at all times.Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐nel must have read and understood the safety-relevant instructions.This is especially important for personnel who work on the engine only on an occasional basis. Thesepersons shall receive repeated instruction.Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.

Working clothes and protective equipmentWear proper protective clothing for all work.Depending on the kind of work, use the necessary personal protective equipment.

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1.3 Transport

Transport

Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.Always use the lifting eyes on the engine when transporting an engine separately.Only use transport and lifting devices approved by MTU.Transport the engine/genset in the installation position only, maximum admissible inclination is 10°.Remove any loose parts on the genset.Hoist the engine/genset slowly ensuring that lifting cables/chains do not touch the engine or any of itscomponent parts. Readjust lifting device as necessary.Pay attention to the center of gravity of the engine/genset.When specially wrapped in aluminum foil, suspend the engine/genset by the lifting eyes on the bearingpedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.Fit the crankshaft shipping lock on the engine and fit the engine mount locking devices prior to transport.Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip‐ping and tipping when driving up or down inclines and ramps.

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

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1.4 Crankshaft transport locking device

Transport locking deviceThis locking device protects the crankshaft bearings from shocks and vibration damage during enginetransport.For removal of the transport locking device, observe the following:• The transport locking device should remain installed as long as possible during engine installation in

order to avoid damage.• Starting or barring the engine is allowed only with the transport locking device removed. If the genera‐

tor is already mounted on the engine, ensure that the transport locking device of the generator is re‐moved.

• Prior to every engine transport (without generator), this transport locking device must be reinstalledaccording to the instructions.

Removing the transport locking device from driving end (KS)• Release the locknuts (6) on both sides of the flywheel housing, remove screws (5) and take off the two

locks (4).• Remove screws (2), washers (3), cover plate (8) with label (7) and plates (1).Store the removed parts of the transport locking device carefully for possible reuse!

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Fitting the transport locking device on driving end (KS)• Secure the two plates (1) with screws (5) and nuts (6) together with cover plate (8) at the bores on

both sides of the flywheel housing. Tightening torque: 250 Nm + 25 Nm, lubricant: engine oil.• Screw nut (6) onto screws (5) up to the end of the thread.• Fit the locks (4) through the openings of plates (1) and fasten with the screws (5).• Tighten screws (5) in alternating steps on both sides. Tightening torque : 30 Nm + 3 Nm, lubricant: en‐

gine oil.• Screw on nuts (6) of both screws (5) at plates (1) and secure.• Mark the engine as "Fitted with transportation locking device".

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1.5 Safety regulations for startup and operation

Safety requirements for initial operationPrior to initial operation of the unit, install the assembly or unit according to the specifications and checkthe installation according to the MTU specifications.Before putting the device or plant into operation, always ensure:• that all maintenance and repair work is completed,• that all loose parts have been removed from rotating machine components,• that nobody is in the danger area of moving machine parts.Immediately after putting the device or plant into operation, make sure that all control and display instru‐ments as well as the signaling and alarm systems work properly.

Safety requirements for operatorsThe procedures for cases of emergency must be practiced regularly.The operator must be familiar with the control and display elements.The operator must be familiar with the consequences of any operations performed.During operation, the display instruments and monitoring units must be permanently observed with re‐gard to present operating status, violation of limit values and warning or alarm messages.The following steps must be taken if a malfunction of the system is recognized or reported by the system:• inform supervisor(s) in charge,• analyze the message,• if required, carry out emergency operations e.g. emergency engine stop.

Engine operationThe following conditions must be fulfilled before starting the engine:• Wear ear protection.• Ensure that the engine room is well ventilated.• Do not inhale engine exhaust gases.• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.• Protect battery terminals, battery-charger terminals and cables against accidental contact.• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Operation of electrical equipmentWhen electrical equipment is in operation, certain components of these appliances are electrically live.Observe the safety instructions for these devices.

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1.6 Explosion hazard when removing inspection port cover onengine

DANGER Explosion hazard due to oil vapors.Risk of serious injury – danger to life!• Allow the engine to cool down before opening the crankcase!• Avoid open flames, electrical sparks and ignition sources.

Safety instructionsu Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion

due to oil vapors).

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1.7 Safety regulations for maintenance and repair work

Safety regulations for maintenance and repair workHave maintenance and repair work carried out by qualified and authorized personnel only.Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.Take special care when removing ventilation or plug screws from the engine. Cover the screw or plugwith a rag to prevent fluids escaping under pressure.Take special care when draining hot fluids ⇒ Risk of injury.When changing the engine oil or working on the fuel system, ensure that the engine room is adequatelyventilated.Allow the engine / system to cool down before starting to work.Observe the maintenance and repair instructions.Never carry out maintenance and repair work with the engine running unless expressly instructed to doso.Secure the engine against accidental starting.Disconnect the battery when electrical starters are fitted.Close the main valve on the compressed-air system and vent the compressed-air line when pneumaticstarters are fitted.Disconnect the control equipment from the assembly or system.Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.Carry out work only on assembles and/or units which are properly secured.Never use lines for climbing.Keep fuel injection lines and connections clean.Always seal connections with caps or covers if a line is removed or opened.Take care not to damage lines, in particular fuel lines, during maintenance and repair work.Ensure that all retainers and dampers are installed correctly.Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐tact with other components. Do not place fuel or oil lines near hot components.Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐ly protected.Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐nents are placed on stable surfaces.Observe special cleanness when conducting maintenance and repair work on the assembly or system.After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐bly or system.Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guardshave been reinstalled and that all tools and loose parts have been removed after working on the engine.The following additional instructions apply to starters with beryllium copper pinion:• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐

ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing orthe starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐vice as an additional measure.

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Welding workNever carry out welding work on the assembly, system, or engine-mounted units. Cover the engine whenwelding in its vicinity.Do not use the assembly or system as ground terminal.Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding currentmay otherwise induce an interference voltage in the wiring harnesses which could conceivably damagethe electrical system.Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removalCheck the function and safe operating condition of tools and fixtures to be used. Use only the specifieddevices for hydraulic removal/installation procedures.Observe the max. permissible push-on pressure specified for the equipment.Do not attempt to bend or apply force to lines.Before starting work, pay attention to the following:• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the

equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).• For hydraulic installation, screw on the tool with the piston retracted.• For hydraulic removal, screw on the tool with the piston extended.For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaftend until correct sealing is established.During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of thecomponent to be installed/removed.

Working on electrical/electronic assembliesAlways obtain the permission of the person in charge before commencing maintenance and repair workor switching off any part of the electronic system required to do so.De-energize the appropriate areas prior to working on assemblies.Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged duringoperation by contact with sharp objects, by rubbing against other components or by a hot surface.Do not secure cables on lines carrying fluids.Do not use cable binders to secure cables.Always use connector pliers to tighten connectors.Subject the device or system to a function check on completion of all repair work.Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipmentWhen working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐diation.Laser equipment must be fitted with the protective devices necessary for safe operation according totype and application.

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For conducting light-beam procedures and measurement work, only the following laser devices must beused:• Laser devices of classes 1, 2 or 3A.• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700

nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to preventany risk to the eyes.

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1.8 Fluids and lubricants, fire prevention and environmentalprotection

Fire preventionRectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.When starting the engine with an external power source, connect the ground lead last and remove it first.To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source tothe ground lead of the engine or to the ground terminal of the starter.Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with theiruse.

NoiseNoise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicatingdanger are drowned.Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposalModification or removal of mechanical or electronic components or the installation of additional compo‐nents as well as the execution of calibration processes that might affect the emission characteristics ofthe engine are prohibited by emission regulations. Emission control units/systems may only be main‐tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Actand involves the termination of the operating license by the emission authorities. MTU does not acceptany liability for violations of the emission regulations. MTU will provide assistance and advice if emission-relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.Use only fuel of prescribed quality to comply with emission limit values.Dispose of used fluids, lubricants and filters in accordance with local regulations.Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they aresubjected to proper recycling procedures.

Fluids and lubricantsUse only fluids and lubricants that have been tested and approved by MTU.Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants andother chemical substances, follow the safety instructions that apply to the product. Take special carewhen using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and donot smoke.

Used oilUsed oil contains harmful combustion residues.Rub barrier cream into hands.Wash hands after contact with used oil.

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Lead• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not

inhale lead vapors.• Adopt suitable measures to avoid the formation of lead dust.• Switch on extraction system.• Wash hands after contact with lead or lead-containing substances.

Compressed airObserve special safety precautions when working with compressed air:• Pay special attention to the pressure level in the compressed air network and pressure vessel.• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐

mitted pressure for the connecting elements is lower than the pressure required, a pressure reducingvalve and safety valve (set to permitted pressure) must form an intermediate connection.

• Hose couplings and connections must be securely attached.• Wear goggles when blowing off components or blowing away chips.• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).• First shut off compressed air lines before compressed air equipment is disconnected from the supply

line, or before equipment or tool is to be replaced.• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of

containers, results in a risk of explosion.• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for

drying purposes or to check for leaks, results in a risk of bursting.• Carry out leak test in accordance with the specifications.

Painting• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐

sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.• No open flames.• No smoking.• Observe fire prevention regulations.• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.• Avoid body contact (eyes, hands).• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.• Make sure that working area is well ventilated.• Avoid all knocks and jars to the containers, fixtures or workpieces.

Acids and alkaline solutions• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective

clothing.• If such solutions are spilled onto clothing, remove the affected clothing immediately.• Rinse injured parts of the body thoroughly with clean water.• Rinse eyes immediately with eyedrops or clean tap water.

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1.9 Engine – Barring with starting systemPreconditions☑ External pushbutton “Bar engine without starting” is provided.

DANGER Unguarded rotating and moving engine components.Risk of serious injury – danger to life!• before barring or starting the engine, ensure that nobody is in the danger zone.• After working on the engine, check that all protective devices have been reinstalled and all tools

removed from the engine.

Engine – Barring with starting system1. Press pushbutton “Bar engine without starting” and keep depressed.2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds.3. Repeat this procedure after approx. 20 seconds if required.

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1.10 Conventions for safety instructions in the text

DANGER In the event of immediate danger.Consequences: Death or serious injury• Remedial action

WARNING In the event of potentially dangerous situations.Consequences: Death or serious injury• Remedial action

CAUTION In the event of dangerous situations.Consequences: Minor injury or material damage• Remedial action

Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard whichbegin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions1. Read and familiarize yourself with all safety notices before starting up or repairing the product.2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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2 General Information2.1 Engine layout

Engine version with closed-circuit crankcase ventilation

1 Engine lifting eyes2 Cylinder-head cover, cyl‐

inder head3 Coolant inlet4 Intercooler

5 Main PTO6 Charge-air coolant outlet7 Charge-air coolant inlet8 Coolant pump, LT circuit9 Coolant pump, HT circuit

10 Engine oil dipstick11 Engine oil filler neck12 Starter, engine right-hand

side

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1 Engine lifting eyes2 Coolant outlet3 Fan drive4 Centrifugal oil filter5 Engine oil filter6 HP fuel pump7 Vibration damper

8 Oil drain plugs9 Engine oil pan

10 Battery-charging genera‐tor drive

11 Starter, engine left-handside

12 Inspection port cover

13 DDEC electronic enginecontrol system

14 Fuel duplex filter (easy-change filter)

15 Compressor

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1 Battery-charging genera‐tor

2 Combustion-air inlet3 Exhaust turbocharger

4 Crankcase breather ofclosed-circuit crankcaseventilation (oil separator)

5 Exhaust outlet

6 Engine oil heat exchang‐er


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Engine version with open-circuit crankcase ventilation

1 Crankcase breather, Aside

2 Crankcase breather, Bside

3 Crankcase breathermounted on cylinderhead cover

4 Cylinder head cover

5 Vent line to atmosphere

Engine model designationKey to the engine model designation 16V 4000 E2016 Number of cylindersV Cylinder arrangement: V engine4000 SeriesE Application: E=Excavator2 Application segment0 Design index


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2.2 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end ofthe engine.Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 KGS = Free end2 Right engine side

3 KS = Driving end4 Left engine side


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2.3 Sensors and actuators – Overview

Sensors, actuators

1 Sensor (oil pressure)2 Sensor (oil temperature)3 Sensor (crankcase pres‐

sure)4 Sensor (charge-air cool‐

ant temperature)

5 Sensor (reference markTDC cylinder 1)

6 Sensor (LP fuel)7 Sensor (fuel temperature)8 Sensor (HP fuel)

9 Sensor (charge-air cool‐ant pressure)

10 Sensor (coolant pres‐sure)

11 DDEC


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1 Sensor (coolant tempera‐ture)

2 Connector power supply /interface to vehicle

3 Sensor (crankshaft anglesensor for injection timingof any cylinder)

4 Sensor (charge-air tem‐perature)

5 Sensor (charge-air pres‐sure)


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3 Technical Data3.1 16V 4000 E20 engine data

Explanation:DL Ref. value: Continuous power (CP)BL Ref. value: Fuel stop power (FSP)

A Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated, without change (e.g. of power setting)N Not yet defined value- Not applicable

X Applicable

REFERENCE CONDITIONSEngine model 16V 4000Application group 5AIntake air temperature °C 25Charge-air coolant temperature °C 55Raw water inlet temperature °C -Barometric pressure mbar 1000Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)Number of cylinders 16V 4000Engine rated speed A rpm 1800Net brake power (without fan)(fuel stop power ISO 3046)

A kW 1600

GENERAL CONDITIONS (for maximum power)Number of cylinders 16V 4000Intake air depression (new filter) A mbar 25Intake air depression L mbar 50Exhaust backpressure A mbar 30Exhaust backpressure, max. L mbar 50Fuel temperature at fuel feed connection R °C 30

CONSUMPTIONNumber of cylinders 16V 4000Specific fuel consumption (be) 100% BL (+5%; EN 590; 42.8MJ/kg) G g/kWh 194Lube oil consumption after 100 h operation, average (B = fuel con‐sumption per hour)

R % of B 0.3

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MODEL-RELATED DATA (basic design)Number of cylinders 16V 4000Number of cylinders 16Cylinder configuration: V angle degrees 90Bore mm 165Stroke mm 190Cylinder displacement liter 4.06Total displacement liter 65.0Number of inlet valves, per cylinder 2Number of exhaust valves, per cylinder 2

COMBUSTION AIR / EXHAUST GASNumber of cylinders 16V 4000Charge-air pressure before cylinder (abs.) R bar ABS 2.7Exhaust temperature after turbocharger R °C 410

COOLING SYSTEM (HT circuit)Number of cylinders 16V 4000Coolant temperature (at engine outlet to cooling equipment; withmax. 40% antifreeze)

A °C 92

Coolant temperature after engine, alarm R °C 95Coolant temperature after engine, shutdown L °C 97Coolant antifreeze content, max. permissible L % 40Coolant pump: inlet pressure, min. L bar 0.2Coolant pump: inlet pressure, max. L bar 2.2Thermostat, starts to open R °C 77Thermostat, fully open R °C 85

COOLING SYSTEM (LT circuit)Number of cylinders 16V 4000Coolant temperature (at engine outlet to cooling equipment) R °C 65Coolant temperature before intercooler (with max. 40% antifreeze) A °C 55Coolant temperature differential after/before intercooler, max. L °C 15Coolant antifreeze content, max. permissible L % 40Thermostat, starts to open R °C 32Thermostat, fully open R °C 44

LUBE OIL SYSTEMNumber of cylinders 16V 4000Lube oil operating temperature before engine, from R °C 88Lube oil operating temperature before engine, to R °C 93Lube oil operating pressure before engine, from R bar 5.0

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Number of cylinders 16V 4000Lube oil operating pressure before engine, to R bar 6,0Lube oil pressure before engine, alarm R bar 4.5Lube oil pressure before engine, shutdown L bar 4.0Lube oil fine filter (main circuit) differential pressure, max. L bar 1.0

FUEL SYSTEMNumber of cylinders 16V 4000Fuel pressure at supply connection to engine (when engine is start‐ing), min. admissible

L bar 0.1

Fuel pressure at supply connection to engine (when engine is start‐ing), max. admissible

L bar 1.5

Fuel pressure before injection pump, from(H.P. pump)

R bar 4.0

Fuel pressure before injection pump, to(H.P. pump)

R bar 6.0

Fuel pressure before injection pump, min.(H.P. pump)

R bar 3.5

GENERAL OPERATING DATANumber of cylinders 16V 4000Coolant preheating: preheating temperature (min.) R °C 40

INCLINATIONS STANDARD OIL SYSTEM (Ref.: waterline)Number of cylinders 16V 4000Longitudinal inclination, continuous max., driving end down(Option: max. operating inclinations)

L degrees 22.5

Longitudinal inclination, continuous max., driving end up(Option: max. operating inclinations)

L degrees 10

CAPACITIESNumber of cylinders 16V 4000Engine coolant capacity (without cooling equipment) R liter 210Engine oil capacity, initial filling (standard oil system) (Option: max.operating inclinations)

R liter 520

Oil pan capacity, dipstick mark min. (standard oil system) (Option:max. operating inclinations)

L liter 360

Oil pan capacity, dipstick mark max. (standard oil system) (Option:max. operating inclinations)

L liter 460

WEIGHTS / MAIN DIMENSIONSNumber of cylinders 16V 4000Engine dry weight (basic engine) R kg 7490


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FREE-FIELD SOUND PRESSURE LEVELNumber of cylinders 16V 4000Exhaust noise, unsilenced, 1m distance R db(A) 118

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3.2 Firing order

Firing orderNumber of cylin‐ders

Firing order

8V A1-B4-A4-A2-B3-A3-B2-B112V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B616 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B720 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8


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4 Operation4.1 Putting the engine into operation after extended out-of-

service periods (>3 months)

Preconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Putting into operation after long out-of-service periods (>3 months)Item ActionEngine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..).Valve gear Lubricate valve gear every ≥ 6 months (→ Page 75).Lube oil system Check engine oil level (→ Page 96).Fuel prefilter Fill with fuel (→ Page 90)(→ Page 91).Fuel system Vent (→ Page 88).Coolant circuit If engine is out of service for more than one year, change engine coolant

(→ Page 104).Change charge-air coolant (→ Page 111).

Coolant circuit Check engine coolant level (→ Page 103);Check charge-air coolant level (→ Page 110).

Coolant circuit Preheat coolant with preheating unit, if fitted.DDEC Check plug-in connections (→ Page 130).

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4.2 Putting the engine into operation after scheduled out-of-service-period

Preconditions☑ Engine is stopped and starting disabled.

StartupItem ActionLube oil system Check engine oil level (→ Page 96).Coolant circuit Check engine coolant level (→ Page 103);

Check charge-air coolant level (→ Page 110).Coolant circuit Preheat coolant with coolant preheating unit (if applicable).Engine control system Put into operation.

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4.3 Engine – Start in manual mode

Preconditions☑ Engine with no load.☑ External start interlock is not activated.

DANGER Unguarded rotating and moving engine components.Risk of serious injury – danger to life!• Before barring or starting the engine, make sure that nobody is in the danger zone.

WARNING Engine noise above 85 dB (A).Risk of damage to hearing!• Wear ear protectors.

PreparationItem MeasureOperating mode switch (ifapplicable)

Switch to manual mode.

Coolant preheating unit (ifapplicable).

Switch on.

Starting the engineItem MeasureSwitch cabinet, operatorstation etc. (depending onmanufacturer).

If coolant temperature is• > 40 °C (with coolant preheating unit, if applicable)press start button.• Automatic starting sequence is executed• Engine speed display instrument indicates increasing speed• After the starting sequence is completed, engine is running at idle

speed.

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4.4 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.


Operational checksItem ActionControl and display panels Check readings of operational data (speed, temperature, pressures).Engine operation Check engine visually for leaks and general condition;

Check for abnormal running noise, exhaust discoloration and vibrations(→ Page 41).

HP pump Check relief bore (→ Page 81).Fuel prefilter Drain water and contaminants via drain cock on fuel prefilter

(→ Page 90)(→ Page 91).(→ Page 90)Check reading on differential pressure gage of fuel prefilter(if fitted).

Engine coolant pump Check relief bore (→ Page 108).Charge-air coolant pump Check relief bore (→ Page 116).

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4.5 Engine – Shutdown in manual mode

Preconditions☑ Engine is not under load☑ Engine in manual mode

CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine.Risk of overheating, damage to components!• Before stopping the engine, operate it at idle speed until operating temperatures decrease and

stable values are indicated.

PreparationItem MeasureEngine Operate engine at idling speed for approx. 5 minutes.

Shutting the engine downItem MeasureSwitch cabinet, operatorstation etc. (depending onmanufacturer)

Press stop button.• Automatic stopping sequence is executed.

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4.6 After stopping the engine

Preconditions☑ MTU Fluids and Lubricants Specification (A001061/..) is available.

After stopping the engineItem TaskCoolant circuit Drain coolant (→ Page 105)(→ Page 112)if freezing temperatures are ex‐

pected and:• the engine is to remain out of service for an extended period and cool‐

ant has no antifreeze additive;• the coolant is not maintained at a suitable temperature;• antifreeze concentration is 50 % and outside temperature is below

-40°C.Engine control system Switch OFF.Air intake and exhaust sys‐tem

Out-of-service-period > 1 week:Seal engine's air and exhaust sides.Out-of-service-period > 1 month:Preserve engine (→ MTU Fluids and Lubricants SpecificationsA001061/.. ).

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4.7 Plant – Cleaning

Preconditions☑ Engine is stopped and starting disabled.☑ Operating voltage is not applied.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Steam jet cleaner - 1Cleaner (Hakupur 312) 30390 1

WARNING Compressed airRisk of injury!• Do not direct compressed-air jet at persons.• Wear protective goggles / safety mask and ear protectors.

WARNING Water jet.Risk of injury and scalding!• Do not direct water jet at persons.• Wear protective clothing, gloves, and goggles / safety mask.

CAUTION Excessive reaction time of cleaning agents on components.Damage to component!• Observe manufacturer's instructions.• Wear protective clothing, gloves, and goggles / safety mask.

Note: There is a risk of damaging sensors with compressed air.

Plant – Cleaning1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐

tection).2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit

carefully and observe the safety precautions.3. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.4. Carry out external cleaning as follows:

a) Remove coarse dirt.b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.c) Use the high-pressure jet to remove the loosened dirt.d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet

(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 mmust be observed. The temperature of the cleaning medium must not exceed 80 °C.

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5 Maintenance5.1 Maintenance task reference table [QL1]

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

Task Maintenance tasksW0500 Check engine oil level (→ Page 96)W0501 Visually inspect engine for leaks and general condition (→ Page 36)W0504 Check HP fuel pump weep holes (→ Page 36)W0505 Check relief bores of coolant pump(s) (→ Page 108)

(→ Page 116)W0506 Check engine for abnormal running noises, exhaust color

and vibrations(→ Page 36)

W0507 Drain water and dirt from fuel prefilter (if fitted) (→ Page 36)W0508 Check reading on differential pressure gage of fuel prefilter (if

fitted)(→ Page 36)

W0525 Check battery-charging generator for contamination, clean ifnecessary

(→ Page 119)

W1001 Replace fuel filter or fuel filter element (→ Page 89)W1002 Check valve clearance (→ Page 76)W1003 Check drive belt condition and tension, replace if necessary (→ Page 117)W1006 Replace fuel injectors (→ Page 82)W1008 Replace engine oil filter at each oil change or when the time

limit (years) is reached, at the latest(→ Page 100)

W1009 Check layer thickness of oil residue, clean and replace filtersleeve of centrifugal oil filter (if fitted) at every oil change, atthe latest

(→ Page 101)

W1011 Perform endoscopic inspection of combustion chambers (→ Page 67)W1022 Check engine wiring system externally for damage (→ Page 127)W1044 Crankcase breather: Clean filter (→ Page 74)W1209 Remove battery-charging generator and clean thoroughly

with compressed air(→ Page 120)

W1697 Check carbon brushes at flywheel (if fitted), replace if neces‐sary

-

W1698 Replace carbon brushes at flywheel (if fitted) -

Table 1: Maintenance task reference table [QL1]

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6 Troubleshooting6.1 Troubleshooting

Engine does not turn when starter is actuatedComponent Cause ActionBattery Low or faulty Charge or replace (see manufacturer's

documentation).Cable connections faulty Check if cable connections are proper‐

ly secured (see manufacturer's docu‐mentation).

Starter Engine cabling or starter faulty Check if cable connections are proper‐ly secured, contact Service.

Engine cabling Faulty Check (→ Page 127).Engine/generatorcontrol system

Assemblies or connectors possiblyloose

Perform visual inspection (see manu‐facturer's documentation).

DDEC Plug-in connections possibly loose Check plug-in connections(→ Page 130).

Engine Running gear blocked (engine cannotbe barred manually)

Contact Service.

Engine turns but does not fireComponent Cause ActionStarter Poor rotation by starter: Battery low or

faultyCharge or replace battery (see manu‐facturer's documentation).

Engine cabling Faulty Check (→ Page 127).Fuel system Air in fuel system Vent fuel system (→ Page 88).DDEC Faulty Contact Service.

Engine fires unevenlyComponent Cause ActionFuel injection equip‐ment

Injector faulty Replace (→ Page 82).

Engine cabling Faulty Check (→ Page 127).Fuel system Air in fuel system Vent fuel system (→ Page 88).DDEC Faulty Contact Service.

Engine does not reach rated speedComponent Cause ActionFuel supply Fuel prefilter clogged Clean or replace filter element.

Easy-change fuel filter clogged Replace (→ Page 89).Air supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 93).

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Component Cause ActionFuel injection equip‐ment


Engine cabling Faulty Check (→ Page 127).Engine Overloaded Contact Service.

Engine speed not steadyComponent Cause ActionFuel injection equip‐ment


Speed sensor Faulty Contact Service.Fuel system Air in fuel system Vent fuel system (→ Page 88).DDEC Faulty Contact Service.

Charge air temperature too highComponent Cause ActionEngine coolant Engine coolant treatment incorrect Check (MTU test kit).Intercooler Contaminated Contact Service.Engine room Air-intake temperature too high Check fans and intake/exhaust lines.

Charge-air pressure too lowComponent Cause ActionAir supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 93).Intercooler Contaminated Contact Service.Exhaust turbocharger Faulty Contact Service.

Coolant leaks at intercoolerComponent Cause ActionIntercooler Leaking, major coolant discharge Contact Service.

Black exhaust gasComponent Cause ActionAir supply Air filter clogged Check signal ring position of service in‐

dicator (→ Page 93).Fuel injection equip‐ment


Engine Overloaded Contact Service.

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Blue exhaust gasComponent Cause ActionEngine oil Too much oil in engine Drain engine oil (→ Page 97).

Filter element in oil separator is clog‐ged

Replace (→ Page 72).

Exhaust turbocharg‐er, cylinder head, pis‐ton rings, cylinder lin‐er

Faulty Contact Service.

White exhaust gasComponent Cause ActionEngine Not at operating temperature Run engine to reach operating temper‐

ature.Fuel system Water in fuel Drain fuel prefilter (→ Page 90)

(→ Page 91).Check fuel system.

Intercooler Leaking Contact Service.


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6.2 DDEC alarms

The DDEC generates alarms which are indicated in different ways depending on the equipment configu‐ration:• Two-digit flash code• Fault code and text on a display or PC screenTo facilitate troubleshooting without additional auxiliary equipment, the two-digit flash codes can be readout from the DDEC by means of the vehicle-side alarm lamps CHECK ENGINE LIGHT (yellow) andSTOP ENGINE LIGHT (red).For this purpose, two DIAGNOSTIC REQUEST switches must be provided in the vehicle). The firstswitch is used for reading out the flash codes of the master DDEC unit, the second one to read out thereceiver DDEC unit. The flash-code signals from master and receiver are transmitted to the same alarmlamps.

Active codes: Inactive codes:indicated by STOP ENGINE LIGHT (red) indicated by CHECK ENGINE LIGHT (yellow)

Activation of flash codes:1. Operate IGNITION switch to position ON.2. Operate DIAGNOSTIC REQUEST switch of master or receiver unit.3. Read off codes.4. Identify the fault according to the DDC fault code list.

Example:Active code 23: Inactive code 34:STOP ENGINE LIGHT lampis flashing:

CHECK ENGINE LIGHT lampis flashing:

Flashing phase 1 Flashing phase 2 Flashing phase 1 Flashing phase 2О О О О О О О О О О О Оtwo times flashing three times flashing three times flashing four times flashing

There is a pause of 0.5 seconds between the flashing phases 1 and 2. When a fault code changes fromactive to inactive, the pause is 3 seconds.To terminate flash code indication, switch DIAGNOSTIC REQUEST and IGNITION switches off.IGNITION is allowed to be switched on again only after 30 seconds.This method does not allow exact fault diagnostics, since a flash code may indicate faults with severalcauses.The Diagnostic Data Reader (DDR) facilitates more detailed troubleshooting.The Diagnostic Data Reader (DDR) is intended to:• Read out alarms from the DDEC electronic system• Change parameters (limited extent)The DDR provides the possibility to read out active and inactive fault codes via separate menus. Addi‐tionally, the inactive fault codes stored in the DDEC can be deleted.For detailed functional description, refer to the description of the DDR.The DDR (Part No. 5355383601/77) consists of:• the Pro Link 9000 basic unit• the MPC Cartridge to integrate a PCMCIA card• a PCMCIA card• a connection cable• an additional adapter cable is required (Part No. J 38500 60A)


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Accessory equipment:• Printer (Part No. J-38699) for direct connection to the DDR• Spare paper (Part No. J-38480-5) for printer (5 rolls)The following information will be available by reading out fault codes with the DDR.Example:

33 MID:128 EngineTURBO BOOST SENSORINPUT VOLTAGE HIGH▴ A1 PID: 102 FMI:3 ▾

Explanation:• 33 → Flash code• MID: 128 →Indicates origin of alarm• TURBO-BOOST-SENSOR-INPUT-VOLTAGE-HIGH → Fault text• ▴ ▾ → further faults are present A= active, I= inactiveMID (Message Identification Character)• Indicates origin of alarm

MID 128 → MasterMID 175 → Receiver 1MID 183 → Receiver 2

PID (Parameter Identification Character)• To identify transmitted data: (e. g. engine speed, coolant temperature etc.)

PID 0-127 → 1 data bytePID 128-191 → 2 data bytesPID 192-253 → variable

SID (Subsystem Identification Character)• Identifies the origin of alarms from subsystems, which can be replaced as a complete unit (e.g. injec‐

tors).FMI (Failure Mode Identifier)• Identifies the type of fault.

FMI 0 → Measured value exceeds the limit value (monitoring for TOO HIGH), example: Coolant tem‐peratureFMI 1 → Measured value does not reach the limit value (monitoring for TOO LOW), example: Lube oilpressureFMI 3 → Signal path interrupted or signal is exceeds the permissible measuring range (sensor defect)FMI 4 → Signal path short circuit against (-) supply of sensor or signal does not reach permissiblemeasuring range (sensor defect)

Flashcode

PID SID FMI Description Tasks

11 187 4 Position sensor of variablespeed governor → voltagetoo low.

Contact Service.

11 187 7 Control system / variablespeed governor→ voltagetoo high.

Contact Service.

12 187 3 Position sensor of variablespeed governor → voltagetoo high.

Contact Service.


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Flashcode


13 111 4 Coolant level sensor, inputvoltage too low.

1. Check coolant condition(→ Page 109).2. Check coolant level, top up ifrequired (→ Page 103).3. Check wiring.4. Contact Service.

13 111 6 Sensor "Top up coolant", in‐put voltage too low.

1. Check coolant condition(→ Page 109).2. Check coolant level, top up ifrequired (→ Page 103).3. Check wiring.4. Contact Service.

14 52 3 Temperature sensor/inter‐cooler, input voltage toohigh.

1. Check wiring.2. Contact Service.

14 110 3 Coolant temperature sen‐sor, input voltage too high.


14 175 3 Oil temperature sensor, in‐put voltage too high.

Contact Service.

15 52 4 Temperature sensor/inter‐cooler, input voltage toolow.


15 110 4 Coolant temperature sen‐sor, input voltage too low.


15 175 4 Oil temperature sensor, in‐put voltage too low.

Contact Service.

16 111 3 Coolant level sensor, inputvoltage too high.

1. Check coolant condition(→ Page 109).2. Check coolant level, top up ifrequired (→ Page 103).3. Check cooler for contamina‐tion.4. Check wiring.5. Contact Service.

16 111 5 Sensor "Top up coolant", in‐put voltage too high.


17 51 3 Throttle sensor, input volt‐age too high.


17 72 3 Blower bypass position, in‐put voltage too high.


17 354 3 Humidity sensor, electriccircuit defective / high (ver‐sion 33.0 or later).



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Flashcode


18 51 4 Throttle sensor, input volt‐age too low.


18 72 4 Blower bypass position, in‐put voltage too low.


18 354 4 Humidity sensor, electriccircuit defective / low (ver‐sion 33.0 or later).


21 91 3 Throttle sensor, input volt‐age too high.


22 91 4 Throttle sensor, input volt‐age too low.


23 174 3 Fuel temperature sensor,input voltage too high.


23 65 Oxygen concentration cir‐cuit, input voltage too high.


24 174 4 Fuel temperature sensor,input voltage too high.


24 65 4 Oxygen concentration cir‐cuit, input voltage too low.


25 Reserved for "No Codes". No search for faults.26 25 11 Auxiliary shutdown 1 active. Contact Service.26 61 11 Auxiliary shutdown 2 active. Contact Service.27 105 3 Inlet elbow temperature

sensor, input voltage toohigh.


27 171 3 Outside temperature sen‐sor, input voltage too high.


27 172 3 Air temperature sensor, in‐put voltage too high.


28 105 4 Inlet elbow temperaturesensor, input voltage toolow.


28 171 4 Outside temperature sen‐sor, input voltage too low.


28 172 4 Air temperature sensor, in‐put voltage too low.


29 351 4 Circuit exhaust turbocharg‐er inlet temperature defec‐tive / low (version 33.0 orlater).



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Flashcode


29 404 4 Temperature sensor / ex‐haust turbocharger outlet,input voltage too low (ver‐sion 32.0 or later).


31 51 3 Auxiliary output 3, open cir‐cuit (side "high") S3.

Contact Service.

31 51 4 Auxiliary output 3, groundshort circuit (side "high")S3.

Contact Service.

31 51 7 Auxiliary output 3, fault inmechanical system S3.

Contact Service.

31 52 3 Auxiliary output 4, open cir‐cuit (side "high") S3.

Contact Service.

31 52 4 Auxiliary output 4, groundshort circuit (side "high")T3.

Contact Service.

31 52 7 Auxiliary output 4, fault inmechanical system T3.

Contact Service.

32 238 3 SEL, short circuit on batterycircuit (plus).


32 238 4 SEL, open circuit . 1. Check wiring.2. Contact Service.

32 239 3 CEL, short circuit on batterycircuit (plus).


32 239 4 CEL, open circuit . 1. Check wiring.2. Contact Service.

33 102 3 Charge-air pressure sensor,input voltage too high.


34 102 4 Charge-air pressure sensor,input voltage too low.


35 19 3 Oil pressure sensor upperlevel, input voltage too high.


35 100 3 Oil pressure sensor, inputvoltage too low.


36 19 4 Oil pressure sensor upperlevel, input voltage too high.


36 100 4 Oil pressure sensor, inputvoltage too low.


37 18 3 Fuel pressure sensor upperlevel, input voltage too high.


37 94 3 Fuel pressure sensor, inputvoltage too high.



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Flashcode


37 95 3 Fuel- differential pressuresensor, input voltage toohigh.


38 18 4 Fuel pressure sensor upperlevel, input voltage too low.


38 94 4 Fuel pressure sensor, inputvoltage too low.


38 95 4 Fuel differential pressuresensor, input voltage toolow.


39 146 2 EGR system leaking,charge-air pressure (ver‐sion 33.0 or later).

Contact Service.

39 146 12 EGR system leaking, ex‐haust brake operation (ver‐sion 33.0 or later).

Contact Service.

39 146 7 EGR valve does not re‐spond (version 33.0 or lat‐er).

Contact Service.

39 147 2 VNT nozzles do not re‐spond, charge-air pressure(version 33.0 or later).

Contact Service.

39 147 11 VNT nozzles at maximum,exhaust brake operation(version 33.0 or later).

Contact Service.

39 147 12 VNT nozzles do not re‐spond, brake pressure (ver‐sion 33.0 or later).

Contact Service.

39 147 14 Exhaust gas recirculationflow too low, VNT nozzlesdo not respond, charge-airpressure (version 33.0 orlater).

Contact Service.

39 147 7 VNT vanes do not respond,EGR (version 33.0 or later).

Contact Service.

39 152 7 No signal from EGR valve(version 29.0 or later).

1. Check signal ring position ofservice indicator (→ Page 93).2. Contact Service.

39 153 7 VNT vanes do not respond,(version 29.0 or later).


41 21 0 Too many SRS (TRS miss‐ing).

Contact Service.

42 21 1 Not enough SRS (SRSmissing).

Contact Service.


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Flashcode


43 111 1 Coolant level too low. 1. Check coolant level, top up ifrequired (→ Page 103).2. Contact Service.

44 52 0 Intercooler coolant temper‐ature too high.

1. Check coolant condition(→ Page 109).2. Check coolant level, top up ifrequired (→ Page 110).3. Check intercooler for contam‐ination.4. Contact Service.

44 105 0 Inlet elbow temperature toohigh.


44 110 0 Coolant temperature toohigh.

1. Check coolant condition(→ Page 109).2. Check coolant level, top up ifrequired (→ Page 103).3. Check cooler for contamina‐tion.4. Contact Service.

44 172 0 Intake air temperature toohigh.


44 175 0 Oil temperature too high. 1. Check engine oil level(→ Page 96).2. Contact Service.

105 14 Inlet elbow temperature:power reduction.


110 14 Coolant temperature: powerreduction.

1. Check coolant condition(→ Page 109).2. Check coolant level, top up ifrequired (→ Page 103).3. Check cooler for contamina‐tion.4. Contact Service.

45 19 1 High range: Oil pressuretoo low.

1. Check engine oil level(→ Page 96).2. Contact Service.

45 100 1 Oil pressure too low. 1. Check engine oil level(→ Page 96).2. Contact Service.

46 168 1 ECM battery voltage toolow.

Contact Service.


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Flashcode


46 214 1 Real-time clock auxiliarybattery, voltage too low(version 29.0 or later).

Contact Service.

46 232 1 Sensor supply voltage toolow.

Contact Service.

47 18 0 High range: Fuel pressuretoo high.

Contact Service.

47 94 0 Fuel pressure too high. Contact Service.47 102 0 Charge-air pressure too

high.Contact Service.

47 106 0 Air intake pressure too high. Contact Service.47 164 0 Injection control pressure

too high.Contact Service.

48 18 1 High range: Fuel pressuretoo low.

1. Check fuel prefilter(→ Page 90) and (→ Page 91).2. Check fuel filter (→ Page 89).3. Top up tank if required.4. Contact Service.

48 94 1 Fuel pressure too low. 1. Check fuel prefilter(→ Page 90) and (→ Page 91).2. Check fuel filter (→ Page 89).3. Top up tank if required.4. Contact Service.

48 106 1 Air intake pressure too low. Contact Service.48 164 1 Injection control pressure

too low.Contact Service.

48 351 1 Exhaust turbocharger inlettemperature below range(version 33.0 or later).

Contact Service.

48 404 1 Exhaust turbocharger outlettemperature too low (ver‐sion 33.0 or later).

Contact Service.

48 411 1 EGR OPD low (version 33.0or later).

Contact Service.

48 412 1 EGR temperature too low(version 33.0 or later).

Contact Service.

48 154 1 EGR temperature too low. Contact Service.48 155 1 EGR differential pressure

too low.Contact Service.

49 351 0 Temperature at exhaust tur‐bocharger inlet above range(version 33.0 or later).

1. Check signal ring position ofservice indicator (→ Page 93).2. Check exhaust system.3. Contact Service.


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Flashcode


49 404 0 Temperature at exhaust tur‐bocharger outlet too high(version 32.0 or later).

1. Check signal ring position ofservice indicator (→ Page 93).2. Check exhaust system.3. Contact Service.

404 14 TCO temperature: powerreduction.

Contact Service.

51 351 3 Temperature sensor on ex‐haust turbocharger inlet, cir‐cuit defective / high.


51 404 3 Temperature sensor on ex‐haust turbocharger outlet,input voltage too high (ver‐sion 32.0 or later).


52 254 12 A/D conversion faulty. Contact Service.53 253 2 Nonvolatile check sum er‐

ror.Contact Service.

53 253 12 Write error EEPROM. Contact Service.53 253 13 Out of calibration. Contact Service.54 84 12 Vehicle's speed sensor de‐

fect.1. Check wiring.2. Contact Service.

55 216 14 Fault of other control unit(version 27.0 or later). Thisfault is stored in connectionwith another fault to refer tomissing information of an‐other control unit.

Contact Service.

55 231 12 Data connection J1939 faul‐ty.

Contact Service.

55 248 8 System-related data con‐nection faulty (master).

Contact Service.

55 248 9 System-related data con‐nection (repeater).

Contact Service.


Contact Service.


Contact Service.

58 92 0 Torque too high. Contact Service.61 xxx 0 Reaction time injection noz‐

zle xxx too long.Contact Service.

62 26 3 Auxiliary output 1, short cir‐cuit on battery circuit (plus)F3.

Contact Service.

62 26 4 Auxiliary output 1, open cir‐cuit F3.

Contact Service.


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62 26 7 Auxiliary output 1, mechani‐cal system does not re‐spond correctly F3.

Contact Service.

62 40 3 Auxiliary output 2, short cir‐cuit on battery circuit (plus)A2.

Contact Service.

62 40 4 Auxiliary output 2, open cir‐cuit A2.

Contact Service.

62 40 7 Auxiliary output 2, mechani‐cal system does not re‐spond correctly A2.

Contact Service.

62 53 3 Auxiliary output 5, short cir‐cuit on battery circuit (plus)W3.

Contact Service.

62 53 4 Auxiliary output 5, open cir‐cuit W3.

Contact Service.

62 53 7 Auxiliary output 5, mechani‐cal system does not re‐spond correctly W3.

Contact Service.

62 54 3 Auxiliary output 6, short cir‐cuit on battery circuit (plus)X3.

Contact Service.

62 54 4 Auxiliary output 6, open cir‐cuit X3.

Contact Service.

62 54 7 Auxiliary output 6, mechani‐cal system does not re‐spond correctly X3.

Contact Service.

62 55 3 Auxiliary output 7, short cir‐cuit on battery circuit (plus)Y3.

Contact Service.

62 55 4 Auxiliary output 7, open cir‐cuit Y3.

Contact Service.

62 55 7 Auxiliary output 7, mechani‐cal system does not re‐spond correctly Y3.

Contact Service.

62 56 3 Auxiliary output 8, short cir‐cuit on battery circuit (plus)A1.

Contact Service.

62 56 4 Auxiliary output 8, open cir‐cuit A1.

Contact Service.

62 56 7 Auxiliary output 8, mechani‐cal system does not re‐spond correctly A1.

Contact Service.

63 57 0 PWM 1 above normalrange.

Contact Service.

63 57 1 PWM 1 below normalrange.

Contact Service.


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63 57 3 PWM 1 short circuit on bat‐tery circuit (plus).

Contact Service.

63 57 4 PWM 1 open circuit. Contact Service.63 58 0 PWM 2 above normal

range.Contact Service.


Contact Service.


Contact Service.




Contact Service.


Contact Service.




Contact Service.


Contact Service.

63 60 4 PWM 4 open circuit. Contact Service.64 103 0 Exhaust turbocharger

speed too high.Contact Service.

64 103 8 Exhaust turbochargerspeed sensor, input signalfaulty (irregular period).

Contact Service.

65 51 0 Throttle position above nor‐mal range.

Contact Service.

65 51 1 Throttle position below nor‐mal range.

Contact Service.

65 51 2 Throttle position not regular. Contact Service.65 51 7 Throttle does not respond. Contact Service.65 107 3 Air filter differential pressure

sensor, voltage too high.1. Check wiring.2. Contact Service.

65 107 4 Air filter differential pressuresensor, voltage too low.


66 99 3 Oil filter differential pressuresensor, voltage too high.


66 99 4 Oil filter differential pressuresensor, voltage too low.



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66 76 0 Engine knock level abovenormal range.

Contact Service.

66 76 3 Knock sensor, input voltagetoo high.

Contact Service.

66 76 4 Knock sensor, input voltagetoo low.

Contact Service.

66 76 7 Knock sensor does not re‐spond.

Contact Service.

67 20 3 Coolant pressure sensor,high range (input voltagetoo high).

Contact Service.

67 20 4 Coolant pressure sensor,high range (input voltagetoo low).

Contact Service.

67 106 3 Air intake pressure sensor,input voltage too high.

Contact Service.

67 106 4 Air intake pressure sensor,input voltage too low.

Contact Service.

67 109 3 Coolant pressure sensor,input voltage too high.

Contact Service.

67 109 4 Coolant pressure sensor,input voltage too low.

Contact Service.

68 230 5 Idling recognition pedaltravel sensor (TPS), fault incircuit (circuit open).

Contact Service.

68 230 6 Idling recognition pedaltravel sensor (TPS), fault incircuit (ground short circuit).

Contact Service.

71 xxx 1 Reaction time injection noz‐zle xxx too short.

Contact Service.

72 84 0 Vehicle's speed too high. Contact Service.72 84 11 Vehicle's speed too high

(absolute).Contact Service.

72 65 0 Oxygen concentration toohigh.

Contact Service.

72 65 1 Oxygen concentration toolow.

Contact Service.

73 107 0 Air filter differential pressuretoo high.


73 77 0 Gas valve position abovenormal range.

Contact Service.

73 77 1 Gas valve position belownormal range.

Contact Service.

73 77 3 Gas valve position inputvoltage too high.

Contact Service.


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73 77 4 Gas valve position inputvoltage too low.

Contact Service.

73 77 7 Gas dosing valve does notrespond.

Contact Service.

73 151 14 ESS transmission, engagedgear step jamming.

Contact Service.

73 226 11 Transmission idling switchdefective, (ESS transmis‐sion).

Contact Service.

73 227 2 Analog auxiliary input: datafailing irregularly or defec‐tive (ESS transmission).

Contact Service.

73 227 3 Analog auxiliary input 1,voltage too high (ESStransmission).

Contact Service.

73 227 4 Analog auxiliary input 1,voltage too low (ESS trans‐mission).

Contact Service.

74 70 4 Optimized idle securityloop) ground short circuit.

Contact Service.

74 99 0 Oil filter plugged. 1. Replace oil filter(→ Page 100)2. Contact Service.

75 168 0 ECM battery voltage toohigh.

Contact Service.

75 214 0 Real time clock backup,battery voltage too high(version 29.0 or later).

Contact Service.

75 232 0 Sensor supply voltage toohigh.

Contact Service.

76 121 0 Engine overspeed with ex‐haust brake.

Contact Service.

77 3 0 Cylinder head temperaturetoo high.

Contact Service.

77 19 0 High range: oil pressure toohigh.

Contact Service.

77 20 0 High range: coolant pres‐sure too high.

Contact Service.

77 72 0 Blower bypass position toohigh.

Contact Service.

77 72 1 Blower bypass position toolow.

Contact Service.

77 73 1 Fire pump pressure too low. Contact Service.77 81 0 Exhaust back pressure too

high.Contact Service.

77 81 1 Exhaust back pressure toolow.

Contact Service.


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77 81 3 Exhaust back pressure sen‐sor voltage too high.

Contact Service.

77 81 4 Exhaust back pressure sen‐sor voltage too low.

Contact Service.

77 81 12 Exhaust back pressure nearlimit for power reduction.

Contact Service.

77 95 1 Fuel filter differential pres‐sure too low.

Contact Service.

77 99 1 Oil filter differential pressuretoo low.

Contact Service.

77 100 0 Engine oil pressure toohigh.

Contact Service.

77 102 1 Charge-air pressure toolow.

Contact Service.

77 105 1 Inlet elbow temperature toolow.

Contact Service.

77 107 1 Air filter differential pressuretoo low.

Contact Service.

77 108 0 Atmospheric pressure toohigh.

Contact Service.

77 108 1 Atmospheric pressure toolow.

Contact Service.

77 109 0 Coolant pressure too high. Contact Service.77 110 1 Coolant temperature too

low.Contact Service.

77 111 0 Coolant level too high. 1. Check coolant level(→ Page 103).2. Contact Service.

77 171 0 Outside temperature toohigh.

Contact Service.

77 171 1 Outside temperature toolow.

Contact Service.

77 172 1 Intake air temperature toolow.

Contact Service.

77 174 0 Fuel temperature too high. Contact Service.77 174 1 Fuel temperature too low. Contact Service.77 175 1 Engine oil temperature too

low.Contact Service.

77 222 14 Theft protection faulty. Contact Service.77 251 10 Clock module with irregular

alteration speed.Contact Service.

77 251 13 Clock module faulty. Contact Service.77 252 10 Clock module with irregular

alteration speed.Contact Service.

77 252 13 Clock module faulty. Contact Service.


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77 354 0 Relative air humidity aboverange (version 33.0 or lat‐er).

Contact Service.

77 354 1 Relative air humidity underrange (version 33.0 or lat‐er).

Contact Service.

77 446 0 Cylinder head temperatureabove range (version 33.0or later).

Contact Service.

77 151 11 Maintenance display lamp,faulty / service interval ex‐ceeded (version 32.0 or lat‐er).

Contact Service.

78 86 14 Self-adaptive speed controlfaulty (version 27.0 or later).

Contact Service.

81 98 3 Oil level sensor, input volt‐age too high.

Contact Service.

81 101 3 Crankcase pressure sen‐sor, input voltage too high.

Contact Service.

81 153 3 Crankcase pressure, inputvoltage too high (version27.0 or later).

Contact Service.

81 164 3 Injection control pressuresensor, input voltage toohigh.

Contact Service.

81 173 3 Exhaust gas temperaturesensor, input voltage toohigh.

Contact Service.

81 411 3 EGR OPD, circuit defec‐tive / high (version 33.0 orlater).

Contact Service.

81 412 3 EGR temperature too high(version 33.0 or later).

Contact Service.

81 129 3 Exhaust duct temperature1, sensor voltage too high(version 32.0 or later).

Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


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Flashcode



Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.

81 154 3 EGR temperature, inputvoltage too high.

Contact Service.

81 155 3 EGR differential pressure,input voltage too high.

Contact Service.

81 277 9 EGR mass flow, intelligentsensor does not respond(version 33.0 or later).

Contact Service.

81 277 12 EGR mass flow, intelligentsensor failure (version 33.0or later).

Contact Service.

82 98 4 Oil level sensor, input volt‐age too low.

Contact Service.

82 101 4 Crankcase pressure sen‐sor, input voltage too low.

Contact Service.


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82 153 4 Crankcase pressure sen‐sor, input voltage (version27.0 or later).

Contact Service.

82 164 4 Injection control pressuresensor, input voltage toolow.

Contact Service.

82 173 4 Exhaust gas temperaturesensor, input voltage toolow.

Contact Service.

82 411 4 EGR OPD, sensor circuitdefective / low (version 33.0or later).

Contact Service.

82 412 4 EGR temperature too low(version 33.0 or later).

Contact Service.

82 129 4 Exhaust duct temperature1, sensor voltage too low(version 32.0 or later).

Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


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Flashcode



Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.

82 154 4 EGR- temperature, inputvoltage too high.

Contact Service.

82 155 4 EGR differential pressureinput voltage too low.

Contact Service.

82 412 9 EGR temperature, intelli‐gent sensor does not re‐spond (version 33.0 or lat‐er).

Contact Service.

82 412 12 EGR temperature, intelli‐gent sensor failure (version33.0 or later).

Contact Service.

83 73 0 Pump pressure too high. Contact Service.83 98 0 Oil level too high. 1. Check engine oil level

(→ Page 96).2. Contact Service.

83 101 0 Crankcase pressure toohigh.

Contact Service.

83 153 0 Crankcase pressure toohigh (version 27.0 or later).

Contact Service.

83 173 0 Exhaust gas temperaturetoo high.

Contact Service.

83 411 0 EGR OPD, high (version33.0 or later).

Contact Service.

83 412 0 EGR temperature too high(version 33.0 or later).

Contact Service.


Contact Service.


Contact Service.


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Flashcode



Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.


Contact Service.

84 98 1 Oil level low. 1. Check engine oil level(→ Page 96).2. Contact Service.

84 101 1 Crankcase pressure toolow.

Contact Service.

84 153 1 Crankcase pressure too low(version 27.0 or later).

Contact Service.


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85 190 0 Engine idle speed too high. Contact Service.85 190 14 Engine overspeed signal

(version 28.0 or later).Contact Service.

86 73 3 Pump pressure sensor, in‐put voltage too high.

Contact Service.

86 108 3 Atmospheric pressure sen‐sor, input voltage too high.

Contact Service.

87 73 4 Pump pressure sensor, in‐put voltage too low.

Contact Service.

87 108 4 Atmospheric pressure sen‐sor, input voltage too low.

Contact Service.

88 20 1 High range: coolant pres‐sure too low.

Contact Service.

88 109 1 Coolant pressure too low. Contact Service.89 95 0 Fuel differential pressure

too high.Contact Service.

89 111 12 Coolant level, maintenancenote, fault.

1. Check coolant level(→ Page 103).2. Contact Service.


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7 Task Description7.1 Engine

7.1.1 Engine – Barring manually


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Barring device F6555766 1Barring device F6783293 1Adapter F6558528 1Ratchet F30006212 1

DANGER Unguarded rotating and moving engine components.Risk of serious injury – Danger to life!• Before barring the engine, ensure that nobody is in the danger zone.

Barring engine manually (lateralinstallation)

1. Remove guard plate.2. Engage barring device (2) in ring gear (3)

and install on flywheel housing.• Use barring device F6555766.

3. Set ratchet (1) onto barring device (2).4. Rotate crankshaft in engine direction of ro‐

tation. Apart from the normal compressionresistance, there should be no resistance.

5. For barring device removal follow reversesequence of working steps.

64 | Task Description | M015241/03E 2011-12

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Barring engine manually(installation on lower side)

1. Remove grounding device or guard plate.2. Engage barring device (2) with ring gear (1)

and mount on flywheel housing.• For 12/16V engines, use barring device

F6555766 with adapter F6558528.• For 20V engines, use barring de‐

vice F6783293.3. Set ratchet (3) onto barring device (2).4. Rotate crankshaft in engine direction of ro‐

tation. Apart from the normal compressionresistance, there should be no resistance.

5. For barring device removal follow reversesequence of working steps.

M015241/03E 2011-12 | Task Description | 65

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7.1.2 Engine – Barring with starting system

DANGER Unguarded rotating and moving engine components.Risk of serious injury – Danger to life!• Before barring the engine, ensure that nobody is in the danger zone.

Engine – Barring with startingsystem

1. Remove screws (1, 3) and take off perforat‐ed plate (2).

2. Withdraw plug (5) from crankshaft anglesensor for injection timing of any cylinder(→ Page 26). For this purpose, unlocklatch (4).

3. Bar engine in unloaded condition: PressSTART button.

Note: Interrupt engine start after maximum tenseconds for thirty seconds to prevent starterfrom overheating.

4. Let the crankshaft rotate until oil pressure isindicated.

Note: If no oil pressure is indicated after threestart cycles, contact Service.

5. Slide on connector (5) until lock (4) latchesinto position.

6. Fit perforated plate (2) and secure with twoscrews (1, 3).


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7.2 Cylinder Liner7.2.1 Cylinder liner – Endoscopic examination

Preconditions☑ Engine is stopped and starting disabled

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Endoscope Y20097353

Preparatory steps1. Remove cylinder head cover (→ Page 80).2. Remove injector (→ Page 83).

Positioning crankshaft at BDC1. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached

BDC.2. Insert endoscope into cylinder liner through injector seat.

Cylinder liner endoscopic examinationFindings Measure• Thin carbon coating on carbon scraper ring• Slight localized additive deposits at top edge• Localized smooth areas at bottom edge• Carbon deposits on entire circumference between top piston ring

and bottom edge of carbon scraper ring• First signs of marks left by top piston ring• Bright mark on entire circumference• Faultless, even honing pattern• First signs of marks left by lower cooling bores• Running pattern seems darker

No action required

• Dark areas with even or varying degrees of discoloration• Beginning and end of the discoloration are not sharply defined and

do not cover the entire stroke area• Dark areas in the upper section of the cooling bore, remaining cir‐

cumference cannot be faulted• Piston rings cannot be faulted

Further endoscopic examina‐tion required as part of main‐tenance work

• On the entire circumference, apart from light areas of discoloration(do not impair operation) clearly darker stripes that start at the toppiston ring

• Heat discoloration in the direction of stroke and honing pattern dam‐age

• Heat discoloration of piston rings

Cylinder liner must be re‐placed; Service must be con‐tacted

1. Compile endoscopy report using the table.2. Use technical terms for description of the liner surface (→ Page 69).3. Depending on findings:

• Do not take any action or• carry out a further endoscopic examination as part of maintenance work or• contact Service; cylinder liner must be replaced.


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Final steps1. Install injector (→ Page 83).2. Install cylinder head cover (→ Page 80).


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7.2.2 Instructions and comments on endoscopic and visual examination of cylinderliners

Terms used for endoscopic examinationUse the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐nation report.

Findings MeasureLight scoring Minor dirt scores can occur during the assembly of a new engine (honing prod‐

ucts, particles, broken-off burrs). Removed cylinders clearly exhibit such scor‐ing on the running surface under endoscope magnification. Cannot be felt withthe fingernail.Findings not critical.

Single scores Clearly visible scores caused by hard particles. They usually start in the TDCarea and cross through the honing pattern in the direction of stroke.Findings not critical.

Scored area These areas consist of scores of different lengths and depths next to one an‐other. In most cases, they are found at the 6-o'clock and 12-o'clock positions(inlet/exhaust) along the transverse engine axis.Findings not critical.

Smoothened area Smoothened areas are changes to the running surface but almost the wholehoning pattern is still visible. Smoothened areas appear brighter and more bril‐liant than the surrounding running surface.Findings not critical.

Polished area Polished areas are on the running surface and show local removal of the hon‐ing pattern. Grooves from the honing process are not visible any more.New cylinder liners must be fitted in the following casesPolished area:covers more than 20% of the entire piston running surface,covers more than 30° of the circumference and extends over more than 50%of piston stroke,is wider than 15 mm over the entire piston stroke.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tem‐perature differences around the liner. It appears rather darker within the honedstructure in contrast to the bright metallic running surface. The honing patternis undisturbed. Discolorations extend in stroke direction and may be interrupt‐ed.Findings not critical.

Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves inthe overlap (open) position. They are clearly visible due to the dark color of thehoning groove bottom.This corrosion is not critical unless there is corrosion pitting.

Black lines Black lines are a step towards heat discoloration. They are visible as a cleardiscoloration from TDC to BDC in the running surface and the start of localizeddamage to the honing pattern.Cylinders with a number of black lines around the running surface have limitedservice life and should be replaced.


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Findings MeasureDiscolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they

run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ringand becoming more visible from the second TDC-ring onwards and less pro‐nounced from TDC-ring 1. The honing pattern is usually no longer visible anddisplays a clearly defined (straight) edge to the undisturbed surface. The dam‐aged surface is usually discolored. The circumferential length varies.Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.

Seizures, Seizuremarks

Seizure marks are of irregular circumferential length and depth. Can becaused by either the piston skirt or the piston crown. Material deposits on theliner (smears) show heavy discoloration and scoring.Replace liner.

Evaluation of findings and further measuresThe findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough in‐vestigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid un‐necessary disassembly work, it is recommended that another inspection be carried out after further oper‐ation of the engine.


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7.3 Crankcase Breather7.3.1 Crankcase breather – Oil separator check

Preconditions☑ Engine is running.

Checking oil separator

Note: A thin oil film is admissible.1. Check oil separator for damage and exces‐

sive oil discharge (arrow).2. Replace oil separator if it is defective

(→ Page 72).


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7.3.2 Crankcase breather – Filter element replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench 10-60 Nm F30510423 1Filter element (→ Spare Parts Catalog)

WARNING Hot oil.Oil can contain combustion residues which are harmful to health.Risk of injury and poisoning!• Wear protective clothing, gloves, and goggles / safety mask.• Avoid contact with skin.• Do not inhale oil vapor.

Crankcase breather (closed-circuitcrankcase ventilation) – Filterelement replacement

1. Loosen clamps (1), push rubber sleeves (2)over tubes (3).

2. Operate lever (6) to relieve clamping band(4).

3. Remove cover (7).4. Replace filter element (5).5. Fit cover (7).6. Operate lever (6) to tension clamping band

(4).7. Push back rubber sleeve (2) and tighten

clamp (1).8. Replace further filter elements in the same

way.


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Crankcase breather (open-circuitcrankcase ventilation) – Filterelement cleaning or replacement

1. Clean filter (6) outside.2. Undo clamp (2) and screw (7).3. Pull hose (1) off cover (3).4. Loosen clamp (5).5. Remove cover (3).6. Clean filter element (4) (→ Page 74) or re‐

place.7. Fit cover (3).8. Use torque wrench to tighten clamp (5) to

specified torque 12 Nm to 14 Nm.9. Push hose (1) onto cover (3).

10. Tighten clamp (2) and screw (7).11. Replace further filter elements (2) in the

same way.


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7.3.3 Crankcase breather (open-circuit crankcase ventilation) – Filter elementcleaning



CAUTION Excessive reaction time of cleaning agents on components.Damage to component!• Observe manufacturer's instructions.• Wear protective clothing, gloves, and goggles / safety mask.

Filter element – Removal / installation .u (→ Page 72)

Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning1. Clean filter element with cleaning agent.2. Remove cleaning agent.3. Blow out filter element thoroughly with compressed air.


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7.4 Valve Drive7.4.1 Valve gear – Lubrication


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Engine oil

Valve gear – Lubrication1. Remove cylinder head covers (→ Page 80).2. Fill oil chambers of rocker arms and adjust‐

ing screws with oil.3. Install cylinder head covers (→ Page 80).


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7.4.2 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 partsDesignation / Use Part No. Qty.Feeler gage Y20010128 1Torque wrench 60-320 Nm F30047446 1Socket box wrench F30039526 1Engine oil

Preparatory steps1. Remove cylinder head cover (→ Page 80).2. Install barring gear (→ Page 64).3. Turn crankshaft in direction of engine rota‐

tion with barring gear until “OT-A1” markand pointer are aligned.


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Diagram for 8V – Two crankshaftpositions

1. Crank drive position 1: cylinder A1 in firingTDC

2. Crank drive position 2: cylinder A1 in over‐lap TDC

3. Inlet valve (I)4. Exhaust valve (X)










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Checking valve clearance in two crankshaft positions1. Check TDC position of piston in cylinder A1:

• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.

2. Check valve clearance with cold engine:• Inlet valves (long rocker arm) = 0.2 mm• Exhaust valves (short rocker arm) = 0.5 mm

3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) asper diagram.

4. Use feeler gage to determine the distance between valve bridge and rocker arm.5. If the deviation from the specified value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance1. Release locknut (1).2. Insert feeler gage between valve bridge and

rocker arm.3. Turn adjusting screw (2) with Allen key until

appropriate valve clearance is set.4. Feeler gage must just pass through the

gap.

5. Tighten locknut (1) to specified torque using a torque wrench holding adjusting screw (2) firmly in so do‐ing.

Name Size Type Lubricant Value/Standard

Nut M16 x 1.5 Tightening torque (Engine oil) 90 Nm +9 Nm

6. Replace or rectify adjusting screws and/or locknuts which do not move freely.7. Check valve clearance.


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Final steps1. Remove barring gear (→ Page 64).2. Install cylinder head cover (→ Page 80).


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7.4.3 Cylinder head cover – Removal and installation

Preconditions☑ Engine shut down and starting disabled.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Gasket (→ Spare Parts Catalog)

Removing cylinder head cover1. Clean cylinder head covers prior to removal

if they are heavily soiled.2. Remove screws.3. Remove cylinder head cover with gasket

from cylinder head.

Installing cylinder head cover1. Clean mating face.2. Check condition of gasket, replace if necessary.3. Place gasket and cylinder head cover on cylinder head.4. Install cylinder head cover.


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7.5 Injection Pump / HP Pump7.5.1 HP pump – Relief bore check



Checking HP pump relief bore1. Check relief bore for oil and fuel discharge

by visual inspection.2. If relief bore is contaminated, stop the en‐

gine, disable engine start, and clean reliefbore.

3. Note the following in case of fluid dis‐charge:• Heavy discharge means continuous dis‐

charge of fluids (leakage). Contact Serv‐ice.

• Minor discharge of fluids up to 10 dropsper day is normal (moistening) and notconsidered a leakage.


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7.6 Injection Valve / Injector7.6.1 Injector – Replacement

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Injector (→ Spare Parts Catalog)

Replacing injectoru Remove injector and install new injector (→ Page 83).


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7.6.2 Injector – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Installation and removal tool for injector F6790161 1Milling cutter F30452739 1Slotted nut screwdriver F30452578 1Torque wrench, 0.5-5 Nm 0015384230 1Torque wrench, 10-60 Nm F30510423 1Torque wrench, 60-320 Nm F30047446 1Assembly paste (Optimoly Paste White T) 40477 1Grease (Kluthe Hakuform 30-10/emulsifier) X00058060 1Engine oil

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

CAUTION Removal of all injectors.Damage to component!• Ensure that the high-pressure fuel accumulator is secured on the engine through two HP lines.

CAUTION Cable damage during operation.Fire hazard!• Twist cables when installing.• Ensure that cables do not touch components.

Preparatory steps1. Shut off fuel inlet to engine.2. Remove cylinder head cover (→ Page 80).


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Removing injector

Note: Always replace the first and last injectors ofone engine side first. Replace the inner in‐jectors only after the installation of the outerinjectors on this engine side is completed.

1. Undo cable terminal screws (arrow) on in‐jector and remove cable terminals.

2. Remove screw (2) and take off hold-downclamp (1).

3. Remove high-pressure fuel line (5).

4. Install installation/removal device on cylin‐der head.

5. Remove injector with installation/removaldevice.

6. Remove installation/removal device.


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7. Remove sealing ring (1) from injector or usea self-made wire hook to extract it from thecylinder head.

8. Remove O-rings (2) from injector.9. Cover all connections and bores, or seal

with suitable plugs.

Installing injector1. Remove all plugs before installing.2. Coat nozzle retaining nut area of injector

with assembly paste.3. Fit new O-rings on injector and coat with

grease.4. Fit new sealing ring on injector with grease

ensuring correct installation position of seal‐ing ring.

5. Clean sealing surface on cylinder head andprotective sleeve with milling cutter.

6. Insert injector into cylinder head ensuringthat the HP line connection is aligned cor‐rectly.

7. Press in injector with installation/removaldevice.

8. Remove installation/removal device.


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9. Use slotted screwdriver to check thrust ringat both line ends for secure seating.

10. Tighten loose thrust ring to the specified tightening torque.


Thrust ring Tightening torque 5 Nm to 10 Nm

11. Coat screw head mating face (2) andthread with engine oil.

12. Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to thespecified initial tightening torque.


Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm

13. Fit O-rings (4) and (6) on high-pressure fuel line (5) and coat with grease.14. Tighten high-pressure fuel line (5) to the specified initial tightening torque.


HP line Preload torque (Engine oil) 5 Nm to 10 Nm

15. Tighten screw (2) to specified torque using a torque wrench.


Screw M12 Tightening torque 100 Nm + 10 Nm


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16. Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench.


Union nut Tightening torque 140 Nm + 10 Nm

17. Tighten union nut of connecting piece (injector) to specified torque using a torque wrench.


Union nut Tightening torque 120 Nm +10 Nm

18. Twist cable several times.

19. Insert cable terminals (arrows) underneath screws on injector and tighten screws to specified torque us‐ing a torque wrench.


Screw Tightening torque 1.5 Nm

Final steps1. Install cylinder head cover (→ Page 80).2. Open up fuel inlet to engine.


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7.7 Fuel System7.7.1 Fuel system – Venting


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filling device B80144852 1Diesel fuel


Venting LP fuel system1. Connect filling device to connection (3).2. Disconnect return line at connection (4).3. Use hand pump to fill fuel system, providing

pressure of min. 0.5 bar / max. 2.0 bar, untilfuel emerges without bubbles at connection(4).

4. Connect return line to connection (4).5. Open vent plug (1) on filter housing (2).6. Use hand pump to fill fuel system, providing

pressure of min. 0.5 bar / max. 2.0 bar, untilfuel emerges without bubbles at connection(1).

7. Close vent plug (1).8. Remove filling device and seal connection

(3).


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7.8 Fuel Filter7.8.1 Fuel filter – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrench F30379104 1Engine oilEasy-change filter (→ Spare Parts Catalog)


Replacing fuel filter1. Remove easy-change filter using filter

wrench.2. Clean sealing surface on filter head.3. Slightly lubricate seal on the easy-change

filter.4. Screw on easy-change filter by hand until

the seal connects and tighten manually.5. Vent fuel system (→ Page 88).6. Replace other easy-change filters in the

same way.


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7.8.2 Fuel prefilter – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuel


Draining fuel prefilter1. Shut down the filter unit (5/8) to be changed

at valves (3) and (4) or (9) and (10).2. Open threaded vent plug (1) or (2) on filter

to be drained.3. Open drain valve (6) or (7).4. Drain water and contaminants from the filter

until pure fuel emerges.5. Close drain valve (6) or (7).6. Open fuel return line (3) or (10).7. Open fuel inlet (4) or (9).8. Close threaded vent plug (1) or (2) on filter

to be drained when clean fuel emerges.


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7.8.3 Edge-type fuel filter – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Diesel fuelSealing ring (→ Spare Parts Catalog)


Edge-type fuel filter – Draining1. Rotate edge-type filter (2) with handle (1)

clockwise several times.2. Do not apply force when rotating handle.3. Close fuel supply.4. Remove drain plug (3) from edge-type filter

(2).5. Drain water and contaminants through drain

plug opening (3) until pure fuel emergesfrom filter.

6. Fit drain plug (3) with new sealing ring andscrew in.

7. Open fuel supply.


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7.9 Charge-Air Cooling7.9.1 Intercooler – Check drain for coolant leakage and obstruction




Intercooler – Check drain forcoolant leakage and obstruction

1. Verify that air emerges from condensatedrain bore(s) on left and right engine sidesat driving end when engine is running. If noair emerges:• Clean drain bore(s)• Blow out with compressed air

2. If a large amount of coolant is continuouslydischarged, the intercooler is leaking. Con‐tact Service.

Emergency measures prior to engine start with a leaking intercooler1. Remove injectors (→ Page 83).2. Bar engine manually (→ Page 64).3. Crank engine on starting system to blow out combustion chambers (→ Page 66).4. Install injectors (→ Page 83).


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7.10 Air Intake7.10.1 Service indicator – Check

See manufacturer's documentation.


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7.11 Starting Equipment7.11.1 Starter – Condition check


Checking starter condition1. Check securing screws of starter for secure seating and tighten if required.2. Check wiring (→ Page 127).


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7.11.2 Cold start system with ether injection – Check


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Ether cartridge (→ Spare Parts Catalog)

DANGER Cleaner is an explosive and poisonous substance.Danger to life, major material damage!• Avoid open flames, electrical sparks and ignition sources.• Wear goggles/facial protection.• Only work in a well-ventilated room.• Do not smoke.

Checking filling level and conditionof system

Note: After two successive starting trials with coldstart system, make next starting trial after10 minutes only. If the next two staring trialsfail, contact Service.

1. If the indicator lamp on the relay module (5)lights up, fit a new ether cartridge (1).

2. Check the condition of lines (2) and con‐nections. If damage is found, contact Serv‐ice.

3. Check the condition of electric lines (4) andconnections. If damage is found, contactService.

4. In case of system failure, check the fuses inthe fuse holder (3). If fuses are broken, con‐tact Service.


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7.12 Lube Oil System, Lube Oil Circuit7.12.1 Engine oil level – Check


Checking oil level prior to enginestart

1. Withdraw oil dipstick from guide tube andwipe it.

2. Insert oil dipstick into guide tube up to stop,withdraw after approx. 10 seconds andcheck oil level.

Note: After extended standstill, the oil level mayexceed the mark (1) by up to 2 cm. Thiscan be caused by oil flowing from e.g. oil fil‐ter or heat exchanger back to the oil pan.

3. The oil level must reach mark (1) or exceedmark (1) by up to 2 cm.

4. Top up with oil to mark (1) as necessary(→ Page 97).

5. Insert oil dipstick into guide tube up to thestop.

Checking oil level after the engine is stopped1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.2. Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level.3. Oil level must be between marks (1) and (2).4. Top up with oil to mark (1) as necessary (→ Page 97).5. Insert oil dipstick into guide tube up to the stop.


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7.12.2 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 partsDesignation / Use Part No. Qty.Torque wrench, 40-200 Nm F30027337 1Ratchet adapter F30027341 1Engine oilSealing ring (→ Spare Parts Catalog)


Procedure without pump: Draining oil via drain plug(s) on oil pan1. Provide a suitable container to collect the oil.2. Remove drain plug(s) and drain oil.3. Install drain plug(s) with new sealing ring.

Procedure with pump: Oil extraction1. Provide a suitable container to collect the oil.2. Extract all oil from oil pan using the pump.

Draining residual oil at equipmentcarrier

1. Provide a suitable container to collect theoil.

2. Remove drain plug (1) and drain oil (ap‐prox. 7 liters) from oil heat exchanger andoil filter.

3. Remove drain plugs (2) and (3) and drainoil:• at drain plug (2) approx. 12 liters• at drain plug (3) approx. 5 liters

4. Install drain plug(s) with new sealing ring.


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5. Tighten drain plugs (2) and (3) with torque wrench to the specified torque.


Screw M26 x 1.5 Tightening torque (Engine oil) 100 Nm +10 Nm

Filling with new oil1. Open cover on filler neck.2. Fill oil through filler neck up to "max." mark

at oil dipstick.3. Close cover on filler neck.4. Check engine oil level (→ Page 96).5. After oil change, bar engine with starting

system (→ Page 66).


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7.12.3 Engine oil – Sample extraction and analysis

Preconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1




Engine oil sample extraction andanalysis

1. With the engine running at operating tem‐perature, open screw on flange of centrifu‐gal oil filter by 1 to 2 rotations.

2. Drain approx. 2 liters engine oil to flush outthe oil sludge.

3. Drain approx. 1 liter engine oil into a cleancontainer.

4. Close screw.5. Using the equipment and chemicals of the

MTU test kit, examine oil for:• Dispersing capacity (spot test);• Water content;• Fuel dilution.


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7.13 Oil Filtration / Cooling7.13.1 Engine oil filter – Replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrench F30379104 1Engine oilOil filter (→ Spare Parts Catalog)


Engine oil filter – Replacement1. Remove oil filter using the filter wrench.2. Clean the sealing surface of the filter head.

Note: Use only oil filters with integrated safetyvalve.

3. Check condition of the new sealing ring andcoat it with oil.

4. Screw on and tighten new oil filter by hand.5. Replace further oil filters in the same way.6. After each oil change and filter replace‐

ment, bar engine with starting system(→ Page 66).

7. Check oil level (→ Page 96).


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7.13.2 Centrifugal oil filter – Cleaning and filter sleeve replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrench F30379104 1Torque wrench, 6-50 Nm F30027336 1Ratchet adapter F30027339 1Cold cleaner (Hakutex 60) 50602 1Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1Filter sleeve (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)Sealing ring (→ Spare Parts Catalog)




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Cleaning centrifugal oil filter andreplacing filter sleeve

1. Undo screw (1) and remove.2. Remove clamp (3) and take off hood (2).3. Carefully remove rotor (5) from housing.4. Hold rotor assembly (5) firmly in position

with filter wrench and undo knurled nut (7).5. Take off rotor cap (8).6. Remove filter sleeve (9), stiffener plate (10)

and sealing ring (11).7. Measure thickness of oil residues on filter

sleeve.8. If maximum layer thickness of oil residues

exceeds 30 mm, shorten maintenance in‐terval.

9. Remove standpipe (12) from lower rotorsection (13).

10. Wash hood (2), rotor cap (8), stiffenerplate, (10) standpipe (12), rotor lower sec‐tion (13) and nozzles (14) with cold cleanerand blow out with compressed air. Do notuse sharp objects for cleaning.

11. Check nozzles (14) for obstructions.12. Press standpipe (12) onto rotor lower sec‐

tion (13).13. Insert new filter sleeve (9) with stiffener

plate (10) into rotor cap (8), ensuring thatsmooth surface of filter sleeve (9) faces ro‐tor cap (8).

14. Check sealing ring (11), replace if necessa‐ry. Coat sealing ring with grease and insertin groove of rotor cap (8).

15. Place rotor cap (8) onto standpipe (12).16. Hold rotor assembly (5) firmly in position

with filter wrench and tighten knurlednut (7).

17. Lubricate bearings of rotor (5) with oil, in‐sert into housing (6) and check for ease ofmovement.

18. Check sealing ring (4), replace if necessary.Fit sealing ring on housing (6).

19. Fit hood (2).20. Tighten screw (1) by hand.21. Install clamp (3) and tighten to specified torque using a torque wrench.


Clamp Tightening torque 6 Nm + 1 Nm



Screw Tightening torque 6 Nm + 1 Nm


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7.14 Coolant Circuit, General, High-Temperature Circuit7.14.1 Coolant level - Check

Preconditions☑ Engine shut down 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.

Checking coolant level at filler neck:1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to

escape.2. Continue to turn breather valve counterclockwise and remove.3. Check coolant level (coolant must be visible at the lower edge of the cast-in eye).

Checking coolant level at remotecooler:

1. Check coolant level (coolant must be visibleat marking plate).

2. Top up coolant if necessary (→ Page 106).3. Check and clean breather valve.4. Place breather valve on filler neck and

close.

Coolant level check by means of level sensor:1. Switch on engine control system and check readings on the display.2. Top up coolant if necessary (→ Page 106).


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7.14.2 Engine coolant – Change

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Engine coolant

Changing engine coolant1. Drain engine coolant (→ Page 105).2. Fill with engine coolant (→ Page 106).


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7.14.3 Engine coolant – Draining



Preparatory steps1. Provide an appropriate container to drain the coolant into.2. Switch off preheating unit.

Engine coolant – Draining1. Turn breather valve on coolant expansion

tank counterclockwise up to the first stopand allow pressure to escape.

2. Continue to turn breather valve counter‐clockwise and remove.

3. Draw off separated corrosion inhibitor oil inexpansion tank through the filler neck.

4. Open drain valves and/or drain plugs anddrain coolant at the following points:• At the preheating unit;• At the HT coolant pump elbow;• At the crankcase, left and right side.

5. Additional drain points on 12/16V 4000 Mengines:• T-piece (3) on engine driving end;• Intercooler (2), left and right side;• Carrier-housing cover (1), left and right

side.6. Close all open drain points.7. Place breather valve on filler neck and

close.


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7.14.4 Engine coolant – Filling


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Engine coolant


CAUTION Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!• Fill / top up coolant only into cold engine.

Preparatory steps1. Turn breather valve of filler neck on coolant

expansion tank counterclockwise to firststop and allow pressure to escape.



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Filling coolant with pump1. Connect appropriate pump with hose to

drain valve.2. Open drain valve and pump coolant into en‐

gine at 0.5 bar minimum.3. Fill expansion tank until overflow edge is

reached.4. Close drain valve.5. Check proper condition of breather valve,

clean sealing faces if required.6. Set breather valve onto filler neck and close

it.7. Start engine (→ Page 35).8. After the engine has run at unloaded condi‐

tion for 10 seconds, stop engine(→ Page 37).

9. Turn breather valve of filler neck on coolantexpansion tank counterclockwise to firststop and allow pressure to escape.


11. Check coolant level (→ Page 103) and topup if required:

a) Fill in coolant in expansion tank until thecoolant level at top edge of filler neckremains constant.

b) Set breather valve onto filler neck andclose it.

c) Repeat the steps from "Start engine"(→ Step 7) until coolant is no longerneeded to be topped up.

d) Disconnect pump and hose.

Filling coolant through filler neck1. Alternatively: Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains

constant.2. Check proper condition of breather valve, clean sealing faces if required.3. Set breather valve onto filler neck and close until first stop is reached.4. Start engine (→ Page 35).5. After the engine has run at unloaded condition for 10 seconds, stop engine (→ Page 37).6. Turn breather valve counterclockwise and remove.7. Check coolant level (→ Page 103) and top up if required:

a) Repeat the steps from "Start engine" (→ Step 4) until coolant is no longer needed to be topped up.b) Check proper condition of breather valve, clean sealing faces if required.c) Set breather valve onto filler neck and close it.

Final steps1. Start the engine and operate it at unloaded condition for some minutes.2. Check coolant level (→ Page 103) and top up if required.


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7.14.5 Engine coolant pump – Relief bore check



Checking relief bore on enginecoolant pump

1. Checking relief bore for oil and coolant dis‐charge.

2. Stop engine (→ Page 37) and disable en‐gine start, observe general safety instruc‐tions for maintenance and repair.

3. Clean the relief bore with a wire if it is dirty.• Permissible coolant discharge: up to 10

drops per hour.• Permissible oil discharge: up to 5 drops

per hour.4. If discharge exceeds the specified limits:

Contact Service.


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7.14.6 Coolant – Sample extraction and analysis

Preconditions☑ MTU Fluids and Lubricants Specifications (A001061/..) are available.

Special tools, Material, Spare partsDesignation / Use Part No. Qty.MTU test kit 5605892099/00 1




Coolant sample extraction andanalysis

1. With the engine running, open drain valve(1).

2. Flush sample-extraction point by drainingapprox. 1 liter coolant.

3. Drain approx. 1 liter coolant into a cleancontainer.

4. Close drain valve (1).5. Using the equipment and chemicals of the

MTU test kit, check the coolant for:• Antifreeze concentration• Corrosion inhibitor concentration• pH value.

6. For coolant change intervals, see (→ MTUFluids and Lubricants Specifications.)


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7.15 Low-Temperature Circuit7.15.1 Charge-air coolant – Level check



Checking charge-air coolant levelat filler neck:

1. Turn breather valve on coolant expansiontank counterclockwise to the first stop andallow pressure to escape.


3. Check coolant level (coolant must be visibleat marking plate).

4. Top up coolant if necessary (→ Page 113).5. Check proper condition of breather valve,

clean sealing faces if required.6. Fit breather valve and close it.

Checking charge-air coolant level by means of level sensor:1. Switch on engine control system and check display (coolant level is automatically monitored by engine

control system).2. Top up coolant if necessary (→ Page 113).


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7.15.2 Charge-air coolant – Change

Special tools, Material, Spare partsDesignation / Use Part No. Qty.Charge-air coolant

Charge-air coolant – Change1. Drain charge-air coolant (→ Page 112).2. Fill with charge-air coolant (→ Page 113).


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7.15.3 Charge-air coolant – Draining


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Sealing ring (→ Spare Parts Catalog)


Charge-air coolant – Draining1. Provide an appropriate container to drain

the coolant into.2. Turn breather valve of filler neck on coolant

expansion tank counterclockwise to firststop and allow pressure to escape.


4. Draw off separated corrosion inhibitor oil inexpansion tank through the filler neck.

5. Open drain valves and/or drain plugs anddrain coolant at the following points:• At the LT coolant pump;• At the coolant lines to and from the inter‐

cooler.

6. Draining of residual coolant:• At the intercooler

7. Close all drain valves and screw in drainplugs with new sealing rings.

8. Set breather valve onto filler neck and closeit.


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7.15.4 Charge-air coolant – Filling


Special tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantSealing ring (→ Spare Parts Catalog)


CAUTION Cold coolant in hot engine can cause thermal stress.Formation of cracks in components!• Fill / top up coolant only into cold engine.

Preparatory steps1. Turn breather valve of coolant expansion

tank counterclockwise to the first stop andallow pressure to escape.

2. Turn breather valve counterclockwise andremove.


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Filling with coolant using a pump1. Connect a suitable pump with a hose to the

drain valve (arrowed).

2. Open vent on intercooler (arrow).3. Open drain valve and pump coolant into en‐

gine at 0.5 bar minimum.4. Close venting point when coolant emerges.5. Fill expansion tank up to overflow.6. Close drain valve.7. Check proper condition of breather valve

and clean sealing faces if required.8. Place breather valve on filler neck and

close.9. Start engine (→ Page 35).

10. After 10 seconds of running the enginewithout load, shut down the engine(→ Page 37).

11. Turn breather valve of coolant expansiontank counterclockwise to the first stop andallow pressure to escape.


13. Check coolant level (→ Page 110) and topup coolant as required:

a) Top up with coolant via expansion tankuntil the coolant level is constant at theoverflow.

b) Place breather valve on filler neck andclose.

14. Repeat the steps from "Start engine"(→ Step 8) until coolant is no longer neededto be topped up.

15. Disconnect pump and hose.


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Alternatively: Filling coolantthrough filler neck

1. Remove plug screws from filling points (ar‐rows) on coolant lines from and to the inter‐cooler.

2. Open air bleed on the intercooler (arrow).3. Fill coolant via the filling points on the cool‐

ant lines to and from the intercooler and viathe expansion tank up to the overflow.

4. Close venting point when coolant emerges.5. Install plug screws of filling points with new

sealing rings.6. Check proper condition of breather valve

and clean sealing faces if required.7. Set breather valve onto filler neck and turn

to the first stop.8. Start engine (→ Page 35).9. After 10 seconds of running the engine

without load, shut down the engine(→ Page 37).


11. Check coolant level (→ Page 110) and topup coolant as required:

a) Top up with coolant via expansion tankuntil the coolant level is constant at theoverflow.

b) Place breather valve on filler neck andclose.

12. Repeat the steps from "Start engine"(→ Step 7) until coolant is no longer neededto be topped up.

Final steps1. Start the engine and run it without load for some minutes.2. Check coolant level (→ Page 110) and top up coolant as required.


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7.15.5 Charge-air coolant pump – Relief bore check



Charge-air coolant pump – Reliefbore check

1. Check relief bore for oil and coolant dis‐charge.

2. Stop engine (→ Page 37) and disable en‐gine start, observe general safety instruc‐tions for maintenance and repair.

3. Clean the relief bore with a wire if it is dirty.• Permissible coolant discharge: up to 10

drops per hour.• Permissible oil discharge: up to 5 drops

per hour.4. If discharge exceeds the specified limits:

Contact Service.


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7.16 Belt Drive7.16.1 Drive belt – Condition check

Preconditions☑ Engine is stopped and starting disabled.☑ Guard is removed.

Drive belt – Condition check

Item Findings ActionDrive belt A Singular cracks NoneDrive belt Belt is oily, shows signs of over‐

heatingReplace(→ Page 122)

Drive belt B Cracks on entire circumferenceDrive belt C Chunking


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7.17 Battery-Charging Generator7.17.1 Battery-charging generator – Condition check


Battery-charging generator – Condition check1. Check if securing screws of battery-charging generator fit firmly.2. Tighten any loose threaded connections.3. Check wiring (→ Page 127).


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7.17.2 Battery-charging generator – Check



Checking battery-charging generatorItem Findings MeasureVentilation area (arrow) Clean NoneVentilation area (arrow) Contaminated Clean

Cleaning battery-charging generatorNote: Dry-clean battery-charging generator only.

1. Remove coarse dirt from battery-charging generator.2. Blow out ventilation area (arrow) with compressed air until all dust is cleared.


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7.17.3 Battery-charging generator – Removal and installation


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Torque wrench, 20-100 Nm F30026582 1Ratchet adapter F30027340 1

WARNING Heavy object.Risk of crushing!• Use appropriate lifting devices and appliances.

Removing battery-charginggenerator

1. Undo screws (1), (2) and (3).2. Remove protective cover (8).3. Mark electric cables on battery-charging

generator and remove.4. Protect all cables from damage.5. Slacken screws (4) and (5) by half a turn.6. Place socket adapter or box wrench on

screw (6) and press belt tensioner in the di‐rection indicated by the arrow as far as itwill go.

7. Tighten screw (4).8. Remove drive belt (7).

9. Release screws (arrow).10. Remove battery-charging generator (1).11. Clean battery-charging generator (1) thor‐

oughly (→ Page 119).12. Install battery-charging generator (1) follow‐

ing reverse sequence of working steps.


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Tensioning drive belt1. Fit drive belt (7).2. Slacken screw (4) by half a turn.

Result: Belt tensioner moves against the drive belt and tensions it.3. Use torque wrench to tighten screw (4) to specified tightening torque.


Screw M10x1.5 Tightening torque 60 Nm +5 Nm

4. Use torque wrench to tighten screw (5) to specified tightening torque.


Screw M10x1.5 Tightening torque 42 Nm

5. Install protective cover (8).6. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 123).


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7.17.4 Battery-charging generator drive – Drive belt and belt tensioner replacement



WARNING Heavy object.Risk of crushing!• Use appropriate lifting devices and appliances.

Replacing drive belt and belttensioner

1. Undo screws (1), (2) and (3).2. Remove protective cover (8).3. Slacken screws (4) and (5) by half a turn.4. Place socket adapter or box wrench on

screw (6) and press belt tensioner in the di‐rection indicated by the arrow as far as itwill go.

5. Tighten screw (4).6. Remove drive belt (7).7. Screw on screw (5) and replace belt ten‐

sioner.8. Fit new drive belt (7).

Tensioning drive belt1. Slacken screw (4) by half a turn.

Result: Belt tensioner moves against the drive belt and tensions it.2. Use torque wrench to tighten screw (4) to specified tightening torque.



3. Use torque wrench to tighten screw (5) to specified tightening torque.



4. Install protective cover (8).5. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 123).


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7.17.5 Battery-charging generator drive – Drive belt tension adjustment



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

Adjusting belt tension1. Undo screw (arrow) and remove protective

cover (3).2. Slacken screws (1) and (2) by half a turn.

Result: Belt tensioner moves against the drive beltand tensions it.







5. Install protective cover (3).


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7.18 Fan Drive7.18.1 Fan drive belt– Tension check / adjustment


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Optibell 2 belt tension tester Y4345711 1

Preparatory steps1. Remove guard cover.2. Check belt condition visually (→ Page 117).

Result: If required, replace drive belt (→ Page 126).

Checking Vee belt tension1. Switch on belt tension tester.2. Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrowed) with a suitable tool.3. Hold belt tension tester over belt drive until the measured value is indicated.

Initial assembly at MTU Initial operation with fan Belt tension adjustment36 Hz ± 5 Hz 49 Hz ± 5 Hz 44 Hz ± 5 Hz


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Adjusting drive belt tension1. Release screws (2) until fan coupling can

be moved.2. Tighten stud (1) until the required frequency

is achieved.3. Tighten screws (2) to 250 Nm ± 25 Nm.


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7.18.2 Fan drive – Drive belt replacement


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Drive belt (→ Spare Parts Catalog)

Preparatory steps1. Remove protective cover.2. Remove fan.

Replacing drive belt1. Release screws (2).2. Slacken off stud (1) until drive belt can be

removed.3. Clean belt pulleys.4. Fit new drive belt on belt pulleys, ensuring

that it is not under tension.5. Adjust belt tension (→ Page 124).


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7.19 Wiring (General) for Engine/Gearbox/Unit7.19.1 Engine wiring – Check


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Isopropyl alcohol X00058037 1

Engine wiring – Check1. Check securing screws of cable clamps on engine and tighten loose threaded connections.2. Ensure that cables are fixed in their clamps and cannot swing freely.3. Check that cable ties are firm, tighten loose cable ties.4. Replace faulty cable ties.5. Visually inspect the following electrical line components for damage:

• connector housings;• contacts;• sockets;• cables and terminals;• plug-in contacts.

6. (→ Contact Service) if cable conductors are damaged.Note: Close male connectors that are not plugged in with the protective cap supplied.

7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.8. Ensure that all sensor connectors are securely engaged.


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7.20 Accessories for (Electronic) Engine Governor / ControlSystem

7.20.1 DDEC and connectors – Cleaning


Special tools, Material, Spare partsDesignation / Use Part No. Qty.Isopropyl alcohol

DANGER Cleaner is an explosive and poisonous substance.Danger to life, major material damage!• Avoid open flames, electrical sparks and ignition sources.• Wear goggles/facial protection.• Only work in a well-ventilated room.• Do not smoke.

DDEC and connectors – Cleaning1. Remove coarse dirt from housing surface

using a cloth moistened with isopropyl alco‐hol.

2. Remove dirt from surface of connectors (1),connector sockets and shrink sleeves (2)using a cloth moistened with isopropyl alco‐hol.

3. Check legibility of cable labels.• Clean or replace illegible labels.


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Cleaning severely contaminatedconnectors on DDEC

1. Disconnect connectors on both sides ofDDEC. For this purpose, withdraw connec‐tors (1).

2. Unscrew connectors (3).3. Remove covers (2).4. Clean connector housings, connector sock‐

et housings and all contacts with isopropylalcohol.

5. When connectors, sockets and all contactsare dry: Install connectors and check plug-in connection on DDEC (→ Page 130).


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7.20.2 DDEC – Checking plug-in connections


Checking plug-in connections onDDEC

1. Check all plug-in connections on both sidesof DDEC for secure seating.

2. Slide connectors (1) on until they latch intoposition.

3. Screw in connectors (3) securely.4. Seal non-assigned connector bases with

covering caps (2).5. If plug-in connection is defective, contact

Service.


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8 Appendix A8.1 Abbreviations

Abbreviation Meaning ExplanationA/D Analog/Digital Transformer: transforms sensor voltages into

numeric valuesADEC Advanced Diesel Engine Controller Engine management systemAFRS Air Filter Restriction SensorANSI American National Standards Institute Association of American standardization or‐

ganizationsATL Abgasturbolader Exhaust turbocharger (ETC)ATS Air Temperature SensorBR Baureihe SeriesBV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications,

Publication No. A01061/..CAN Controller Area Network Data bus system, bus standardCDC Calibration Drift Compensation Setting of drift compensation in engine gov‐

ernor with DiaSysCEL Stop Engine Light 1st function: Warning lamp (rectify fault as

soon as possible)2nd function: Read out fault codes

CKT CircuitCLS Coolant Level Sensor Monitors coolant levelCPS Coolant Pressure Sensor Monitors coolant pressureCTS Coolant Temperature Sensor Monitors coolant temperatureDDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Die‐

selDDL Diagnostic Data Link Diagnostic linesDDR Diagnostic Data Reader Diagnostic unitDIN Deutsches Institut für Normung e. V. At the same time identifier of German stand‐

ards (DIN = “Deutsche Industrie-Norm”)DL Default Lost Alarm: Default CAN bus failureDOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel

particulate filterDPF Diesel Particulate FilterDT Diagnostic Tool Diagnostic unitECM Electronic Control Module Electronic control unit of the DDEC systemECU Engine Control Unit Engine governorEDM Engine Data Module Memory module for engine dataEEPROM Electrically Erasable Programmable

Read Only MemoryEFPA Electronic Foot Pedal Assembly

M015241/03E 2011-12 | Appendix A | 131

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Abbreviation Meaning ExplanationEGR Exhaust Gas RecirculationEMU Engine Monitoring UnitETK Ersatzteilkatalog Spare Parts Catalog (SPC)EUI Electronic Unit InjectorFPS Fuel Pressure Sensor Monitors fuel pressureFRS Fuel - Differential Pressure SensorFTS Fuel Temperature Sensor Monitors fuel temperatureFWCP Fire Water Control Panel Control cabinetGND GroundHD Hochdruck High Pressure (HP)HI High Alarm: Measured value exceeds 1st maxi‐

mum limitHIHI High High Alarm: Measured value exceeds 2nd maxi‐

mum limit valueHT High TemperatureIDM Interface Data Module Memory module for interface dataINJ InjectorISO International Organization for Stand‐

ardizationInternational umbrella organization for all na‐tional standardization institutes

KGS Kraftgegenseite Engine free end in accordance with DIN ISO1204

KS Kraftseite Engine driving end in accordance with DINISO 1204

LED Light Emitting DiodeLO Low Alarm: Measured value lower than 1st mini‐

mum limit valueLOLO Low Low Alarm: Measured value lower than 2nd mini‐

mum limit valueLSG Limiting Speed GovernorN/A Not ApplicableLP Low PressureOEM Original Equipment ManufacturerOI Optimized IdleOLS Oil Level Sensor Monitors oil levelOPS Oil Pressure Sensor Monitors oil pressureOTS Oil Temperature Sensor Monitors oil temperatureOT Oberer Totpunkt Top Dead Center (TDC)PAN Panel Control panelPIM Peripheral Interface ModulePWM Modulated signalP-xyz Pressure-xyz Pressure measuring point, xyz specifies the

measuring point designationRL Redundancy Lost Alarm: Redundant CAN bus failure

132 | Appendix A | M015241/03E 2011-12

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Abbreviation Meaning ExplanationSAE Society of Automotive Engineers U.S. standardization organizationSD Sensor Defect Alarm: Sensor failureSEL Stop Engine Light 1st function: Warning lamp (stop engine and

rectify fault)2nd function: Read out fault codes

SID System IdentifierSRS Synchronous Reference Sensor TDC cylinder 1SS Safety System Safety system alarmTBS Turbocharger Boost Sensor Monitors charge-air pressureTCI Turbo Compressor InletTCO Turbo Compressor OutletTD Transmitter Deviation Alarm: Deviation in transmitter valuesTPS Throttle Position SensorTRS Timing Reference SensorT-xyz Temperature-xyz Temperature measuring point, xyz specifies

the measuring point designationUT Unterer Totpunkt Bottom Dead Center (BDC)VNT Variable Nozzle TurbineVSG Variable-Speed GovernorVSS Vehicle Speed SensorWZK Werkzeugkatalog Tool Catalog (TC)

M015241/03E 2011-12 | Appendix A | 133

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8.2 MTU contacts/service partners

ServiceOur worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters ensures fast and direct support on site and the high availability of our products.

Local supportExperienced 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 hotlineWith our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you- either during operation, for preventive maintenance, corrective work in case of malfunction or changedoperating conditions, or for spare parts supply.Your contact at Headquarters:[email protected]

Spare parts serviceFast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right sparepart at the right time at the right place.With this aim in mind, we can call on a globally networked spares logistics system- a central depot at Headquarters, as well as decentralized depots among our subsidiaries, representa‐tives and contractual workshops.Your contact at Headquarters:E-mail: [email protected]: +49 7541 908555Fax: +49 7541 908121

134 | Appendix A | M015241/03E 2011-12

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9 Appendix B9.1 Special Tools

Adapter

Part No.: F6558528Qty.:Used in:

1 7.1.1 Engine – Barring manually (→ Page 64)

Barring device



Barring device



Endoscope

Part No.: Y20097353Qty.:Used in:

7.2.1 Cylinder liner – Endoscopic examination (→ Page 67)

Feeler gage


1 7.4.2 Valve clearance – Check and adjustment (→ Page 76)

Filling device

Part No.: B80144852Qty.:Used in:

1 7.7.1 Fuel system – Venting (→ Page 88)

Filter wrench


1 7.8.1 Fuel filter – Replacement (→ Page 89)

Qty.:Used in:

1 7.13.1 Engine oil filter – Replacement (→ Page 100)

Qty.:Used in:

1 7.13.2 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 101)

M015241/03E 2011-12 | Appendix B | 135

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Installation and removal tool for injector


1 7.6.2 Injector – Removal and installation (→ Page 83)

Milling cutter



MTU test kit

Part No.: 5605892099/00Qty.:Used in:

1 7.12.3 Engine oil – Sample extraction and analysis (→ Page 99)

Qty.:Used in:

1 7.14.6 Coolant – Sample extraction and analysis (→ Page 109)

Optibell 2 belt tension tester


1 7.18.1 Fan drive belt– Tension check / adjustment (→ Page 124)

Ratchet



Ratchet adapter


1 7.12.2 Engine oil – Change (→ Page 97)

Ratchet adapter



Ratchet adapter


1 7.17.3 Battery-charging generator – Removal and installation (→ Page 120)

Qty.:Used in:

1 7.17.4 Battery-charging generator drive – Drive belt and belt tensioner replacement (→Page 122)

Qty.:Used in:

1 7.17.5 Battery-charging generator drive – Drive belt tension adjustment (→ Page 123)

136 | Appendix B | M015241/03E 2011-12

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Slotted nut screwdriver



Socket box wrench



Steam jet cleaner

Part No.: -Qty.:Used in:

1 4.7 Plant – Cleaning (→ Page 39)

Torque wrench 10-60 Nm


1 7.3.2 Crankcase breather – Filter element replacement (→ Page 72)

Torque wrench 60-320 Nm



Torque wrench, 0.5-5 Nm

Part No.: 0015384230Qty.:Used in:


Torque wrench, 10-60 Nm





1 7.17.3 Battery-charging generator – Removal and installation (→ Page 120)

Qty.:Used in:

1 7.17.4 Battery-charging generator drive – Drive belt and belt tensioner replacement (→Page 122)

Qty.:Used in:

1 7.17.5 Battery-charging generator drive – Drive belt tension adjustment (→ Page 123)

M015241/03E 2011-12 | Appendix B | 137

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1 7.12.2 Engine oil – Change (→ Page 97)







138 | Appendix B | M015241/03E 2011-12

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9.2 Index16V 4000 E20 engine data 28

AAbbreviations 131After stopping the engine 38

BBattery-charging generator– Check 119Battery-charging generator drive – Drive belt and belt

tensioner replacement 122Battery-charging generator drive – Drive belt tension ad‐

justment 123Battery-charging generator – Condition check 118Battery-charging generator – Removal and installation

120

CCentrifugal oil filter– Cleaning and filter sleeve replacement 101Charge-air coolant– Change 111– Draining 112– Filling 113– Level check 110Charge-air coolant level– Check 110Charge-air coolant pump– Relief bore check 116Cold start system with ether injection – Check 95Contact persons 134Coolant– Sample extraction and analysis 109Coolant - charge air– Level check 110Coolant - charge-air– Change 111Coolant level– Check 103Crankcase breather– Oil separator check 71Crankcase breather (open-circuit crankcase ventilation) –

Filter element cleaning 74Crankcase breather – Filter element replacement 72Crankshaft transport locking device 10Cylinder head cover– Removal and installation 80Cylinder liner– Endoscopic examination 67

DDDEC alarms 44DDEC and connectors – Cleaning 128DDEC – Checking plug-in connections 130Drive belt– Condition check 117

EEdge-type fuel filter – Draining 91Engine– Barring manually 64– Shutdown in manual mode 37– Start in manual mode 35– Wiring check 127Engine coolant– Change 104Engine coolant pump– Relief bore check 108Engine coolant – Draining 105Engine coolant – Filling 106Engine layout 21Engine oil– Change 97– Sample extraction and analysis 99Engine oil filter – Replacement 100Engine oil level– Check 96Engine side and cylinder– Designations 25Engine wiring– Check 127Engine – Barring with starting system 66

FFan drive– Drive belt replacement 126Fan drive belt– Tension check / adjustment 124Fire prevention and environmental protection 17Firing order 32Fluids and lubricants 17Fuel filter– Replacement 89Fuel prefilter - Draining 90Fuel system – Venting 88

GGeneral conditions 7

HHP pump– Relief bore check 81

IInjector– Removal and installation 83– Replacement 82Inspection port cover– Explosion hazard 13Instructions and comments on endoscopic and visual ex‐

amination of cylinder liners 69Intercooler– Drain, coolant leakage 92

M015241/03E 2011-12 | Appendix B | 139

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MMaintenance and repair work– Safety regulations 14MTU contact persons 134

OOperational checks 36

PPersonnel and organizational requirements 8Plant– Cleaning 39Putting the engine into operation– Preparation after scheduled out-of-service-period

34Putting the engine into operation after extended out-of-

service periods (>3 months) 33

SSafety instructions 20Sensors and actuators – Overview 26Service indicator– Check 93Service partners 134Starter– Condition check 94Startup and operation– Safety regulations 12

TTransport 9Troubleshooting 41

VValve clearance– Adjustment 76– Check and adjustment 76Valve gear– Lubrication 75

WWiring - engine– Check 127

140 | Appendix B | M015241/03E 2011-12

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