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

Technical Publication

Diesel Engine 8V 4000 G 12V 4000 G 16V 4000 G

Tolerances and Wear Limits List M070040/00E

Printed in Germany  2002 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten. vorbehalten. Printed in Germany  2002 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming 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 damage during operation. Subject to alterations and amendments. Imprimé en Allemagne  2002 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, électroniques, y compris les bases de données et les services en ligne. Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. Modifications réservées. Impreso en Alemania  2002 Copyright MTU Friedrichshafen GmbH Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su reproducción, difusión, transformación, traducción, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones. Stampato in Germania  2002 Copyright MTU Friedrichshafen GmbH Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm ed alla memorizzazione memorizzazione od all’elaborazione all’elaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH. II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’ utente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche.

Printed in Germany  2002 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten. vorbehalten. Printed in Germany  2002 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming 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 damage during operation. Subject to alterations and amendments. Imprimé en Allemagne  2002 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, électroniques, y compris les bases de données et les services en ligne. Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. Modifications réservées. Impreso en Alemania  2002 Copyright MTU Friedrichshafen GmbH Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su reproducción, difusión, transformación, traducción, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones. Stampato in Germania  2002 Copyright MTU Friedrichshafen GmbH Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm ed alla memorizzazione memorizzazione od all’elaborazione all’elaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH. II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’ utente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche.

Amendment Service!

Any changes in contents will be sent to you in the form of an amendment, provided you complete the reverse of this receipt card and return it to us.

Postcard

MTU Friedrichshafen GmbH Department SCT 88040 Friedrichshafen GERMANY

No.

Date

Please mark all filed amendments here. 1.

02-07

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Please use block capitals!

Receipt

Amendment No.

1. 2. 3. 4.

Publication number:

M070040/00E

5. 6.

Name

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

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

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Fax

....................Telephone.....................

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02-07

Name

Contents

Page

1

Contents

General Information 010 Crankcase 020 Gear train 030 Running gear 040 Cylinder head 050 Valve gear 200 Coolant system Preliminary Note Data Sheets

M070040/00E 02-07

© MTU

Page

2

Contents

General Information The tolerances and wear limits indicated in this publication are intended as a guide for the examination of engine components during inspection and repair. Explanation of terms for dimensions of new components H6

Tol. size

Designed size followed by a letter/number symbol (e.g. 24 ) or by the permissible dimensional deviation (e.g. +0.013 24 )

Basic size

Designed size without fit symbol or quotation of dimensional deviation

Deviation

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

Clearance

Difference between bore and shaft diameters when bore diameter is greater than shaft diameter

Interference

Difference between bore and shaft diameters when bore diameter is smaller than shaft diameter

Explanation of terms for reconditioning and operational limits Wear limit

The limit dimensions specified do not represent the absolute maximum values permissible for satisfactory engine operation. They indicate that the next basic overhaul can be reached safely. If a limit value is exceeded, the component must be replaced.

Reconditioning instructions

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

Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limit values, unless exceptions are specifically indicated. All dimensions are given in "mm", unless alternative units of measurement are specifically indicated.

M070040/00E 00-01

© MTU

Crankcase

Group Page

010 1

Cylinder Liner

No.

Stage

Tol. size Basic size

Housing bore - upper fit

0 1

196.000 H7 196.500

0 1 0 1 0 1

196.000 j6 196.500 j6 H7 189.000 H7 189.500 189.000 f6 189.500 f6 H7 170.000

- 0.013

3

Cylinder liner - upper fit Housing bore - lower fit Cylinder liner - lower fit Bush bore

170.000 g7

- 0.054

4

Scraper ring OD Scraper ring bore

1

2

Designation

5

Bush bore - installed

6

Marking for stage

H7

Deviation lower upper 0

0 - 0.079 0

Clearance min. max.

+ 0.046

0.059

Interference min. max.

Wear limit

0.016

+ 0.016 + 0.046

0.050

0.125

0.014

0.094

- 0.050 + 0.040 - 0.014

164.000

H8

0

+ 0.063

165.000

H7

0

+ 0.040

Reconditioning instructions: Re 1 and 2:

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

Re 3 and 4:

Check scraper ring OD and ID when fitted

Re 6:

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

M070040/00E 00-01

© MTU

Group Page

010 2

Crankcase

Crankshaft Bearing Cap

No. 1 2 3

Designation

Stage


Deviation lower upper

Bearing cap bed

298.000

E9

+ 0.110

+ 0.240

Bearing cap width

298.000 p6

+ 0.056

+ 0.088

H7

Bearing cap bed

298.000

0

Bearing cap width

298.000 p6

+ 0.056

+ 0.088

Screw length

348.000

- 0.500

+ 0.500

Clearance min. max. 0.022


Wear limit

0.184

+ 0.052

0.004

0.088

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

M070040/00E 00-01

© MTU

Crankcase

Group Page

010 3

Crankshaft Bearing Bore

Insert crankshaft bearing cap in crankcase as per installation instructions and tighten screws as per tightening specification. Measure main bearing bores: - Determine diameters a, b1 and b2 each in 2 measuring planes and from the results determine the mean values of a, b1 and b2. - Check roundness of bores: Possible deviations from roundness result from the mean values of a, b1 and b2 in accordance with the equation 0.5 (b1+b2)-a Vertical ovality - a greater than 0.5 (b1+b2) - is not permissible.

M070040/00E 00-01

© MTU

Group Page

010 4

Crankcase

Coaxiality of Crankcase Bores for Crankshaft Bearings

Max. permissible deviation from coaxiality

New condition

Wear limit

a

in each case, adjacent left and right bearings

dia. 0.040

dia. 0.050

b

8 V from crankshaft bearing 1 to 5

dia. 0.060

dia. 0.100

c

12 V from crankshaft bearing 1 to 7

dia. 0.080

dia. 0.120

d

16 V from main bearing 1 to 9

dia. 0.120

dia. 0.140

e

applicable for all bearings



0.100



0.120

f


O

0.010

O

0.035

g

applicable for all bearings, not concave

-

0.010

-

0.012

h


//

0.015

//

0.018

M070040/00E 00-01

© MTU

Crankcase

Group Page

010 5

Coaxiality of Crankcase Bores for Camshaft Bearings


New condition

Wear limit

a


dia. 0.040

dia. 0.050

b

8 V from camshaft bearing 1 to 5

dia. 0.060

dia. 0.100

c


dia. 0.080

dia. 0.120

d


dia. 0.120

dia. 0.140

M070040/00E 00-01

© MTU

Group Page

01 6

M070040/00E 00-01

Crankcase

© MTU

Gear Train

Group Page

020 1

Idler Gear, Free End

No. 1

2 3

4

5

6

Designation Equipment carrier bore Axle OD

Stage

Tol. size Basic size 81.000

H7


Clearance min. max.

0

0

81.000 h7

- 0.035

H7

+ 0.035


0.070

Wear limit Clearance max. 0.080

0

Gear bore Bush OD Bush bore - installed - removed Axle OD

80.000 80.000 s6

0 + 0.059

+ 0.030 + 0.078

75.000 E6 75.000 75.000 e7

H8

0 + 0.060 - 0.090

+ 0.046 + 0.079 - 0.060

0.060

0.136

Equipment carrier bore Axle OD

75.000

P7

- 0.051

- 0.021

0.009

0.069

Clearance max. 0.080

75.000 e7

- 0.090

- 0.060

Equipment carrier width Gear width Crankcase

41.200

0.050

0.800


40.700

0 - 0.100

+ 0.200 0

0.029

0.078

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

M070040/00E 00-01

© MTU

Group Page

020 2

M070040/00E 00-01

Gear Train

© MTU

Running Gear

Group Page

030 1

Crankshaft Bearing Arrangement, Free End

No. 1

2

Designation

Stage


Equipment carrier bore Bearing OD - not installed

193.000

Bearing bush bore

H6


+ 0.029

193.204

0

+ 0.029

180.121

0

+ 0.069

Clearance min. max.

Interference min. max. 0.175

0.321

0.430

0.233

Wear limit Interference min. 0.150


- bearing fitted Driver flange OD - not press-fitted

M070040/00E 00-01

179.800 h7

- 0.040

0

© MTU

Group Page

030 2

Running Gear

Crankshaft Seal, Free End

No. 1

Designation

Stage

Tol. size Basic size H7


Inner star bore

198.000

Driver flange OD - not press-fitted

198.000 j6

Seal carrier bore

230.000

Shaft seal OD

230.470

- 0.120

3

Running surface OD

199.800 h9

- 0.115

4

Radial-lip oil seal fitted flush

2

H8

0 - 0.013 0

+ 0.046

Clearance min. max.


0.059

Wear limit

0.016

+ 0.016 + 0.072

0.278

0.590

+ 0.120 0

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

M070040/00E 00-01

© MTU

Running Gear

Group Page

030 3

Crankshaft Bearing Arrangement, Alignment Bearing

No. 1

2

Designation Housing bore

Alignment bearing diameter - installed

Main bearing journal OD

M070040/00E 00-01

Stage


0-0 0-1 0-2 0-3 1-0 1-1 1-2 1-3

171.000 H6 171.000 H6 171.000 H6 171.000 H6 171.500 H6 171.500 H6 171.500 H6 171.500

0

+ 0.025

0

+ 0.025

0-0 0-1 0-2 0-3 1-0 1-1 1-2 1-3

160.120 159.620 159.120 158.620 160.120 159.620 159.120 158.620

0

+ 0.054

0

+ 0.054

0-0 0-1 0-2 0-3 1-0 1-1 1-2 1-3

160.000 h6 159.500 h6 159.000 h6 158.500 h6 160.000 h6 159.500 h6 159.000 h6 158.500 h6

H6


Clearance min. max.


Wear limit 171.035 Transverse ovality max. 0.050 171.535 Transverse ovality max. 0.050

- 0.025

0

- 0.025

0

0.120

0.199

Transverse ovality max. 0.050

159.970 159.470 158.970 158.470 159.970 159.470 158.970 158.470

© MTU

Group Page

030 4

Running Gear

Crankshaft Mounting, Alignment Bearing Spreading Dimension

No.

Designation

Stage


1

Alignment bearing, upper half

2

Alignment bearing, lower half

3

Spreading dimension - Alignment bearing, upper and lower halves

M070040/00E 00-01

0-0 0-1 0-2 0-3 1-0 1-1 1-2 1-3

171.200 171.200 171.200 171.200 171.700 171.700 171.700 171.700


0

+ 0.500

0

+ 0.500

Clearance min. max.


Wear limit

© MTU

Running Gear

Group Page

030 5

Crankshaft Bearing Arrangement

No. 1

2

Designation Housing bore

Crankshaft bearing diameter - installed

Main bearing journal dia.

M070040/00E 00-01

Stage


0-0 0-1 0-2 0-3 1-0 1-1 1-2 1-3

171.000 H6 171.000 H6 171.000 H6 171.000 H6 171.500 H6 171.500 H6 171.500 H6 171.500

0

+ 0.025

0

+ 0.025

0-0 0-1 0-2 0-3 1-0 1-1 1-2 1-3

160.120 159.620 159.120 158.620 160.120 159.620 159.120 158.620

0

+ 0.054

0

+ 0.054

0-0 0-1 0-2 0-3 1-0 1-1 1-2 1-3

160.000 h6 159.500 h6 159.000 h6 158.500 h6 160.000 h6 159.500 h6 159.000 h6 158.500 h6

H6


- 0.025

0

- 0.025

0

Clearance min. max.


Wear limit 171.035 Transverse ovality max. 0.050

0.120

0.199

171.535 Transverse ovality max. 0.050 Transverse ovality max. 0.050

159.970 159.470 158.970 158.470 159.970 159.470 158.970 158.470

© MTU

Group Page

030 6

Running Gear

Crankshaft Bearing Arrangement

No.

Designation

Stage

1

Main bearing, upper half

2

Main bearing, lower half

3

Spreading dimension - Main bearing, upper and lower halves

M070040/00E 00-01

0-0 0-1 0-2 0-3 1-0 1-1 1-2 1-3


171.400 171.400 171.400 171.400 171.900 171.900 171.900 171.900


0

+ 1.000

0

+ 1.000

Clearance min. max.


Wear limit

© MTU

Running Gear

Group Page

030 7

Axial Clearance - Crankshaft

No.

Designation

1

Axial clearance - crankshaft

2

Flywheel fitted flush

M070040/00E 00-01

Stage




0.600


Wear limit Clearance min. 0.100 max. 0.700

© MTU

Group Page

030 8

Running Gear

Crankshaft Seal, Driving End

No .

Designation

Stage

Tol. size lower

upper

Flywheel bore - not shrink-fitted Flywheel OD

707.030

707.290

673.990

708.180

Flywheel bore

673.050

673.130

673.075

673.125

Flywheel housing bore

240.000

240.072

Radial-lip shaft seal OD

240.350

240.590

4

Running surface OD

209.585

209.700

5

Radial-lip shaft seal flush-fitted

6

Flywheel fitted flush

1

2

Adapter OD 3

Clearance min.

max.

Interference min.

max.

0.700

1.150

0.065

Wear limit

0.075 0.278

0.590

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

M070040/00E 00-01

© MTU

Running Gear

Group Page

030 9

Crankshaft Bearing Shells

Install bearing shells and tighten bearing cap according to tightening specifications. Measure crankshaft bearing bores: - Determine diameters, a, b1 and b2 in measuring planes 1 and 2 and in each case calculate mean values of a, b1 and b2. - Check roundness of bores: Possible deviations from roundness result from the mean values of a, b1 and b2 in accordance with the equation 0.5 (b1+b2) -a Replace bearing shells - If deviation from roundness  0.040 - If b1 to b2 greater than / less than 0.040 - With vertical ovality - a

M070040/00E 00-01

0.5 (b1+b2) - is not permissible.



© MTU

Group Page

030 10

Running Gear

Counterweight Fixture

No. 1

Designation

Stage

Screw length - removed


Deviation lower upper - 0.400

0

Clearance min. max.


Wear limit max. length 132.000

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

M070040/00E 00-01

© MTU

Running Gear

Group Page

030 11

Crankshaft Gear, Free End

No. 1

Designation Gear press-fitted - Crankshaft end to gear face

M070040/00E 00-01

Stage


Deviation lower upper - 0.300

Clearance min. max.


Wear limit

+ 0.300

© MTU

Group Page

030 12

Running Gear

Crankshaft, Coaxiality of Main Bearing Journal 8 V 4000


New condition

From main bearing journal 1 to main bearing journal 5



0.100

From main bearing journal to main bearing journal



0.050

Wear limit

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

M070040/00E 00-01

© MTU

Running Gear

Group Page

030 13

Crankshaft, Concentricity of Main Bearing Journal 12 V 4000


New condition




0.100




0.050

Wear limit


M070040/00E 00-01

© MTU

Group Page

030 14

Running Gear

Crankshaft, Concentricity of Main Bearing Journal 16 V 4000


New condition




0.100




0.050

Wear limit


M070040/00E 00-01

© MTU

Running Gear

Group Page

030 15

Crankshaft, Dynamic Balancing 8 V 4000

Balancing specification

New condition

Max. operating speed:

1900 rpm

Mass of balancing group:

463 kg

Wear limit

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

150 rpm

Permissible residual imbalance for each balancing plane during initial balancing:

135 gcm

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

400 gcm

Reconditioning instructions: It will only be necessary to rebalance the crankshaft if the counterweights have been replaced. If a crankshaft has been reworked to the next repair stage, rebalancing will not be necessary provided that the counterweights have not been replaced. Mark the counterweights and reassemble them according to marking.

M070040/00E 00-01

© MTU

Group Page

030 16

Running Gear



New condition


2100 rpm


525

Wear limit

kg


150 rpm


200 gcm


600 gcm


M070040/00E 00-01

© MTU

Running Gear

Group Page

030 17



New condition


1800 rpm


710

Wear limit

kg


150 rpm


200 gcm


300 gcm


M070040/00E 00-01

© MTU

Group Page

030 18

Running Gear

Conrod Bearing

No.

Designation

Stage


1

Conrod bore

2

Conrod bearing bore - Conrod bearing installed

0-0 0-1 0-2 0-3

117.082 116.882 116.682 116.482

Crankpin journal dia.

0-0 0-1 0-2 0-3

117.000 h6 116.800 h6 116.600 h6 116.400 h6

- 0.022

Crankpin length

97.500

- 0.100

Conrod width

48.600

- 0.100

3 4

Spreading dimension - Conrod bearing shell, upper and lower halves

M070040/00E 00-01

126.000


0-0 0-1 0-2 0-3

126.400 126.400 126.400 126.400

0

+ 0.025

0

+ 0.048

0


0.152

0.200

0.600


Wear limit

0

+ 0.100 0 + 1.000

© MTU

Running Gear

Group Page

030 19

Conrod Bearing, Locating Pin

No. 1

Designation

Stage


Locating pin bore

7.000

Locating pin OD

7.000 r6

M070040/00E 00-01

Deviation lower upper 0 + 0.019

+ 0.015

Clearance min. max.


Wear limit

0.028

+ 0.028

© MTU

Group Page

030 20

Running Gear

Conrod Bearing Bore

No. 1

Designa Designation tion Screw length - removed

Stage Stage

Tol. Tol. size size Basic size 103.000

Deviati Deviation on lower upper - 0.400

Cleara Clearance nce min. max.

+ 0.200

Interfe Interferen rence ce min. max.

Wear limit limit 104.500

Note: Tighten conrod - conrod cap as per tightening specifications. Conrod bearing - measure bearing bore in a, b and c. Min. dimension must be in direction a. Re 1: If wear limit has been exceeded: replace screw

M070040/00E 00-01

© MTU

Running Gear

Group Page

030 21

Conrod Bearing Shells

No. 1

Designa Designation tion Screw length - removed

Stage Stage

Tol. Tol. size size Basic size 103.000

Deviati Deviation on lower upper - 0.400


+ 0.200


Wear limit limit 104.500

Note: Tighten conrod bearing - conrod - conrod cap as per tightening specifications. Conrod bearing - measure bearing bore in a, b and c. Min. dimension must be in direction a. Re 1: If wear limit has been exceeded: replace screw

M070040/00E 00-01

© MTU

Group Page

030 22

Running Gear

Parallellity of Conrod Bores

No.

Designa Designation tion

1

Conrod length - with bush and without bearing shells Conrod length - without bush and without bearing shells Parallellity of axles

2

Stage Stage

Tol. Tol. size size Basic size

Deviati Deviation on lower upper

354.000

- 0.100

+ 0.100

354.000

- 0.100

+ 0.100



Wear limit limit

0.070 measured at 100 mm distance

Inclination max. 0.100

0.250 measured at 100 mm distance

Twist max. 0.350

- Inclination 3

Parallellity of axles - twist Conrod weight

M070040/00E 00-01

9.530 kg

- 0.060 kg

+ 0.060 kg

© MTU

Running Gear

Group Page

030 23

Piston Bearing

No. 1

2

3

4

Designation

Stage



Conrod bore

0 1 2

75.000 H6 75.200 H6 75.400

0

Bush OD

0 1 2

75.000 v6 75.200 v6 75.400 v6

+ 0.120

+ 0.139

Bush ID - finishedmachined Piston pin OD

68.000

+ 0.070

+ 0.080

68.000

- 0.005

Bush ID - finishedmachined

68.000

+ 0.008

Piston pin OD

68.000

- 0.005

Clearance min. max.

+ 0.019


0.139

Wear limit Axial test load for bush installed min. 17000 N

0.070

0.085


0.008

0.023


0 + 0.018

0

MTU part number and stage stamped on

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

M070040/00E 00-01

© MTU

Group Page

030 24

Running Gear

Piston Rings

No.

Designation

Stage



1

Groove width

4.000

+ 0.170

4.000

- 0.035

2

Rectangular-section ring Groove width

4.000

+ 0.080

4.000

- 0.035

3

Rectangular-section ring Groove width

5.000

+ 0.080

Oil control ring

5.000

- 0.035

4

Ring end clearance Rectangular-section ring Rectangular-section ring Oil control ring

+ 0.190


0.225

0 + 0.100

Wear limit Clearance max. 0.300

0.080

0.135

0 + 0.100



0.080

0.135

0


0.400 1.000 0.450

0.700 1.300 0.800

Max. play: 0.900 1.500 1.000

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

M070040/00E 00-01

H6

© MTU

Running Gear

Group Page

030 25

Piston Clearance in Cylinder Liner

No. 1 2 3 4 5 6 7

Designation

Stage


Cylinder liner bore

165.000

Piston skirt OD

164.805

Cylinder liner bore

165.000

Piston skirt OD

164.720

Cylinder liner bore

165.000

Piston crown OD

164.580

Cylinder liner bore

165.000

Piston crown OD

164.665

Scraper ring bore

164.000

Piston crown OD

163.390

Scraper ring bore

164.000

Piston crown OD

163.255

H7


Clearance min. max.

0

0.184

0.246

0.270

0.330

0.400

0.840

0.315

0.355

0.585

0.698

0.720

0.833

- 0.011 H7

0 - 0.010

H7

0 - 0.020

H7

0 - 0.020

H8

0 - 0.025

H8

0 - 0.025

+ 0.040


Wear limit

+ 0.011 + 0.040 + 0.010 + 0.040 + 0.020 + 0.040 + 0.020 + 0.063 + 0.025 + 0.063 + 0.025

Piston skirt, crowned-oval

Reconditioning instructions: Re 1 to 5:

Measure piston crown dia. and piston skirt dia. vertically to piston pin axis

M070040/00E 00-01

© MTU

Group Page

030 26

Running Gear

Piston Crown Fixture

No. 1 2 3

Designation Screw length - removed Screw length - removed

Stage



49.000

- 0.100

+ 0.100

50.000

- 0.100

+ 0.100

Clearance min. max.


Wear limit max. length 49.800 max. length 50.800

Designation - ZB Kolben - Piston upper section

Note:

Re 1 and 2: If wear limit has been exceeded: replace screw Re 3:

Marking XXXX, last four digits of piston assembly applied here. Marking YYYY, last four digit s of piston upper section applied here. (See table for piston 524 030 20 17)

M070040/00E 00-01

© MTU

Cylinder Head

Group Page

040 1

Valve Guides, Inlet, Exhaust

No. 1 2

Designation

Stage


Cylinder head bore

19.000

Valve guide OD

19.000 r6

Valve guide bore - installed Valve stem dia.

11.000

Deviation lower upper 0 + 0.028

H7

10.935

0 - 0.010

Clearance min. max.

+ 0.021


Wear limit

0.041

+ 0.041 + 0.018

0.055

0.093

+ 0.010

Note: Re 2: Finish-machine valve guide bore after pressing into cylinder head. Pushing slightly, it must be possible to insert the go-end of the plug gauge on the valve guide length. The no-go end of the plug gauge must not make contact Max. clearance exceeded: Install manufactured valve guide. Manufactured valve guide for repair version No. 1

2

Designation

Stage


Cylinder head bore

0 1 2

19.000 H7 19.100 H7 19.300

Valve guide OD

0 1 2

19.000 r6 19.100 r6 19.300 r6

Valve guide bore - installed Valve stem dia.

H7

11.000 10.935

H9


+ 0.028

0 - 0.010

Clearance min. max.

+ 0.021


Wear limit

0.041

+ 0.041

+ 0.043

0.055

0.108

+ 0.100

Reconditioning instructions: Re 1: Cylinder head bore max. dimension exceeded: Ream to next stage Re 2: Max. clearance exceeded: Install new manufactured valve guide Pushing slightly, it must be possible to insert the go-end of the plug gauge on the valve guide length. No-go side plug gauge contact max. 5 mm

M070040/00E 00-01

© MTU

Group Page

040 2

Cylinder Head

Valve Clearance

No.

Designation

Stage



Clearance min. max.


Wear limit

1

Valve clearance - Exhaust

0.400

max. 2.400

2

Valve clearance - Inlet

0.500

max. 2.500

M070040/00E 00-01

© MTU

Cylinder Head

Group Page

040 3

Valve Seats, Exhaust

No.

Designation

1

Plug gauge diameter Valve seat surface Check dimension - Plug gauge Cylinder head depth - Combustion chambers sealing ring surface

2

3

Stage


4.800 13.800


- 0.100 0

Clearance min. max.


Wear limit

0

+ 0.100

min. 2.300

+ 0.100

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

M070040/00E 00-01

© MTU

Group Page

040 4

Cylinder Head

Valve Seats, Inlet

No.

Designation

1

Plug gauge diameter Valve seat surface Check dimension - Plug gauge Cylinder head depth - Combustion chambers sealing ring surface

2

3

Stage


4.800 13.800


- 0.100 0

Clearance min. max.


Wear limit

0

+ 0.100

min. 2.300

+ 0.100

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

M070040/00E 00-01

© MTU

Cylinder Head

Group Page

040 5

Exhaust Valve

No.

Designation

1

Valve head OD Check dimension - with ring gauge - Valve seat dia. - Valve seat height

2

3

Stage

Check dimension - without ring gauge - Valve seat height



Clearance min. max.


Wear limit

56.000

- 0.200

+ 0.200

54.000 4.180

- 0.200

+ 0.100

min. 3.480

3.200

- 0.200

+ 0.100

min. 2.500


Recondition valve seat height only until good support is achieved.

M070040/00E 00-01

© MTU

Group Page

040 6

Cylinder Head

Inlet Valve

No.

Designation

1

Valve head OD Check dimension - with ring gauge - Valve seat dia. - Valve seat height

2

3

Stage

Check dimension - without ring gauge - Valve seat height



Clearance min. max.


Wear limit

57.000

- 0.200

+ 0.200

54.000 4.050

- 0.200

+ 0.100

min. 3.350

3.200

- 0.200

+ 0.100

min. 2.500


Recondition valve seat height only until good support is achieved.

M070040/00E 00-01

© MTU

Cylinder Head

Group Page

040 7

Outer Valve Springs

No.

Designation

Stage



Clearance min. max.

1

Spring length - Unloaded

83.900

2

Spring length - Loaded

66.000

Spring force with spring length 66.00 Spring length - Loaded

530.000 N

Spring force with spring length 51.75

952.000 N

4

Spring length - Block dimension

47.700

5

Coil dia.

34.400

6

Wire dia.

5.300

e1

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

e2

Spring support permissible deviation from parallelism max 0.600

2.1 3 3.1

M070040/00E 00-01


Wear limit

51.750 - 39 N

+ 39 N

Spring power min. 897.000 N Block dimension max. 47.700

© MTU

Group Page

040 8

Cylinder Head

Inner Valve Springs

No.

Designation

Stage



Clearance min. max.

1

Spring length - Unloaded

78.400

2

Spring length - Loaded

61.000

Spring force with spring length 61.00 Spring length - Loaded

256.000 N

Spring force with spring length 46.75

466.000 N

4

Spring length - Block dimension

42.500

5

Coil dia.

23.000

6

Wire dia.

3.600

e1

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

e2

Spring support permissible deviation from parallelism max 0.400

2.1 3 3.1

M070040/00E 00-01


Wear limit

46.750 - 19 N

+ 19 N

Spring power min. 420.000 N Block dimension max. 42.500

© MTU

Cylinder Head

Group Page

040 9

Cylinder Head - Mating Face - Protective Sleeve - Valve Bridge

No. 1 2 3

4

5 6

Designation

Stage



Cylinder head height Protective sleeve support Protective sleeve bore Protective sleeve OD Cylinder head thread

184.000

Protective sleeve thread Cylinder head bore

M 24x1.5 14.000

- 0.023

- 0.005

Sliding pin dia. Valve bridge bore Sliding pin dia.

14.000m6 D7 14.000 14.000m6

+ 0.007 + 0.050 + 0.007

+ 0.018 + 0.068 + 0.018

M070040/00E 00-01

- 0.100 0

+ 0.200

44.200

0

+ 0.100

- 0.100


Wear limit

+ 0.100

124.000

44.100

Clearance min. max.

0.100

0.300

0

M 24x1.5

N7

0.012 0.032

0.041

0.061

© MTU

Group Page

040 10

M070040/00E 00-01

Cylinder Head

© MTU

Valve Gear

Group Page

050 1

Camshaft, Coaxiality of Bearings


New condition

from bearing 1 to bearing 2



0.050

a

from bearing to bearing



0.025

b

all cams and bearings

// __

0.010 0.010

M070040/00E 00-01

Wear limit

© MTU

Group Page

050 2

Valve Gear

Camshaft Bearing

No. 1

2

Designation

Stage



Housing bore

0-0 1-0

97.000 H6 97.500

0

+ 0.022

Bush OD - not installed

0-0 1-0

97.080 97.580

0

+ 0.050

Bush bore - installed

92.012

0

+ 0.052

Camshaft OD

92.000 e7

- 0.107

a


b

from camshaft bearing 1 to 2

M070040/00E 00-01

Clearance min. max.


0.084

Wear limit

0.130

0.171

- 0.072

© MTU

Valve Gear

Group Page

050 3

Axial Clearance - Camshaft

No. 1 2

Designation

Stage


Gear bore

32.000

Camshaft OD

32.000 h7

Axial play - Camshaft

M070040/00E 00-01


Clearance min. max.

0

0

0.050

0.100

0.178

- 0.025

+ 0.025


Wear limit

0

© MTU

Group Page

050 4

Valve Gear

Rocker Arm Bearing, Inlet and Exhaust

No. 1 2

3

Designation

Stage


Rocker arm bore

50.000

Bush OD

50.000 s6

Bush bore - installed - not installed Rocker shaft OD

0 + 0.043

+ 0.050 + 0.006 - 0.025

U7

- 0.086

- 0.061

- 0.041

- 0.025

Rocker shaft OD

45.000 f6


Wear limit

+ 0.059

0 + 0.050 - 0.041

45.000

Clearance min. max.

+ 0.025

45.000 E6 45.000 45.000 f6

Bearing pedestal bore

M070040/00E 00-01


0.025


0.091

0.020

0.061

© MTU

Valve Gear

Group Page

050 5

Rocker Arm Bearing, Inlet and Exhaust

No. 1 2

3 4 5

Designation

Stage


0 + 0.043

Clearance min. max.

Rocker arm bore Bush OD Bush bore - installed - not installed Shaft OD

32.000 E6 32.000 32.000 f6

0 + 0.050 - 0.041

+ 0.050 + 0.066 - 0.025

0.025

0.091

Roller bore Bush OD Bush bore

21.000 21.000 h7 E7 14.000

E7

+ 0.040 - 0.021 + 0.032

+ 0.061 0 + 0.050

0.040

0.082

0.032

0.058

Pin OD Rocker arm bore Pin OD

14.000 h5 P6 14.000 14.000 h5

- 0.008 - 0.026 - 0.008

0 - 0.015 0

M070040/00E 00-01

36.000 36.000 s6

Deviation lower upper + 0.025 + 0.059


Wear limit

0.059 Clearance max. 0.100

Clearance max. 0.090 Clearance max. 0.065 0.007

0.026

© MTU

Group Page

050 6

M070040/00E 00-01

Valve Gear

© MTU

Coolant System

Group Page

200 1

Engine Coolant Pump for H.P. Temperature System

No. 1 2 3 4 5 6 7

Designation

Stage


Seal carrier bore

90.000

Bearing OD

90.000

K7

Deviation lower upper - 0.025 - 0.015

K7

+ 0.010

90.000

- 0.025

Bearing OD

90.000

- 0.015

0

Bearing bore

40.000

- 0.012

0

Shaft OD

40.000 k5

+ 0.002

+ 0.013

Spacer sleeve bore

40.000

N7

- 0.033

- 0.008

Shaft OD

40.000 k5

+ 0.002

+ 0.013

K7

+ 0.010

- 0.021

+ 0.009

Housing bore

80.000

Bearing OD

80.000

- 0.013

0

Bearing bore

40.000

- 0.012

0

Shaft OD

40.000 k5

Gear bore

39.000

Shaft OD

39.000 s6

M070040/00E 00-01

+ 0.002 0 + 0.043


0.025

0.025

0.025

0.025

Wear limit

0

Housing bore

H7

Clearance min. max.

0.002

0.025

0.010

0.046

0.022

0.021 0.002

0.025

0.018

0.059

+ 0.013 + 0.025 + 0.059

© MTU

Group Page

200 2

Coolant System

Engine Coolant Pump for H.P. Temperature System

No. 1 2 3 4 5

Designation

Stage


Seal carrier bore

72.000

Shaft seal OD

72.000

Shaft OD

48.000

Seal carrier bore

78.100

Rotary seal OD

78.200

Deviation lower upper 0 + 0.130 - 0.100

H7

0 - 0.030

H5

Impeller bore

30.000

Shaft OD

30.000 t5

0 + 0.041

Clearance min. max.

+ 0.046


0.230

0.040

0.100

0.032

0.050

Wear limit

+ 0.230 0 + 0.030 0 + 0.009 + 0.050

Rotary seal Counter ring

Note: Re 2:Running surface worn: Metal-spray pump shaft and grind using feed-in method Re 5:In the event of wear marks, replace parts together

M070040/00E 00-01

© MTU

Coolant System

Group Page

200 3

Engine Coolant Pump for L.P. Temperature System

No. 1 2 3 4 5 6 7

Designation

Stage


Seal carrier bore

90.000

Bearing OD

90.000

K7

Deviation lower upper - 0.025 - 0.015

K7

- 0.025

+ 0.010

90.000

Bearing OD

90.000

- 0.015

0

Bearing bore

40.000

- 0.012

0

Shaft OD

40.000 k5

+ 0.002

+ 0.013

Spacer sleeve bore

40.000

N7

- 0.033

- 0.008

Shaft OD

40.000 k5

+ 0.002

+ 0.013

K7

+ 0.010

- 0.021

+ 0.009

Housing bore

80.000

Bearing OD

80.000

- 0.013

0

Bearing bore

40.000

- 0.012

0

Shaft OD

40.000 k5

Gear bore

39.000

Shaft OD

39.000 s6

M070040/00E 00-01

+ 0.002 0 + 0.043


0.025

0.025

0.025

0.025

Wear limit

0

Housing bore

H7

Clearance min. max.

0.002

0.025

0.010

0.046

0.022

0.021 0.002

0.025

0.018

0.059

+ 0.013 + 0.025 + 0.059

© MTU

Group Page

200 4

Coolant System

Engine Coolant Pump for L.P. Temperature System

No. 1 2 3 4 5

Designation

Stage


Seal carrier bore

72.000

Shaft seal OD

72.000

Shaft OD

48.000

Seal carrier bore

78.100

Rotary seal OD

78.200

Deviation lower upper 0 + 0.130 - 0.100

H7

0 - 0.030

H5

Impeller bore

30.000

Shaft OD

30.000 t5

0 + 0.041

Clearance min. max.

+ 0.046


0.230

0.040

0.100

0.032

0.050

Wear limit

+ 0.230 0 + 0.030 0 + 0.009 + 0.050

Rotary seal Counter ring

Reconditioning instructions: Re 2:Running surface worn: Metal-spray pump shaft and grind using feed-in method Re 5:In the event of wear marks, Replace parts together

M070040/00E 00-01

© MTU

Preliminary Note 00

Data Sheets

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

M070040/00E 02-07

© MTU

Preliminary Note 00

M070040/00E 02-07

© MTU

Data Sheet 01

Cylinder Liner, Installed Engine model: Engine No.: Order No.: Crankcase No.: Cylinder liner Part No.: Specified bore dimension: To measure: In measurement direction a (direction of travel) and b (transverse). Measurement plane 1 - 2

Cyl. No.

Measur- Basic ement dimendirecsion tion

Actual dimensions Measuring planes 1

a

A1

b a

A2

b a

A3

b a

A4

b a

A5

b a

A6

b a

A7

b a

A8

b a

A9

b a

A10

b

Cyl. No.

Measur- Basic ement dimendirecsion tion

2

Actual dimensions Measuring planes 1

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

2

a b a b a b a b a b a b a b a b a b a b

Remarks:

Date:

..........................

M070040/00E 02-07

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

© MTU

Data Sheet 01

M070040/00E 02-07

© MTU

Data Sheet 02

Cylinder Liner, Upper Fit Engine model: Engine No.: Order No.: Crankcase No.: Cylinder liner Part No.: Specified dimension, upper fit: - Crankcase bore - Cylinder liner OD

mm mm mm

Specified clearance:

mm Actual dimensions

Cylinder No.

1

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

B5

B6

B7

B8

B9

B10

Crankcase bore Cylinder liner OD Clearance/overlap

Actual dimensions Cylinder No.

1

B1

B2

B3

B4


Remarks:

Date:

.........................

M070040/00E 02-07

Checked by:

........................................................

© MTU

Data Sheet 02

M070040/00E 02-07

© MTU

Data Sheet 03

Cylinder Liner, Lower Fit Engine model: Engine No.: Order No.: Crankcase No.: Cylinder liner Part No.: Specified dimension, lower fit: - Crankcase bore - Cylinder liner OD

mm mm mm

Specified clearance:

mm Actual dimensions

Cylinder No.

1

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

B5

B6

B7

B8

B9

B10


Actual dimensions Cylinder No.

1

B1

B2

B3

B4


Remarks:

Date:

.........................

M070040/00E 02-07

Checked by:

........................................................

© MTU

Data Sheet 03

M070040/00E 02-07

© MTU

Data Sheet 04

Main Bearing (Bearing Installed) Measurement and Entry: Diameter a, b1 and b2 Measuring planes 1 and 2 Determining bearing clearance: One-part bearing: Min. dimension a, b1 or b2 Standard: Min. dimension a

Engine model: Engine No.: Order No.: Crankcase No.: Crankshaft No.:

Free end:

Crankshaft bearing

Specified dia.:

mm

Drive flange

Specified dia.:

mm

Specified dia.:

mm

Specified dia.:

mm

Main bearing:

Specified dia.:

mm

Crankshafts

Specified dia.:

mm

Driving end: Crankshaft bearing Drive flange

Radial clearance:

Free end: Driving end: Main bearing:

Crankshaft axial clearance:

mm (min.) mm (min.) mm (min.)

mm (max.) mm (max.) mm (max.)

mm (min.)

Actual dimension:

mm (max.)

mm

Actual dimensions Bearing No.

1

2

3

4

5

6

7

8

9

10

1 Bearing dia. b1

2 1

Bearing dia. b2

2 1

Bearing dia. a

2

Crankshaft dia. (actual dimension) Bearing clearance (radial) Remarks:

Date:

..........................

M070040/00E 02-07

Checked by:

........................................................

© MTU

Data Sheet 04

M070040/00E 02-07

© MTU

Data Sheet 05

Conrod Bearing (Bearing Shells Installed) Engine model:

Specified dimensions:

Engine No.:

- Conrod bearing bore

mm

Order No.: Crankcase No.:

- Radial clearance

Crankshaft No.:

min.:

mm

max.:

mm

Conrod, A bank To measure: Diameter a, b, c

Actual dimensions, dia. Cyl. No.

Rod No.

Batch

Basic dimension

Crankshaft

a

b

Radial clearance

To determine clearance Min. dimension a, b or c

c

1 2 3 4 5 6 7 8 9 10

Conrod, B bank Actual dimensions, dia. Cyl. No.

Rod No.

Batch

Basic dimension

Crankshaft

a

b

Radial clearance

c

1 2 3 4 5 6 7 8 9 10

Remarks:

Date:

..........................

M070040/00E 02-07

Checked by:

........................................................

© MTU

Data Sheet 05

M070040/00E 02-07

© MTU

Data sheet 06

Timing Engine model: Engine No.: Order No.: 1. Timing Diagram: Specified in °

Tolerance

Actual Cylinder No. A1

Exhaust valve opens before BDC

±

Inlet valve opens before TDC

±

Exhaust valve closes after TDC

±

Inlet valve closes after BDC

± Specified in °

A2

A3

A4

A5

A6

A7

A8

A9

A10

B4

Actual Cylinder No. B5 B6

B7

B8

B9

B10

A4

Cylinder No. A5 A6

A7

A8

A9

A10

B4

Actual Cylinder No. B5 B6

B7

B8

B9

B10

Tolerance B1

Exhaust valve opens before BDC

±

Inlet valve opens before TDC

±

Exhaust valve closes after TDC

±

Inlet valve closes after BDC

±

B2

B3

Settings for valve timing correspond to t he adjustment diagram 2. Cam Lift/Valve Lift: Specified in mm

Tolerance

Actual A1

Exhaust

±

Inlet

± Specified in mm

A2

A3

Tolerance B1

Exhaust

±

Inlet

±

B2

B3

3. Injection Timing: For start of delivery, see engine master card Remarks:

Date:

..........................

M070040/00E 02-07

Checked by:

........................................................

© MTU

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

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