MTU 16V 2000 G83 Engine

Tools: Belt-tension tester

1. Remove guard cover.
2. Check belt for contamination by oil, cracks, wear and overheating; replace if defective.
3. Place belt-tension tester onto drive belt midway between the belt pulleys.
4. Press button uniformly down until spring disengagement can be heard and felt.
5. Take off belt-tension tester without changing position of indication arm.
6. Read off measuring value at intersection of indication arm and 'KG' scale.
7. Specified belt tension for new drive belt: 450 N -50 N; used drive belt: 350 N -50 N.
8. If measured value deviates, readjust belt tension.
9. To adjust: loosen securing screws, tension belt with tensioning nut, tighten securing screw (2) to 40 Nm +/- 4 Nm, tighten securing screw (3).
10. Install guard cover.

Tools: Feeler gauge, Torque wrench

1. Remove cylinder-head cover.
2. Bar engine until markings are aligned.
3. Check TDC position of piston in cylinder A1.
4. Check valve clearance with cold engine: Inlet 0.4 mm, Exhaust 0.6 mm.
5. Check all valve clearances in two crankshaft positions (firing and overlap TDC for cylinder A1) per diagram.
6. Use feeler gauge between valve bridge and rocker arm.
7. If deviation exceeds 0.1 mm, adjust valve clearance.
8. Loosen locknut and unscrew adjusting screw a few threads.
9. Insert feeler gauge between valve bridge and rocker arm.
10. Readjust adjusting screw so feeler gauge just passes through.
11. Tighten locknut to 50 Nm holding adjusting screw firmly.
12. Check feeler gauge just passes through between valve bridge and rocker arm.
13. Remove barring tool, install cylinder-head cover and cover.

Tools: Belt-tension tester, Torque wrench

1. Remove guard cover.
2. Check V-belt for contamination, cracks, wear, chunking and overheating; replace if defective.
3. Belt-tension check 12/16V: place belt-tension tester midway between pulleys; press button until spring disengagement is heard and felt.
4. Read off measured value; new V-belt 660 N, used V-belt 510 N.
5. Belt-tension adjustment 12/16V: loosen securing screws, release locknut, screw in tensioning screw to set specified belt tension, tighten locknut, tighten securing screws to 100 Nm.
6. Belt-tension check 18V: new drive belt 670 N -50 N, used drive belt 570 N -50 N.
7. Belt-tension adjustment 18V: loosen securing screws, screw in tensioning screw to tension V-belt, tighten securing screws to 69 Nm.
8. Install guard cover and tighten screws.

1. Loosen clamp.
2. Remove air filter and clamp from flange of intake housing.
3. Verify there are no objects in the flange of the intake housing and clean it.
4. Place new air filter with clamp onto intake housing.
5. Tighten clamp.

⚠ Unguarded rotating and moving engine components.

⚠ Engine noise above 85 dB (A).

1. Check relief bore for oil and water discharge.
2. Stop engine and disable engine start.
3. Clean the relief bore with a wire if dirty.
4. Permissible coolant discharge up to 10 drops/hour; permissible oil discharge up to 5 drops/hour.
5. If discharge exceeds specified limits, contact Service.

Tools: Torque wrench

1. Remove cover with O-ring.
2. Remove filter element from housing.
3. Insert new filter element into housing observing correct installation position, fit cover with new sealing ring.
4. Tighten screws of cover to 6 Nm +/- 2 Nm.
5. Replace filter elements of further oil separators in the same way.
6. For diaphragm check remove cover, take off spring, seal and diaphragm; check and replace if damaged; install new seal and spring with cover; tighten screws to 6 Nm +/- 2 Nm.

Tools: Torque wrench

1. On covers with crankcase breather: loosen clamps and slide rubber sleeves onto the pipe.
2. Remove screws.
3. Remove cylinder-head cover with gasket from cylinder head.
4. Clean mating faces.
5. Check condition of gasket and replace if damaged.
6. Place covers onto crankcase and tighten screws to 20 Nm.
7. Slide rubber sleeves onto pipe connection and tighten all clamps.

⚠ Unguarded rotating and moving engine components; risk of serious injury / danger to life.

Tools: Barring tool for 12V engines, Barring tool for 16/18V engines

1. Remove cover from flywheel housing.
2. Install barring tool on flywheel housing.
3. Rotate crankshaft in engine direction of rotation; apart from normal compression resistance there should be no abnormal resistance.
4. If resistance exceeds normal compression resistance, contact Service.
5. For barring-tool removal follow reverse sequence.

⚠ Unguarded rotating and moving engine components.

Tools: Connector pliers

1. Disengage bayonet ring-nut of connector X4 with connector pliers and withdraw connector from ECU.
2. Bar engine in unloaded condition: press START button.
3. Let crankshaft rotate until oil pressure is indicated.
4. Engine start is automatically interrupted when specified starting period expires; if necessary re-start after approx. 20 seconds.
5. Plug connector X4 and secure the bayonet ring by turning clockwise until it latches.

⚠ Coolant is hot and under pressure; risk of injury and scalding.

1. Provide appropriate container to drain the coolant into.
2. Switch off preheating unit.
3. Turn breather valve of filler neck counterclockwise to first stop and allow pressure to escape, then remove.
4. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
5. Open drain cocks or drain plugs and drain coolant at preheating unit, HT coolant pump and crankcase right side.
6. Drain residual coolant at crankcase left side and oil heat exchanger.
7. Seal all open drain points.
8. Set breather valve onto filler neck and close it.

⚠ Coolant is hot and under pressure; risk of injury and scalding.

⚠ Cold coolant in hot engine can cause thermal stress - fill only into cold engine.

1. Turn breather valve on coolant expansion tank counterclockwise to first stop and allow pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Fill coolant through filler neck or filling line until coolant level reaches lower edge of cast-in eye or marking plate.
4. Check proper condition of breather valve and clean sealing faces.
5. Set breather valve onto filler neck and close it.
6. Start the engine and operate it at idle speed for some minutes.
7. Check coolant level and top up if required.

⚠ Hot engine oil; risk of injury and scalding.

1. Provide suitable container to collect the oil.
2. Draining at drain plug: remove drain plug and drain oil; install drain plug with new sealing ring.
3. Oil extraction: extract all oil from oil pan using the hand pump.
4. Replace engine oil filter.
5. Determine amount of engine oil required for oil change.
6. Open cover of filler neck; pour oil in up to 'max.' mark at oil dipstick.
7. Close cover of filler neck.
8. Check oil level.
9. After oil change and oil filter replacement, bar engine with starting system.