MTU 16V2000G Engine

Tools: Feeler gauge, Barring tool, Screwdriver

1. Rotate engine with barring tool until markings are aligned.
2. Rocker arms on cylinder A1 unloaded = firing TDC; loaded = overlap TDC.
3. Set valve clearances at initial TDC position per valve clearance setting diagram.
4. Rotate crankshaft a further 360° to second TDC position.
5. Set remaining valve clearances per valve clearance setting diagram.
6. Release locknut, unscrew adjusting screw, insert feeler gauge between valve bridge and rocker arm.
7. Set adjusting screw so feeler gauge can just be pulled through.
8. Tighten locknut to 50 Nm holding adjusting screw; recheck valve clearance.

Tools: Barring tool, Measuring unit, Dial gauge, Index plate, Pointer

1. Set piston cylinder A1 to TDC.
2. Install pointer on flywheel housing.
3. Install index plate with barring tool on flywheel, set to TDC marking of A1 and tighten.
4. Install dial gauge under preload in measuring unit in cylinder head.
5. Bar crankshaft in normal direction to 5° before TDC; read dial gauge.
6. Bar past TDC approx. 10°, then bar opposite direction to 5° after TDC; read dial gauge.
7. Calculate mean value and bar crankshaft until dial gauge reads mean value.
8. Set pointer of graduated disk to 5° after TDC and tighten.

⚠ Suspended load. Risk of injury! Use suitable tools and lifting equipment. Never stand beneath a suspended load.

Tools: Rope slings, Crane, Assembly screws

1. Wipe crankshaft bearing surfaces; inspect oil bores with lamp.
2. Insert four assembly screws on first and last bearing to protect crankshaft.
3. Lift crankshaft with rope slings and crane.
4. Align crankshaft horizontally and vertically with line of bores in crankcase.
5. Ensure markings on crankshaft gear and camshaft gear are aligned.
6. Carefully lower crankshaft into bearing shells.
7. Remove assembly screws.
8. Do not rotate crankshaft until axial alignment bearing has been installed.

⚠ Components have sharp edges. Risk of injury. Handle components only when wearing protective gloves.

Tools: Socket insert, Angle-of-rotation measuring tool, Depth gauge

1. Remove all plugs and ensure oil bores are perfectly clean.
2. Wipe cylinder head and crankcase interface and check.
3. Insert new spring pins into crankcase until they contact the stop.
4. Fit cylinder head gasket.
5. Mount cylinder head via spring pins on cylinder head gasket.
6. Measure shaft length of double-hex screws (max. 212 mm).
7. Coat threads and screw head seating surfaces with engine oil.
8. Tighten in stages 10/50/100/200 Nm, then 90°+10° twice per tightening diagram.

Tools: Removal and installation tool for cylinder liner, Bore gauge, Dial gauge

1. Coat new sealing rings with petroleum jelly and insert into crankcase grooves.
2. Fit new Tombak ring on cylinder liner collar seat in crankcase.
3. Check cylinder liner repair stage and assign according to crankcase data sheet.
4. Lightly coat cylinder liner lower fit and chamfer with petroleum jelly.
5. Insert cylinder liner in same installation position according to markings.
6. Screw studs into threaded bores for cylinder head screws.
7. Fit pressure plate, support and spindle; press liner in by turning nut.
8. Remove installation tool and studs; measure cylinder liner ID.

⚠ Fuels are combustible. Risk of fire and explosion! No open flame, no electric sparks, avoid all sources of ignition.

Tools: Removal tool for injector, Barring tool

1. Bar engine several times to blow out any remaining fuel.
2. Check sealing surface on cylinder head and nozzle holder; clean if necessary.
3. Coat new sealing ring with petroleum jelly and fit on injector.
4. Attach new copper sealing ring with grease to injector.
5. Press injector into cylinder head by hand; pin at 11 o'clock position to engine longitudinal axis.
6. Install clamping element with hex screw, correctly seated on injector and end cover.
7. Tighten hex screw to specified tightening torque (50 Nm).

Tools: Engine barring tool, Socket and extension

1. Coat both sealing rings with petroleum jelly and fit on injection pump.
2. Coat roller of injection pump with engine oil.
3. Check sealing surfaces and fuel bores in crankcase are perfectly clean.
4. Using engine barring tool, set pump cams of camshaft to base circle.
5. Press injection pump into crankcase against spring power (distance approx. 4 mm).
6. Insert both double-hex screws with socket and extension and tighten.
7. Attach plug-in clips of wiring to solenoid valve and tighten screws.

Tools: Screwdriver Torx 30

1. Coat O-ring with petroleum jelly and insert into groove in oil separator housing.
2. Insert diaphragm (curve upwards) into oil separator housing.
3. Fit spring on diaphragm, ensuring it is correctly seated.
4. Fit cover on spring and tighten screws diagonally to 6 Nm + 2 Nm.
5. Coat O-ring with petroleum jelly and insert into groove in oil separator housing.
6. Insert aerosol element into oil separator housing.
7. Fit cover on housing and insert screws with screwdriver (Torx 30).
8. Tighten screws to specified tightening torque and check oil separator for leaks.

⚠ Hard water jet. Risk of injury! Never direct water jet at humans or at electric or electronic components.

Tools: Compressed air, Steam cleaner / H.P. cleaning unit

1. Blow through cooler with compressed air jet parallel to the cooling fins.
2. Or spray a powerful water jet opposite to the cooling air flow.
3. If greasy or oily deposits have formed, clean cooler with a steam cleaner.
4. Use nozzle for multi-point water jet at approx. 80 bar.
5. Use clear water at approx. 70 °C to prevent steam.
6. After cleaning, blow through cooling air ducts with compressed air in vertical direction.

Tools: Dialogue unit for ECU, Test stand instrumentation

1. Install engine on test stand and connect to brake or alternator.
2. Connect air intake, exhaust, engine coolant, raw water and fuel pipework.
3. Fill expansion tank with coolant and 2% corrosion inhibitor oil to max. mark.
4. Vent coolant lines until bubble-free coolant emerges.
5. Vent fuel system with hand pump.
6. Fill oil system up to max. mark with fresh oil.
7. Start engine via ECS; after approx. 1 min no-load shut down and check oil level.
8. Run in engine and record measurements in accordance with running-in schedule.

Tools: Removal and installation tool for cylinder liner

1. Mark installation position of cylinder liner in crankcase.
2. Screw studs into threaded bores for cylinder head screws.
3. Insert removal plate into cylinder liner and fit on bottom collar.
4. Place support on spindle and studs and tighten.
5. Turn nut to withdraw cylinder liner until released from crankcase bore.
6. Remove removal tool.
7. Remove cylinder liner from crankcase.
8. Remove Tombak ring and sealing rings from crankcase.

Tools: Removal tool, Twist drill, Special tap, Installation tool, Screw shearer, Pointed pliers

1. If necessary, remove thread insert with suitable removal tool from bore.
2. Bore core hole with suitable twist drill – see table.
3. Cut thread with special tapped bore.
4. Do not countersink bore.
5. Mount spindle and snout corresponding with thread.
6. Insert thread insert into spindle; driver journal must be in groove.
7. Mount installation tool on threaded hole and install insert without pressure.
8. Insert 1/2 to 1 1/2 turns deeper than bore surface; remove driver journal.