MTU 16 V 4000 G63 Generator Set

Tools: Feeler gauge Y20010128, Torque wrench 60-320 Nm F30047446, Ring socket, 24 mm F30039526

1. Remove cylinder head cover
2. Install barring tool
3. Rotate crankshaft until marking OT-A1 and pointer are aligned
4. Check TDC position of piston in cylinder A1
5. Check valve clearance with cold engine: inlet 0.2 mm, exhaust 0.5 mm
6. Check all valve clearances at two crankshaft positions
7. Use feeler gauge to determine distance between valve bridge and rocker arm
8. If deviation exceeds 0.1 mm, adjust valve clearance
9. Release locknut and set adjusting screw with Allen key
10. Tighten locknut to 90 +9 Nm holding adjusting screw firm

Tools: Rigid endoscope Y20097353

1. Remove cylinder-head cover
2. Remove injector
3. Turn crankshaft until crankpin of cylinder to be tested has reached BDC
4. Insert endoscope into cylinder liner through injector seat
5. Compile endoscopy report using the table
6. Depending on findings: no action, further examination, or contact Service (liner replacement)
7. Install injector
8. Install cylinder-head cover

1. Loosen clamp.
2. Remove air filter and clamp from flange of intake housing.
3. Verify that 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.
6. Reset signal ring of service indicator.

1. Loosen clamp
2. Remove air filter and clamp from flange of intake housing
3. Verify no objects in flange and clean it
4. Place new air filter with clamp onto intake housing
5. Tighten clamp
6. Reset signal ring of service indicator

⚠ Spring/circlip/tensioning roller preload. Risk of injury!

1. Remove guard cover
2. Slacken screws (1) and (2) by half a turn
3. Place socket adapter or box wrench on screw (3) and press belt tensioner as far as it will go
4. Tighten screw (2), remove used drive belt and fit new drive belt
5. Slacken screw (2) by half a turn so tensioner tensions the belt
6. Tighten screw (1) to 42 Nm and screw (2) to 60-65 Nm
7. Install guard cover
8. Readjust belt tension after 30 minutes and after 8 hours engine runtime

⚠ Hot oil. Oil can contain combustion residues which are harmful to health.

⚠ Compressed air. Risk of injury!

Tools: Torque wrench 6-50 Nm F30027336

1. Remove clamp, release Tommy nut and take off cover
2. Lift rotor, allow oil to drain and remove from housing
3. Release rotor cover nut and take off rotor cover
4. Remove filter sleeve and measure thickness of oil residues
5. If maximum layer thickness exceeds 45 mm, shorten maintenance interval
6. Disassemble rotor tube, conical disk and rotor base, wash with cleaner and blow out with compressed air
7. Check sealing ring, fit new one if necessary
8. Insert new filter sleeve with smooth paper surface facing the wall
9. Mount rotor cover with sealing ring and tighten rotor cover nut to 35-45 Nm
10. Fit cover, tighten Tommy nut by hand, fit clamp and tighten 8-10 Nm, tighten cover nut 5-7 Nm

⚠ Hot oil. Oil can contain combustion residues which are harmful to health.

Tools: Torque wrench 6-50 Nm F30027336

1. Remove cover with O-ring
2. Remove filter element from housing
3. Insert new filter element in housing
4. Fit cover with new O-ring
5. Tighten screws of cover to 10 Nm -2 Nm
6. Checking diaphragm: remove cover, take off spring, seal and diaphragm
7. Check diaphragm for damage, fit new if damaged
8. Mount diaphragm on housing
9. Install new seal and spring with cover and tighten screws to 10 Nm -2 Nm

1. Verify that all plug-in connections are securely seated
2. Secure loose connectors and latch

⚠ Unguarded rotating and moving engine components. Risk of serious injury - danger to life!

Tools: Barring tool F6555766, Ratchet F30006212

1. Remove guard plate
2. Engage barring tool with ring gear and mount on flywheel housing
3. Set ratchet onto barring tool
4. Rotate crankshaft in engine direction of rotation
5. No abnormal resistance apart from normal compression resistance
6. For removal follow reverse sequence

⚠ Unguarded rotating and moving engine components. Risk of serious injury - danger to life!

1. Release latch of connector X4
2. Disconnect connector from ECU
3. Bar engine in unloaded condition: press START button
4. Let crankshaft rotate until oil pressure is indicated
5. If starting period expires, re-start after approx. 20 seconds
6. Connect connector X4 to ECU and latch in position

⚠ Coolant is hot and under pressure. Risk of injury and scalding!

⚠ Cold coolant in hot engine can cause thermal stress.

1. Turn breather valve of filler neck counterclockwise to first stop and allow pressure to escape
2. Continue to turn breather valve counterclockwise and remove
3. Filling with pump: connect pump with hose to drain valve, open it and pump coolant in at 0.5 bar minimum
4. Fill expansion tank until overflow edge is reached
5. Close drain valve and fit breather valve
6. Start engine, run unloaded 10 seconds, stop engine
7. Check coolant level and top up if required
8. Alternatively fill coolant through filler neck until level at top edge of filler neck remains constant

⚠ Hot oil. Oil can contain combustion residues which are harmful to health.

Tools: Torque wrench F30027337, Ratchet adapter F30027341

1. Provide container to collect oil
2. Remove drain plug(s) and drain oil
3. Install drain plug(s) with new sealing ring
4. Extract all oil from oil pan using hand pump (if used)
5. Remove drain plug and drain approx. 7 liters from oil heat exchanger and oil filter
6. Remove drain plugs (2) and (3): approx. 12 liters and approx. 5 liters
7. Replace engine oil filter
8. Tighten drain plugs (2) and (3) to 100 Nm +10 Nm
9. Fill with new oil at filler neck up to max. mark
10. Bar engine with starting system after oil change and filter replacement