MTU 12 V 2000 M86, 12 V 2000 M96, 16 V 2000 M96, 12 V 2000 M96L, 16 V 2000 M96L Operating Instructions Manual

Operating Instructions

Diesel engine

12 V 2000 M86
12 V 2000 M96
12 V 2000 M96L
16 V 2000 M86
16 V 2000 M96
16 V 2000 M96L

MS150119/00E

Engine model kW/cyl. Application group

12V2000M86 102 kW/cyl. 1D, Continuous operation, variable, medium load

12V2000M96 112 kW/cyl. 1DS, Continuous operation, variable, low load

12V2000M96L 119 kW/cyl. 1DS, Continuous operation, variable, low load

16V2000M86 102 kW/cyl. 1D, Continuous operation, variable, medium load

16V2000M96 112 kW/cyl. 1DS, Continuous operation, variable, low load

16V2000M96L 121 kW/cyl. 1DS, Continuous operation, variable, low load

Table 1: Applicability

© 2014 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 consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla­tion, microfilming and storage or processing in electronic systems including databases and online services.

All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen
GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents

1 Safety

1.1 Important requirements for all products 5

1.2 Personnel and organizational requirements 6

1.3 Transport 7

1.4 Safety requirements for startup and
operation 8

1.5 Safety requirements for maintenance and
repair work 9

1.6 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 12

1.7 Standards for safety notices in the text 14

2 General Information

2.1 Torque specifications for screws and nuts 15

2.2 Engine side and cylinder designations 26

2.3 Product description 27

2.4 Engine layout 33

2.5 Sensors and actuators – Overview 35

3 Technical Data

3.1 12V 2000 M86/M96/M96L engine data 40

3.2 16V 2000 M86/M86/M96L engine data 43

3.3 Firing order 46

3.4 Engine – Main dimensions 47

4 Operation

4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 48

4.2 Engine – Putting into operation after
scheduled out-of-service-period 49

4.3 Operational checks 50

4.4 Starting the engine 51

4.5 Engine – Shutdown 52

4.6 Emergency engine stop 53

4.7 After stopping the engine 54

4.8 Plant – Cleaning 55

5 Maintenance

5.1 Maintenance task reference table [QL1] 56

6 Troubleshooting

6.1 Troubleshooting 57

7 Task Description

7.1 SOLAS 60

7.1.1 SOLAS shielding as per MTN 5233 –
Installation 60

7.1.2 SOLAS shielding – Installation 61

7.1.3 Installation locations for SOLAS shielding 62

7.2 Engine 67

7.2.1 Engine – Barring manually 67

7.2.2 Engine – Cranking on starting system 68

7.3 Cylinder Liner 69

7.3.1 Instructions and comments on endoscopic and
visual examination of cylinder liners 69

7.3.2 Cylinder liner – Endoscopic examination 71

7.4 Crankcase Breather 73

7.4.1 Crankcase breather – Cleaning oil pre­separator element 73

7.4.2 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 74

7.5 Valve Drive 76

7.5.1 Cylinder head cover – Removal and
installation 76

7.5.2 Valve clearance – Check and adjustment 77

7.6 Injection Pump / HP Pump 79

7.6.1 HP fuel pump – Filling with engine oil 79

7.7 Injector 80

7.7.1 Injector – Replacement 80

7.7.2 Injector – Removal and installation 81

7.8 Fuel System 83

7.8.1 Fuel system – Venting 83

7.9 Fuel Filter 84

7.9.1 Fuel filter – Replacement 84

7.9.2 Fuel prefilter – Differential pressure check
and adjustment of gauge 85

7.9.3 Fuel prefilter – Draining 86

7.9.4 Fuel prefilter – Flushing 88

7.9.5 Fuel prefilter – Filter element replacement 90

7.10 Charge-Air Cooling 92

7.10.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 92

7.11 Air Filter 93

7.11.1 Air filter – Replacement 93

7.11.2 Air filter – Removal and installation 94

7.12 Air Intake 95

7.12.1 Service indicator – Signal ring position check 95

7.13 Starting Equipment 96

7.13.1 Starter – Condition check 96

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7.14 Lube Oil System, Lube Oil Circuit 97

7.14.1 Engine oil – Level check 97

7.14.2 Engine oil – Change 98

7.15 Oil Filtration / Cooling 99

7.15.1 Engine oil filter – Replacement 99

7.16 Coolant Circuit, General, High-Temperature
Circuit 100

7.16.1 Engine coolant drain and venting points 100

7.16.2 Engine coolant – Level check 103

7.16.3 Engine coolant – Change 104

7.16.4 Engine coolant – Draining 105

7.16.5 Engine coolant – Filling 106

7.16.6 HT coolant pump – Relief bore check 107

7.16.7 Engine coolant – Sample extraction and
analysis 108

7.17 Low-Temperature Circuit 109

7.17.1 Charge-air coolant – Draining 109

7.18 Raw Water Pump with Connections 110

7.18.1 Raw water pump – Relief bore check 110

7.19 Engine Mounting / Support 111

7.19.1 Engine mounting – Checking securing screws
for firm seating 111

7.19.2 Engine mounting – Checking condition of
resilient mounts 112

7.20 Belt Drive 113

7.20.1 Drive belt – Condition check 113

7.21 Battery-Charging Generator 114

7.21.1 Battery-charging generator drive – Drive belt
replacement 114

7.22 Wiring (General) for Engine/Gearbox/Unit 115

7.22.1 Еngine wiring ‒ Check 115

7.23 Accessories for (Electronic) Engine
Governor / Control System 116

7.23.1 Engine governor and connectors – Cleaning 116

7.23.2 EMU and connectors – Cleaning 117

7.23.3 Engine governor plug connections – Check 118

7.23.4 Engine Monitoring Unit EMU 8 – Plug
connections check 119

7.23.5 Interface module EIM plug connections –
Check 120

7.23.6 Engine Control Unit – Self-test 121

7.23.7 Engine governor ECU 9 – Removal and
installation 122

7.23.8 Engine Monitoring Unit – Removal and
installation 123

7.23.9 Engine Interface Module EIM – Removal and
installation 124

7.23.10 Diagnostic features of EIM 125

8 Appendix A

8.1 List of abbreviations 128

8.2 MTU contact persons/service partners 130

9 Appendix B

9.1 Special Tools 131

9.2 Index 138

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1 Safety

1.1 Important requirements for all products

Nameplate

The product is identified by a nameplate, model designation or serial number which must match the
information on the title page of this manual.

Nameplate, model designation or serial number can be found on the product.

General information

This product may pose a risk of injury or damage in the following cases:

• Improper use

• Operation, maintenance and repair by unqualified personnel

• Changes or modifications

• Noncompliance with the safety instructions and warning notices

Intended use

The product is intended for use in accordance with its contractually-defined purpose as described in the
relevant technical documents only.

Intended use entails operation:

• Within the permissible operating parameters in accordance with the (→ Technical data)

• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri­cants Specifications of the manufacturer)

• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU
contact/Service partner)

• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ­ing (including engine management/parameters)

• In compliance with all safety regulations and in accordance with all warning notices in this manual

• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the
useful life of the product

• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques

• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair

• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul

Any other use shall be considered non-intended. Such improper use increases the risk of injury and
damage when working with the product. The manufacturer shall not be held liable for any damage re­sulting from improper, non-intended use.

Changes or modifications

Unauthorized changes to the product represent a contravention of its intended use and compromise
safety.

Changes or modifications shall only be considered to comply with the intended use when expressly au­thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from
unauthorized changes or modifications.

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1.2 Personnel and organizational requirements

Organizational measures of the operator

This manual must be issued to all personnel involved in operation, maintenance, repair or transporta­tion.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte­nance, repair and transport personnel at all times.

Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe­ty-relevant instructions, in particular, must be read and understood.

This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.

Personnel requirements

All work on the product shall be carried out by trained and qualified personnel only.

• Training at the Training Center of the manufacturer

• Qualified personnel specialized in mechanical and plant engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, re­pair and transport.

Working clothes and personal protective equipment

Wear proper protective clothing for all work.

When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec­tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.

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1.3 Transport

Transport

Use only the lifting eyes provided to lift the engine.

Only use transport and lifting devices approved by MTU.

Take the engine's center of gravity into account.

Transport the engine in the installation position only, max. permissible diagonal pull 10°.

In the case of special packaging with aluminum foil, suspend the engine by the lifting eyes of the trans­port pallet or transport with equipment suitable for heavy loads (forklift truck).

Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans­portation.

Secure the engine against tilting during transportation. The engine must be additionally secured against
slipping or tilting when going up or down inclines and ramps.

Setting down the engine following transportation

Set the engine down on a firm, level 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-to­case basis .

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1.4 Safety requirements for startup and operation

Safety requirements for startup

The product must be installed and accepted in accordance with manufacturers' specifications prior to
initial startup.

All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior
to initial startup.

Whenever the product is started, always ensure that:

• All maintenance and repair work has been completed.

• All loose parts have been removed from rotating machine components.

• Wearers of cardiac pacemakers or other active medical implants are well clear.

• The operating room is adequately ventilated.

• Exhaust pipework is leak-tight and routed to atmosphere.

• Battery terminals, generator terminals and cables are guarded to preclude accidental contact.

• All personnel is clear of the danger zone represented by moving parts.

Immediately after putting the product into operation, make sure that all control and display instruments
as well as the monitoring, signaling and alarm systems are working properly.

Safety requirements for operation

The operator must be familiar with the controls and displays.

The operator must be aware of the consequences of any operations he/she performs.

During operation, the display instruments and monitoring units must be constantly observed in regard
of present operating status, limit value violation and warning or alarm messages.

Malfunctions and emergency stop

Emergency procedures, in particular emergency stop, must be practiced on a regular basis.

Take the following steps if a system malfunction is detected or signaled by the system:

• Inform the duty supervisor(s).

• Evaluate the message.

• Respond to the emergency appropriately, e.g. execute an emergency stop.

Operation

Do not stay in the operating room when the product is running unless absolutely necessary and then as
briefly as possible.

Keep a safe distance away from the product whenever possible. Do not touch the product unless ex­pressly instructed to do so.

Do not inhale exhaust gases emitted by the product.

Ensure that the following requirements have been fulfilled before starting the product:

• Ear protectors are worn.

• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.

Operation of electrical equipment

Some components are live (high voltage) when electrical equipment is in operation.

Observe the safety instructions for these appliances.

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1.5 Safety requirements for maintenance and repair work

Safety requirements before commencing maintenance and repair work

Have maintenance or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants,
risk of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use
suitable collection vessels with a sufficient filling volume.

Ensure that the operating room is adequately ventilated when changing the oil or working on the fuel
system.

Do not perform maintenance or repair work when the product is running unless:

• expressly instructed to do so.

• the product is running in the low load range and only for as long as necessary to complete the task.

Lock-out the product to preclude undesired starting, e.g. start interlock.

Tag-out the product with a “Do Not Start” sign in the operation room or on the control facility.

Disconnect the battery. Lock the contactor.

Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.

Disconnect the control facility from the product.

For starters with pinions made of copper-beryllium alloy:

• Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the
starter with compressed air. Clean the interior of the flywheel housing with a class H dust extractor.

• Observe the safety data sheet.

Safety requirements during maintenance and repair work

Take special care when removing vent plugs or plug screws from the product. Hold a cloth over the
screw or plug to prevent discharge of highly pressurized liquids.

Take care when draining hot fluids and lubricants (risk of burning).

Use suitable and calibrated tools only. Observe the specified tightening torques during assembly or dis­assembly.

Carry out work only on assembles and/or installations which are properly secured.

Never climb up on the lines.

Keep fuel injection lines and connections clean.

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

Avoid damaging lines, particularly the fuel lines.

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
contact with other components. Never route fuel or oil lines in the vicinity of hot components.

Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized
or resinous appearance.

Observe the cooling time for components which have been heated for installation or removal (risk of
burning!).

Always use suitable ladders and work platforms when working above head-height. Ensure that compo­nents or assemblies are placed on stable surfaces.

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Pay particular attention to cleanliness at all times.

Safety requirements after completing maintenance and repair work

Ensure that all personnel is clear of danger zones before cranking.

Check that all access ports/apertures which have been opened to facilitate working are closed again.

Check that all safety equipment has been installed and that all tools and loose parts have been re­moved (especially the barring gear).

Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps).

Welding work

Do not perform welding on the product or its attachments. Cover the product when performing welding
work in the vicinity.

Before commencing welding work:

• Switch off the master power supply switch.

• Disconnect the battery.

• Disconnect electronic and genset grounds.

Do not perform maintenance or repair work on the product when welding is in progress in its vicinity.
Risk of explosion or fire due to oil vapors and highly flammable process materials.

Do not use the product as a grounding terminal.

Do not route the welding cable over or near the wiring harnesses of the product. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.

Remove components (e.g. exhaust pipe) from the product before performing necessary welding work .

Hydraulic installation and removal

Check function and satisfactory condition of the jigs and fixtures to be used. Use only the specified jigs
and fixtures for hydraulic removal/installation.

Observe the max. permissible force-on pressure specified for the installation/removal jig.

Do not attempt to bend or exert force on HP lines.

Before starting work, pay attention to the following:

• Vent the installation/removal jig, the pumps and the pipework at the relevant designated points.

• For hydraulic installation, screw on the jig with the piston retracted.

• For hydraulic removal, screw on the jig with the piston extended.

For hydraulic installation/removal jigs with central expansion pressure supply, screw the spindle into
the shaft end until correct sealing has been established.

During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.

Working with batteries

Observe the safety requirements of the battery manufacturer when working with batteries.

Gases released from the battery are explosive. Avoid sparks and naked flames.

Do not allow electrolyte (battery acid) to come into contact with skin or clothing.

Wear goggles and protective gloves.

Do not place tools on the battery.

Check polarity before connecting the cable to the battery. Battery polarity reversal may lead to injury by
the sudden discharge of acid or bursting of the battery unit.

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Working on electrical/electronic assemblies

Always obtain the permission of the duty supervisor before commencing maintenance or repair work or
switching off any part of the electronic system required to do so.

De-energize the appropriate areas prior to working on assemblies.

Avoid damaging cabling during removal. When reconnecting, ensure that cabling cannot be damaged
during operation by:

• Contact with sharp edges

• Chafing on components

• Contact with hot surfaces.

Do not secure cabling to lines bearing fluids.

Do not use cable ties to secure cabling.

Always use connector pliers to tighten union nuts on connectors.

Subject the device and also the product to appropriate function testing whenever repair work has been
completed. In particular, check the function of the emergency stop feature.

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack­age faulty electronic components or assemblies properly before dispatching for repair:

• Moisture-proof

• Shock-proof

• Wrapped in antistatic foil if necessary.

Working with laser equipment

Always wear special laser-protection goggles when working with laser equipment (danger due to in­tensely focused radiation).

Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.

For conducting light-beam procedures and measurement work, only the following laser devices must be
used:

• Laser devices of classes 1, 2 or 3A.

• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 nm to
700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to pre­vent any risk to the eyes.

Measuring component deviations

Workpieces, components and measuring instruments are within specified tolerances at a reference
temperature of 20°C.

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1.6 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials

Fire prevention

Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al­ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.

Do not carry out welding work on 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 to the 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
their use.

Noise

Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.

Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).

Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com­ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu­facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.

Dispose of used fluids, lubricants and filters in accordance with local regulations.

Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.

Fluids and lubricants and auxiliary materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera­tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.

Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum­ables and other chemical substances, follow the safety regulations that apply to the product. Take spe­cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
coming into contact with ignition sources and do not smoke.

Used oil

Used oil contains combustion residues that are harmful to health.

Rub barrier cream into hands.

Wash hands after contact with used oil.

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Lead

• Adopt suitable measures to avoid the formation of lead dust.

• Switch on extraction system.

• When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.

• Wash hands after contact with lead or lead-containing substances.

Compressed air

Observe special safety precautions when working with compressed air:

• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.

• Wear goggles when blowing dirt off workpieces or blowing away swarf.

• Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.

• Pay special attention to the pressure in the compressed air system or pressure vessel.

• Assemblies or products to be connected must either be designed for that pressure, or, if the permis­sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.

• Hose couplings and connections must be securely attached.

• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).

• First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.

• Carry out leak test in accordance with the specifications.

Paints and varnishes

• Observe the relevant safety data sheet for all materials.

• When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.

• There must be no naked flames in the vicinity.

• No smoking.

• Observe fire prevention regulations.

• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen

• Observe the relevant safety data sheet for all materials.

• Work with liquid nitrogen may be carried out only by qualified personnel.

• Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).

• Avoid body contact (eyes, hands).

• Wear protective clothing, protective gloves, closed shoes and safety goggles.

• Make sure that working area is well ventilated.

• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.

Acids/alkaline solutions/urea (AdBlue®, DEF)

• Observe the relevant safety data sheet for all materials.

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

• Do not inhale vapors.

• If urea solution is swallowed, rinse out mouth and drink plenty of water.

• If spilled onto clothing, remove the affected clothing immediately.

• After contact with skin, rinse affected parts of the body with plenty of water.

• Rinse eyes immediately with eye drops or clean tap water. Seek medical attention as soon as possi­ble.

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1.7 Standards for safety notices in the text

DANGER

In the event of immediate danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

WARNING

In the event of a situation involving potential danger.

Consequences: Death, serious or permanent injury!

• Remedial action.

CAUTION

In the event of a situation involving potential danger.

Consequences: Minor or moderate injuries!

• Remedial action.

NOTICE

In the event of a situation involving potentially adverse effects on the product.

Consequences: Material damage!

• Remedial action.

• Additional product information.

Safety notices

1. This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.

2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to
personal injury shall be considered to include a warning of potential damage.

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2 General Information

2.1 Torque specifications for screws and nuts

Tightening torques for setscrew and connections as per MTN 5008 standard

The standard applies to setscrews and the associated nuts as specified in the following standards when
not subjected to dynamic loading:

• MMN 384

• DIN 912

• ISO 4014 (DIN 931-1)

• ISO 4017 (DIN 933)

• EN 28765 (DIN 960)

• EN 28676 (DIN 961)

• DIN 6912

The standard applies to studs and the associated nuts as specified in the following standards:

• DIN 833

• DIN 835

• DIN 836

• DIN 938

• DIN 939

The standard does not apply to heat-resistant screws in the hot-component area.

Tightening torques MA are specified for screws of strength class 8.8 (surface condition bare, phosphat­ized or galvanized) and 10.9 (surface condition bare or phosphatized).

The values in the table are based on a friction coefficient µtot = 0.125.

Coat thread and mating faces of screws and nuts with engine oil prior to assembly.

An assembly tolerance of +10% of the table values is admissible when tightening manually (to specified
torque).

The admissible assembly tolerance is ±15% for machine tightening.

Thread

Hand-tightening Machine-tightening

8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)

M6 9 12 8 11

M8 21 31 20 28

M8 x 1 23 32 21 30

M10 42 60 40 57

M10 x 1.25 45 63 42 60

M12 74 100 70 92

M12 x 1.25 80 110 75 105

M12 x 1.5 76 105 72 100

M14 115 160 110 150

M14 x 1.5 125 180 120 170

M16 180 250 170 235

M16 x 1.5 190 270 180 255

M18 250 350 240 330

M18 x 1.5 280 400 270 380

M20 350 500 330 475

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Thread

Hand-tightening Machine-tightening

8.8 MA (Nm) 10.9 MA (Nm) 8.8 MA (Nm) 10.9 MA (Nm)

M20 x 1.5 390 550 350 520

M22 480 680 450 650

M22 x 1.5 520 730 490 700

M24 600 850 570 810

M24 x 1.5 680 950 640 900

M24 x 2 660 900 620 850

M27 900 1250 850 1175

M27 x 2 960 1350 900 1275

M30 1200 1700 1100 1600

M30 x 2 1350 1900 1250 1800

MA = Tightening torques

Tightening torque for stress bolt connections as per MTN 5007 standard

The standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load
of strength class 10.9 as well as to the associated nuts.

Shaft and transition dimensions as per MMN 209 standard and material and machining as per
MMN 389 standard (bright surface or phosphatized).

The values in the table are based on a friction coefficient µtot = 0.125.

Coat thread and mating faces of screws and nuts with engine oil prior to assembly.

An assembly tolerance of +10% of the table values is admissible for unavoidable deviations during the
tightening process.

The values in the tables are for manual tightening using a torque wrench.

Thread

Not torsion-protected MA(Nm) Torsion-protected MA(Nm)

M6 9 12

M8 21 28

M8 x 1 24 30

M10 42 55

M10 x 1.25 46 60

M12 75 93

M12 x 1.5 78 99

M14 120 150

M14 x 1.5 135 160

M16 180 225

M16 x 1.5 200 245

M18 250 315

M18 x 1.5 300 360

M20 350 450

M20 x 1.5 430 495

M22 500 620

M22 x 1.5 560 675

M24 640 790

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Thread

Not torsion-protected MA(Nm) Torsion-protected MA(Nm)

M24 x 2 700 850

M27 900 1170

M27 x 2 1000 1230

M30 1250 1575

*Protect screw shaft from torsion when tightening.

MA = Tightening torques.

Tightening torques for plug screws as per MTN 5183-1 standard

The standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed plug
DIN 3852, model A (sealed by sealing ring DIN 7603-Cu).

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Tightening torques MA are given for plug screws made of steel (St) with surface protected by a phos­phate coating and oiled or galvanized.

Coat thread and mating faces beneath heads with engine oil prior to assembly.

An assembly tolerance of +10% of the table values is admissible for unavoidable deviations during the
tightening process.

Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed plug).

Thread

inserted in

Steel/gray cast iron M

A

(Nm)

Al alloy M

A

(Nm)

M10 x 1 15 15

M12 x 1.5 30 25

M14 x 1.5 35 30

M16 x 1.5 40 35

M18 x 1.5 50 40

M20 x 1.5 60 50

M22 x 1.5 70 70

M24 x 1.5 85 80

M26 x 1.5 100 100

M27 x 2 100 100

M30 x 1.5 110 110

M30 x 2 120 120

M33 x 2 160 160

M36 x 1.5 190 180

M38 x 1.5 220 200

M42 x 1.5 260 240

M45 x 1.5 290 270

M48 x 1.5 310 300

M52 x 1.5 325 320

M56 x 2 380 360

M64 x 2 400 400

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MA = Tightening torques

Tightening torque for plug screws DIN 7604C (with long screwed end)

Thread

inserted in

Steel/gray cast iron M

A

(Nm)

Al alloy M

A

(Nm)

M8 x 1 10 10

M22 x 1.5 80 65

M26 x 1.5 105 90

M30 x 1.5 130 130

M38 x 1.5 140 120

M45 x 1.5 160 140

MA = Tightening torques

Tightening torque for banjo screws as per MTN 5183-2 standard

The standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603­Cu.

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The stated tightening torques MA apply to steel (St) banjo screws with a phosphatized surface and oiled
or galvanized and for copper-aluminum alloy.

Coat thread and mating faces beneath heads with engine oil prior to assembly.

An assembly tolerance of +10% of the table values is admissible for unavoidable deviations during the
tightening process.

Tightening torques for steel banjo screws

Thread

Screwed into steel/gray cast iron/Al alloy M

A

(Nm)

M8 x 1 10

M10 x 1 15

M12 x 1.5 20

M14 x 1.5 25

M16 x 1.5 25

M18 x 1.5 30

M22 x 1.5 60

M26 x 1.5 90

M30 x 1.5 130

M38 x 1.5 140

M45 x 1.5 160

MA = Tightening torques

Tightening torques for copper-aluminum alloy banjo screws

Thread

Screwed into steel/gray cast iron/Al alloy M

A

(Nm)

M10 x 1 15

M16 x 1.5 30

MA = Tightening torques

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Tightening torques for male connectors as per MTN 5183-3 standard

The standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852, model A (sealed
by sealing ring DIN 7603-Cu).

Tightening torques MA are given for male connectors made of steel (St) with surface protected by a
phosphate coating and oiled or galvanized.

Coat thread and mating faces beneath heads with engine oil prior to assembly.

An assembly tolerance of +10% of the table values is admissible for unavoidable deviations during the
tightening process.

Thread

Screwed into steel/gray cast iron M

A

(Nm)

M10 x 1 15

M12 x 1.5 20

M14 x 1.5 35

M16 x 1.5 50

M18 x 1.5 60

M22 x 1.5 70

M26 x 1.5 100

M32 x 2 160

M42 x 2 260

M48 x 2 320

MA = Tightening torques

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Tightening torques for union nuts as per DIN 3859-2

1 Union nut
2 Screw fixture
3 O-ring
4 Ball-type union

Union nut: When installing the ball-type union, first tighten the union nut firmly by hand (noticeable in­crease in force), then tighten another 1/4 turn (90°) past this point.

Tightening torques for threaded journals with O-rings as per ISO 6149-2

Thread Torque (Nm) +10%

M8 x 1 10

M10 x 1 20

M12 x 1.5 35

M14 x 1.5 45

M16 x 1.5 55

M18 x 1.5 70

M20 x 1.5

1)

80

M22 x 1.5 100

M27 x 2 170

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Thread Torque (Nm) +10%

M33 x 2 310

M42 x 2 330

M48 x 2 420

M60 x 2 500

1)

Only for closing off installation spaces for screw-in valves (see ISO 7789).

Tightening torques for threaded journals with O-rings as per ISO 6149-3

Thread Torque (Nm) +10%

M8 x 1 8

M10 x 1 15

M12 x 1.5 25

M14 x 1.5 35

M16 x 1.5 40

M18 x 1.5 45

M22 x 1.5 60

M27 x 2 100

M33 x 2 160

M42 x 2 210

M48 x 2 260

M60 x 2 315

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Tightening torques for plug screw joints as per MTN 5183-6

Thread

inserted in

Steel/gray cast iron M

A

(Nm)

Al alloy M

A

(Nm)

M10 x 1 20 10+ 2

M12 x 1.5 35 14+ 2

M14 x 1.5 45 15+ 3

M16 x 1.5 55 18+ 3

M18 x 1.5 70 23+ 3

M22 x 1.5 100 33+ 4

M27 x 2 170 57+ 5

M33 x 2 310 103+ 10

M42 x 2 330 110+ 11

M48 x 2 420 140+ 14

M60 x 2

1)

200+ 20

1)

Value still to be determined.

Assembly instructions and tightening torque for hose fittings with union nuts

These instructions do not apply to ORFS valves and fittings. When connecting hose fittings with sealing
heads and the associated adapters proceed as follows contrary to the instructions for pipe unions.

Hose fitting, metallic sealing with union nut: Tighten union nut by hand then tighten max. 1/4 turn with
wrench.

Hose fitting with O-ring and union nut: Tighten union nut by hand then tighten max. 1/2 turn with
wrench.

Align hoselines appropriately before tightening the union nuts.

Sealing head/sealing cone with metric union nut

Metric thread Pipe outer Ø Torque (Nm)

M12 x 1.5 6 20

M14 x 1.5 8 38

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Sealing head/sealing cone with metric union nut

Metric thread Pipe outer Ø Torque (Nm)

M16 x 1.5 8

10

45

M18 x 1.5 10

12

51

M20 x 1.5 12 58

M22 x 1.5 14

15

74

M24 x 1.5 16 74

M26 x 1.5 18 105

M30 x 2 20

22

135

M36 x 2 25

28

166

M42 x 2 30 240

M45 x 2 35 290

M52 x 2 38

42

330

Sealing head with BSP union nut

BSPP thread Torque (Nm)

G1/4 20

G3/8 34

G1/2 60

G5/8 69

G3/4 115

G1 140

G1.1/4 210

G1.1/2 290

G2 400

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2.2 Engine side and cylinder designations

1 Left engine side (A-side)
2 Engine free end in accord-

ance with DIN ISO 1204
(KGS = Kupplungsgegen­seite)

3 Right engine side (B-side)
4 Engine driving end in ac-

cordance with
DIN ISO 1204 (KS = Kup­plungsseite)

Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4).

For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on
the left-hand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The
cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4).

The numbering of other engine components also starts with 1 at driving end (4).

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2.3 Product description

Description of the engine

Engine

The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection,
sequential turbocharging and charge-air cooling.

An electronic management system provides engine control and monitoring.

Fuel system with Common Rail injection

Controlled by the electronic engine management system, the common rail injection system determines
injection pressure, injection timing and injection quantity independently of the engine speed.

Injection pressures up to 1800 bar ensure optimum fuel injection and combustion conditions.

Turbocharging system

The charging system comprises charge-air system, exhaust system and sequential turbocharging.

The exhaust system is equipped with triple-walled, water-cooled exhaust lines.

The triple-walled design permits

• low surface temperature,

• reduced thermal load,

• absolute gas-tightness.

Lube oil system

Wet-sump forced-feed lubrication system

Components supplied with oil:

• Bearings

• Piston cooling

• Control and actuating elements of the sequential turbocharging system

Cooling system

• Two separate cooling circuits:
– Engine coolant
– Raw water

• Coolant cooling by raw water-cooled plate-core heat exchanger

• Thermostat-controlled coolant system

• Coolant-cooled / preheated charge-air

• Coolant-cooled fuel return

Electronic system

Electronic control and monitoring system with integrated safety and test system with interfaces to the
Remote Control System (RCS) and to the Monitoring and Control System (MCS).

Connection box EIM (Engine Interface Module)

The Engine Interface Module (EIM) is the central connection box on the engine. It covers the entire mini­mum scope of a Series marine engine. It has no controls or parts requiring maintenance.

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Functions:

• Starter control (start repetition, tooth alignment, starter protection)

• Generator monitoring

• Open bus interface to the plant (SAE J1939)

• Emergency stop function with line break monitoring

• Redundant power supply

• Optional control of emergency air-shutoff flaps

• Key switch logic

• Interface to ECU and EMU

• MCS5 dialog interface

• Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)

• Connection facility for an MTU Local Operating Station (LOS)

Serial RS422 interface for diagnosis

The engine interface is divided into two parts. The first part is integrated in the engine wiring harness
via the 62-pole Tyco connector X52. The second part is formed by those signals involving a higher cur­rent. Such signals are routed out via M threaded pins and are also integrated in the engine wiring har­ness.

Functions

• ECU supply

• EMU supply

• Plant signals (ECU7 connector X1)

• Bus interface (2x MCS5 CAN)

• CAN dialog output (1x MCS5 CAN)

• ECU and EMU emergency stop

• Electric starter

• Terminal 45 starter A/B (engaged)

• Pneumatic starter

• Starting air pressure valve

• Starting air pressure sensor

• Barring gear (Barring Gear 1 and 2)

• Generator (with exciter control)

• Optional emergency air-shutoff flaps

• Activation of SDAF 1+2

• Feedback from SDAF 1+2

Electronic engine control unit (ECU)

Closed-loop control:

• Engine speed

• Fuel HP

Open-loop control:

• Injection (fuel pressure, injection timing, injection duration, operating status)

• Sequential turbocharging (cutting-in and out) with secondary turbocharger

• Engine protection with multi-stage safety systems:
– Power reduction
– Power limitation
– Emergency stop

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Monitoring:

• Exhaust gas temperature, A side

• Exhaust temperature, B-side

• Engine speed

• Oil pressure

• Differential oil pressure

• Coolant temperature

• Coolant level

• Exhaust turbocharger speed

• Leak fuel level

• Oil temperature

• Coolant pressure

• Fuel pressure after filter

Monitoring in engine room

Engine control and monitoring unit (LOP)

Functions:

• Engine speed, oil pressure and coolant temperature are monitored and displayed

• Integrated safety system

• Integrated Test System

• Redundant CAN bus interface to governor and higher-level control and monitoring system

• 24 V DC supply

SOLAS – Fire protection specifications

Special connections

In case of leakage, the connection types shown above are spray-protected even without a cover and
have been confirmed compliant with SOLAS by GL and DNV.

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Plug-in pipe union

The sleeve (3) covers the joint to prevent lateral spray.

Only leak-off along the line is possible, the pressure decreases significantly if an O-ring (2) fault occurs.

The connection is confirmed as compliant with SOLAS by DNV and GL.

Plugs and sensors

Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).

In case of a loose thread or a faulty sealing ring (1), the liquid first has to pass the thread.

The pressure is so greatly reduced by this and the faulty sealing ring (1) that any leakage is not under
pressure.

HP line between fuel injector and HP accumulator

1 Support ring
2 V-ring
3 Thrust ring

4 HP line
5 Thrust screw
6 Support ring

7 Thrust ring
8 V-ring
9 Union nut

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HP line between distributor and HP accumulator

1 Union nut
2 O-ring
3 Thrust ring

4 Thrust screw
5 O-ring
6 O-ring

7 Thrust ring
8 Pressure pipe
9 Jacket pipe

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HP line between distributor and HP accumulator

1 Jacket pipe
2 O-ring
3 O-ring
4 Thrust ring

5 O-ring
6 Thrust screw
7 Thrust ring
8 O-ring

9 HP line

10 Pressure pipe

Leak-off fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump,
from where it is routed at atmospheric pressure into a level-monitored leak-fuel tank.

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2.4 Engine layout

Overview of free end

Also applies similarly to 12V.

1 Engine oil heat exchanger
2 Engine oil filter
3 Diverter lever for engine

oil filter
4 Fuel cooler
5 Engine lifting eye (free

end)
6 Engine governor
7 Air filter (air intake)
8 Air collecting housing
9 Engine lifting eye (driving

end)

10 Exhaust turbocharger,

right (secondary turbo-

charger)

11 Exhaust turbocharger (pri-

mary turbocharger)

12 Exhaust turbocharger, left

(secondary turbocharger)

13 Actuating cylinder for ex-

haust flap

14 Actuating cylinder for air

flap
15 Cylinder head cover
16 Electric starter
17 Engine mounting
18 Exhaust housing
19 Oil filler neck
20 Oil dipstick
21 Engine coolant filler neck
22 Coolant distribution hous-

ing with integrated expan-

sion tank

23 Battery-charging generator
24 Raw water pump
25 Plate-core heat exchanger
26 Fuel duplex filter (switcha-

ble)
a Air intake
b Exhaust outlet (horizontal)
c Raw water connection to

gearbox cooling system
d Raw water connection

from sea
e Raw water connection to

sea

KGS = Kupplungsgegenseite

(free end)

Overview of driving end

Also applies similarly to 12V.

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1 Carrier housing upper sec-

tion
2 Air filter (air intake)
3 Thermostat housing
4 Exhaust housing
5 Crankcase vent line
6 HP fuel pump

7 Fuel delivery pump
8 Exhaust turbocharger oil

valve

9 Carrier housing middle

section
10 Drive flange
11 Flywheel housing
11 Fuel filter

12 Carrier housing lower sec-

tion

13 Bleeder valve

a Air intake
b Exhaust outlet

KS = Kupplungsseite (driving

end)

Engine model designation

Key to the engine model designation 12V/16V 2000 Mxyz

12/16 Number of cylinders

V Cylinder arrangement: V engine

2000 Series

M Application

x Application segment (4, 5, 6, 7, 8, 9)

y Design index (0,1, 2,...)

z Special features

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2.5 Sensors and actuators – Overview

Sensors and actuators on engine driving end

Item Name Monitoring of

1 B4.21 ETC temperature, A side

2 B4.22 ETC temperature, B side

3 B13.1 Crankshaft speed

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Sensors and actuators on engine free end

Item Name Monitoring of

1 B5.3 Lube oil pressure before filter

2 B5.2 Lube oil pressure after filter

3 B5.1 Lube oil pressure after filter

4 F33 Coolant level probe in expansion tank

5 B21 Raw water pressure

6 B6.2 Coolant temperature

7 B6.1 Coolant temperature

8 B34 Fuel pressure after filter

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Sensors and actuators on left side

Item Name Monitoring of

1 Y27.1 4/2 directional control valve, A side

2 B54 Oil replenishment pump pressure

3 A18 EIM Engine Interface Module

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Sensors and actuators on right side

Item Name Monitoring of

1 M52 Exhaust gas recirculation (bypass at ETC)

2 B48 HP fuel pressure

3 Y45.1 Pressure regulating valve

4 A19 EIL electronic label

5 B16 Coolant pressure

6 M8 CR pump

7 F46 Leak fuel level

8 B1 Camshaft speed, B side

9 B13.2 Crankshaft speed

10 Y27.2 4/2 directional control valve, B side

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Sensors and actuators on engine top

Item Name Monitoring of

1 B3 Intake air temperature

2 Y35 4/2 mixing valve, intercooler

3 Y56 4/2 directional control valve, recirculation

4 A77 EMU Engine Monitoring Unit

5 B7 Lube oil temperature

6 B33 Fuel temperature

7 Y45.2 Pressure regulating valve

8 B9 Charge air temperature

9 B10 Charge air pressure

10 B44 ETC speed

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3 Technical Data

3.1 12V 2000 M86/M96/M96L engine data

Explanation:

DL Ref. value: Continuous power
BL Ref. value: Fuel stop power

A Design value

G Guaranteed value

R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power settings).

N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Reference conditions - Unit Value

Application group - - 1DS

Intake air temperature - °C 25

Raw water inlet temperature - °C 25

Barometric pressure - mbar 1000

Site altitude above sea level - m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Power-related data - Unit Value

Number of cylinders - - 12

Rated engine speed A rpm 2450

Fuel stop power ISO 3046: 12V 2000 M86 A kW 1268

12V 2000 M96 A kW 1342

12V 2000 M96L A kW 1432

GENERAL CONDITIONS (for maximum power)

General conditions - Unit Value

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

MODEL-RELATED DATA (basic design)

Model-related data - Unit Value

Cylinder arrangement: V-angle - Degrees

(°)

90

Bore - mm 135

Stroke - mm 156

Displacement, cylinder - Liters 2.23

Displacement, total - Liters 26,76

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Model-related data - Unit Value

Number of inlet valves per cylinder - - 2

Number of exhaust valves per cylinder - - 2

RAW WATER CIRCUIT (open circuit)

Raw water circuit - Unit Value

Raw water pump: Inlet pressure, min. L bar -0.4

Raw water pump: Inlet pressure, max. L bar +0.5

Pressure loss in engine-external raw water system, max. L bar 0.7

LUBE OIL SYSTEM

Lube oil system - Unit Value

Lube-oil operating temperature before engine, from R °C -

Lube oil operating temperature before engine, to R °C -

Lube oil operating pressure upstream of engine, from R bar -

Lube-oil operating pressure before engine, to R bar -

Lube oil operating pressure (low idle) (meas. point: before engine) R bar -

FUEL SYSTEM

Fuel system - Unit Value

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at supply connection to engine, min. (when engine is running) L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. R Liter/min -

GENERAL OPERATING DATA

Engine speed - Unit Value

Firing speed, from R rpm 100

Firing speed. to R rpm 120

STARTER (electric)

Starter - Unit Value

Rated starter voltage (standard design) R V= 24

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Inclinations, standard oil system - Unit Value

Longitudinal inclination, continuous max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

-

Longitudinal inclination, temporary max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

-

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

L Degrees

(°)

-

Longitudinal inclination, temporary max. driving end up (option: max. operating
inclinations)

L Degrees

(°)

-

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Inclinations, standard oil system - Unit Value

Transverse inclination continuous max. (option: max. operating inclinations) L Degrees

(°)

-

Transverse inclination, temporary max. (option: max. operating inclinations) L Degrees

(°)

-

CAPACITIES

Capacities - Unit Value

Engine coolant capacity, engine side (with cooling equipment) R Liters 125

Engine oil capacity, initial filling (standard oil system) (design: max. operating
inclinations)

R Liters 123

Oil change quantity max. (standard oil system) (design: max. operating inclina­tions)

R Liters -

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

L Liters -

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

L Liters -

WEIGHT

Weight - Unit Value

Engine dry weight (with mounted standard accessories, w/o coupling) R kg -

NOISE

Noise - Unit Value

Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis­tance, ISO 6798, +3dB(A) tolerance)

R dB(A) -

Engine surface noise with attenuated intake noise (filter) - BL (free-field sound­pressure level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance)

R dB(A) -

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3.2 16V 2000 M86/M86/M96L engine data

Explanation:

DL Ref. value: Continuous power
BL Ref. value: Fuel stop power

A Design value
G Guaranteed value
R Guideline value

L Limit value, up to which the engine can be operated, without change (e.g. of power settings).
N Not yet defined value

- Not applicable

X Applicable

REFERENCE CONDITIONS

Reference conditions - Unit Value

Application group - - 1DS

Intake air temperature - °C 25

Raw water inlet temperature - °C 25

Barometric pressure - mbar 1000

Site altitude above sea level - m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)

Power-related data - Unit Value

Number of cylinders - - 16

Rated engine speed A rpm 2450

Fuel stop power ISO 3046 16V 2000 M86 A kW 1630

16V 2000 M96 A kW 1790

16V 2000 M96L A kW 1939

GENERAL CONDITIONS (for maximum power)

General conditions - Unit Value

Intake depression (new filter) A mbar 15

Intake depression, max. L mbar 30

MODEL-RELATED DATA (basic design)

Model-related data - Unit Value

Cylinder arrangement: V-angle - Degrees

(°)

90

Bore - mm 135

Stroke - mm 156

Displacement, cylinder - Liters 2.23

Displacement, total - Liters 35.68

Number of inlet valves per cylinder - - 2

Number of exhaust valves per cylinder - - 2

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RAW WATER CIRCUIT (open circuit)

Raw water circuit - Unit Value

Raw water pump: Inlet pressure, min. L bar -0.4

Raw water pump: Inlet pressure, max. L bar +0.5

Pressure loss in engine-external raw water system, max. L bar 0.7

LUBE OIL SYSTEM

Lube oil system - Unit Value

Lube-oil operating temperature before engine, from R °C -

Lube oil operating temperature before engine, to R °C -

Lube oil operating pressure upstream of engine, from R bar -

Lube-oil operating pressure before engine, to R bar -

Lube oil operating pressure (low idle) (meas. point: before engine) R bar -

FUEL SYSTEM

Fuel system - Unit Value

Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3

Fuel pressure at supply connection to engine, min. (when engine is running) L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25

Fuel supply flow, max. A Liter/min -

GENERAL OPERATING DATA

Engine speed - Unit Value

Firing speed, from R rpm 100

Firing speed. to R rpm 120

STARTER (electric)

Starter - Unit Value

Rated starter voltage (standard design) R V= 24

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)

Inclinations, standard oil system - Unit Value

Longitudinal inclination, continuous max. driving end down (option: max. oper­ating inclinations)

L Degrees

(°)

20

Longitudinal inclination, temporary 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

(°)

15

Longitudinal inclination, temporary max. driving end up (option: max. operating
inclinations)

L Degrees

(°)

17.5

Transverse inclination continuous max. (Option: max. operating inclinations) L Degrees

(°)

15

Transverse inclination, temporary max. (option: max. operating inclinations) L Degrees

(°)

22.5

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CAPACITIES

Capacities - Unit Value

Engine coolant capacity, engine side (with cooling equipment) R Liters 135

Engine oil capacity, initial filling (standard oil system) (design: max. operating
inclinations)

R Liters 145

Oil change quantity max. (standard oil system) (design: max. operating inclina­tions)

R Liters 134

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

L Liters 106

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

L Liters 134

WEIGHT

Weight - Unit Value

Engine dry weight (with mounted standard accessories, w/o coupling) R kg 3160

NOISE

Noise - Unit Value

Exhaust noise, unsilenced - BL (free-field sound-pressure level Lp, 1m dis­tance, ISO 6798, +3dB(A) tolerance)

R dB(A) -

Engine surface noise with attenuated intake noise (filter) - BL (free-field sound­pressure level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance)

R dB(A) -

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3.3 Firing order

Firing order

12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1

16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7

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3.4 Engine – Main dimensions

Main dimensions

Engine model Length (A) Width (B) Height (C)

16V 2000 M86
16V 2000 M96
16V 2000 M96L

2495 mm 1318 mm 1455 mm

12V 2000 M86
12V 2000 M96
12V 2000 M96L

2082 mm 1292 mm 1440 mm

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4 Operation

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

Preconditions

☑Engine is stopped and starting disabled.

☑MTU Preservation and Represervation Instructions (A001070/..) available.

Putting the engine into operation (out-of-service period > 3 months)

Item Action

Engine Depreserve (→ MTU Preservation and Represervation Instructions

A001070/..).

Lube oil system Check engine oil level (→ Page 97).

Fuel prefilter Fill with fuel (→ Page 90).

Fuel prefilter, pressure gage Align adjustable pointer with position of pressure indicator (→ Page 85).

Fuel system Vent (→ Page 83).

Raw water pump (if located
above waterline)

Prime (approx. 3 to 4 liters).
Filling point (→ Page 100).

Coolant circuit If engine is out of service for more than one year, change engine coolant

(→ Page 104).

Coolant circuit Check coolant level (→ Page 103).

Coolant circuit Heat engine coolant with coolant preheating unit.

Engine Control Unit ECU Check plug connections (→ Page 118).

Engine Interface Module EIM Check plug connections (→ Page 120).

Engine Monitoring Unit EMU Check plug connections (→ Page 119).

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4.2 Engine – Putting into operation after scheduled out-of-service­period

Preconditions

☑Engine is stopped and starting disabled.

Putting into operation

Item Action

Lube oil system Check engine oil level (→ Page 97).

Coolant circuit Check coolant level (→ Page 103).

Coolant circuit Heat engine coolant with coolant preheating unit.

Fuel prefilter Drain water and contaminants (→ Page 86).

Battery-charging generator
drive

Check condition of drive belt (→ Page 113).

Engine Control Unit ECU Check plug connections (→ Page 118).

Engine Interface Module EIM Check plug connections (→ Page 120).

Engine Monitoring Unit EMU Check plug connections (→ Page 119).

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4.3 Operational checks

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Operational checks

Item Measure

Engine under load
Engine at nominal speed

Visually inspect engine for leaks and general condition;
Check for abnormal running noises and vibration;
Check exhaust color (→ Page 57).

Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter is within the limit

(→ Page 85).
Drain water and contaminants (→ Page 86).

Air filter Check signal ring position of contamination indicator (→ Page 95).

Replace air filter (→ Page 93), if the signal ring is completely visible in the
service indicator observation window.

HT coolant pump Check relief bore for oil and coolant discharge and contamination

(→ Page 107).

Raw water pump Check relief bore for oil and water discharge and contamination

(→ Page 110).

Intercooler Check condensate drain (if applicable) (→ Page 92).

Engine oil Check engine oil level (→ Page 97).

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4.4 Starting the engine

Preconditions

☑External start interlock is not active.

☑Emergency air shut-off flaps (if fitted) are open.

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Before cranking the engine with starter system, make sure that there are no persons in the en­gine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

The engine can be started from the following points

Item Action

Control stand (→ Operating instructions for electronic system)

Local Operating Panel LOP (→ Operating instructions for electronic system)

Local Operation Station LOS (→ Operating instructions for electronic system)

CCU (→ Operating instructions for electronic system)

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4.5 Engine – Shutdown

Preconditions

☑Engine is running in Local mode

NOTICE

Stopping the engine when it is running at full load causes extreme stress to the engine.

Risk of overheating, damage to components!

• Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes
until engine temperatures have dropped and constant values are displayed.

The engine can be stopped from the following points

Item Action

Control stand (→ Operating instructions for electronic system)

Local Operating Panel LOP (→ Operating instructions for electronic system)

Local Operation Station LOS (→ Operating instructions for electronic system)

CCU (→ Operating instructions for electronic system)

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4.6 Emergency engine stop

NOTICE

An emergency stop causes extreme stress to the engine plant.

Risk of overheating, damage to components!

• Initiate emergency stop only in emergency situations.

An emergency engine stop can be initiated from the following points

Item Action

Control stand (→ Operating instructions for electronic system)

Local Operating Panel LOP (→ Operating instructions for electronic system)

Local Operation Station LOS (→ Operating instructions for electronic system)

CCU (→ Operating instructions for electronic system)

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4.7 After stopping the engine

Preconditions

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

After stopping the engine

Item Measure

Coolant circuit Drain coolant (→ Page 105) if:

•

freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;

•

the engine room is not heated;

•

the coolant is not kept at a suitable temperature;

•

the antifreeze concentration is insufficient for the engine-room tem­perature;

•

antifreeze concentration is 50 % and engine-room temperature is be­low -40°C.

Raw water Drain

•

if freezing temperatures are to be expected and the engine is to re­main out of service for an extended period.

Engine control system Switch off.

Air intake and exhaust sys­tem

Out-of-service-period > 1 week

•

Seal engine's air and exhaust sides.

Engine Out-of-service-period > 1 month

•

Depreserve engine (→ MTU Preservation and Represervation Specifica­tions A001070/..)

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4.8 Plant – Cleaning

Preconditions

☑Engine is stopped and starting disabled.

☑Operating voltage is not applied.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Steam jet cleaner

- 1

Cleaner (Hakupur 312)

30390 1

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

WARNING

Steam jet cleaner ejects jet of pressurized water.

Risk of injury to eyes and scalding!

• Never direct water jet at people.

• Wear protective clothing, protective gloves and safety goggles/face mask.

NOTICE

Cleaning agents should not be left to take effect for too long.

Damage to components is possible!

• Observe manufacturer's instructions.

NOTICE

Blowing down product with compressed air.

Entry of dirt and damage to components is possible!

• Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.

Plant – Cleaning

1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).

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 of the plant with water or steam-jet cleaners:

• The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.

• A minimum distance between spray nozzle and plant of 1 m must be observed.

• The temperature of the cleaning medium must not exceed 80°C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.

Note: Never aim compressed air directly at electronic components.

5. Carry out external cleaning as follows:

a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.

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5 Maintenance

5.1 Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.

The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.

Task

Option

Maintenance tasks

W0500 Check engine oil level. (→ Page 97)

W0501 Visually inspect engine for leaks and general condition. (→ Page 50)

W0502 X Check intercooler drain(s). (→ Page 92)

W0503 Check maintenance indicator of air filter. (→ Page 95)

W0505 Check relief bores of water pump(s). (→ Page 107) (→ Page 110)

W0506 Check engine for abnormal running noises, exhaust color

and vibrations.

(→ Page 50)

W0507 X Drain water and contaminants from fuel prefilter. (→ Page 86)

W0508 X Check reading on differential pressure gage of fuel prefilter. (→ Page 85)

W1001 Replace fuel filter or fuel filter element. (→ Page 84)

W1002 Check valve clearance and adjust as necessary. (→ Page 77)

W1005 Replace air filter. (→ Page 93)

W1006 Replace fuel injectors. (→ Page 80)

W1008 Replace engine oil filter when changing engine oil, or when

the interval (years) is reached, at the latest.

(→ Page 99)

W1009 X Check layer thickness of oil residue, clean out and replace

filter sleeve when engine oil is changed at the latest.

-

W1011 Perform endoscopic examination. (→ Page 71)

W1244 X Check function of rod electrode . -

W1245 X Check alarm function of differential pressure gage . -

W1246 X Check pump capacity. -

W1675 X Replace fuel prefilter or fuel prefilter element. (→ Page 90)

Table 2: Maintenance task reference table [QL1]

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6 Troubleshooting

6.1 Troubleshooting

Engine does not turn when starter is actuated

Cause Corrective action

Battery flat or defective. u Charge or replace (see manufacturer's documentation).

Cable connections on battery
are defective.

u Check if cable connections are properly secured (see

manufacturer's documentation).

Engine wiring or starter
defective.

u Check if cable connections are properly secured, contact

Service.

Engine wiring faulty. u Check (→ Page 115).

Plug connections are loose at
interface module EIM.

u Check plug connections (→ Page 120).

Engine turns but does not fire

Cause Corrective action

Poor rotation by starter: Battery
flat or defective.

u Charge or replace battery (see manufacturer's documentation).

Engine wiring faulty. u Check (→ Page 115).
Air in fuel system. u Vent fuel system (→ Page 83).

Engine governor ECU is
defective.

u Contact Service.

Engine fires unevenly

Cause Corrective action

Injector faulty. u Replace (→ Page 80).
Injection pump faulty. u Contact Service.
Engine wiring faulty. u Check (→ Page 115).
Air in fuel system. u Vent fuel system (→ Page 83).

Engine does not reach full load speed

Cause Corrective action

Fuel supply blocked. u Completely open shutoff valve upstream of fuel prefilter.
Fuel prefilter clogged. u Replace filter element (→ Page 90).
Easy-change fuel filter clogged. u Replace (→ Page 84).
Air filter clogged. u Check signal ring position of contamination indicator

(→ Page 95).

Injector faulty. u Replace (→ Page 80).
Injection pump faulty. u Contact Service.
Engine wiring faulty. u Check (→ Page 115).
Overload. u Contact Service.

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Engine speed not steady

Cause Corrective action

Injector faulty. u Replace (→ Page 80).
Injection pump faulty. u Contact Service.
Speed sensor is faulty. u Contact Service.
Air in fuel system. u Vent fuel system (→ Page 83).

Charge-air temperature too high

Cause Corrective action

Incorrect engine coolant
concentration.

u Check (MTU test kit).

Charge-air cooler is
contaminated.

u Contact Service.

Air inlet temperature in engine
room is too high.

u Check fan

Check air inlet/outlet ducts.

Charge-air pressure too low

Cause Corrective action

Air filter clogged. u Check signal ring position of contamination indicator

(→ Page 95).

Charge-air cooler is
contaminated.

u Contact Service.

Exhaust turbocharger faulty. u Contact Service.

Coolant leaks at intercooler

Cause Corrective action

Major coolant discharge at
charge-air cooler. Charge-air
cooler leaky.

u Contact Service.

Black exhaust gas

Cause Corrective action

Air filter clogged. u Check signal ring position of contamination indicator

(→ Page 95).

Injector faulty. u Replace (→ Page 80).
Injection pump faulty. u Contact Service.
Overload. u Contact Service.

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Blue exhaust gas

Cause Corrective action

Too much oil in engine. u Drain engine oil (→ Page 98).

Oil separator or oil preseparator
of crankcase breather clogged.

u Replace (→ Page 74).

Exhaust turbocharger faulty. u Contact Service.
Cylinder head is faulty. u Contact Service.
Piston rings are defective. u Contact Service.
Cylinder liner defective. u Contact Service.

White exhaust gas

Cause Corrective action

Engine is not at operating
temperature.

u Run engine to reach operating temperature.

Water in fuel. u Check fuel system at fuel prefilter.

Drain fuel prefilter (→ Page 86).

Charge-air cooler leaky. u Contact Service.

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7 Task Description

7.1 SOLAS

7.1.1 SOLAS shielding as per MTN 5233 – Installation

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Shield A4

735233000100 10

Shield A5

735233000101 14

Shield A7

735233000103 6

Shield A8

735233000104 2

SOLAS shielding – Installation

1. Pinpoint installation location (→ Page 62).

2. Install suitable shielding.

3. Press shielding until locked.

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7.1.2 SOLAS shielding – Installation

Preconditions

☑Engine is stopped and starting disabled.

☑Engine is cooled down to ambient temperature.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Oil filter shield

X00009628

Fuel filter shield

X00009654

Installing SOLAS shield on oil fil­ter and fuel filter

1. Pinpoint installation location (→ Page 62).

2. Install suitable shielding.

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7.1.3 Installation locations for SOLAS shielding

General information

Primarily fit SOLAS shielding as per MTN 5233 (→ Page 60).

Free end B-side

Item Type of shielding Comments

1 (free end, B-side) Shield (A7) On fuel delivery pump

2 (free end, B-side) Shield (A7) On HP fuel pump

Free end

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Item Type of shielding Comments

1 (free end) Shield (A8) On fuel filter

2 (free end) Shield (A7) Above fuel priming pump

3 (free end) Shield (A7) Below fuel priming pump

Driving end A-side

Item Type of shielding Comments

1 (Driving end, A-side) Shield (A5) On air flap

2 (driving end, A-side) Shield (A4) On brazed-on union

3 (driving end, A-side) Shield (A5) On turbocharger flap

4 (driving end, A-side) Shield (A5) On turbocharger flap

Driving end A-side

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Item Type of shielding Comments

1 (Driving end, A-side) Shield (A5) To turbocharger lubrication

2 (driving end, A-side) Shield (A5) On valve plate

Driving end

Item Type of shielding Comments

1 (driving end) Shield (A4) Turbocharger lubrication, left side

2 (driving end) Shield (A4) Turbocharger lubrication, center

Driving end

Item Type of shielding Comments

1 (driving end) Shield (A4) Turbocharger lubrication, right

side

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Driving end B-side

Item Type of shielding Comments

1 (driving end, B-side) Shield (A5) Turbocharger flap

2 (driving end, B-side) Shield (A5) Turbocharger flap

3 (driving end, B-side) Shield (A4) On brazed-on union

4 (driving end, B-side) Shield (A5) On air flap

5 (driving end, B-side) Shield (A4) To turbocharger lubrication

Driving end B-side

Item Type of shielding Comments

1 (driving end, B-side) Shield (A5) On valve plate

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Driving end A-side

Item Type of shielding Comments

1 (Driving end, A-side) Shield (A5) To flap control

Driving end B-side

Item Type of shielding Comments

1 (driving end, B-side) Shield (A5) To flap control

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7.2 Engine

7.2.1 Engine – Barring manually

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Engine barring gear

F6783914 1

Ratchet

F30006212 1

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Before barring the engine, make sure that there are no persons in the engine's danger zone.

• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Barring engine manually

1. Fit ratchet with barring gear on barring gear connection at the vibration damper on engine free end.

2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there
should be no resistance.

Result: If the resistance exceeds the normal compression resistance, contact Service.

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7.2.2 Engine – Cranking on starting system

Preconditions

☑Clutch is disengaged.

☑Engine start is disabled.

☑LOP is accessible and open.

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Before barring the engine, make sure that there are no persons in the engine's danger zone.

• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.

Turning

1. Press and hold down TURN pushbutton on
LMB motherboard of LOP.

Result: Engine is cranked on starter for max.

20 seconds.

2. Release TURN button.

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7.3 Cylinder Liner

7.3.1 Instructions and comments on endoscopic and visual examination of cylinder
liners

Terms used for endoscopic examination

Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex­amination report.

Findings Explanations/Action

Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,

particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.

Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area

and cross through the hone pattern in the direction of stroke.
Findings not critical.

Scored area These areas consist of scores of different length and depth next to one another. 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 on the running surface but almost the whole honing pattern

is still visible. Smoothened areas appear brighter and more brilliant than the sur­rounding running surface.
Findings not critical.

Bright area Bright areas are on the running surface and show local removal of the honing pat-

tern. Grooves from honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-

ture differences around the liner. It appears rather darker within the honed struc­ture in contrast to the bright metallic running surface. The honing pattern is undis­turbed. Discolorations extend in stroke direction and may be interrupted.
Findings not critical.

Corrosion fields /
spots

Corrosion fields / spots result from water (condensed water) with the valves in the
overlap (open) position. They are clearly visible due to the dark color of the honing
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 clear discol-

oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.

Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run

over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be­coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re­placed.

Seizure marks, scuff­ing

Irregular circumference lengths and depths. Can be caused either by the piston
skirt or the piston crown. Material deposits on the liner (smear), heavy discolora­tion. Severe, visible scoring.
Replace liner.

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Evaluation of findings and further measures

The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after
further operation of the engine.

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7.3.2 Cylinder liner – Endoscopic examination

Preconditions

☑Engine is stopped and starting disabled

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Rigid endoscope

Y20097353 1

Preparatory steps

1. Remove cylinder head cover (→ Page 76).

2. Remove injector (→ Page 81).

Positioning crankshaft at BDC

1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached
BDC.

2. Insert endoscope into cylinder liner through injector seat.

Cylinder liner – Endoscopic examination

Findings Task

•

Thin carbon coating around circumference of carbon scraper ring

•

Slight localized additive deposits at top edge

•

Localized smooth areas at bottom edge

•

Carbon deposits around circumference between top piston ring and
bottom edge of carbon scraper ring

•

First signs of marks left by top piston ring

•

Bright mark around circumference

•

Faultless, even honing pattern

•

First signs of marks left by lower cooling bores

•

Running pattern seems darker

No action required.

•

Darker areas of even or varying color intensity

•

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 cir­cumference cannot be faulted

•

Piston rings faultless

Further endoscopic examina­tion required as part of mainte­nance work.

•

On the entire circumference not only bright discoloration (not criti­cal for operation) clearly visible darker stripes that begin at the top
piston ring

•

Heat discoloration in the direction of stroke and honing pattern
damage

•

Heat discoloration of piston rings

Cylinder liner must be replaced,
contact Service.

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 further endoscopic examination as part of maintenance work or

• Contact Service; cylinder liner must be replaced.

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Final steps

1. Install injector (→ Page 81).

2. Install cylinder head cover (→ Page 76).

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7.4 Crankcase Breather

7.4.1 Crankcase breather – Cleaning oil pre-separator element

Preconditions

☑Engine is stopped and starting disabled.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

Crankcase breather – Cleaning
oil pre-separator element

1. Remove cover (5) from housing (4).

2. Take off oil pre-separator element (1), gas­ket (3) and O-ring (2).

3. Wash oil pre-separator element (1) and
housing (4) in fuel and blow out with com­pressed air.

4. Moisten oil pre-separator element (1) with
engine oil.

5. Position oil pre-separator element (1) with
new gasket (3) and O-ring (2) on housing
(4) and install cover (5).

6. Clean other oil pre-separator elements in
the same way.

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7.4.2 Crankcase breather – Oil separator element replacement, diaphragm check and
replacement

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Torque wrench, 6-50 Nm

F30027336 1

Ratchet

F30027340 1

Engine oil

Filter element

(→ Spare Parts Catalog)

Diaphragm

(→ Spare Parts Catalog)

Gasket

(→ 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.

Replacing oil separator element

1. Remove cover (2) with O-ring (3).

2. Remove filter element (1) from housing (4).

3. Insert new filter element in housing (4).

4. Install cover (2) with new O-ring.

5. Use torque wrench to tighten the screws of cover (2) to the specified torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm −2 Nm

6. Replace further oil separator elements in the same way.

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Checking diaphragm

1. Remove cover (4).

2. Remove spring (5), gasket (2) and dia­phragm (3).

3. Check diaphragm (3) for damage, fit new
diaphragm if used one is damaged.

4. Install diaphragm (3) on housing (1).

5. Install new seal (2) and spring (5) together
with cover (4).

6. Use torque wrench to tighten the screws of cover (4) to the specified torque.

Name Size Type Lubricant Value/Standard

Screw Tightening torque (Engine oil) 10 Nm −2 Nm

7. Check diaphragms in further oil separators in the same way.

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7.5 Valve Drive

7.5.1 Cylinder head cover – Removal and installation

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Centering jig

F6783025 1

Sealing

(→ Spare Parts Catalog)

Preparatory steps

1. Remove air filter (→ Page 94).

2. Remove air guide housing.

Removing and installing cylin­der head cover

1. Remove screws (1).

2. Remove cylinder head cover (2) with gas­ket from cylinder head.

3. Clean installation surface.

4. Check condition of gasket of cylinder head
cover.

Result: Replace damaged seals.

5. Align cylinder head cover (2) with centering
jig.

6. Tighten screws (1) to specified torque
20 Nm using a torque wrench.

Final steps

1. Install air filter (→ Page 94).

2. Install air guide housing.

3. Check cylinder head covers for leaks.

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7.5.2 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 parts

Designation / Use Part No. Qty.

Feeler gage

Y4345893 1

Barring gear

F6783914 1

Ratchet

F30006212 1

Double-head box wrench

F30002800 1

Offset screwdriver

F30002816 1

Socket wrench

F30030450 1

Torque wrench, 10-60 Nm

F30510423 1

Measuring instrument

Y4345888 1

Preparatory steps

1. Remove air filter (→ Page 94).

2. Remove cylinder head cover (→ Page 76).

Positioning A1 piston at TDC

Note: With cylinder head and valve gear installed.

1. Insert preloaded dial gage (2) into measur­ing device (4) and secure using screw (1).

2. Install measuring device (4) in cylinder
head and secure using knurled-head
screw (3).

3. Zero dial gage (2).

4. Turn engine using barring gear until piston
A1 reaches firing TDC.

Result: The piston is at firing TDC when both rock-

er arms are unloaded, i.e. have clearance.

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Checking valve clearance at two crankshaft positions

1. 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 loaded on cylinder A1, the piston is in overlap TDC.

2. Check valve clearance with the engine cold:

• Inlet (E) = 0.3 mm;

• Exhaust (A) = 0.4 mm.

3. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the
table below.

4. Use feeler gage to determine the distance between valve bridge and rocker arm.

5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance

Position Cylin-

der

1 2 3 4 5 6 7 8

Firing TDC in
cylinder A1

Bank A “E”, “A” “A” “A” “E” “A” “E” - -

Bank B “E” “A” - “E” “E”, “A” “E” “E”, “A” “A”

Overlap TDC
in cylinder A1

Bank A - “E” “E” “A” “E” “A” “E”, “A” “E”, “A”

Bank B “A” “E” “E”, “A” “A” - “A” - “E”

1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.

2. Insert feeler gage between valve bridge and
rocker arm.

3. Readjust adjusting screw (2) so that the
feeler gage just passes through the gap.

4. Tighten locknut (1) with torque wrench to
the prescribed tightening torque of 50 Nm
while holding the adjusting screw (2) with
an Allen key.

5. Insert feeler gage between valve bridge and
rocker arm to verify that the gage just
passes through the gap.

Result: If not, adjust valve clearance.

Final steps

1. Remove barring gear.

2. Install cylinder head cover (→ Page 76).

3. Install air filter (→ Page 94).

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7.6 Injection Pump / HP Pump

7.6.1 HP fuel pump – Filling with engine oil

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Engine oil

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

Oils/oil vapors are combustible/explosive.

Risk of fire and explosion!

• Avoid open flames, electric sparks and ignition sources.

• Do not smoke.

NOTICE

HP fuel pump not filled with engine oil.

Damage to components, major material damage!

• Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.

Filling HP pump

1. Remove plug screw (1).

2. Fill HP pump with engine oil using pump
oiler until engine oil emerges.

3. Install plug screw.

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7.7 Injector

7.7.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Injector

(→ Spare Parts Catalog)

Injector – Replacement

u Remove injector and install new one (→ Page 81).

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7.7.2 Injector – Removal and installation

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Screwdriver bit T45

F30454548 1

Assembly sleeve

F30454554 1

Puller

F6795554 1

Puller

F6790991 1

Puller

F6790992 1

Puller

F6795777 1

Torque wrench, 10-60 Nm

F30452769 1

Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933 1

Engine oil

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Preparatory steps

1. Close off fuel supply to engine.

2. Remove upper part of cylinder head cover (→ Page 76).

Removing injector

1. Remove HP line (1) using socket wrench.

2. Disconnect cable at control cable connec­tion (5) of injector (2).

3. Remove lower part of cylinder head cov­er (6).

4. Remove retaining screw (3) from hold­down clamp (4).

5. Take off hold-down clamp (4).

6. Remove injector (2) with puller.

7. Remove O-rings from injector (2).

8. Mask all connections and bores or seal
with suitable plugs.

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Installing injector

1. Prior to installation, remove all blanking plugs.

2. Fit new O-rings on injector (2) and coat with grease.

3. Secure new sealing ring on injector (2) with grease observing installation position of sealing ring.

4. Clean sealing surface on cylinder head and protective sleeve.

5. Insert injector (2) in cylinder head, ensuring correct alignment with HP line connection.

6. Fit hold-down clamp (4) in correct position, coat hold-down clamp retaining screw (3) with engine oil.

7. Screw in retaining screw (3) of hold-down clamp (4) and tighten by hand.

8. Install lower part of cylinder head cover (6).

9. Coat thread and sealing cone of HP line (1) and injector (2) with engine oil.

10. Align injector (2) and HP line (1) with alignment device.

11. Connect HP line (1) to HP accumulator and tighten by hand.

12. Connect HP line (1) to injector (2) and tighten by hand.

13. Tighten retaining screw (3) of hold-down clamp (4) to specified torque using a box wrench adapter and
a torque wrench.

14. Tighten HP line (1) to specified torque using socket wrench and torque wrench.

Name Size Type Lubricant Value/Standard

HP line Tightening torque (Engine oil) 37 Nm + 3 Nm

15. Connect cable.

Final steps

1. Install upper part of cylinder head cover (→ Page 76).

2. Open up fuel supply to engine.

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7.8 Fuel System

7.8.1 Fuel system – Venting

Preconditions

☑Engine is stopped and starting disabled.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Fuel system – Venting

1. Unlock fuel priming pump, unscrew handle.

2. Open threaded vent plug (1) on filter head.

3. Operate the pump (2) with the handle until
bubble-free fuel emerges at the nipple.

4. Close vent plugs on filter head.

5. Lock fuel priming pump, screw in handle.

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7.9 Fuel Filter

7.9.1 Fuel filter – Replacement

Preconditions

☑Engine is stopped and starting disabled

☑Coolant temperature is below 40 °C

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Oil filter wrench

F30379104 1

Fuel

Easy-change filter

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Replacing easy-change fuel filter
with the engine stopped

1. Stop engine and disable engine start.

2. Unscrew easy-change filter (2) from filter
base (1) using an oil filter wrench.

3. Clean sealing surface on filter head.

4. Check seal on new easy-change filter and
moisten with fuel.

5. Fit SOLAS shield.

6. Screw on easy-change filter and tighten by
hand.

7. Replace further fuel filters in the same way.

8. Vent fuel system (→ Page 83).

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7.9.2 Fuel prefilter – Differential pressure check and adjustment of gauge

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Setting adjustable pointer of dif­ferential pressure gauge

1. After installation of a new filter element,
align adjustable pointer (2) with pressure­indicating pointer (3) of pressure gauge (1).

2. Verify that differential pressure is within
the limit.

Fuel prefilter – checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).

2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 88).

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7.9.3 Fuel prefilter – Draining

Preconditions

☑Engine is stopped and starting disabled.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Draining fuel prefilter

1. Switch off filter which is to be drained (A or
B):

1 Filter A switched off
2 Filter B switched off

2. Open threaded vent plug (1) of the filter to
be drained.

3. Open drain valve (2).

4. Drain water and contaminants from the fil­ter until pure fuel emerges.

5. Close drain valve (2).

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6. Connect filling pump to filling connection
(1) on suction side of filter.

7. Open vent valve (2) and fill with fuel until it
emerges from the vent pipe (3).

8. Close vent valve (2).

9. Turn slide (4) a little (approx. 30°) and
open vent valve(s) (2) until fuel emerges
from the vent pipe (3).

10. Close vent valve(s) (2).

11. Turn slide (4) back to the locked position.

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7.9.4 Fuel prefilter – Flushing

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Diesel fuel

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

Flushing fuel prefilter

1. Cut out contaminated filter (A or B):
1 Filter A cut out
2 Filter B cut out

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2. Open threaded vent plug (1) of filter to be
flushed.

3. Open drain valve (2) and drain fuel.

Result: Fuel flows from filtered side back to the un-

filtered side, flushing the filter deposits
downwards out of the filter.

4. Close threaded vent plug (1) and drain
valve (2).

Filling fuel prefilter with fuel

1. Stop engine (→ Page 52) and disable engine start.

2. Connect filling pump to filling connec­tion (1) on the intake side of the filter.

3. Open vent valve (2) and fill with fuel until
fuel emerges from the vent pipe (3).

4. Close vent valve (2).

5. Open rotary slide valve (4) a little (by ap­prox. 30°) and open vent valve(s) (2), until
fuel emerges from the vent pipe (3).

6. Close vent valve(s) (2).

7. Turn rotary slide valve (4) back to locked
position.

8. Check differential pressure (→ Page 85).

Result: If flushing did not improve differential pres-

sure, replace filter element in fuel prefilter
(→ Page 90).

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7.9.5 Fuel prefilter – Filter element replacement

Preconditions

☑Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Diesel fuel

Filter element

(→ Spare Parts Catalog)

Sealing

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Replacing filter element

1. Switch off filter which is to be changed (A
or B):

1 Filter A switched off
2 Filter B switched off

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2. Open threaded vent plug (1) of contaminat­ed filter.

3. Unlock drain valve (5) by pressing toggle
and open it.

4. Drain water and dirt from filter.

5. Close drain valve (5).

6. Remove screws securing cover (2) and take
off cover.

7. Remove spring cartridge (3) and filter ele­ment (4).

8. Insert new filter element (4) and spring car­tridge (3).

9. Fill filter housing with clean fuel.

10. Place new seal in cover.

11. Fit cover with gasket and secure it with
screws (2).

12. Cut in the cut-out filter again.

13. Close threaded vent plug (1) when fuel
emerges.

14. Set adjustable pointer of differential pres­sure gage (→ Page 85).

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7.10 Charge-Air Cooling

7.10.1 Intercooler – Checking condensate drain line for coolant discharge and
obstruction

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

WARNING

Compressed air gun ejects a jet of pressurized air.

Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!

• Never direct air jet at people.

• Always wear safety goggles/face mask and ear defenders.

Intercooler – Checking conden­sate drain line for coolant dis­charge and obstruction

1. With the engine running, check the conden­sate drain line (1) on engine driving end
and free end for air discharge.

2. If no air emerges, remove condensate drain
line (1) and blow out with compressed air.

3. Replace obstructed drain line (1) by new
one.

4. Install condensate drain line (1).

5. If a large amount of coolant is continuously
discharged, the intercooler is leaking. Con­tact Service.

Emergency measures prior to engine start with a leaking intercooler

1. Remove injectors (→ Page 80).

2. Bar engine manually (→ Page 67).

3. Bar engine with starting equipment to blow out cylinder chambers (→ Page 68).

4. Install injectors (→ Page 81).

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7.11 Air Filter

7.11.1 Air filter – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Air filter

(→ Spare Parts Catalog)

Replacing the air filter

1. Remove old air filter and install new air filter (→ Page 94).

2. Reset signal ring of contamination indicator (→ Page 95).

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7.11.2 Air filter – Removal and installation

Preconditions

☑Engine is stopped and starting disabled.

Air filter – Removal and installa­tion

1. Loosen clamp (2).

2. Remove air filter (3) and clamp (2) from
connecting flange of intake housing (1).

3. Clean connecting flange (1) of intake hous­ing and check for obstruction.

4. Place new air filter (3) with clamp (2) onto
intake housing (1).

5. Tighten screw on clamp (2) to specified tor­que using a torque wrench.

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7.12 Air Intake

7.12.1 Service indicator – Signal ring position check

Preconditions

☑Engine is stopped and starting disabled.

Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
(→ Page 93).

2. After installation of new filter, press reset
button (1).

Result: Engaged piston with signal ring moves

back to initial position.

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7.13 Starting Equipment

7.13.1 Starter – Condition check

Preconditions

☑Engine is stopped and starting disabled.

Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.

2. Check wiring (→ Page 115).

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7.14 Lube Oil System, Lube Oil Circuit

7.14.1 Engine oil – Level check

Preconditions

☑Engine is stopped and starting disabled.

Oil level check prior to engine
start

1. Withdraw oil dipstick from guide tube and
wipe it.

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

3. Oil level must be between "min." (2) and
"max." (1) marks.

4. Top up with oil up to the "max" (1) mark
(→ Page 98) if required.

5. Insert oil dipstick into guide tube up to the
stop.

Oil level check after the engine is stopped

1. 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 the stop, withdraw after approx. 10 seconds and check oil level.

3. Oil level must be between "min." and "max." marks.

4. Top up to "max." if required (→ Page 98).

5. Insert oil dipstick into guide tube up to the stop.

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7.14.2 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 parts

Designation / Use Part No. Qty.

Engine oil

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.

Version with extraction equipment: Engine oil extraction

1. Position a suitable container to drain the engine oil into.

2. Extract all engine oil from oil pan using the extraction equipment.

Filling with new engine oil

1. Determine amount of engine oil required
for oil change (→ Page 40).

2. Open cap (1) on filler neck.

3. Pour engine oil in at filler neck up to “max.”
mark at oil dipstick.

4. Close cap (1) on filler neck.

5. Check engine oil level (→ Page 97).

6. After oil change, bar engine with starting
system.

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7.15 Oil Filtration / Cooling

7.15.1 Engine oil filter – Replacement

Special tools, Material, Spare parts

Designation / Use Part No. Qty.

Oil filter wrench

F30379104 1

Engine oil

Oil filter

(→ Spare Parts Catalog)

Cover for SOLAS

(→ Spare Parts Catalog)

DANGER

Rotating and moving engine parts.

Risk of crushing, danger of parts of the body being caught or pulled in!

• Only run the engine at low power. Keep away from the engine's danger zone.

WARNING

High level of engine noise when the engine is running.

Risk of damage to hearing!

• Wear ear protectors.

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.

NOTICE

Damage to component!

Severe material damage!

• For filter replacement with the engine running, operate the engine at low engine load.

• The filter which is to be replaced must be cut out for a brief period only.

Replacing oil filter with the en­gine stopped

1. Stop engine (→ Page 52) and disable en­gine start.

2. Unscrew oil filter with oil filter wrench.

3. Clean sealing face on connecting piece.

4. Check condition of the new oil filter sealing
ring and coat it with oil.

5. Fit SOLAS shield .

6. Screw on and tighten new engine oil filter
by hand.

7. Replace other oil filters in the same way.

8. After each oil change and filter replace­ment, bar engine with starting system
(→ Page 68).

9. Check oil level (→ Page 97).

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7.16 Coolant Circuit, General, High-Temperature Circuit

7.16.1 Engine coolant drain and venting points

16V 2000 M96L

1 Engine coolant drain screw 2 Filling screw on seawater

pump

3 Seawater pump drain

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