Task Descriptions 647

3.14 Coolant System

3.14.1 Coolant system – Overview

1 Coolant drain plug 15 Hose connection 29 Coolant pump

2 Coolant manifold, left 16 Hose connection 30 Restrictor
3 Coolant drain plug 17 Coolant inlet (HT) 31 Drain plug
4 Vent line 18 Coolant expansion line 32 Coolant manifold
5 Expansion tank 19 Measuring connection 33 Crankcase
6 Divider plate 20 Coolant inlet before pump 34 Drain plug
7 Filler neck 21 Measuring connection 35 End housing
8 Level monitor 22 Measuring connection 36 Thermostat, engine coolant
9 Heat exchanger (LT coolant circuit) 23 Coolant pump preheater
10 Fan cooler 24 Drain plug 37 Circulating pump
11 Heat exchanger (HT coolant circuit) 25 Thermostat (LT coolant circuit) 38 Non-return flap
12 Coolant inlet connection 26 Thermostat (HT coolant circuit) 39 Preheating unit
13 Measuring connection 27 Oil heat exchanger
14 Coolant expansion tank connection 28 Drain plug

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3.14.2 Engine coolant pump – Overview

1 Engine coolant pump 4 Screw 7 Washer

2 O-ring 5 Screw
3 Screw 6 Nut

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1 Water pump shaft 8 Angular-contact ball bearing 15 O-ring

2 Impeller 9 Cylindrical roller bearing 16 Screw
3 Bearing housing 10 Snap ring 17 Washer
4 Seal carrier 11 Shaft seal 18 Screw
5 Volute 12 Rotary seal 19 Washer
6 Spacer sleeve 13 O-ring 20 Sealing ring
7 Gear 14 O-ring 21 Plug screw

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3.14.3 Engine coolant pump – Removal

Preconditions
• Engine is stopped and starting disabled.

Special tools
Designation / Use Part No. Qty.
Lifting gear T80091388 1
Support bracket T80091384 1

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.

Preparatory steps

When performing these tasks, a distinction must be made as to whether:

1 The engine is to be completely disassembled
2 The engine is removed but not to be disassembled
3 The engine is to remain installed

1 2 3 Operations See

X – – Remove engine (ĺ Page 63)

X – – Disassemble engine (ĺ Page 64)

– – X Disable engine start (ĺ Page 17)
– – X Drain engine coolant (ĺOperating Instructions)
– – X Remove coolant supply for engine coolant pump, (ĺ Page 673)
intake side

Engine coolant pump – Removal

1. Attach engine coolant pump with lifting gear and support bracket to crane using a slightly tensioned rope.
2. Screw in screws for engine coolant pump according to the overview drawing (ĺ Page 648) .
3. Use crowbar to separate engine coolant pump from front cover and remove.
4. Remove O-ring.
5. Seal openings with suitable covers.

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3.14.4 Engine coolant pump – Disassembly

Special tools
Designation / Use Part No. Qty.
Hydraulic spindle F6781539 1
Removal tool for impeller F6780562 1
Removal tool for gear F6780561 1
Holding fixture F6781573 1
Carrier for several mandrels F30275611 1
Press fit tool F30379316 1
Snap ring pliers

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Equipment can drop off.

Liquid is highly pressurized.
WARNING Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
• Wear protective clothing, gloves, and goggles / safety mask.

Spring/circlip/tensioning roller preload.

Risk of injury!
WARNING • Only use specified tool and equipment.

Remove engine coolant pump (ĺ Page 650).

Engine coolant pump – Disassembly

1. Mark installation position of bearing housing (1)
and volute (3) towards one another.
2. Remove all screws (2) securing the volute (3) to
the bearing housing (1).
3. Use crowbar to loosen volute (3) from bearing
housing (1) and take off.

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4. Place engine coolant pump in (2) retaining

device (1).

5. Use hydraulic spindle (1) and removal tool for

impeller (2) to remove impeller (3) from water
pump shaft.
6. Holding the gear firmly in the retaining device
thoughout.
7. Take off impeller (3) from engine coolant pump.
8. Take engine coolant pump out of retaining device.

9. Place bearing housing (3) with pump shaft in vice

with aluminium jaws.
10. Use hydraulic spindle (1) and removal tool (2) to
remove gear from water pump shaft

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11. Use snap ring pliers (4) to remove snap ring (2)
for cylindrical roller bearing (3) from bearing
housing (1).

12. Remove all screws (1) for seal carrier using a

box wrench (2).

13. Take bearing housing (2) out of vise and take

off seal carrier (1).

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14. Use hydraulic press (1) to force pump shaft (2) off
bearing housing (3).

15. Place pump shaft (2) in holding fixture (6).

16. Press pump shaft (2) from inner race (3), spacer
sleeve (4) and angular-contact ball bearing (5) with
hydraulic press (1).

17. Use hydraulic press (1) and mandrel (2) to press

cylindrical roller bearing out of bearing housing (4).

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18. Use screwdriver to press counterring (2) from

impeller (1).

19. Remove shaft seal, intermediate washer and

rotary shaft seal (arrow) from seal carrier (3) with
mandrel (2) and hydraulic press (1).
20. Remove all O-rings.

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3.14.5 Engine coolant pump – Cleaning

Material
Designation / Use Part No. Qty.
Cleaning agent

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Disassemble engine coolant pump (ĺ Page 651).

Engine coolant pump – Cleaning

1. Clean all components with cleaning agent.
2. Remove cleaning agent.
3. Blow all components thoroughly with compressed air.

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3.14.6 Engine coolant pump – Check

Special tools
Designation / Use Part No. Qty.
Precision bore gauge
Outside micrometer

Material
Designation / Use Part No. Qty.
Red penetrant dye for surface crack-testing procedure
Fluorescent magnetic powder for magnetic crack-testing procedure

Spare parts
Designation / Use Part No. Qty.
Engine coolant pump
Water pump shaft
Rotor
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.

Clean engine coolant pump (ĺ Page 656).

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Engine coolant pump – Check

Item Findings Task

Check volute and impeller for Cavitation visible. Replace

cavitation.

Check bearing housing, impeller Signs of cracks Replace

and volute with red dye penetrant
for cracks.

Check water pump shaft with Signs of cracks Replace

fluorescent magnetic powder for
cracks.

Check coolant pump shaft for wear • Wear traces • Reconditioning: smooth minor
and damage. • Damage traces of wear with emery cloth.
Visible • Replace

Visually inspect sealing surfaces for • Wear • Reconditioning: smooth with

wear, pitting and cavitation. • Pitting oilstone or emery cloth.
• Cavitation • Replace
Visible

Check gear for indentations, traces • Wear traces • Reconditioning: smooth with
of wear and damage. • Indentations oilstone or emery cloth.
• Damage • Replace gear.
Visible

Measure bearing seats and Values out of tolerance Replace

diameters on engine coolant pump,
impeller, seal carrier and bearing
housing and gear with inside and
outside micrometer. Values and
measuring points (ĺ Page 659)

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3.14.7 Engine coolant pump – Tolerances

No. Designation Stage Tol. size Deviation Clearance Interference Wear

Basic limit
size
lower upper min. max. min. max.

1 Seal carrier 90.000 K7 í0.025 +0.010 0.025 0.025

Angular-contact 90.000 í0.015 0

ball bearing outer
diam.

2 Bearing housing 90.000 K7 í0.025 +0.010 0.025 0.025

bore

Angular-contact 90.000 í0.015 0

ball bearing
outer diam.

3 Angular contact 40.000 í0.012 0 0.002 0.025

ball bearing bore

Shaft outer diam. 40.000 k5 +0.002 +0.013

4 Spacer sleeve 40.000 N7 í0.033 –0.008 0.010 0.046

bore

Shaft outer diam. 40.000 k5 +0.002 +0.013

5 Bearing housing 80.000 K7 í0.021 +0.009 0.022 0.021

bore

Cylindrical roller 80.000 í0.013 0

bearing

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No. Designation Stage Tol. size Deviation Clearance Interference Wear

Basic limit
size
lower upper min. max. min. max.

6 Cylindrical roller 40.000 í0.012 0 0.002 0.025

bearing bore

Shaft outer diam. 40.000 k5 +0.002 +0.013

7 Gear bore 39.000 H7 0 +0.025 0.018 0.059

Shaft outer diam. 39.000 s6 +0.043 +0.059

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No. Designation Stage Tol. size Deviation Clearance Interference Wear

Basic limit
size
lower upper min. max. min. max.

1 Sealing-ring 72.000 H8 0 +0.046 0.084 0.230

holder bore

Shaft seal outer 72.000 +0.130 +0.230

diam.

2 Shaft outer diam. 48.000 í0.100 0

If running surface is worn: Recondition pump shaft by spray-metallizing and plunge-cut grinding.

3 Sealing-ring 78.100 H7 0 +0.030 0.040 0.100

holder bore

Rotary seal outer 78.200 í0.030 0

diam.

4 Impeller bore 30.000 H5 0 +0.009 0.032 0.050

Shaft outer diam. 30.000 t5 +0.041 +0.050

5 Rotary seal

Counterring

If wear traces are found: Replace components together

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3.14.8 Engine coolant pump – Assembly

Special tools
Designation / Use Part No. Qty.
Press fit tool for angular-contact ball bearings F30378152 1
Press fit tool for ball bearings F30378153 1
Press fit tool for shaft seal F30378550 1
Press fit tool for rotary seal F30378151 1
Support for bearing housing F6780563 1
Carrier for several mandrels F30275611 1
Retaining device F6780561 1
Snap ring pliers

Material
Designation / Use Part No. Qty.
Denatured ethanol
Petroleum jelly, white
Engine oil

Spare parts
Designation / Use Part No. Qty.
Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Shaft seal
Rotary seal
O-ring

Component is hot.
Risk of burning!
WARNING • Wear protective gloves.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Spring/circlip/tensioning roller preload.

Risk of injury!
WARNING • Only use specified tool and equipment.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Check engine coolant pump (ĺ Page 657).

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Engine coolant pump – Assembly

Note: Apply pressure to bearing outer race.

1. Use hydraulic press (1) and mandrel (2) to press

cylindrical roller bearing into bearing housing (4).

2. Place snap ring (2) in groove of bearing

housing (3), using snap ring pliers (1).
3. Check that snap ring (2) is correctly seated.

4. Force angular-contact ball bearing (3) onto pump

shaft (4) with hydraulic press (1) and mandrel (2).

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664 Task Descriptions

5. Force spacer sleeve (3) onto pump shaft (4) with

hydraulic press (1) and mandrel (2).

6. Press inner race (2) of cylindrical roller bearing

onto pump shaft (3) with hydraulic press and
mandrel (1).

Note: Apply pressure to bearing outer race (3).

7. Use hydraulic press (1) and mandrel (2) to press

pump shaft into bearing housing (4).

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Task Descriptions 665

Note: Ensure that the shaft seal (2) is correctly

seated.

8. Insert shaft seal (2) into press-in mandrel (1).

9. Use hydraulic press (1) and mandrel (2) to press

shaft seal into seal carrier (3).

10. Place intermediate washer in seal carrier (4).

11. Coat rotary shaft seal (3) with a soap solution
(water : soap mixture = 2:1).
12. Use hydraulic press (1) and mandrel (2) to press
rotary shaft seal (3) into seal carrier (4).
13. Clean running surface with denatured ethanol
after assembly.

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14. Coat O-ring with petroleum jelly and place into

groove.
15. Place bearing housing (1) in holding fixture (4).
16. Use screws (2) to install seal carrier on bearing
housing (1) and tighten them evenly.

17. Heat gear (2) to 200 °C.

18. Place bearing housing (3) with seal carrier and
holding fixture (4) onto hydraulic press (1).
19. Use hydraulic press (1) to push heated gear (2)
onto shaft to stop position and hold until shrink
connection between shaft and gear is fixed.

Note: Insert counterring (2) only after heating.

20. Heat impeller (1) to 210 °C.

21. Coat O-ring with petroleum jelly and place into
counterring (2).
22. Place counterring (2) in heated impeller (1).
23. Clean counterring surface with denatured ethanol.

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24. Place engine coolant pump onto hydraulic

press (1).
25. Place two feeler gauges (clearance
S1 = 0.7 mm to 1.1 mm), on seal carrier (3)
arranged at 180° towards one another.
26. Push heated impeller (2) with hydraulic press (1)
until it stops at feeler gauges.
27. Measure clearance S1 between impeller (2) and
seal carrier (3) with feeler gauge.
28. If measured value is out of tolerance, determine
the cause and replace components, if necessary.

29. Set volute (3) onto bearing housing (1) according

to the installation position marking made before
removal.
30. Tighten screws (2).
31. Turn pump shaft to check freedom of rotation.
32. Measure clearance S2 (0.6 mm to 1.5 mm)
between impeller and volute (3) with feeler gauge.
33. If measured value is out of tolerance, determine
the cause and replace components, if necessary.

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3.14.9 Engine coolant pump – Installation

Special tools
Designation / Use Part No. Qty.
Lifting gear T80091388 1
Support bracket T80091384 1

Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil

Spare parts
Designation / Use Part No. Qty.
O-ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.

Assemble engine coolant pump (ĺ Page 662).

Engine coolant pump – Installation

1. Remove all covers prior to installation.
2. Coat O-ring (1) with petroleum jelly.
3. Insert O-ring (1) in groove on bearing housing of
engine coolant pump.

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4. Attach engine coolant pump with lifting gear

and support bracket to crane using a slightly
tensioned rope.
Note: Make sure that gears are correctly meshed.

5. Install coolant pump (1) in bore on equipment

carrier, ensuring it is correctly positioned.
6. Install screws (2) and washers and tighten
uniformly.
7. Remove lifting gear and support bracket.

Final steps

When performing these tasks, a distinction must be made as to whether:

1 The engine has been completely disassembled
2 The engine is removed but not disassembled
3 The engine is installed

1 2 3 Operations See

X – – Assemble engine (ĺ Page 67)

X – – Install engine (ĺ Page 69)

– – X Fill engine coolant (ĺOperating Instructions)
– – X Assemble in reverse sequence to disassembly (ĺ Page 650)
– – X Enable engine start –

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670 Task Descriptions

3.14.10 Coolant supply for engine coolant pump, intake side – Overview

Elbow with attachments

1 Elbow 6 Washer 11 Connector

2 Plug 7 Bracket 12 Banjo screw
3 Sealing ring 8 Hex screw 13 Sealing ring
4 O-ring 9 Washer
5 Hex screw 10 Drain valve

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Plug-in pipe with flange

1 Plug-in pipe
2 O-ring
3 Flange
4 Hex screw
5 O-ring

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672 Task Descriptions

Coolant pipework

1 Plug-in pipe 4 Hex screw 7 O-ring

2 O-ring 5 O-ring 8 Flange
3 Flange 6 Plug-in pipe 9 Hex screw

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Task Descriptions 673

3.14.11 Engine coolant pump pipework, intake side – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether

1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See
x – – Remove engine (ĺ Page 63)
x – – Disassemble engine (ĺ Page 64)
– – x Disable engine start (ĺ Page 17)
– – x Drain engine coolant (ĺOperating Instructions)

Removing coolant lines

1. Before removing the lines it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove all monitoring units installed in coolant lines.
3. Remove lines as shown in overview drawing (ĺ Page 670) .
4. Seal all openings with suitable plugs.

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674 Task Descriptions

3.14.12 Coolant supply for engine coolant pump, intake side – Cleaning

Special tools
Designation / Use Part No. Qty.
Cleaning brush

Material
Designation / Use Part No. Qty.
Cleaning agent

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Unsuitable cleaning tools.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Use appropriate cleaning tool.

Remove coolant supply for engine coolant pump, intake side (ĺ Page 673).

Cleaning coolant lines

1. Clean coolant lines with cleaning agent and cleaning brush.
2. Remove cleaning agent.
3. Blow dry coolant lines with compressed air and preserve in oil bath.

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Task Descriptions 675

3.14.13 Engine coolant pump pipework, intake side – Check

Spare parts
Designation / Use Part No. Qty.
Elbow
Flange
Plug-in pipe
Bracket
Connector
Drain valve

Compressed air is pressurized.

Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean engine coolant pump pipework, intake side (ĺ Page 674).

Engine coolant pump pipework, intake side – Check

Item Findings Action

Visually inspect brackets, plug-in • Wear • Recondition: smooth with

connections and annular grooves on • Pitting oilstone or emery cloth.
elbows and connecting lines for wear, • Cavitation • Replace
pitting and cavitation. visible

Check sealing and mating faces for Damaged • Recondition: smooth with
wear and damage. oilstone or emery cloth.
• Replace

Pressure-test coolant lines with air Leaking Replace

in water bath for leaks as necessary.
Maintain a coolant temperature of min.
= 30 °C or max. = 40 °C at a test
pressure of 0.5 bar.

Check operation of drain valve. Damaged Replace

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3.14.14 Engine coolant pump pipework, intake side – Installation

Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil

Spare parts
Designation / Use Part No. Qty.
Sealing rings
O-rings

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Check engine coolant pump pipework, intake side (ĺ Page 675).

Installing coolant lines

1. Remove all plugs.
2. Blow out coolant lines with compressed air.
3. Coat all O-rings with petroleum jelly.
4. Install coolant lines with new sealing rings and O-rings as per overview drawing (ĺ Page 670), ensuring they
are free from tension.
5. Install all monitoring units in coolant lines.

Final steps

A distinction must be made as to whether

1 the engine was completely disassembled
2 the engine was removed but not disassembled
3 the engine is still installed

1 2 3 Operations See
x – – Assemble engine (ĺ Page 67)
x – – Install engine (ĺ Page 69)
– x x Fill engine coolant system (ĺOperating Instructions)
– x x Release engine start –

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Task Descriptions 677

3.14.15 Coolant pipework after cylinder – Overview

Coolant pipework after cylinder – Overview

Also applies analogously to 12 V.

1 Connecting piece 7 O-ring 13 O-ring

2 Screw 8 Plug 14 O-ring
3 O-ring 9 Coolant manifold 15 O-ring
4 Connecting piece 10 Coolant manifold 16 Screw
5 Screw 11 Coolant manifold 17 Screw
6 Screw 12 Coolant manifold

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678 Task Descriptions

3.14.16 Coolant pipework after cylinder – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether

1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See
x – – Remove engine (ĺ Page 63)
x – – Perform operations as per Disassembly Plan (ĺ Page 64)
– – x Disable engine start (ĺ Page 17)
– – x Drain engine coolant (ĺOperating Instructions)

Removing coolant lines

1. Remove lines as shown in overview drawing (ĺ Page 677) .
2. After removal, seal all connections with plugs.

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Task Descriptions 679

3.14.17 Coolant pipework after cylinder – Cleaning

Special tools
Designation / Use Part No. Qty.
Cleaning brush

Material
Designation / Use Part No. Qty.
Cleaning agent

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Unsuitable cleaning tools.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Use appropriate cleaning tool.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Remove coolant pipework after cylinder (ĺ Page 678).

Coolant pipework after cylinder – Cleaning

1. Clean coolant pipework after cylinder with cleaning agent and cleaning brush.
2. Remove cleaning agent.
3. Thoroughly blow out coolant pipework after cylinder with compressed air and preserve in oil bath.

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3.14.18 Coolant pipework after cylinder – Check

Spare parts
Designation / Use Part No. Qty.
Coolant manifold
Connector

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Compressed air is pressurized.

Hot testing liquid.
WARNING Risk of injury and scalding!
• Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Clean coolant pipework after cylinder (ĺ Page 679).

Coolant pipework after cylinder – Check

Item Findings Action

Visually inspect plug-in connections and Damaged • Recondition: smooth with

annular grooves on connector and manifold oilstone or emery cloth.
for wear, pitting and cavitation. • Replace

Check coolant lines for leaks in water Leaking Replace

bath, using compressed air and corrosion
inhibitor. Maintain a coolant temperature
of min. = 30 °C or max. = 40 °C at a test
pressure of 0.5 bar.

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Task Descriptions 681

3.14.19 Coolant pipework after cylinder – Installation

Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white

Spare parts
Designation / Use Part No. Qty.
O-ring

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Check coolant pipework after cylinder (ĺ Page 680).

Coolant pipework after cylinder – Installation

1. Remove all plugs.
2. Blow out coolant pipework with compressed air.
3. Coat O-rings with petroleum jelly.
4. Install coolant pipework after cylinder as shown in overview drawing, (ĺ Page 677) ensuring they are free
from tension.

Final steps

A distinction must be made as to whether

1 the engine was completely disassembled
2 the engine was removed but not disassembled
3 the engine is still installed

1 2 3 Operations See
x – – Assemble engine (ĺ Page 67)
x – – Install engine (ĺ Page 69)
– x x Fill engine coolant system (ĺOperating Instructions)
– x x Release engine start –

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682 Task Descriptions

3.14.20 Preheating unit – Repair

Preheating unit – Repair

See special publication M060715.

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Task Descriptions 683

3.14.21 Engine coolant drain lines – Overview

Coolant lines

1 Pipe 10 Blanking cone 19 Spacer bush

2 Blanking cone 11 Nut 20 Bracket
3 Nut 12 Bracket 21 Hex screw
4 Pipe 13 Pipe clamp half 22 Spacer bush
5 Pipe 14 Grommet 23 Pipe clamp half
6 Blanking cone 15 Hex screw 24 Pipe clamp half
7 Nut 16 Washer 25 Grommet
8 Pipe 17 Hex nut 26 Hex screw
9 T-piece 18 Hex screw

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684 Task Descriptions

3.14.22 Engine coolant drain lines – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

When performing these tasks, a distinction must be made as to whether:

1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See
x – – Remove engine (ĺ Page 63)
x – – Disassemble engine (ĺ Page 64)
– – x Disable engine start (ĺ Page 17)
– – x Drain engine coolant (ĺOperating Instructions)

Removing drain lines

1. Before removing the lines it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove lines as shown in overview drawing (ĺ Page 683).
3. After removal, seal all connections with suitable plugs.

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Task Descriptions 685

3.14.23 Engine coolant drain lines – Cleaning

Special tools
Designation / Use Part No. Qty.
Cleaning brush

Material
Designation / Use Part No. Qty.
Cleaning agent

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Unsuitable cleaning tools.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Use appropriate cleaning tool.

Remove engine coolant drain lines (ĺ Page 684).

Engine coolant drain lines – Cleaning

1. Clean coolant drain lines with cleaning agent and cleaning brush.
2. Remove cleaning agent.
3. Blow dry coolant drain lines with compressed air and preserve in oil bath.

M020109/01E 05-12 © MTU

686 Task Descriptions

3.14.24 Engine coolant drain lines – Check

Spare parts
Designation / Use Part No. Qty.
Pipe
Blanking cone
T-piece
Bracket
Spacer bush

Compressed air is pressurized.

Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Clean coolant drain lines (ĺ Page 685).

Engine coolant drain lines – Check

Item Findings Action

Check T-piece, brackets and lines for Damaged Replace

damage.

Pressure-test coolant lines with air and Leaking Replace

corrosion inhibitor in water bath for
leaks as necessary. Maintain a coolant
temperature of min. = 30 °C or max.
= 40 °C at a test pressure of 0.5 bar.

Check thread and damage for ease of Damaged or sluggish • Recondition: recut threads
movement • Replace

M020109/01E 05-12 © MTU

Task Descriptions 687

3.14.25 Engine coolant drain lines – Installation

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
Grommet

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Check engine coolant drain lines (ĺ Page 686).

Engine coolant drain lines – Installation

1. Remove all blanking plugs.
2. Blow out coolant drain lines with compressed air.
3. Install coolant drain lines as shown in overview drawing (ĺ Page 683)free of tension and secure with pipe
half-clamps.

Final steps

When performing these tasks, a distinction must be made as to whether:

1 The engine is completely disassembled
2 The engine is removed but not disassembled
3 The engine is still installed

1 2 3 Operations See
x – – Assemble engine (ĺ Page 67)
x – – Install engine (ĺ Page 69)
– x x Fill engine coolant system (ĺOperating Instructions)
– x x Enable engine start –

M020109/01E 05-12 © MTU

688 Task Descriptions

3.14.26 Engine coolant and charge-air coolant ventilation – Overview

Engine coolant vent lines

1 Union 20 Sealing ring 39 Union

2 Sealing ring 21 Pipe 40 Sealing ring
3 Pipe 22 Holder 41 Union
4 Holder 23 Pipe half-clamp 42 Sealing ring
5 Pipe half-clamp 24 Grommet 43 Pipe
6 Grommet 25 Screw 44 Bracket
7 Screw 26 T-piece 45 Pipe half-clamp
8 Union 27 Pipe 46 Grommet
9 Sealing ring 28 Union 47 Screw
10 Vent line 29 Sealing ring 48 Spacer bush
11 T-piece 30 Pipe 49 Pipe half-clamp
12 Pipe 31 T-piece 50 Grommet
13 Holder 32 Pipe 51 Screw
14 Pipe half-clamp 33 Union 52 Pipe
15 Grommet 34 Sealing ring 53 Pipe
16 Screw 35 Pipe 54 Union
17 T-piece 36 Union 55 Sealing ring
18 Vent line 37 Sealing ring
19 Union 38 Pipe

M020109/01E 05-12 © MTU

Task Descriptions 689

Engine coolant vent lines

1 Elbow 15 Elbow 29 Holder

2 Threaded union 16 Threaded union 30 Pipe half-clamp
3 Sealing ring 17 Distributor piece 31 Pipe half-clamp
4 T-piece 18 Holder 32 Screw
5 Pipe 19 Screw 33 Washer
6 Union 20 Washer 34 Pipe half-clamp
7 Sealing ring 21 Plug screw 35 Pipe half-clamp
8 Pipe 22 Plug screw 36 Grommet
9 Threaded union 23 Sealing ring 37 Screw
10 Union 24 Sealing ring 38 Pipe half-clamp
11 Sealing ring 25 Union 39 Pipe half-clamp
12 Pipe 26 Sealing ring 40 Spacer sleeve
13 T-piece 27 Blanking cone 41 Grommet
14 Pipe 28 Nut 42 Screw

M020109/01E 05-12 © MTU

690 Task Descriptions

3.14.27 Engine coolant ventilation and charge air cooling – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

When performing these tasks, a distinction must be made as to whether:

1 The engine is to be completely disassembled
2 The engine is to be removed but not disassembled
3 The engine is to remain installed

1 2 3 Operations See
x – – Remove engine (ĺ Page 63)
x – – Disassemble engine (ĺ Page 64)
– – x Disable engine start (ĺ Page 17)
– – x Drain engine coolant (ĺOperating Instructions)

Removing vent lines

1. Before removing the lines it is advisable to take photographs of the fitted lines or to mark lines and attachments.
2. Remove lines as shown in overview drawing (ĺ Page 688).
3. After removal, seal all connections with suitable plugs.

M020109/01E 05-12 © MTU

Task Descriptions 691

3.14.28 Engine coolant ventilation and charge air cooling – Cleaning

Special tools
Designation / Use Part No. Qty.
Cleaning brush

Material
Designation / Use Part No. Qty.
Cleaning agent

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Unsuitable cleaning tools.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Use appropriate cleaning tool.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Remove engine coolant ventilation and charge air cooling (ĺ Page 690).

Engine coolant ventilation and charge air cooling – Cleaning

1. Clean coolant ventilation and charge air cooling with cleaning agent and cleaning brush.
2. Remove cleaning agent.
3. Thoroughly blow out coolant ventilation and charge air cooling with compressed air and preserve in oil bath.

M020109/01E 05-12 © MTU

692 Task Descriptions

3.14.29 Engine coolant and charge air coolant ventilation – Check

Spare parts
Designation / Use Part No. Qty.
Pipe
Elbow
Vent line
Distributor
T-piece
Bracket
Angle
Spacer sleeve

Compressed air is pressurized.

Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Clean engine coolant and charge air coolant ventilation (ĺ Page 691).

Engine coolant and charge air coolant ventilation – Check

Item Findings Action

Check lines, elbow, distributor, T-piece, retainer, Damaged Replace

bracket and spacer sleeve for damage.

Check coolant lines for leaks in water bath, using Leaking Replace
compressed air and corrosion inhibitor. Maintain a
coolant temperature of min. = 30 °C or max. = 40 °C
at a test pressure of 0.5 bar.

Check thread and damage for ease of movement. Damaged or sluggish • Recondition: recut
threads
• Replace

M020109/01E 05-12 © MTU

Task Descriptions 693

3.14.30 Engine coolant ventilation and charge air cooling – Installation

Material
Designation / Use Part No. Qty.
Engine oil

Spare parts
Designation / Use Part No. Qty.
Grommet
Pipe half-clamp

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Check engine coolant ventilation and charge air cooling system (ĺ Page 692).

Engine coolant ventilation and charge air cooling – Installation

1. Remove all plugs.
2. Blow out coolant ventilation and charge air cooling with compressed air.
3. Install engine coolant ventilation and charge air cooling as shown in overview drawing (ĺ Page 688) free of
tension and secure with pipe half-clamps.

Final steps

A distinction must be made whether:

1 The engine is completely disassembled
2 The engine is removed but not disassembled
3 The engine is installed

1 2 3 Operations See
x – – Assemble engine (ĺ Page 67)
x – – Install engine (ĺ Page 69)
– x x Fill engine coolant system (ĺOperating Instructions)
– x x Fill charge-air cooling system (not applicable to marine (ĺOperating Instructions)
applications)
– x x Enable engine start –

M020109/01E 05-12 © MTU

694 Task Descriptions

3.14.31 Coolant pipework from/to exhaust turbochargers – Overview

1 Adapter 14 Sealing ring 27 Grommet

2 Sealing ring 15 Coolant line 28 Washer
3 Coolant line 16 Adapter 29 Screw
4 Adapter 17 Sealing ring 30 Adapter
5 Sealing ring 18 Coolant line 31 Sealing ring
6 Coolant line 19 Adapter 32 Coolant line
7 Bracket 20 Sealing ring 33 Pipe half-clamp
8 Pipe half-clamp 21 Coolant line 34 Pipe half-clamp
9 Pipe half-clamp 22 Adapter 35 Grommet
10 Grommet 23 Sealing ring 36 Washer
11 Washer 24 Coolant line 37 Screw
12 Screw 25 Pipe half-clamp
13 Adapter 26 Pipe half-clamp

M020109/01E 05-12 © MTU

Task Descriptions 695

3.14.32 Coolant pipework from/to exhaust turbocharger – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

When performing these tasks, a distinction has to be made as to whether:

1 the engine is to be completely disassembled
2 the engine is removed but not to be disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (ĺ Page 63)

X – – Disassemble engine (ĺ Page 64)

– – X Disable engine start (ĺ Page 17)
– – X Drain engine coolant (ĺOperating Instructions)

Removing coolant lines

1. Before removing the lines, take photos or label add-on components and lines.
2. Remove lines as shown in overview drawing (ĺ Page 688).
3. Seal openings with suitable covers.

M020109/01E 05-12 © MTU

696 Task Descriptions

3.14.33 Coolant pipework from/to exhaust turbochargers – Cleaning

Material
Designation / Use Part No. Qty.
Cleaning agent

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Unsuitable cleaning tools.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Use appropriate cleaning tool.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Install coolant pipework from/to exhaust turbocharger (ĺ Page 695).

Coolant pipework from/to exhaust turbochargers – Cleaning

1. Clean parts with cleaning agent and cleaning brush.
2. Remove cleaner.
3. Thoroughly blow out all parts with compressed air.

M020109/01E 05-12 © MTU

Task Descriptions 697

3.14.34 Coolant pipework from/to turbochargers – Check

Spare parts
Designation / Use Part No. Qty.
Coolant line
Bracket
Pipe half-clamp
Grommet

Compressed air is pressurized.

Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Clean coolant pipework from/to exhaust turbochargers (ĺ Page 696).

Coolant pipework from/to turbochargers – Check

Item Findings Measure

Visually check lines, pipe clamp halves, Damaged Replace

grommets and brackets for damage.

Check coolant lines for leaks in water bath, Leaking Replace

using compressed air and corrosion inhibitor.
Maintain a coolant temperature of min. = 30 °C
or max. = 40 °C at a test pressure of 0.5 bar.

M020109/01E 05-12 © MTU

698 Task Descriptions

3.14.35 Coolant pipework from/to turbochargers – Installation

Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Incorrect installation of components and lines.

Damage to component!
CAUTION • Ensure that components/lines are installed so that they are never under tension or strain.
• Ensure correct installation position of components.

Check coolant pipework from/to exhaust turbocharger (ĺ Page 697).

Coolant pipework from/to turbochargers – Installation

1. Before installation, remove all covers.
2. Install coolant pipework from/to exhaust turbocharger as shown in overview drawing (ĺ Page 694).

Final steps

When performing these tasks, a distinction has to be made as to whether:

1 the engine was completely disassembled
2 the engine is removed but was not disassembled
3 the engine is still installed

1 2 3 Operations See

X – – Assemble engine (ĺ Page 67)

X – – Install engine (ĺ Page 69)

– X X Fill engine coolant system (ĺOperating Instructions)
– X X Enable engine start –

M020109/01E 05-12 © MTU

Task Descriptions 699

3.14.36 Charge-air coolant pump – Overview

Charge-air coolant pump – Overview

1 Charge-air coolant pump 4 Screw 7 Drain valve

2 O-ring 5 Nut
3 Screw 6 Washer

M020109/01E 05-12 © MTU

700 Task Descriptions

1 Water pump shaft 8 Angular-contact ball bearing 15 Screw

2 Impeller 9 Cylindrical roller bearing 16 Washer
3 Bearing housing 10 Snap ring 17 O-ring
4 Seal carrier 11 Shaft seal 18 Screw
5 Volute 12 Rotary seal 19 Washer
6 Spacer sleeve 13 O-ring
7 Gear 14 O-ring

M020109/01E 05-12 © MTU

Task Descriptions 701

3.14.37 Charge-air coolant pump – Removal

Preconditions
• Engine is stopped and starting disabled.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.

Preparatory steps

A distinction must be made as to whether

1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (ĺ Page 63)

X – – Disassemble engine (ĺ Page 64)

– – X Disable engine start (ĺ Page 17)
– – X Drain charge-air coolant (ĺOperating Instructions)

Charge-air coolant pump – Removal

1. Remove securing screws for engine coolant pump as shown in overview drawing (ĺ Page 699) .
2. Use crowbar to separate charge-air coolant pump from equipment carrier and remove.
3. Mask installation hole for charge-air coolant pump.
4. Remove O-ring from charge-air coolant pump.

M020109/01E 05-12 © MTU

702 Task Descriptions

3.14.38 Charge-air coolant pump – Disassembly

Special tools
Designation / Use Part No. Qty.
Retaining device
Hydraulic spindle
Puller tool for impeller
Puller tool for gear
Snap ring pliers
Holding fixture
Carrier for several mandrels
Ejection mandrel

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Equipment can drop off.

Liquid is highly pressurized.
WARNING Risk of injury, knocks or crushing!
• Only use specified and tested equipment.
• Do not enter the danger zone.
• Wear protective clothing, gloves, and goggles / safety mask.

Spring/circlip/tensioning roller preload.

Risk of injury!
WARNING • Only use specified tool and equipment.

Remove charge-air coolant pump (ĺ Page 701).

Charge-air coolant pump – Disassembly

1. Mark installation position of bearing housing (1)
and volute (3) in relation to one another.
2. Remove all bolts (2).
3. Use crowbar to separate volute (3) from bearing
housing (1) and remove it.

M020109/01E 05-12 © MTU

Task Descriptions 703

4. Insert charge-air coolant pump (2) into retaining

device (1).

5. Use hydraulic spindle (1) and puller (2) to remove

impeller (3) from coolant pump shaft.
6. Hold the gear firmly in the retaining device
throughout.
7. Remove impeller (3) from charge-air coolant pump.
8. Remove charge-air coolant pump from retaining
device.

9. Place bearing housing (3) with coolant pump shaft

in vise with aluminum jaws.
10. Use hydraulic spindle (1) and puller (2) to separate
gear from coolant pump shaft.

M020109/01E 05-12 © MTU

704 Task Descriptions

11. Use snap ring pliers (4) to remove snap ring (2)
for cylindrical roller bearing (3) from bearing
housing (1).

12. Remove all bolts (1) using box wrench (2).

13. Take bearing housing (2) out of vise and take

off seal carrier (1).

M020109/01E 05-12 © MTU

Task Descriptions 705

14. Use hydraulic press (1) to force pump shaft (2) off
bearing housing (3).

15. Place pump shaft (2) in holding fixture (6).

16. Use hydraulic press (1) to force pump shaft
(2) out of inner race (3), spacer sleeve (4) and
angular-contact ball bearing (5).

17. Use hydraulic press (1) and ejection mandrel (2)

to press cylindrical roller bearing out of bearing
housing (4).

M020109/01E 05-12 © MTU

706 Task Descriptions

18. Use screwdriver to press counterring (2) out

of impeller (1).

19. Use hydraulic press (1) and ejection mandrel (2) to

press shaft seal and rotary seal (arrow) out of
seal carrier (3).
20. Remove all O-rings.

M020109/01E 05-12 © MTU

Task Descriptions 707

3.14.39 Charge-air coolant pump – Cleaning

Material
Designation / Use Part No. Qty.
Cleaner

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Disassemble charge-air coolant pump (ĺ Page 702).

Charge-air coolant pump – Cleaning

1. Clean all parts with cleaner.
2. Remove cleaner.
3. Thoroughly blow all parts clean with compressed air.

M020109/01E 05-12 © MTU

708 Task Descriptions

3.14.40 Charge-air coolant pump – Check

Special tools
Designation / Use Part No. Qty.
Inside calliper
Outside micrometer

Material
Designation / Use Part No. Qty.
Red dye penetrant for surface crack test procedure
Fluorescent magnetic powder for magnetic crack test procedure

Spare parts
Designation / Use Part No. Qty.
Charge-air coolant pump
Water pump shaft
Impeller
Bearing housing
Seal carrier
Volute
Spacer sleeve
Gear

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.

Clean charge-air coolant pump (ĺ Page 707).

M020109/01E 05-12 © MTU

Task Descriptions 709

Charge-air coolant pump – Check

Item Findings Action

Check volute and impeller for Cavitation visible Replace

cavitation.

Check bearing housing, impeller Cracks evident Replace

and volute with red dye penetrant
for cracks.

Check coolant pump shaft for cracks Cracks evident Replace

with fluorescent magnetic powder.

Check coolant pump shaft for wear • Wear • Recondition: smooth away
and damage. • Damage minimal wear using crocus
visible cloth
• Replace

Visually inspect sealing surfaces for • Wear • Recondition: burnish using

wear, pitting, and cavitation. • Pitting crocus cloth or oilstone
• Cavitation • Replace
visible

Check gear for indentations, traces • Wear • Recondition: burnish using

of wear and damage. • Indentations crocus cloth or oilstone
• Damage • Replace gear.
visible

Measure bearing seats and mating Dimensions not as specified Replace

diamters on water pump shaft,
impeller, seal carrier, and bearing
housing and gear with inside and
outside micrometers. Values and
measuring points (ĺ Page 710).

M020109/01E 05-12 © MTU

710 Task Descriptions

3.14.41 Charge-air coolant pump – Tolerances

No. Designa- Stage Tol. size Deviation Clearance Interference Wear

tion Basic size limit

lower upper min. max. min. max.

1 Seal carrier 90.000 K7 –0.025 +0.010 0.025 0.025

Angular- 90.000 –0.015 0

contact ball
bearing
outer Ø

2 Bearing 90.000 K7 –0.025 +0.010 0.025 0.025

housing
bore

Angular- 90.000 –0.015 0

contact ball
bearing
outer Ø

3 Angular 40.000 –0.012 0 0.002 0.025

contact ball
bearing
bore

Shaft 40.000 k5 +0.002 +0.013

outer Ø

M020109/01E 05-12 © MTU

Task Descriptions 711

No. Designa- Stage Tol. size Deviation Clearance Interference Wear

tion Basic size limit

lower upper min. max. min. max.

4 Spacer 40.000 N7 –0.033 –0.008 0.010 0.046

sleeve bore

Shaft 40.000 k5 +0.002 +0.013

outer Ø

5 Bearing 80.000 K7 –0.021 +0.009 0.022 0.021

housing
bore

Cylindrical 80.000 –0.013 0

roller
bearing

6 Cylindrical 40.000 –0.012 0 0.002 0.025

roller
bearing
bore

Shaft 40.000 k5 +0.002 +0.013

outer Ø

7 Gear bore 39.000 H7 0 +0.025 0.018 0.059

Shaft 39.000 s6 +0.043 +0.059

outer Ø

M020109/01E 05-12 © MTU

712 Task Descriptions

No. Designa- Stage Tol. size Deviation Clearance Interference Wear

tion Basic size limit

lower upper min. max. min. max.

1 Sealing- 72.000 H8 0 +0.046 0.084 0.230

ring
holder
bore

Shaft seal 72.000 +0.130 +0.230

outer Ø

2 Shaft 48.000 –0.100 0

outer Ø

If running surface is worn: Recondition pump shaft by spray-metallizing and plunge-cut grinding.

3 Sealing- 78.100 H7 0 +0.030 0.040 0.100

ring
holder
bore

Rotary 78.200 –0.030 0

seal
outer Ø

4 Impeller 30.000 H5 0 +0.009 0.032 0.050

bore

Shaft 30.000 t5 +0.041 +0.050

outer Ø

M020109/01E 05-12 © MTU

Task Descriptions 713

No. Designa- Stage Tol. size Deviation Clearance Interference Wear

tion Basic size limit

lower upper min. max. min. max.

5 Rotary seal

Counterring

If wear traces are found: Replace components together

M020109/01E 05-12 © MTU

714 Task Descriptions

3.14.42 Charge-air coolant pump – Assembly

Special tools
Designation / Use Part No. Qty.
Press-in tool
Snap ring pliers
Holding fixture
Support
Retaining device

Material
Designation / Use Part No. Qty.
Denatured ethanol
Petroleum jelly, white
Corrosion inhibitor oil, Shell Oil 9156
Surface sealant, Loctite No. 573

Spare parts
Designation / Use Part No. Qty.
Angular-contact ball bearing
Cylindrical roller bearing
Snap ring
Shaft seal
Rotary seal
O-ring

Component is hot.
Risk of burning!
WARNING • Wear protective gloves.

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Spring/circlip/tensioning roller preload.

Risk of injury!
WARNING • Only use specified tool and equipment.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Check charge-air coolant pump (ĺ Page 708).

M020109/01E 05-12 © MTU

Task Descriptions 715

Charge-air coolant pump – Assembly

Note: Apply pressure to bearing outer ring.

1. Use hydraulic press (1) and mandrel (2) to press

cylindrical roller bearing into bearing housing (4).

2. Place snap ring (2) in groove of bearing

housing (3), using snap ring pliers (1).
3. Check that snap ring (2) is correctly seated.

4. Force angular-contact ball bearing (3) onto

coolant pump shaft (4) with hydraulic press (1)
and mandrel (2).

M020109/01E 05-12 © MTU

716 Task Descriptions

5. Force spacer sleeve (3) onto pump shaft (4) with

hydraulic press (1) and mandrel (2).

6. Force inner ring (2) of cylindrical roller bearing

onto pump shaft (3) with hydraulic press and
mandrel (1).

Note: Apply pressure to bearing outer ring (3).

7. Use hydraulic press (1) and mandrel (2) to press

pump shaft into bearing housing (4).

M020109/01E 05-12 © MTU

Task Descriptions 717

Note: Make sure shaft seal (2) is in the correct

position.

8. Insert shaft seal (2) into press-in mandrel (1).

9. Use hydraulic press (1) and mandrel (2) to press

shaft seal into seal carrier (3).

10. Use denatured ethanol to clean sliding and

counterring surfaces of the rotary seal, and the
seal carrier.
11. Coat outer surface of rotary seal (3) with surface
sealant.
12. Use hydraulic press (1) and mandrel (2) to press
rotary seal into seal carrier (4).
13. Clean sliding surface with denatured ethanol
after assembly.

M020109/01E 05-12 © MTU

718 Task Descriptions

14. Coat O-ring with petroleum jelly and place into

groove.
15. Place bearing housing (1) in holding fixture (4).
16. Use screws (2) to install seal carrier on bearing
housing (1) and tighten them evenly.

17. Heat gear (2) to 200 °C.

18. Place bearing housing (3) with seal carrier and
holding fixture (4) onto hydraulic press (1).
19. Use hydraulic press (1) to push heated gear (2)
onto shaft to stop position and hold until shrink
connection between shaft and gear is fixed.

Note: Insert counterring (2) only after heating.

20. Heat impeller (1) to 210 °C.

21. Coat O-ring (2) with corrosion inhibitor oil and
place into counterring.
22. Place counterring (2) in heated impeller (1).
23. Clean counterring surface with denatured ethanol.

M020109/01E 05-12 © MTU

Task Descriptions 719

24. Place charge-air coolant pump on hydraulic

press (1).
25. Use hydraulic press (1) to push heated impeller (2)
onto coolant pump shaft to stop position.

26. Set volute (3) onto bearing housing (1) according

to the installation position marking made before
removal.
27. Tighten screws (2).
28. Turn pump shaft to check freedom of rotation.
29. Use feeler gauge to check clearance S2 (0.6 mm to
1.52 mm) between impeller and volute (3).
30. If measured clearance is out of tolerance,
determine the cause and replace components,
if necessary.

M020109/01E 05-12 © MTU

720 Task Descriptions

3.14.43 Charge-air coolant pump – Installation

Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil

Spare parts
Designation / Use Part No. Qty.
O-ring

Heavy object.
Risk of crushing!
WARNING • Use appropriate lifting devices and appliances.

Components have sharp edges.

Risk of injury!
WARNING • Wear protective gloves.

Assemble charge-air coolant pump (ĺ Page 714).

Preparing charge-air coolant pump for installation

1. Remove all plugs.
2. Coat O-ring (1) with petroleum jelly.
3. Insert O-ring (1) in groove on the bearing housing
of charge-air coolant pump.

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Task Descriptions 721

Note: Make sure that gears are correctly meshed.

4. Insert charge-air coolant pump (1) into the correct

position in the bore hole on the front cover.
5. Screw in screws (2) with washers.
6. Tighten screws (2) evenly.

Final steps

A distinction must be made as to whether

1 the engine was completely disassembled
2 the engine was removed but not disassembled
3 the engine is still installed

1 2 3 Operations See

X – – Assemble engine (ĺ Page 67)

X – – Install engine (ĺ Page 69)

– – X Fill with charge-air coolant (ĺOperating Instructions)
– – X Enable engine start –

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722 Task Descriptions

3.14.44 Coolant pipework from/to intercooler – Overview

Coolant pipework

1 Pipe 10 Rubber sleeve 19 Clamp

2 Gasket 11 Clamp 20 Bracket
3 Hex screw 12 Bracket 21 Spacer washer
4 Bracket 13 Spacer washer 22 Screw
5 Screw 14 Screw 23 Gasket
6 Hex nut 15 Coolant line 24 Hex screw
7 Coolant line 16 Coolant line 25 Washer
8 Plug 17 Coolant line 26 Plug
9 Coolant line 18 Rubber sleeve 27 Sealing ring

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Task Descriptions 723

Coolant pipework

1 Adapter union 11 Drain line

2 Sealing ring 12 Drain valve
3 Drain line 13 Bracket
4 Drain valve 14 Hex screw
5 Bracket 15 Washer
6 Hex screw 16 Spacer bushing
7 Washer 17 Pipe clamp half
8 Pipe clamp half 18 Grommet
9 Grommet 19 Hex screw
10 Hex screw 20 Drain valve

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724 Task Descriptions

3.14.45 Coolant pipework from / to intercooler – Removal

Preconditions
• Engine is stopped and starting disabled.
Preparatory steps

A distinction must be made as to whether

1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (ĺ Page 63)

X – – Disassemble engine (ĺ Page 64)

– – X Disable engine start (ĺ Page 17)
– – X Drain engine coolant (ĺOperating Instructions)

Removing coolant line

1. Take photos or mark attachments and lines before removing lines.
2. Remove lines as shown in overview drawing (ĺ Page 722).
3. Seal openings with suitable covers.

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Task Descriptions 725

3.14.46 Coolant pipework from / to intercooler – Cleaning

Special tools
Designation / Use Part No. Qty.
Cleaning brush

Material
Designation / Use Part No. Qty.
Cleaning agent

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Unsuitable cleaning tools.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Use appropriate cleaning tool.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Remove coolant pipework from / to intercooler (ĺ Page 724).

Coolant pipework from / to intercooler – Cleaning

1. Clean coolant pipework from / to intercooler with cleaning agent and cleaning brush.
2. Remove cleaning agent.
3. Clean coolant pipework from / to intercooler thoroughly with compressed air.

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726 Task Descriptions

3.14.47 Coolant pipework from/to intercooler – Check

Spare parts
Designation / Use Part No. Qty.
Coolant line
Pipe
Rubber sleeve
Gasket
Bracket
Drain valve
Screw
Hex nut
Spacer washer
Spacer bushing
Plug

Compressed air is pressurized.

Risk of injury!
WARNING • Pressure must not exceed 0.5 bar.
• Wear protective clothing, gloves, and goggles / safety mask.

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Clean coolant pipework from/to intercooler (ĺ Page 725).

Coolant pipework from/to intercooler – Check

Item Findings Action

Check sealing surfaces for irregularities. Uneven • Recondition: smooth with

oilstone or emery cloth.
• Replace

Check all components for damage. Damaged Replace

Check thread for ease of movement and Damaged or sluggish • Recondition: recut threads
damage. • Replace

Pressure-test coolant lines with air and Leaking Replace

corrosion inhibitor in water bath for leaks as
necessary. Maintain a coolant temperature
of min. = 30 °C or max. = 40 °C at a test
pressure of 0.5 bar.

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Task Descriptions 727

3.14.48 Coolant pipework from/to intercooler – Installation

Material
Designation / Use Part No. Qty.
Engine oil
Petroleum jelly, white

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Check coolant pipework from/to intercooler (ĺ Page 726).

ICoolant pipework from/to intercooler – Installation

1. Remove all plugs.
2. Blow out coolant pipework from/to intercooler with compressed air.
3. Install coolant pipework from/to intercoolers as per overview drawing, (ĺ Page 722) ensuring they are
tension-free, and secure with pipe half clamps.

Final steps

A distinction must be made as to whether

1 the engine was completely disassembled
2 the engine was removed but not disassembled
3 the engine is still installed

1 2 3 Operations See
x – – Assemble engine (ĺ Page 67)
x – – Install engine (ĺ Page 69)
– x x Fill engine coolant system (ĺOperating Instructions)
– x x Enable engine start –

M020109/01E 05-12 © MTU

728 Task Descriptions

3.14.49 Coolant pipework with thermostat – Overview

Coolant pipework with thermostat

1 Coolant distribution housing 13 O-ring 24 O-ring

2 Cover 14 O-ring 25 Screw
3 O-ring 15 O-ring 26 Screw
4 Screw 16 Screw 27 O-ring
5 Cover 17 Screw 28 Restrictor
6 Screw 18 O-ring 29 Thermostat housing (low-
7 Blank flange 19 Screw temperature circuit)
8 O-ring 20 Screw 30 Thermostat insert
9 Screw 21 Thermostat housing (high- 31 Sealing ring
10 Elbow temperature circuit) 32 Screw
11 Gasket 22 Thermostat insert 33 Screw
12 Screw 23 Sealing ring 34 Washer

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Task Descriptions 729

3.14.50 Coolant pipework with thermostat – Removal

Preconditions
• Engine is stopped and starting disabled.

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Preparatory steps

A distinction must be made as to whether

1 the engine is to be completely disassembled
2 the engine is to be removed but not disassembled
3 the engine is to remain installed

1 2 3 Operations See

X – – Remove engine (ĺ Page 63)

X – – Disassemble engine (ĺ Page 64)

– – X Disable engine start (ĺ Page 17)
– – X Drain engine coolant (ĺOperating Instructions)
– – X Drain charge-air coolant (ĺOperating Instructions)
– X X Remove MDEC with holder –

– X X Remove oil filter (ĺ Page 595)

– X X Remove centrifugal oil filter (ĺ Page 608)
– X X Disassemble crankcase breather (ĺ Page 152)
– X X Remove oil cooler (ĺ Page 620)
– X X Remove coolant pipework after cylinder (ĺ Page 678)
– X X Remove charge-air coolant pump (ĺ Page 701)
– X X Disconnect and remove electrical lines (engine wiring (ĺ Page 782)
harnesses)

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730 Task Descriptions

Removing thermostat housing (high temperature

circuit)
1. Remove screws from flanges (1) and (2).
2. Press the flanges off the sealing faces.

3. Remove pipes (3) and (4) as shown in overview

drawing (ĺ Page 722) .
4. Remove flange (1).
5. Remove screws (2) from thermostat housing (5).

6. Replace two screws from thermostat housing with

guide pins (arrow).
7. Remove thermostat housing from coolant
distribution housing.

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Task Descriptions 731

8. Remove thermostat inserts, sealing rings, and

O-rings.

Removing coolant distribution housing

1. Screw eyebolts into coolant distribution housing
and suspend the housing using crane and rope.
2. Remove screws and washers from coolant
distribution housing as shown in overview drawing
(ĺ Page 728) .
3. Using crane and rope, remove coolant distribution
housing from gearcase.
4. Remove O-rings.
5. After removal, seal all connections with plugs.

Removing thermostat housing (low temperature circuit)

1. Remove screws from thermostat housing.
2. Remove thermostat housing as shown in overview drawing (ĺ Page 728) .

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732 Task Descriptions

3.14.51 Coolant pipework with thermostat – Cleaning

Material
Designation / Use Part No. Qty.
Cleaner

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Excessive reaction time of cleaning agents on components.

Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Remove coolant pipework with thermostat (ĺ Page 729).

Coolant pipework with thermostat – Cleaning

1. Clean all components with cleaner.
2. Remove cleaner.
3. Thoroughly blow out all components with compressed air.

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Task Descriptions 733

3.14.52 Coolant pipework with thermostat – Check

Material
Designation / Use Part No. Qty.
Red penetrant dye for surface crack-testing procedure

Spare parts
Designation / Use Part No. Qty.
Coolant distribution housing
Thermostat housing
Thermostat insert
Cover
Blank flange
Elbow
Restrictor

Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

Component is hot.
Risk of burning!
WARNING • Wear protective gloves.

Clean coolant pipework with thermostat (ĺ Page 732).

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734 Task Descriptions

Coolant pipework with thermostat – Check

Item Findings Action

Check all components for condition Damaged Replace

and damage.

Using red penetrant dye, check the Cracks indicated Replace

coolant distribution housing and
thermostat housing for cracks.

Check all mating and sealing faces • Wear • Recondition: smooth with
for wear and damage. • Damage oilstone or emery cloth.
visible • Replace

Check support bores of thermostat Damaged • Recondition: smooth with

elements for damage. oilstone.
• Replace

Check threads in coolant distribution Sluggish Replace thread inserts.

housing for ease of movement.

Gaskets, sealing rings and O-rings – Replace

Check coolant and oil chambers Leaking Replace

of coolant distribution housing for
leaks with air and corrosion inhibitor
under water. Maintain a coolant
temperature of min. = 30 °C or max.
= 40 °C at a test pressure of 0.5 bar.

Checking thermostat element (high- and

low-temperature circuits)

Technical data - Thermostat elements

Hightemperature circuit Start of opening (B) = 75 °C ± 2 °C Full opening (A) = 88 °C ± 2 °C

Lowtemperature circuit Start of opening (B) = 38 °C ± 2 °C Full opening (A) = 51 °C ± 2 °C

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Task Descriptions 735

Note: The thermostat element must not be in

contact with the container.

1. Suspend the thermostat element by means of a

wire in a container filled with water.
2. Heat water with suitable heat source.
Note: Start-of-opening temperature is stamped
on thermostat insert.

3. Check thermostat insert for start of opening

with heat supply uniform and water constantly
circulated. At approx. 10°C below opening
temperature (B), the heating speed must not
exceed 1°C per minute.
4. Replace thermostat insert if results of check
are negative.
5. Continue to heat coolant to full-opening
temperature (A).
Result: Thermostat insert must be completely
open after 6 to 8 minutes.
6. Measure stroke travel of thermostat insert. Stroke
must be min. 9.5 mm.
7. If stroke travel is less than 9.5 mm, replace
thermostat insert.

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736 Task Descriptions

3.14.53 Coolant pipework with thermostat – Installation

Special tools
Designation / Use Part No. Qty.
Eyebolts
Lifting rope

Material
Designation / Use Part No. Qty.
Petroleum jelly, white
Engine oil
Surface sealant Loctite 518

Spare parts
Designation / Use Part No. Qty.
O-rings

Suspended load.
Danger to life!
DANGER • Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.

Contamination of components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Check components for special cleanness.

Check coolant pipework with thermostat (ĺ Page 733).

Installing coolant distribution housing

1. Coat Orings with petroleum jelly and insert into
grooves (1) in equipment carrier.
2. Insert plug screw (2).
3. Coat mating face of coolant distribution housing on
equipment carrier with surface sealant (see arrow).

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Task Descriptions 737

Note: When fitting coolant distribution housing

in position, make sure O-rings are not
damaged.

4. Carefully place coolant distribution housing on

equipment carrier with crane and rope and align.
5. Secure coolant distribution housing as per
overview drawing (ĺ Page 728).

Installing thermostat elements

1. Fit sealing ring (2) with flat side to installation
mandrel (1).
2. Drive sealing rings with installation mandrel flush
into thermostat housing.

3. Coat sealing surfaces (arrow) of thermostat

elements with petroleum jelly.
4. Insert thermostat elements.
5. Coat O-rings with petroleum jelly.
6. Insert O-rings in groove.

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738 Task Descriptions

Installing thermostat housing (high-temperature

circuit)
1. Insert restrictor (arrow) into support bore.
2. Install thermostat housing on coolant distribution
housing by means of guide pins.

3. Insert securing screws (2) of thermostat housing

(5).
4. Install flange (1).
5. Install pipes (3) and (4) as per overview drawing
(ĺ Page 722).

6. Install flanges (1) and (2).

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Task Descriptions 739

Final steps

A distinction must be made as to whether

1 the engine was completely disassembled
2 the engine was removed but not disassembled
3 the engine is still installed

1 2 3 Operations See
x – – Assemble engine (ĺ Page 67)
x – – Install engine (ĺ Page 69)
– x x Assemble in reverse sequence to disassembly. (ĺ Page 729)
– x x Fill with charge-air coolant (ĺOperating Instructions)
– x x Fill engine coolant system (ĺOperating Instructions)
– – x Fill engine oil system (ĺOperating Instructions)
– – x Fill fuel system (ĺOperating Instructions)
– – x Vent fuel system (ĺOperating Instructions)
– – x Enable engine start –

M020109/01E 05-12 © MTU