MTU Detroit 16V 2000S(R1638k40) 16V 2000C(R1638K40) Diesel Engine M020155 00E Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
MTU Detroit 16V 2000S(R1638k40) 16V 2000C(R1638K40) Diesel Engine M020155 00E Workshop Manual – PDF DOWNLOAD
General assembly instructions:
Components that are in contact with oil, fuel, coolant or combustion air must be clean. Components for which “particular cleanness” is required (e.g. components carrying oil or fuel) must be cleaned using suitable processes and checked for cleanness prior to installation. Remove component wrappings immediately prior to installation. Elastomer components such as rubber must not be cleaned using diesel fuel, solvents or cold cleaner.
They must therefore only be cleaned (not washed) with an abrasion-proof paper cloth before installation. The surfaces of sliding parts must be coated with SAE 30 engine oil prior to installation unless otherwise specified. O-rings and surfaces moving against them during installation (bores and shafts) must be coated with petroleum jelly, unless otherwise specified. When installing O-rings with counterrings in coolant pumps, always follow the installation instructions. After installing O-rings in shaft grooves, pass a rounded marking tool under the O-ring in the direction of the circumference if the O-ring diameter is sufficiently large. Ensure that the O-ring is not damaged. Prior to shaft seal installation:
- On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft running surface with thin-film lubricant or SAE 30 engine oil.
- In the support bore, in the case of a metal outer jacket the outer surface must be coated with surface sealant, unless otherwise specified in the drawing. For elastomer outer jackets or combined metal/elastomer outer jackets, the outer surface must be coated with denaturated ethanol.
TABLE OF CONTENTS:
MTU Detroit 16V 2000S(R1638k40) 16V 2000C(R1638K40) Diesel Engine M020155 00E Workshop Manual – PDF DOWNLOAD
1 General 09
11 Important Notes 09
111 Reman assemblies – Prerequisites for maintenance tasks and general assembly
instructions 09
12 General Regulations 11
121 General conditions 11
122 Personnel and organizational requirements 12
123 Safety precautions when working on the engine 13
124 Auxiliarymaterials, fire prevention and environmental protection 16
125 Standards for warning notices in the publication 18
126 General information regarding the Tolerances and Wear Limits List 19
127 Engine side and cylinder designations20
128 Torque specifications for screws, bolts and nuts 21
129 Settings 34
1210 Conversion tables 36
1211 Repairing threaded bores with threaded inserts (Heli-Coil)42
1212 Transport 44
2 Operation Schedules 45
21 Engine – Checking condition before a major overhaul 45
22 Preface 46
23 Maintenance schedule matrix 48
24 Maintenance tasks 50
25 Engine – Removal 52
26 Engine – Disassembly 53
27 Engine – Assembly 55
28 Engine – Installation 57
29 Engine – Running in 58
3 Task Descriptions 61
31 Crankcase and Attachments 61
311 Engine layout 61
312 Crankcase and attachments – Overview 62
313 Crankcase – Overview 63
314 Crankcase – Disassembly 64
315 Crankcase – Cleaning 67
316 Crankcase – Check 68
317 Crankcase – Tolerances 74
318 Crankcase – Assembly 84
319 Dowel pin for crankshaft bearing cap – Replacement 88
3110 Cylinder liner – Overview 89
3111 Cylinder liner – Removal 90
3112 Cylinder liner – Cleaning 94
3113 Cylinder liner – Check 95
3114 Cylinder liners – Tolerances 97
M020155/00E 2005-12 © MTU
02 Table of Contents
3115 Cylinder liner – Installation 99
3116 Oil pan – Overview 103
3117 Oil pan – Removal 104
3118 Oil pan – Cleaning 106
3119 Oil pan – Check 107
3120 Oil pan – Installation 108
3121 Engine lifting equipment – Overview 110
3122 Engine lifting equipment – Removal111
3123 Engine lifting equipment – Cleaning112
3124 Engine lifting equipment – Check 113
3125 Engine lifting equipment – Installation114
3126 Crankcase ventilation – Overview 115
3127 Crankcase ventilation – Removal 116
3128 Crankcase ventilation – Cleaning 117
3129 Crankcase ventilation – Check 118
3130 Crankcase ventilation – Installation119
3131 Crankcase ventilation – Replacement of wiremesh 120
32 Gear Train 121
321 Gear train – Overview 121
322 Flywheel housing – Overview 123
323 Flywheel housing – Removal 125
324 Flywheel housing – Disassembly 127
325 Flywheel housing – Cleaning 129
326 Flywheel housing – Check 130
327 Flywheel housing – Tolerances 131
328 Flywheel housing – Assembly 133
329 Flywheel housing – Installation 136
3210 Sensor sleeve – Removal and installation 140
3211 Gearcase, free end – Overview 141
3212 Gearcase, free end – Removal 143
3213 Gearcase, free end – Disassembly 145
3214 Gearcase free end – Cleaning 146
3215 Gearcase, free end – Check 147
3216 Gearcase, free end – Tolerances 149
3217 Gearcase, free end – Assembly 150
3218 Gearcase, free end – Installation 152
3219 Gearcase main bearing, free end – Removal and installation156
3220 Gear train, free end – Overview 157
3221 Gear train, free end – Removal 158
3222 Gear train, free end – Cleaning 160
3223 Gear train, free end – Check 161
3224 Gear train, free end – Tolerances 162
3225 Gear train, free end – Installation 163
3226 Bearing bush – Removal and installation 166
3227 Belt drive – Overview 168
3228 Belt drive – Removal 169
3229 Belt drive – Cleaning 170
3230 Belt drive – Check 171
3231 Belt drive – Installation 172
M020155/00E 2005-12 © MTU
Table of Contents 03
33 Running Gear 173
331 Running gear – Overview 173
332 Crankshaft – Overview 174
333 Crankshaft – Removal 178
334 Crankshaft – Disassembly 181
335 Crankshaft – Cleaning 183
336 Crankshaft – Check 184
337 Crankshaft – Tolerances 188
338 Crankshaft – Assembly 198
339 Crankshaft – Balancing 202
3310 Main bearing shells – Check 205
3311 Crankshaft bearing bore – Check 207
3312 Crankshaft – Installation 210
3313 PTO flange driving end, flywheel – Overview 216
3314 PTO flange, driving end, flywheel – Removal 218
3315 Radial-lip shaft seal, driving end – Removal 222
3316 PTO flange, driving end, flywheel – Cleaning 223
3317 PTO flange, driving end – Flywheel check 224
3318 Radial-lip shaft seal, driving end – Installation 225
3319 PTO flange, driving end – Flywheel installation 227
3320 Vibration damper on PTO, free end – Overview 232
3321 Vibration damper on PTO, free end – Check 235
3322 Vibration damper on PTO, free end – Disassembly 237
3323 Vibration damper on PTO, free end – Cleaning 238
3324 Vibration damper on PTO, free end – Check 239
3325 Vibration damper at PTO free end – Tolerances 240
3326 Vibration damper on PTO, free end – Installation 241
3327 Vibration damper on PTO, free end – Replacement of track ring 244
3328 Piston and conrod – Overview 246
3329 Piston and conrod – Removal 248
3330 Piston and conrod – Disassembly 251
3331 Piston – Cleaning 253
3332 Piston – Check254
3333 Piston – Tolerances 257
3334 Conrod – Cleaning 261
3335 Conrod – Check 262
3336 Conrod – Tolerances 268
3337 Conrod – Repair 272
3338 Conrod – Assembly 274
3339 Conrod bearing shells – Check 276
3340 Piston – Assembly 277
3341 Piston and conrod – Installation 281
34 Cylinder Head 287
341 Cylinder head with attachments – Overview 287
342 Valve-seat turning machine for cylinder head 288
343 Cylinder head – Overview 293
344 Cylinder head – Removal 296
345 Cylinder head – Disassembly 298
346 Cylinder head – Cleaning 301
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04 Table of Contents
347 Cylinder head – Check 302
348 Cylinder head – Tolerances 304
349 Cylinder head – Repair 314
3410 Cylinder head – Assembly 320
3411 Cylinder head – Installation 323
3412 Cylinder head seals – Repair 325
35 Valve Gear 326
351 Valve gear – Overview 326
352 Camshaft – Overview 327
353 Camshaft – Removal 328
354 Camshaft – Cleaning 330
355 Camshaft – Check 331
356 Camshaft – Tolerances 333
357 Camshaft – Installation 336
358 Camshaft timing – Check 340
359 Valve roller tappet, pushrod – Overview 343
3510 Roller tappet and pushrod – Removal344
3511 Roller tappet, pushrod – Cleaning 346
3512 Roller tappet, pushrod – Check 347
3513 Roller tappet, pushrod – Tolerances 348
3514 Roller tappet, pushrod – Installation349
3515 Valve drive – Overview 351
3516 Valve drive – Removal 353
3517 Valve drive – Disassembly 355
3518 Valve drive – Cleaning 356
3519 Valve drive – Check 357
3520 Valve drive – Tolerances 359
3521 Valve drive – Assembly 361
3522 Valve drive – Installation 362
3523 Cylinder head cover – Overview 364
3524 Cylinder head cover – Removal 365
3525 Cylinder head cover – Cleaning 366
3526 Cylinder head cover – Check 367
3527 Cylinder head cover – Installation 368
36 Fuel System – High Pressure 370
361 HP fuel system – Overview 370
362 Injection pump – Overview 371
363 Injection pump – Removal 372
364 Injection pump – Disassembly 374
365 Injection pump – Check 375
366 Injection pump – Installation 376
367 Fuel injector – Overview 378
368 Fuel injector – Removal 379
369 Injector – Disassembly 381
3610 Fuel injector – Check 382
3611 Fuel injector – Installation 383
3612 HP fuel line – Overview 386
3613 HP fuel line – Removal 387
3614 HP fuel line – Cleaning 388
M020155/00E 2005-12 © MTU
Table of Contents 05
3615 HP line – Check 389
3616 High-pressure line – Installation 390
37 Fuel System – Low Pressure 392
371 Fuel delivery pump – Overview 392
372 Fuel delivery pump – Removal 393
373 Fuel delivery pump – Disassembly 394
374 Fuel delivery pump – Cleaning 395
375 Fuel delivery pump – Check 396
376 Fuel delivery pump – Installation 397
377 Fuel pipework fromfuel delivery pump to fuel filter – Overview 399
378 Fuel line from fuel delivery pump to filter – Removal 400
379 Fuel supply line from fuel delivery pump to fuel filter – Cleaning 401
3710 Fuel line from fuel delivery pump to filter – Check 402
3711 Fuel line from fuel delivery pump to filter – Installation 403
3712 Fuel filter – Overview 404
3713 Fuel filter – Removal 405
3714 Fuel filter – Cleaning 406
3715 Fuel filter – Check 407
3716 Fuel filter – Installation 408
3717 Fuel pipework fromfuel filter to low-pressure line – Overview410
3718 Fuel pipework fromfuel filter to low-pressure line – Removal 412
3719 Fuel supply from fuel filter to LP line – Cleaning 413
3720 Fuel pipework fromfuel filter to low-pressure line – Check 414
3721 Fuel pipework fromfuel filter to low-pressure line – Installation 415
3722 Leak-off fuel system – Overview 417
3723 Leak-off fuel system – Removal 418
3724 Leak-off fuel line – Cleaning 419
3725 Leak-off fuel system – Check 420
3726 Leak-off fuel system – Installation 421
38 Exhaust Turbocharger 422
381 Exhaust turbocharger – Overview 422
382 Exhaust turbocharger – Removal 423
383 Exhaust turbocharger – Cleaning 424
384 Exhaust turbocharger – Check 425
385 Exhaust turbocharger – Installation426
39 Charge Air Cooling 428
391 Charge-air cooling – Overview 428
392 Intercooler – Removal 430
393 Intercooler — Cleaning 431
394 Intercooler – Check 432
395 Intercooler – Installation 434
310 Air Intake/Air Supply436
3101 Air supply system to cylinders – Overview 436
3102 Air supply system to cylinders – Removal 437
3103 Air supply system to cylinders – Cleaning 438
3104 Air supply system to cylinders – Check 439
3105 Air supply to the cylinders – Installation 440
311 Exhaust System 441
M020155/00E 2005-12 © MTU
06 Table of Contents
3111 Exhaust lines downstream of cylinders – Overview 441
3112 Exhaust pipework after cylinder – Removal 442
3113 Exhaust pipework after cylinder head – Cleaning 443
3114 Exhaust lines downstream of cylinders – Check 444
3115 Exhaust lines downstream of cylinders – Installation 445
312 Starting System 446
3121 Electric starter – Overview 446
3122 Starter – Removal 447
3123 Starter – Disassembly 448
3124 Starter – Cleaning 449
3125 Starter – Inspection 450
3126 Starter – Installation 451
313 Lube Oil System 452
3131 Lube-oil pump with drive – Overview 452
3132 Lube-oil pump with drive – Removal453
3133 Lube oil pump with drive – Disassembly 454
3134 Lube oil pump with drive – Cleaning455
3135 Lube oil pump with drive – Check 456
3136 Lube-oil pump with drive – Installation458
3137 Oil pump connections – Overview 461
3138 Connections for oil pump – Removal 462
3139 Oil pump connections – Cleaning 463
31310 Connections for oil pump – Check 464
31311 Connections for oil pump – Installation465
31312 Filling and measuring equipment – Overview 466
31313 Filling and measuring equipment – Removal 468
31314 Filling and measuring equipment – Cleaning 469
31315 Filling and measuring equipment – Check 470
31316 Filling and measuring equipment – Installation 471
31317 Oil filter – Overview 472
31318 Oil filter – Removal 473
31319 Oil filter housing – Cleaning 474
31320 Oil filter housing – Check 475
31321 Oil filter – Installation 476
31322 Oil heat exchanger – Overview 478
31323 Oil heat exchanger – Removal 479
31324 Oil heat exchanger – Cleaning 480
31325 Oil heat exchanger – Check 482
31326 Oil heat exchanger – Installation 484
31327 Oil system in crankcase – Overview486
31328 Oil system in crankcase – Removal487
31329 Oil system in crankcase – Cleaning488
31330 Oil system in crankcase – Check 489
31331 Oil system in crankcase – Installation 490
31332 Gear train oil supply – Overview 493
31333 Gear train oil supply – Removal 494
31334 Gear train oil supply – Cleaning 495
31335 Gear train oil supply – Check 496
31336 Gear train oil supply – Installation 497
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Table of Contents 07
31337 Exhaust turbocharger oil supply – Overview 498
31338 Turbocharger oil supply – Removal499
31339 Turbocharger oil supply – Cleaning500
31340 Turbocharger oil supply – Check 501
31341 Turbocharger oil supply – Installation 502
31342 Oil return line from exhaust turbocharger – Overview 504
31343 Exhaust turbocharger oil return line – Removal 505
31344 Exhaust turbocharger oil return line – Cleaning 506
31345 Exhaust turbocharger oil return line – Check 507
31346 Oil return line from exhaust turbocharger – Installation 508
314 Coolant System 509
3141 Engine coolant pump – Overview 509
3142 Engine coolant pump – Removal 511
3143 Engine coolant pump – Installation 512
3144 Engine coolant pump – Replacement 514
3145 Coolant pump pipework – Overview515
3146 Coolant pump lines – Removal 516
3147 Coolant pump lines – Cleaning 517
3148 Coolant pump pipework – Check 518
3149 Coolant pump lines – Installation 519
31410 Coolant pipework after coolant pump – Overview 520
31411 Coolant pipework after coolant pump – Removal 522
31412 Coolant pipework after coolant pump – Cleaning 523
31413 Coolant pipework after coolant pump – Check 524
31414 Coolant pipework after coolant pump – Installation 525
31415 Charge-air coolant pump – Overview 527
31416 Charge-air coolant pump – Removal 529
31417 Charge-air coolant pump – Installation530
31418 Charge-air coolant pump – Replacement 532
31419 Coolant pipework from – to intercooler – Overview 533
31420 Coolant pipework from – to intercooler – Removal 535
31421 Coolant pipework from – to intercooler – Cleaning 536
31422 Coolant pipework from – to intercooler – Check 537
31423 Coolant pipework from – to intercooler – Installation 538
31424 Coolant pipework with thermostat – Overview 540
31425 Coolant pipework with thermostat – Removal 541
31426 Coolant pipework with thermostat – Cleaning 543
31427 Coolant lines with thermostat – Check544
31428 Coolant pipework with thermostat – Installation 546
31429 Coolant pipework with thermostat, charge air cooling circuit – Overview 549
31430 Coolant pipework with thermostat, charge air cooling circuit – Removal 550
31431 Coolant pipework with thermostat, charge air cooling circuit – Cleaning 551
31432 Coolant pipework with thermostat, charge air cooling circuit – Check 552
31433 Coolant pipework with thermostat, charge air cooling circuit – Installation 554
315 Power Supply, Engine Side 556
3151 Battery-charging generator – Overview 556
3152 Battery-charging generator – Removal557
3153 Battery-charging generator – Disassembly 559
3154 Battery-charging generator – Cleaning560
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08 Table of Contents
3155 Battery-charging generator – Check561
3156 Battery-charging generator – Installation 564
316 Cooling Air System 566
3161 Mechanical fan drive – Overview 566
3162 Mechanical fan drive – Removal 573
3163 Mechanical fan drive – Disassembly 575
3164 Mechanical fan drive – Cleaning 576
3165 Mechanical fan drive – Check 577
3166 Mechanical fan drive – Assembly 580
3167 Mechanical fan drive – Installation 582
317 Mounting/Support 584
3171 Engine mounts – Overview 584
3172 Engine mounts – Removal 585
3173 Engine mounts – Cleaning 586
3174 Engine mounts – Check 587
3175 Engine mounts – Installation 588
318 Monitoring and Control Devices 590
3181 Monitoring and control devices – Overview 590
3182 DDEC electronic control – Removal591
3183 DDEC electronic control – Cleaning592
3184 DDEC electronic control – Check 593
3185 DDEC electronic control – Installation594
3186 Wiring and engine wiring harnesses – Overview 595
3187 Engine wiring harnesses – Removal 597
3188 Engine wiring harnesses – Check 598
3189 Engine wiring harnesses – Installation599
31810 Sensors, actuators and injectors – Overview 600
31811 Sensors, actuators and injectors – Removal 601
31812 Sensors, actuators and injectors – Check 603
31813 Sensors, actuators and injectors – Installation 604
4 Special Tools 607
41 Standard tools – Overview 607
42 General workshop equipment – Overview 608
43 Measuring tools – General overview 614
5 Appendix619
51 Manufacturer’s documentation 619
52 MTU contact/service partner 620
53 Index 621
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