MTU 12 V 2000 M94 User manual

Operating Instructions
Diesel engine
12 V 2000 M94
16 V 2000 M94
MS150061/04E

Printed in Germany
© 2012 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 permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Table of Contents
1 Safety
1.1 General conditions 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Safety regulations for startup and operation 9
1.5 Safety regulations for maintenance and
repair work 10
1.6 Auxiliary materials, fluids and lubricants,
fire prevention and environmental
protection 13
1.7 Conventions for safety instructions in the
text 15
2 General Information
2.1 Tightening specifications for screws, nuts
and bolts 16
2.2 Engine side and cylinder designations 27
2.3 Product description 28
2.4 Engine - Overview 34
2.5 Sensors, actuators and injectors –
Overview 36
3 Technical Data
3.1 12V 2000 M94 engine data 41
3.2 16V 2000 M94 engine data 44
3.3 Firing order 47
3.4 Engine – Main dimensions 48
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3
months) 49
4.2 Engine – Putting into operation after
scheduled out-of-service-period 50
4.3 Tasks after extended out-of-service periods
(>3 weeks) 51
4.4 Checks prior to start-up 52
4.5 Fuel treatment system – Putting into
operation 53
4.6 Operational checks 55
4.7 Fuel treatment system – Switching on 56
4.8 Starting the engine 57
4.9 Stopping the engine 58
4.10 Emergency stop 59
4.11 After stopping the engine 60
4.12 Fuel treatment system – Shutdown 61
4.13 Plant cleaning 62
5 Maintenance
5.1 Maintenance task reference table [QL1] 63
6 Troubleshooting
6.1 Fuel treatment system – Troubleshooting 64
6.2 Troubleshooting 65
7 Task Description
7.1 SOLAS 68
7.1.1 SOLAS shielding as per MTN 5233 –
Installation 68
7.1.2 SOLAS shielding – Installation 69
7.1.3 Installation locations for SOLAS shielding 70
7.2 Engine 75
7.2.1 Engine – Barring manually 75
7.2.2 Engine – Barring with starting equipment 76
7.3 Cylinder Liner 77
7.3.1 Cylinder liner – Endoscopic examination 77
7.3.2 Cylinder liner – Instructions and comments on
endoscopic and visual examination 79
7.4 Crankcase Breather 81
7.4.1 Crankcase breather – Cleaning oil pre-
separator element 81
7.4.2 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 82
7.5 Valve Drive 84
7.5.1 Valve clearance – Check and adjustment 84
7.5.2 Cylinder-head cover – Removal and
installation 87
7.6 Injection Valve / Injector 88
7.6.1 Injector – Replacement 88
7.6.2 Injector – Removal and installation 89
7.7 Fuel System 91
7.7.1 Fuel system – Venting 91
7.8 Fuel Filter 92
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7.8.1 Fuel filter – Replacement 92
7.8.2 Fuel prefilter – Differential pressure check and
adjustment of gauge 94
7.8.3 Fuel prefilter – Draining 95
7.8.4 Fuel prefilter ‒ Flushing 96
7.8.5 Fuel prefilter – Filter element replacement 98
7.9 Charge-Air Cooling 100
7.9.1 Intercooler – Checking condensate drain line
for coolant discharge and obstruction 100
7.10 Air Filter 101
7.10.1 Air filter – Replacement 101
7.10.2 Air filter – Removal and installation 102
7.11 Air Intake 103
7.11.1 Contamination indicator – Signal ring position
check (optional) 103
7.12 Starting Equipment 104
7.12.1 Starter – Condition check 104
7.13 Lube Oil System, Lube Oil Circuit 105
7.13.1 Engine oil – Level check 105
7.13.2 Engine oil – Change 106
7.14 Oil Filtration / Cooling 107
7.14.1 Engine oil filter – Replacement 107
7.14.2 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 109
7.15 Coolant Circuit, General, High-
Temperature Circuit 112
7.15.1 Drain and venting points 112
7.15.2 Engine coolant – Level check 117
7.15.3 Engine coolant – Change 118
7.15.4 Engine coolant – Draining 119
7.15.5 Engine coolant – Filling 120
7.15.6 HT coolant pump — Relief bore check 121
7.15.7 Engine coolant – Sample extraction and
analysis 122
7.15.8 Coolant filter – Replacement 123
7.16 Raw Water Pump with Connections 124
7.16.1 Raw water pump – Relief bore check 124
7.17 Belt Drive 125
7.17.1 Drive belt – Condition check 125
7.18 Battery-Charging Generator 126
7.18.1 Battery-charging generator drive – Drive belt
replacement 126
7.19 Fuel Supply System 127
7.19.1 Water drain valve – Check 127
7.19.2 Differential pressure gauge – Check 128
7.19.3 Water level probe (3-in-1 rod electrode) –
Check 129
7.19.4 Pump capacity – Check 130
7.19.5 Coalescer filter element – Replacement 131
7.20 Wiring (General) for Engine/Gearbox/Unit 133
7.20.1 Engine wiring – Check 133
7.21 Accessories for (Electronic) Engine
Governor / Control System 134
7.21.1 Engine governor and connectors – Cleaning 134
7.21.2 Engine governor – Checking plug-in
connections 135
7.21.3 EMU – Checking plug-in connections 136
7.21.4 Engine governor – Carry out self-test 137
7.21.5 EMU and connectors – Cleaning 138
7.21.6 ECU 7 engine governor – Removal and
installation 139
7.21.7 Engine monitoring unit – Removal and
installation 140
8 Appendix A
8.1 Abbreviations 141
8.2 MTU contact persons/service partners 144
9 Appendix B
9.1 Special Tools 145
9.2 Consumables 152
9.3 Spare Parts 154
9.4 Index 156
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1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements
Personnel requirements
All work on the engine shall be carried out by trained and qualified personnel only.
The specified legal minimum age must be observed.
The operator must specify the responsibilities of the operating, maintenance and repair personnel.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair
and transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on
explaining safety-relevant instructions.
This is particularly important in the case of personnel who only occasionally perform work on or around
the engine. This personnel must be instructed repeatedly.
For the identification and layout of the spare parts during maintenance or repair work, take photos or use
the spare parts catalog.
Working clothes and protective equipment
Wear proper protective clothing for all work.
Use the necessary protective equipment for the given work to be done.
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1.3 Transport
Transport without flange-mounted gearbox
A max. permissible diago‐
nal pull 70°
B max. permissible diago‐
nal pull 35°
Illustration is valid for 12/16V 2000 M engines
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Transport with flange-mounted gearbox
Illustration is valid for 12/16V 2000 M engines
Lift the engine only with the lifting eyes provided.
The eyebolts mounted at the driving end and on the gearbox must not be used for transporting plants
with flange-mounted gearboxes.
Only use transport and lifting devices approved by MTU.
Take the engine's center of gravity into account.
The engine must only be transported in installation position, max. permissible diagonal pull with flange-
mounted gearbox is 10°.
If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear‐
ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans‐
portation.
Secure the engine against tilting during transport. In particular when going down inclines or ramps, the
engine must be secured against moving and tilting.
Setting the engine down after transport
Only set down engine on a firm, level surface.
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-to-
case basis.
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1.4 Safety regulations for startup and operation
Safety precautions when putting the equipment into operation
Prior to initial operation of the assembly or plant, install the assembly or unit according to the specifica‐
tions and check the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that all persons are clear of the danger zone of moving machine components.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the monitoring, signaling and alarm systems are working properly.
Safety regulations for equipment operation
Emergency procedures must be practiced regularly.
The operator must be familiar with the controls and displays.
The operator must be familiar with the consequences of all operations to be performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protectors.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding
agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Observe the safety instructions for these devices.
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1.5 Safety regulations for maintenance and repair work
Safety regulations for maintenance and repair work
Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
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 con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.
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Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
Hydraulic installation and removal
Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.
Working on electrical/electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and 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.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
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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 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.
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1.6 Auxiliary materials, fluids and lubricants, fire prevention and
environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires –
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld 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 accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Environmental protection and disposal
Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and involves the termination of the operating license by the emission authorities. MTU does not accept
any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-
relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐
ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.
Auxiliary materials, fluids and lubricants
Use only fluids and lubricants that have been tested and approved by MTU.
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using
them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐
line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
not smoke.
Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.
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Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Wear goggles when blowing off components or blowing away chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Carry out leak test in accordance with the specifications.
Paints and lacquers
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids and alkaline solutions
• When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and
protective clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water.
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1.7 Conventions for safety instructions in the text
DANGER In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action
WARNING In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action
CAUTION In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action
NOTICE In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.
Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
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2 General Information
2.1 Tightening specifications for screws, nuts and bolts
Tightening torques for setscrew and stud joints as per MTN 5008 standard
This works standard applies to setscrews subjected to little dynamic load as per MMN 384, DIN 912, EN
24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to
studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.
It 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, phosphat‐
ized or galvanized) and 10.9 (surface condition bare or phosphatized).
The values given in the table are based on a friction coefficient µtot.= 0.125. Prerequisite: Threads and
mating faces of screws and nuts must be lubricated with engine oil prior to assembly.
When tightening manually (tightening specifications), an assembly tolerance of +10% of the table values
is permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process – e.g. resulting from inaccurate readings and overtightening during assembly.
When machine-tightening, the permissible assembly tolerance is +15 %.
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
M2 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
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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)
M27 x 2 960 1350 900 1275
M30 1200 1700 1100 1600
M30 x 2 1350 1900 1250 1800
MA= tightening torques
Tightening torques for stress bolt connections as per MTN 5007 standard
This standard applies to statically and dynamically loaded stress bolt connections of strength class 10.9
and for corresponding 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 given in the table are based on a friction coefficient µtot.= 0.125. Prerequisite: Threads and
mating faces of screws and nuts must be lubricated with engine oil prior to assembly.
When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is
permitted for unavoidable deviations of the tightening torque from the table value during the tightening
process – e.g. resulting from inaccurate readings and overtightening during assembly.
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
M24 x 2 700 850
M27 900 1170
M27 x 2 1000 1230
M30 1250 1575
*Protect screw shank against torsion when tightening.
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MA= tightening torques
Tightening torques for plug screws as per MTN 5183-1 standard
This standard applies to plug screws as per DIN 908, DIN 910 and DIN 7604 with screwed plug
DIN 3852 shape 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 phosphatized surface-protection
and oiled or galvanized. Thread and mating faces beneath heads must be coated in engine oil prior to
assembly. When tightening manually (defined tightening), an assembly tolerance of +10 % of the table
values is permitted for unavoidable deviations of the tightening torque from the table value during the
tightening process – e.g. resulting from inaccurate readings and overtightening during assembly.
Tightening torques for plug screws DIN 908, DIN 910 and DIN 7604A (with short screwed plug).
Thread
Screwed into
Steel/gray cast iron MA
(Nm)
AI alloy MA
(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
MS150061/04E 2012-07 | General Information | 19
TIM-ID: 0000002333 - 010

Thread
Screwed into
Steel/gray cast iron MA
(Nm)
AI alloy MA
(Nm)
M56 x 2 380 360
M64 x 2 400 400
MA= tightening torques
Tightening torques for plug screws DIN 7604C (with long screwed plug)
Thread
Screwed into
Steel/gray cast iron MA
(Nm)
Al alloy MA
(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 torques for banjo screws as per MTN 5183-2 standard
This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603-
Cu.
20 | General Information | MS150061/04E 2012-07
TIM-ID: 0000002333 - 010