--a.

Engineer’s Handbook M 25
Contents .

Camshaft zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Camshaft bearings 30
Mounting of camshaft 29
Tightening torques 28
Vibration damper mounting 28
!P
: --w

Charge air cooler

Tightening torques 44 - 47 zyxwvutsrqponmlkjihgfedcb

Connecting rod
Reference dimension 19

Tightening torques 19

Crankshaft
Counterweight mounting 22
Crank web deflection 22

Crankshaft bearing
Gap - measurement 20
located main bearing 21
Marking 21
Tightening torque 20

Cylinder head
Exhaust gas manifold 6
Fitted valve stems: 12

Fitting of inlet and exhaust valve seats 4 2 * 13

Fuel delivery pipe connection 9-70

Fuel injection valve 9

11 -12
Grinding of inlet and exhaust valves
1
Guiding bolts - valve bridges
Indicating and safety valve 8

Sleeve for the fuel injection valve 8

Starting valve 3

Tightening torques 5

7
Valve clearance
7
Valve guide
5-6
Valve rocker bracket

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 Engineer’s Handbook M 25
Contents

Engine data 4

Exhaust gas manifold zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Tightening torques 39

: w
Flywheel mounting
; --*
Clearances 35
Mounting 35
Tightening torques 35 _ 36

Fuel injectiosl pump

Articulated lever 32
Check of commencement of fuel delivery 33
Mounting ?’
bL
Setting 33
Starting process 32
Tightening torques 31

Gear train
Backlash
Camshaft gear wheel
Gear wheel on crankshaft
Intermediate wheel mounting
tub. oil injectors for the gear drive

Governor drive
Bushes in the cylinder crankcase 27
Clearances 26
Tightening torqes 26 zyxwvutsrqponmlkjihgfedc

Liners
Assembly 18
Canyon 16
Nominal size 16
Pocket l?
Score 16
16
Wear zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
lim its
Wedge shape 16

Lower valve drive

Clearances 34
Tightening torques 34

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 Engineer’s Handbook M 25
Contents

Opposite side of coupling zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Mounting of pump carrier 37
Mounting with power take-off 38
Mounting without power take-off 37

,; --)
* Piston
:

Mounting 14
Piston rings 14 15
Tightening torques 13 zyxwvutsrqponmlkjihgfedcbaZY

Pump carrier with attached Pumps

Cooling water circulation pumps mounting 39
tub. oil pumps - mounting 39
Tightening torques pump carrier 39

Regulating shaft
Clearances 34
Tightening torques 34

Sires and weights 48 50

Turbocharger mounting
/
Tightening torques 40 33

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 Engineer’s-- Handbook WI 25
Engine data En_qine operatinq data

-- 4ocI
Stroke zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
mm Temperatures

Lub. oil

Speed, rpmi -- ]2O - 750

v zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Encjne inlet 60 - 65” C
* ”

Main bearing Temperature rise 10 - 14” c

Inside 0 - 240 in m Fresh water circulation cooling

Outside 0 - 252 mm Engine outlet 80 - 90” c

Big end bearing Temperature rise 7- 10” c

Inside 0 - 193 mm Charge air

Outside 0 - L04
r) mm Engine inlet 4 5 - 60” C

Valves, inlet and exhaust Pressures

Length - 446 mm Lub. oil

Shaft 0 - i 8.50 mm At the last main bearing 4 .0 - 4 .5 bar

Valve disk 0 - a4 mm Fresh water circulation cooling

Valve guide -> 2.5 bar

Length - 235 mm With attached pumps 2.0 bar

Inside 0 - 19.10 mm
Nuzzle cooling 1.5 - 3.0 bar

Fuel pressure before injection pumps

4.0 - 5.0 bar

Details for rated engine output and nominal

engine speed.

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 Engineer’s Handbook M 25
Cylinder head
Tightening zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
torque zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA \
The tightening torque fur inserting the tie bolts is + M = 450 Nm

1. Tighten round nuts with pin by hand.

/ -J
2, Lengthm.bQlk with --+ P = 820 bar
\ /
and tighten round nuts with pin taking care Gf easy motion.
The zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
pressure IYIWS~
tm~ain constant, when the pump is not operated otherwise faulty
tightening.

B lf the cylinder head nuk cannot be loosened with P = &?Oba/; an increase by 50

bar is possible. Further pressure increase involves the risk that the thread will expand and-
the nuk will jam.

At the control bore 1 - leakages between cylinder

head, flame ring and coolingwater distributing
housingcan be detected.

Valve rocker bracket

The tightening torque for inserting the studs - 1 - is -+ i M I 115 Nm ‘I
-4

Tighten nuts - 2 - with -+ M = 160 Nm

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Service document of Page
28/H/1997 MaK Motoren GmbH & Co. KG 5
 Engineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedcbaZY
-+
Reference size for zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
t he bush after pressing-in
B 59.99 t 0.12 zyxwvutsrqponmlkjihgfedcbaZYXW
mm
L

The bush shall recede after pressing-in by -+

0 5 9 .9 9 t 0 .1 2 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Before pressing-in slightly co& the bushes with oil, Molykate must not be used.

Radial clearance
Original size +
\
Clearance limit --+ f 0.359 mm

Exhaust gas manifold

Tighten screws to cyl. head alternately in 2 steps.
\
1st step up to + M = 150 Nm
\
and

2nd step up to -3 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

High temperature! Use paste DAG 5080

Screws 820 x 120 DIN 931; tensiun bush E31 x 55 DIN 2510

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 Engineer’s Handbook M 25
Setting of valve bridges and zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
valve clearances

1. Turn out zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

adjusting screws zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
- 1 - of the valve rockers to
obtain a sufficient clearance.

2. Turn out adjusting screws - 2 - of the valve bridges to

obtain a clearance when valve bridge ,.X” touches
II -w *
#$Y I’.

3. Screw in adjusting screws - 2 - until the valve bridges

rest on the valves without clearance.

4. Hold adjusting screws - 2 - fast and lock them.

5 Adjust valve clearance

Valve clearance \
Inlet -+ 0.50 + oAl mm
/
f 7
Exhaust -+ 0.90 + 61o mm

Valve guide: Inlet - Exhaust \ zyxwvutsrqpon

Nominal clearance -+ 0.10” 0.15 mm

Clearance limit -+ I 0 l 35 mm 1
Measur e diamet er of t he v alv e shaf t in t he guide ar ea. Measur e guide in cr oss dir ect iun of

engine.

Guiding bolts for the valve bridges / \

The tightening torque for the guiding bolts is -+ M = 180 Nm

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 Ensineer’s
_ Handbook M 25
Indicating and safety valve zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
The tightening torque for inserting /
the studs zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
- 1 - is + M = 50 Nm ‘1
\ )

// 2 F
/ /’
Tighten nuts - 2 - with /// M = 50 Nm
,/ /’ 1
? P
?’ -* h ,--’ I

Joint ring

Istuds &wnv 95 DIM 939; 2 nutsn4?2 Dfff 934

Starting valve
Tighten locking screw - 1 - with + i M ~250 Nm‘i
f \
Tighten safety nut - 2 - with M = 35
-+ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Nm
L /
Safety nut V’ 10x1 DIM 980

-.1
2

Tighten the sleeve for the fuel injection valve with -+

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 Enaineer’s Handbook M 25
Fuel injection valve zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA \
The tightening torque for inserting the studs - 1 - is -+ M = 50 Nm
/
Oil hbrica tiun \
Tighten nuts - 2 - with + M = 35 Nm
Slightly coat threads and cuntact s&aces with Mulykote /
paste G.
2’ f
Tighten hoCle*nut%th --+ M = 750 Nm
Oil lubrication \ /

-.- - -.
2

g return

Slightly coat o-ring

with Molykote and re pipe connection
distribute it equally.

high-temperature paste

Fuel pressure pipe

Mounting zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
1 . Tighten nuts of the fuel injection valve with the prescribed torque, loosen them by one turn and
tighten with M = 10 Nm.

2. Put the parts together and care for the correct position of cover - 1 -. Sleeve - 2 - is in a pushed
back position inside the cylinder head.

3. Screw the transverse pressure piece - 3 - with screwing - 4 - loosely into the fuel injection
pump*
On the front side the tranverse pressure piece must fit closely in the fuel injection pump.

4. Screw the radial pressure piece - 5 - together with the transverse pressure piece - 3 - by
tightening thrust bolt - 6 -. 7
Tighten thrust bolt - 6 - finally with -+ M = 13025 Nm
\ /
(Continued on page: 10)

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 Engineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedcbaZ
5. Tighten screwing - 4 -
7
with _I) (M = 15025 Nm

6. Push sleeve - 2 - fur locking into the fuel injection pump zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHG

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1 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 10
 Enaineer’s Handbook M 25
Grinding of inlet and exhaust valves zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Apply small dots of the diamond paste Dp 30/10-l 5 my with a syringe to the new or remachined
valve cone and distribute the paste equally. Thereafter the seat ring surface is to be sprayed with a
thinner (F25) belonging to the diamond paste, for dilution and in order to increase the grip. Insert the
oiled valve stem into the guide bush. Fasten the device at the valve disk
and grind the valve face and seat by hand applying a moderate pressure,
rotating the device. The contact reflection ,,a” which is visible by the
smooth grindifig process shall not exceed 30 % of the seat width
starting from the outside diameter. If the bearing characteristics
described above are not reached, remachining of both sealing surfaces
is necessary. After machining both seats have to be checked with a
luminous magnifier. The fillet must not be refinished.
After machining round off the outside edge with a stone.
The dimensions specified in the sketch are to be observed.

Exhaust valve Inlet valve

.
II

E
Deviations from true running
The deviation from true running on the valve stem must not exceed 0.05 mm on the measuring
distance “S” of 200 mm.
The deviation from true running on the valve cone must not exceed 0.025 mm.
For both measurements the valve stem must touch at points A and B in the measuring device.

0.05 mm

0.025 mm

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 Enaineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedc
Reuse of a valve stem is not possible if:
zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
1. t her e is sever e pit t ing on t he bot t om side of the
valve head (formation of so-called “paving
stones”),

2. there are corrosiun pits and mechanical damages

in the area of the valve, stem, stem transition,
and halve head,

3. the limit for refinishing is exceeded.

4. in case of corrosive material wear of 2 % from

the valve disk diameter. In case of high -
temperature corrosion ,,S” of 1.50 mm.

Fitted valve stems:

MD0 oper at ion 2500.7-22.10.01-01 Inlet valve

2500.7-22.10.01-02 Ex haust valve

HFO oper at ion 2500.7-22.10.01-01 Inlet valve

2500.7-22.10.01-03 Ex haust valve

l zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
ht1 :ing
of inlet and exhaust valve seats
1. Cool valve seat rings down to - 195” C

2. Insert the inlet and exhaust valve seat rings.

3. When the valve seat rings are tight they are

pressed on with the pressure device.

4. Check of the bearirig surface ,,Y 2”, between inlet

valve seat ring and cylinder head no air gap is admissible.

5. Check of the air gap ,,Y 1’1between exhaust valve seat ring and cylinder head. Admissible air

gap 0.4 0 +IL30 mm

Pr essut e t est : Cooling water spaces 10 bar for 8 min.

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 Engineer’s Handbook M 25
Valve seat ring zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Maximum admissible dimension 0 X for refinishing the exhaust valve seat rings 92.00 +UU mm and
on the inlet valve seat rings 85.00 +U mm
At ,,a“ no material may be taken off.

Exhaust valve seat ring Inlet valve seat ring

Refinishing is possible with Mak valve seat ring turning machine or with Mak valve seat milling
fixture. After grinding the bearing portion shall be 30- 50 %, beginning from the outer diameter.

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 Engineer’s Handbook M 25
Piston
Built-up piston zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
2500.7-26.70.00-01 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Coat thread and contact surface with Molykote paste G-n-plus

Tighten screws crosswise with --+

Loosen screws again.

Pretightin s&ws crosswise with -+ i M =20

/
0
and tighten with --+ Dw =: 70 zyxwvutsrqponmlkjihgfedcbaZY
i

Check:
At + M = 45 NM I
the nuts must not turn further.
\
Gap i 0.06 - 0.10
size zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA mm
/

Me a sure gap

ste ws not tightened.

Piston rings Grooves Nominal Wear Clearance

size limit limit

6.00 6.45 0.50

6.00 6.45 0.50

8.00 8 .20 0.30

Fitting
Arrange the ring butts in longitudinal direction of engine alternately opposed, then oil pistons and
piston rings well.
Fit piston zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
r ings w it h mar k ing up wards.

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Sercice document of Page

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 Engineer’s Handbook M 25
Piston rings
MD0 operation zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
1st ring groove rectangular ring 2500.7-26. 7.01-01
2nd ring groove compression ring 2500.7-26. 7.01-02
3rd ring groove oil scraper ring 2500.7-26. 7.01-03

HFO operation
1st ringigroovk rectangular ring 2500.7-26. 1
2nd ring groove compression ring 2500.7-26.17.01-02
3rd ring groove oil scraper ring 2500.7-26.17 .Ol-03

Dismounting
To avoid loosening of the cylinder liner when lifting the cylinder head or during the subsequent
turning process, the liner must always be secured with a holding device in the crankcase.

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Page

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11/I997 MaK Motoren GmbH & Co. KG 15
 Engineer’s Handbook M 25
liners
‘\
/
Nominal size EI (original size) -+ 255.00 t 0.052 mm
/
Wear limits zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Wear and tear value -+ 0.90 mm

Max. ova-lity,
i
0 25
4 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA l mm 1

Wedge shape Height + I 6.00

Depth * +
I 003.
Wedge-shaped indentation across the entire circumference, beginning at TDC 1st pistun
ring

Canyon Max. number +

600
. mm
i ‘i zyxwvutsrqponm
Length ---+

3.50 mm I
Total width

hdiuidual deep blo w-througlz ducts in zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

t he area of the 1st pist un ring fTDC)

Scor e Number -+
f \
Length ---+ l!a.oo mm
i zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPO
J
/ \
Depth + 003
. mm
/
Hard vertical, linear f r ict ion mar k s.

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 Engineer’s Handbook M 25

Pocket Number -+

Length -+ r mm
60.00zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPO

‘)
9
Width ** -+ (20.00 mm 1
i

f- \
Depth zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
* --+ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
002
. mm

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 Engineer’s Handbook M 25
Assembly zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
During installation take care that marking ‘L
- 1 - of the liner coincides with marking
2 --:x:;Eg: , zyxwvutsrqponmlkjihg
- 2 - of the cooling water distributor casing.
The liner must slide into the cylinder
crankcase by its own weight.
At t ent ion! hcor r ect ly he/ t ed liner s may cause ex t ensiv e damages.
; *
m- -+ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

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 Engineer’s Handbook M 25
Connectinq rod
Big end bearing \
1. zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Tighten upper big end bearing bolts successively with + M = 150 Nm

/ \
2. Tighten upper big end bearing bolts successively up to -+ Nm
/
\
3. Tighlenlower big end bearing bolts successively with --+ ’ M = 150 Nm
L

4. Tighten lower big end bearing bolts successively up to --+ M = 300 Nm \

/ \
5. Tighten upper big end bearing bolts successively up to + M = m Nm
\

6. Tighten lower big end bearing bolts successively up to + M = 600 Nm ‘1

7. Tighten upper big end bearing bolts once more \

successively up to -+ M = 6w Nm

Coat threads and contact sun(aces with a thick layer uf Molykote G Rapid Plus.

\\\I
Y * 4
-_--- ---- ___- -- I----L*-_--------*-*---,- -

t
-
t
I

I
[

1
I

Here cylinder No.

tower screws

Reference dimension of the big end bearings after correct tightening.

r \
Size ,,A” -3 193.16 t 0.05 mm

Actual size A+0.04+0.01

Size zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
,,B" + mm 1

The reference dimension of the piston pin bush after shrinking-in f \

into cooled state is 0 -+ 120.11 t 0.08 mm

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 Engineer’s Handbook M 25
Crankshaft bearing
Tightening torque / \ zyxwvutsrqponm
The zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA M = 450
tightening torque for inserting the studs zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
- 1 - is -+ Nm
Md’kote lubrication \ J

Tighten crankshaft bearing nuts

- 2 - steadily by hand. Insert
hexagonscr‘ews -‘3 - with
Molykote and tighten
alternately in 3 steps.

Tighten 1st step up to -+ M = 140 Nm

Tighten 2nd step up to + M = 420 Nm

/ \
Tighten 3rd step up to --+ M = 670 Nm
< /

Lengthen studs - 1 - with --+ P = WI bar

\ /
and tighten crankshaft bearing nuts - 2 - .
Tighten both crankshaft bearing nu& of one bearing pocket in me operatim.

Measurement of gap
1. Remove hexagon screws - 3 - of the crankshaft bearing. Loosen hexagon screws - 3 - of the
adjacent crankshaft bearing.

2. Loosen both crankshaft bearing nuts -2 - of one bearing pocket in one operation.

3. Tighten crankshaft bearing nuts with a pin alternately and steadily until the joint faces
of the bearing shells touch each other.

4. zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Checkthe projecting length of the bearing shell by measuring the gap between cylinder
crankcase and bearing cap on camshaft and exhaust gas side.

Sum of gap --+ i

0.75 - 1 .oo mm 1

After longer operation the sum of gap shall not be less than II) 060
m mm 1
1

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 Engineer’s Handbook M 25
Marking zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
The protection against
Bearing caps and bearing
,,.’ torsion is on camshaft
shells are marked OR side.
camshaft side with relative
cylinder numbers counted
from flywheel side. The parts
must nut I be mixed up.
r -. ff
:I -w

Marking X of the thrust

washers at the
circumference near the

Located and normal main bearings are identical, for axial

fixing on bearing 1 (located main bearing) thrust washers - 1
mwith clamping pins - 2 - are mounted on bearing cap - 3 -.

Located main bearing

End clearance --+ 0.30 - 0.60 mm I

Clearance limit -9 I 0 80
l
mm I

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 Engineer’s Handbook M 25
Crankshaft
Counterweight mounting
Tighten screws zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
with --+ M = 650 Nm
\ /
Lubricant Molykote (G-RapidJ on thread and screw contact surface.

6 cyl. engine zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

1 2 counterweights
i -w B _-

8 cyl. engine 12 counterweights

Crankpin 1 2 PCS.
Crankpin 2 1 PC. left side *
Crankpin 1 PC. right side ’
Crankpin 4 2 PCS.
Crankpin 5 2 PCS.
Crankpin 6 1 PC- left side *
Crankpin 7 1 PC. right side *
Crankpin 8 2 PCS.

9 cyl. engine 12 counterweights

Crankpin 1 2 PCS.
Crankpin 2 1 PC. left side *
Crankpin 3 without counterweight
Crankpin 4 2 PCS.
Crankpin 5 2 PCS.
Crankpin 6 2 PCS.
Crankpin 7 without counterweight
Crankpin 8 1 PC*. right side *
Crankpin 9 2 PCS.
* = seen from camshaft side.

Crank web deflection

Limit values
Cylinder 1 -+
I
011
I mm

Other cylinders --+ ‘0.0, up to - 0.08 mm

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 Engineer’s Handbook M 25
Gear train
Gear wheel on crankshaft
Press gear zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
wheel with device and oil hydraulic mounting f \
-connection Z - -3 P = 500 bar
ORthe crankshaft cone into the final position.

The final positian is reached when the gear wheel touches the spacer; The spacer simu/ates
the lo& fedbLaring, it must be adjusted so that with the gear wheel in final position a
dimension of 126 + 17.f
mm results befween gear wheel and crank web cyl.1.

The slide-on distance is 12 _,,mm.

The device must still remain fitted 20 minutes a&r pressure relict:

Engine sta/f 2 hours after pressure relief at the ear/jest

Spacer

//
Connection

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 Engineer’s Handbook M 25
Intermediate wheel mounting f zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFE
\
Tighten screws zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
- 1 - with --+ M = 130 Nm
L / zyxwvutsrqpon

ElJd clearance S min. -+ mm 1

max. + 060
I mm 1

Gap size

Gap size between axle and locking sheet see - Y -

Min. -+ 030
. mm

Max. --+ 140

. mm

Backlash \
Crankshaft gear .. intermediate wheel + 0.23 - 0.35 mm
\ /
r \
Intermediate wheel - camshaft gear _c) 0.23 - 0.35 mm

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Co. KG 24
 Enaineer’s
v
Handbook M 25
Gear wheel mounting new zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
design zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
- 1 - m ustnotzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
extend into the gear
Jour nal zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

box .
Tur n the camshaft gear wheel - 2 - with the
device into the gear box. Push the journal
until it touches the camshaft gear wheel cone.
Prefit helical gear - 3 - until it touches the
camshaii gear*wheel. Mount the camshaft
gear wheel hydraulically on the bearing
journal cone by tightening screws - 4 - up to
the end of the cone.
Attention! Tighten screws - 4 - steadily.
Final position: Draw helecal wheel - 3 -
against bearing journal - 1 -.
Slide-on distance: 10.5- 2.9mm

Tighten screws - 4 - with M = 130

-+ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
i N m ‘i
Mo l’kute zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
lubr icat iun

M6x 80 DIN 93188

Tighten screws - 5 - with --+ M = 140 Nm \

hioly k ot e hbr icat iun

M14 x 60 DIN 931 lo.9

End clearance S -+ 0.30 - 0.70 mm

tub. oil injectors for the gear drive

Tighten screws with --+ M = 160 Nm 1

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 Engineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedcbaZYX
Governor drive
\
- 1 - with -+ M = 30
Tighten castle nut zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Nm
1
further up to the next
split pin hole. zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Mo ly ko te zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
\
End clearance -P2 - --+ mm
r' -* /

--A
Backlash
- 3 - -+ mm
/

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 Engineer’s Handbook IWI25 zyxwvutsrqponmlkjihgfedcbaZY

_-_
1 __--
_. -._
If the bushes - 1 - and - 2 - in the cylinder crankcase
must be exchanged, take care that the dimensions
stated in .fhe.sketch are observed.
Slightly ail the bushes before pressing them in, do not
use Molykote. zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

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 Engineer’s Handbook M
_~
25 zyxwvutsrqponmlkjihgfedcbaZ
Camshaft \
- 1 - with -+ M = 140
Tighten screws zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Nm
\
Mulyku~e zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
hbr icat iun
/
Ml& 60 &7/ / V 931 lo,9

f 3

Tighten fixing screws for the camshaft bearings with ---+ M = 140 Nm
Moly k ut e lubr icat ion

Allen scr ew s M76 x 100 IA DIN 912

Vibration damper mounting 1

1
Tighten screws - 1 - with -+ M =35
i Nm I
Mulykute lubricatiun
Screws Ml4 x 60 DIN 9318 8
2

Tighten screws - 2 - with -+ =

M 50
Mulykute hbricatiun
Sr cew s M2x 70 DIN 937 8.8

Bore arrangement Bore arrangement for

for 6 / 9 M25 8 M2S zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHG

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 Enaineer’s Handbook M 25
Mounting of camshaft

Flang_e._
,__-__ code number ,X” (see table below)
-.~- .---.
,/ Position of cylinder pin

‘k, Flange
------ code number ,X” (se table below)

Position of cylinder pin

6 cyl. engine 8 cyl. engine

Part cylinder Flange code number Part cylinder Flange code number
1 5 1 1
2 1 2 2
3 6 3 3
4 5 4 4
5 3 5 5
6 7 6 6
7 7
8 8

9 cyl. engine
zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Part cylinder Flange code number

1 5
2 8
3 2
4 6
5 4
6 4
7 6
8 2
9 8 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDC

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 Engineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedcba
Tighten fixing screws - 1 - for the camshaft bearings
f --I
with + zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
M = zyxwvutsrqponmlkjihgfedcbaZYXWVU
130 Nm
hf ulyk o te \ /

Allen scr ew s Ml6 x IOU-ZA D&V 912

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997 MaK Motoren GmbH & Co. KG 30
 Engineer’s Handbook M 25
Fuel iniection pump zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDC

The tightening torque for inserting the studs is + M = zyxwvutsrqponmlkjihgfedcbaZYXWVUTS

120 Nm -1

Tighten fastening nuts with --+ ’ M = 200 Nm1

Mo ly ko re I’
_) e

Pretighten screvus - 1 - with --+

and tighten with -+ M = 9023 Nm

7
I

Tighten screws - 2 - with .3 M = 5322

Tighten screws - 3 - with M = 14kl Nm ‘i

M = 2222 Nm
Tighten screws - 4 - with zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA1

Tighten countersunk screws for

the indicator at the fuel
rack with -+ M = 3.50 + 0.50 Nm

Tighten threaded socket - 5 -

with ---+ M = 155 Nm

5 .

Mixed oil drain

’ Tightening
/”
” torque
max.30 Nm

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 Engineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedcbaZY
Tighten screw - 1 - with -+ = 60 Nm
Malyko te

Mounting
Before mounting the injection pump take care that the roller of the rocking lever is situated on the
cam base circle and that the air passage sleeves are correctly positioned in the coolingwater
distributor casing

Starting process
The engine starting process is controlled via the injection pumps.
Roller of rocking lever on
cam base circle
Plunger in BDC-position Stmtirrg process is released Plunger in TDC-position

Venting is released zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

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 Engineer’s Handbook M 25
Dismounting/mounting zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
During dismounting / mounting attention must be paid that the appertaining distance steel plates are
not removed.
If for any reason removal of the distance steel plates is necessary, they have to be marked with the
relevant cylinder number. zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Jhe thickness of the distance steel plates for each cylinder is stated in the acceptance test
record.
;
: . -w *

Check of commencement of fuel delivery

Commencement
1. Dismount the injection pump deliveryvalve. of delivery
2. Mount dial gauge with extension.
Position of
3. Turn engine so that roller rests on the base circle commencement
of cam and the TDC mark is abt. 45” before the of delivery
dead center indicator.
4. Set dial gauge to ,,o”, turn engine in direction of
rotation until the indication on the gauge is 5 mm
(5 mm on the gauge correspond to 11 O crank angle
on the flywheel).
5. Check the dimension on the
flywheel from zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
TDC- mark to dead e
II
center indicator. i
Il
Setting l
I7

1., Place the gauge with measuring CD

a
%
device on a level support by I
means of the adjusting bush
(dimension = 24.6 mm) and set
gauge to &I”.
2 Insert measuring device into the
l

injection pump bore in the

engine housing and read value
on the dial gauge (roller on the
base circle of cam).
3 * Indicated value = thickness of
the distance steel plates.

The distance steel plates are used

for setting the pre-stroke.

Available sizes:
2.20 mm 2.40 mm
2.60 mm 2.80 mm
3.00 mm 3.20 mm
3.40 mm 3.60 mm

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Edition zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Page
2 8 /l 1/I 997 MaK Motoren GmbH & Co. KG 33
 Engineer’s Handbook M 25
Lower valve drive zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
f >
Tighten screws zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
- 1 - for the bearing brackets with -+
M = 130 Nm

End clearances -+ mm I

,’

1 min.020 A min. OZUj)+

mulating shaft

I =
1
Nm1

-T
Tighten screw - 1 - with + -- I -
-i_ M 130

i
I
I

Clearance at - 2 - -+ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
025 l mm 1

Before inserting the regulating shaft lubricate the bearing spots.

Do not use Molykatt?.

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28/l 1/I 997 MaK Motoren GmbH & Co. KG 34
 Engineer’s Handbook M 25
Flywheel
Insert
studs - 1 - with Loctite 243 into the flywheel. Grind clamping pins - 2 - at the
zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA sharp-edged end
(chamfer abt. 2 x 1 5 0 )and insert them with this end into the gear wheel on the crankshaft. Turn
crankshaft into TDC cyl. 1 position. Guide splash ring - 3 - over the crankshaft cone. Align end cover
- 4 - centered to the crankshaft and flush with the bottom edge of the cylinder crankcase and fit it.
Oil crankshaft tune with hydraulic oil. Hang flywheel in the transfer port and slide it OR the
crankshaft cone until contact is reached. Fit tightening device. Take care that the flywheel is fixed on
the locati’&jcinof the device. In this position the projecting clamping pins at the gear wheel on the
crankshaft are aligned to the relative receiving bores at the flywheel.

Tighten nut on the device with -s M = 16Ml Nm

Press flywheel with tightening device and oil hydraulic mounting into final position zyxwvutsrqponmlkjihgfedcbaZYXWVUT

Oil pressure -9 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

P = 1200 bar 1
f \
The slide-on distance is -+ 23 - 35 mm

End clearance - 7- -+ 5 0.30 t 0.30 mm

(Continued on page: 3 6 )

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 Engineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedcbaZ
The device must not be loosened earlier than 60 minutes after pressure relief Engine start 24 hours
after pressure relief at the earliest in case of an emergency start after 12 hours with max. output of
60%. Mount the splash ring on flywheel,

Tighten screws - 5 - with -+

I3 screws Ml6 x 45 DIN 933

; -+

Mount nuts - 6 - with clamping disk If? DhV67!%

and tighten them with = 75
-+ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
i M Nm 7
10 nuts A410 DIN 934 secured with Loelite 243.

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 Engineer’s Handbook M 25

Mounting without power take-off zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Pretighten screws - 1 - with --+

and tighten with

Molyko te
-+
I Dw = 90
0

6 cyl. engines-- 10 tensiun bolts

8 cyl. engines - 12 tension bolts
9 cyl. engines - 14 tension bolls zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
M = 75 Nm
f 1

SCWW 8lr8ll~~fM’lt Screw arrangement Screw arrangement

6 cyl. engine 8 cyl. engine 9 cyl. engine

Tighening torque for Ml6 screws

fyku te
-+
Mu zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
f
M 130 NM
‘i
= zyxwvutsrqponmlkjihgfedcbaZYXWVUTS

Mounting of pump carrier

Degrease all flange facings. Provide pump
carrier with sealing compound and position
it at the cylinder crankcase using a device.
Screw the carrier on and pin it.
Apply a thin layer of the sealing compound
only in the double-hatched area. Take care
that no sealing compound clogs the oil
ducts.

sealing compound in the hatched area only

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 Engineer’s Handbook M 25
Mounting with power take-off zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Pretighten screws - 1 - with -+ ,M = 250 Nm
1
and tighten with -+ r Dw = 90 0
Mulykate L /
6 cyl. engines - 10 tension bolts
8 cyL engines * 16 tension bolts
9 cyl. ehgiiiei - 16 tensjon bolts

c; From loo0 kW power

G
/A

kW power

Screw arrangement Screw arrangement

6 cyl. engine 8 and 9 cyl. engine

Tighten screws M 12 with + M =60 Nm

Molykute
Tighten screws M 16 with --+
Molyku te
Mounting see page: 37

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38
 Engineer’s Handbook M 25
Pump carrier with attached pumps
Pump carrier f zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFE
Tighten screws with -+ M = 130 Nm

On engines without power take-oh? 20 screws M16 x 60 DIN 931

On engines with power take-oh? zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
34 scr ew s Ml6 x 60 DIN 931

Lub. oil:pumpTs, suction and pressure pump, cooling water circulation pumps
Gear wheel mounting
Check contact reflection on the appertaining pump gear cone with gear wheel cone, covered with
blue paste.
Contact reflection 2 80’. Heat gear wheel up to 9O”C-100°C above temperature of the pump shaf;
and mount it firmly on the pump cone up to stop position. The cone faces must be grease-free and
dry*
Example: 20” C shaft temperature + 110 O bis 120 u C gear wheel temperature.
The slide-on distance is 440 - a4 4 mm.

Tighten screw for the gear wheel with -+ M = 60

I Nm I

Lubricant: Molykate

Backlash + 0.20 * zyxwvutsrqponmlkjihgfedcbaZYXWVUTS

0 .4 5 mm 1

Backlash fuel-feed pump --+ i 0.20 - 0.45 mm 1

-as manifold
/ \
Tighten all M 16 screws with -+ M = 100 Nm
High temperature! Use paste DAG 5080 \ /

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 Enqineer’s
_ Handbook M 25
j zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
Mounting 2500.7-72.50.00-Olcouplingside
oppositesideof coupling f zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHG
2500.7-72.55.00-01 -Y
Tighten screws - 1 - with IL) M Nm
=60 zyxwvutsrqponmlkjihgfedcbaZYXWVU
\ /
Moly k ot e

For 2500~ 7-72.50.00-01 - 10 hex agon scr ew s M12x 55 DIN931

i ‘)
10 t ension sleev es E2lx 20 DIN 2510

I hex agon scr ew M12x 35 DIN933

II w asher s 73 DIN 125

For 2500,7-72 55.00-01 I7 hex agon scr ew s MZx 55 DIN931

11 t ension sleev es E2Ix 20 DIN 2510

I1 w asher s 73 DIN 125

lske ts zyxwvutsrqponmlkjihgfedc

P-----k

L
r-7 ki2J__-J
i zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
I I

kY---- zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Edit ion Sercice document of zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPON

Page

MaK Motoren GmbH & Co. KG

28/U /IzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
997 40
 Engineer’s Handbook M 25 zyxwvutsrqponmlkji
Mounting 2500.7.72.50.00-02coupling
side
r zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHG
2500.7-72.55.00-02oppositesideofcoupling
Tighten screws - 1 - with -+ M = 60 Nm zyxwvutsrqponmlkj
i
Mulyk u te

For 2500.7-7~ 50.00-02 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

8 hex agon screws M16x 60 DIN931

I 8 fension sleeves EXx78 DIN 2510

; -* *
8 washers 13 DIN 125

For 2500.7-72.5500-02 8 hexagon screws MI2x 55 DIN931

8 tension sleeves EZx 20 DIN 2510

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1/I 997 41
 Ensineer’s
_ Handbook M 25 zyxwvutsrqponmlkjihgfedc
Mount ing 2500.7-72.50.00-03 / - 04 coupling side
f zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFED
Tighten screws - 1 -, - 2 - and - 3 - with + M =60 NlTl zyxwvutsrqponmlk
\ /
Mo ly ko te
fur 2500.7-7250.00-03
10 hexagon screws MlZx55 DIN 937
10 tension sleeves EZlx20 DIN 2510
I hexagon screw Ml2~35 DIN 933
9 hexagon scfews MlZr60 DIN 931
9 washtks -Ti;J
DIN 125
Fur 2500.7-72.50.00-04
10 hexagon screws M7Zx55 DIN 931
10 tension sleeves EZlx20 DIN 2510
1 hexagon screw IMlzU35 DIN 933
9 hexagon screws iUUr65 DIN 931

No gaskets here

6 - zyxwvutsrqponmlkjihgfedcbaZYXWV
B (only var. -WI

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 Engineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedc
Mount ing 2500.7-72.50.00-05 coupling side and 2500.7-72.55.00-04 opposite side of coupling
\ zyxwvutsrqponmlkjih
Tighten screws - 1 - with --+ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
M = 130 Nm
/
Md’y k o te I
f
Tighten screws - 2 - with -+ M =60 Nm
Moly k o te 1

f or 250~ 7-72.50.00-05

11 hex &&f ew s Ml2x 65 DIN 931

11 w asher s 13 DiN 125

7 t ension sleev es EZlx 23 DIN 2510

8 hex agon scr ew s Ml6x 60 DIN 931

8 t ension sleev es EZx 18 DIN2510

Fuf 2500.7-72 55 00-04

11 hex agon scr ew s t WlZx 65 DIN 931

11 w asher s 13 D/ Iv 125

8 hex agon scr ew s M16x 60 DIN 931

8 t ension sleev es E26x 20 DIN 2510

Mounting 2500.7-72.55.00-03 opposite side of coupling f

Tighten screws - 1 - with -+ M = 60 Nm
/
Moly k at e

11 hex agon scf ew s MZx 55 DIN 931

17 t ension sleev es EZlx 20 DIN 2510 nc.

Edition zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
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 Engineer’s Handbook M 25
Charge air cooler
Installation zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
2500.7-72.40.00-01 coupling side
2500.7-72.80.00-01 opposite side of coupling zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONML
1 . Fix L-strap - 1 - with screws - 2 - at the charge air cooler without water separator.
2. Loosen landing surface - 3 - at the charge air cooler and press them against the cooler.
3. Push the charge air cooler into the casing.
4. Before screwing the charge air cooler together with the casing, tighten screws - 4 -,
5. Fix ihe-charge air cooler with screws - 5 - and washers at the casing.
6. Push the landing surfaces against the casing and fix them with screws - 6 -.
2 - 2 hexagon screws M8x45 DIN 937 with spacer act. to drawing number
4 = 34 hexagon screws MlZx40 DIN 933 with washers 13 DIN 125
5 = 3 hexagon screws Ml6x80 DIN 93 with washers 17 DIN 739

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44
 Engineer’s Handbook M 25 zyxwvutsrqponmlkjihgfedcbaZ
Tighten screws - 2 - with -+ r \
M = 20 Nm
Mulykote i ,

Fixing screws
Tighten charge air cooler casing - cylinder crankcase f
with + M = zyxwvutsrqponmlkjihgfedcbaZYXWVUT
130 Nm
\ 1
Molyko te
1. --w *
IO hexagon screws M16x90 DIM 931 with tension sleeves E26x24 DIN 2510
5 hexagon screws Ml6x140 DIM931 with washers 17 DIN 7349

Installation 2500.7-72.40.00-02 coupling side

2500.7-72.80.00-02 opposite side of coupling

1. Fix L-strap - 1 - with screws - 2 - at the charge air cooler.

2 Loosen landing surface - 3 - at the charge air cuoler and press them against the cooler.
3. Push the charge air cuoler into the casing.
4 Before screwing the charge air cooler together with the casing, tighten screws - 4 -.
5. Fix the charge air cuuler with screws -5 - and washers at the casing.
6. Push the landing surface against the casing and fix them with screws - 6 -m

2 - 2 hexagon screws M8x45 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

DIM 931 with spacem act. tu drawing Nu.
4 134 hexagon screws M12x40 DIN 933 with washers 13 DIN 125
5 = 3 hexagon screws M16x80 DIN 93 with washers 17 DIIV 7349

Tighten screws - 2 - with -+ M = 20 Nm

Mulyku te

Fixing screws
Tighten charge air cooler casing - cylinder crankcase r \
with + M = 200 Nm
Mulyko te

10 hexagun screws Ml6x90 D/N 931 with tension sleeves E26x24 DIN 2510
9 hexagon screws Ml6x140 DIM 931 with washers 17 DIN 7349

Edition Page
Sercice document of zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONM
28/H/1997 MaK Motoren GmbH & Co. KG 45
 Engineer’s Handbook M 25

/ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
6

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28/l zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
1/I 997 MaK Motoren GmbH & Co. KG 46
 Engineer’s Handbook M 25
Installation zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
coupling side
2500.7-72.40.00-03/2500.7-72.40.00-04
2500.7-72.80.00-03 /2500.7-72.80.00-04 opposite side of coupling
Fix L-strap - 1 - with screws - 2 - at the charge air cooler.
1. zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
2. Push the charge air cooler into the casing.
3. Draw the charge air cooler with screws - 3 - against the sealing surface. Loosenscrews
somewhat again.
4. Fix the charge air cooler with screws - 4 - und - 5 - at the casing.
5. Now draw the charge air cooler with screws - 3 - finally against the sealing surface of the air
inlet of the casing.
2 = 2 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
hexagon sc re w s zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
M8x 4 5 DIN 931

3 = 6 Allen screws Ml&55 D/ IV 912

4 = 34 hex agon scr ew s MlZx 4 0 DIN 933 w it h w asher s 13 DIN 125

5 = 3 hex agon scr ew s Ml6x 80 DIN 933 w it h w asher s I7 DIM 739

Tighten screws - 2 - with -+ Nm ’

J
Molykoie
Fixing screws
Tighten charge air cooler casing - cylinder crankcase
with --+
Molykote
For 2w a 7-72.4 11.00-03

10 hexagon screws M16x 90 D/ N 931 w it & t ension sleev es EZ6x 24 DIN 2510

5 hex agon scr ew s / Ul6x l4 0 D/ N 931 w it h w asher s 17 DIM 734 9

For 2500.7-72.4 0,00-04

10 hexagon screws M16x 90 DIM 931 w it h f ensiun sleev es EZ6x 24 DIIY 2510

9 hex agon scr ew s Ml6x l4 0 DIN 931 w if h w asher s 17 Dlf f 734 9

Sercice document of
Edition zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Page
2 8 /l 1/1 9 9 7 MaK Motoren GmbH & Co. KG 47
 Enaineer’s Handbook M 25
Desiqnation Lenqth mm Breadth mm Heiqht mm Wei_qht

Crankcase, zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
without studs,
with bearing caps and bearing bolts
6 cyl. engine 3287 1.300 1.475 6.640

8 cyl. engine 4.147 1.300 1.475 8.460

; -* ‘a
9 cyl. engine 4.577 1.300 1.475 9.460

Crankshaft
with counterweights
6 cyl. engine 1.917

8 cyl. engine 2.523

9 cyi. engine 2.725

Crankshaft
without counterweights
6 cyl. engine 3.171 456 1445

8 cyl. engine 4.031 456 1850

9 cyl. engine 4.461 456 2082

Counterweight 400 88 215 53

Oil sump
6 cyl. engine 3.369 !Mi8 399 4%

8 cyl. engine 4229 968 399 580

9 cyl. engine 4.659 968 399 637

9 cyl. engine 4.659 968 729 912

Edition Sercice document of Page

28/l 1/I 997 MaK Motoren GmbH & Co. KG 48
 Engineer’s Handbook M 25
Desiqnation Lenqth mm Breadth mm Heiqht mm Weisht
Liner 0 354 780 162

Fire ring 58 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

0 266 2

Main bearing 88 0252 3

Big end bearing 96 0 204 08I

Intermediate wheel
with bush 95 0 356 62

Intermediate wheel 0 98 zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJ

axle zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
320 1 718

Vibration damper
Crankshaft
6 cyl. engine 200 0 850 980

8 cyl. engine 145 0 900 632

9 cyl. engine 145 0 850 558

Vibration damper
Camshaft
6 - 8 - 9 cyl. engine 62 0 330 29

Camshaft part 430 0 205 48

Camshaft bearing 55 0224 28$

Camshaft end bearing 124 0 288 728

End bearing journal 305 0 255 76

Gear wheel on camshaft

compl. with hub 95 0709 2fio

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28/ l 1/ 1997 MaK Motoren GmbH & Co. KG 49

 Engineer’s Handbook M 25
Designation Len_sth mm Breadth mm Heisht mm Wdht kQ

Gear wheel CM crankshaft 122 0 365 44

Charge air cooler

6 cyl. engine zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
1057 34 5 4 86 270

8 - 9 cylA&jne zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA
1287 345 486 309

Cyl. head zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

compl. 265

Cyl. head
without inlet and exhaust valve
with valve guide 725 428 351 194

Valve stem 446 0 84 15I

Cooling waterdistributing housing 263 90

Piston with connecting rod 125

Built-up piston 0 255 390 57

Connecting rod 979 118 82

Piston pin 220 0120 17

zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Pump carrier
Thickness 40 1.075 1.007 198

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28/l 1/I 997 MaK Motoren GmbH & Co. KG 50