M20

m
c
M20
m
Engineer ´s Handbook
M20 c
Contents
Camshaft
Camshaft bearing 34
Dismounting - mounting 35
Tightening torques 35
Vibration damper 34
Charge air cooler mounting

Cleaning 51
Connecting rod
Gap 21
Piston pin bush 20
Reference dimension 21
Crankshaft
Counterweight 27
Crank web deflection 27
Gap 26 - 27
Marking 26
Normal main bearing - located main bearing 27
Cylinder head
Exhaust gas manifold 12
Fuel injection valve 10 - 12
Guiding bolts for the valve bridges 10
Sleeve for fuel injection valve 10
Tightening torque 7
Valve bridge - setting 8
Valve clearance 9
Valve guide 9
Valve rocker 8
Valve rocker bracket 7
Valve rotator 9
Valve seat ring 15
Valve stem - machining 13 - 14
Valve stem - using 9
Engine data 6
Edition Service document of Page

10.08.2001 Caterpillar Motoren GmbH & Co. KG 2
m
M20 c
Contents
Exhaust gas manifold 52
Firing sequences
6 cyl. engines 53
8 cyl. engines 53
9 cyl. engines 53
Flywheel mounting
Flywheel variants 49
Gear rim on flywheel for pneumatic starter 48
Fuel injection pump

Check of commencement of fuel delivery 41
Fuel distributing and collecting pipe 40
Tightening torques 37 - 39
Gear train
Backlashes 31
Gear wheel on camshaft 32
Gear wheel on crankshaft 28
Intermediate wheel - end clearance 31
Intermediate wheel - mounting 30 - 31
Lub. oil injectors for the gear drive 31
Mounting of crankshaft gear wheel 29
Governor drive
Backlashes 33
End clearance 33
Governor drive gear 33
Indication 5

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M20 c
Contents
Liner
Canyon 22
Fire ring 23 - 24
Mounting 24
Nominal size 22
Pocket 22
Score 22
Wear limits 22
Wedge shape 22
Lower valve drive 36
Opposite side of coupling

Vibration damper 45
Piston
Piston rings 19
Tightening torques Mahle 16 - 17
Tightening torques MHW 17
Tightening torques KS 18
Wear and clearance limits 18
Pump carrier with attached pumps

Backlashes 47
Cooling water pump 46 - 47
Fuel feed pump 46 - 47
Lub. oil pump 46 - 47
Pump carrier 46
Pump carrier plate 46
Sizes and weights 54 - 55
Sundries
Fuel indicator 43
Regulating shaft 42 - 43
Cooling water distributing pipe 44
Valve timing
Inlet and exhaust valve 53

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M20 c
Indication
By constructional measures on the injection system and by simple and permanent setting
of the ignition timing and the fuel rack reading - already during assembly of the engine -
adjustment
of the firing pressures during the test bed run can be avoided.
Therefore, firing pressures and compression pressures are not stated in the acceptance
test records.
On the occasion of checks and measuring trips later on indicating shall not be carried
out. Only in exceptional cases and only after consulting the technical service MK the
setting of the injection pumps may be changed.
The following values serve for judgment on possible failures:
1. Engine speed
2. Fuel rack reading
3. Lubricating oil t inlet engine t oil cooler inlet
4. Fresh water t inlet engine t outlet engine
t inlet charge air cooler t outlet charge air cooler
t outlet turbocharger
5. Charge air temperature t before cooler t before engine
6. Exhaust gas temperature t after cylinder t after turbocharger
7. Lub. oil pressure
8. Fresh water pressure
9. Charge air pressure after charge air cooler
10. Differential pressure at the charge air cooler

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M20 c
Engine data Engine operating data
Stroke = 300 mm Temperatures
Bore = 200 mm Lub. oil
Speed, rpm = 900 - 1000 Engine inlet 60 - 65 ° C
Main bearing Temperature rise 10 - 14 ° C
Inside Ø = 180 mm Fresh water circulation cooling
Outside Ø = 190 mm Engine outlet 65 - 80 ° C
Big end bearing Temperature rise 7 - 10 ° C
Inside Ø = 152 mm Charge air
Outside Ø = 161 mm Engine inlet 45 - 60 ° C
Valves, inlet and exhaust Pressures
Length = 336 mm Lub. oil 4.0 - 4.5 bar
Shaft Ø = 14.05 mm Fresh water circulation cooling
Valve head Ø = 66 mm With min. 4 mWs 2.5 - 6.0 bar
Valve guide Nozzle cooling 1.5 - 3.0 bar
Length = 175 mm Fuel pressure before injection

pumps
Inside Ø = 14.14 mm
MDO-operation 3.0 - 5.0 bar
HDO-operation 4.0 - 5.0 bar
Details for rated engine output and nominal

engine speed.

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M20 c
Cylinder head
Tightening torque
The tightening torque for inserting the tie bolts is → M = 300 Nm
Molykote
Lengthen bolts with → P = 600 bar
and tighten nuts with pin by hand. Molykote
Check: Reduce pressure to → P = 550 bar

Loosening the nuts must not be possible any more.
The pressure must remain constant if the pump is not operated, otherwise faulty tightening.
Dismounting: If the cylinder head nuts cannot be loosened with P = 600 bar, an increase by 50
bar is possible. Further pressure increase involves the risk that the thread will expand and the
nuts will jam.
At the control bore - 1 - leakages

between cylinder head, flame ring
and cooling water distributing
housing can be detected.
1
Valve rocker bracket
The tightening torque for inserting
the studs - 1 - is → M = 80 Nm
Oil
Tighten nuts - 2 - with → M = 120 Nm
Molykote
The tightening torque for inserting the studs - 3 - is → M = 40 Nm
Oil
1
Tighten nuts - 4 - with → 2 2 M = 60 Nm
Molykote
3
4

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M20 c
Cylinder head
Valve rocker (inlet and exhaust)
Original size → 0.12 - 0.14 mm
Limit clearance → 0.20 mm
Reference size for the bush after pressing-in Ø → 49.99 + 0.109

mm
The bush shall recede after pressing-in by → 0.20 mm
Before pressing-in slightly coat the bushes with oil, Molykote must not be used. 1
When shrinking-in new ball pins by
supercooling attention must be paid to
the accurate position - 1 - in order to
Z
guarantee perfect oil supply.
(Supercooling to -195 ° C with Z
nitrogen)
0.20
Setting of valve bridges and valve clearances

Valve rocker
1. Turn out adjusting screws - 1 - of the valve rockers to
obtain a sufficient clearance. 1
2. Turn out adjusting screws - 2 - of the valve

bridges to obtain a clearance at „Y“ when
valve bridge touches „X“.
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 bridge
2 Oil supply
The valve bridges were modified.
On modern engines visual checks allow to
ascertain if the valve bridge fits on the Y X
valve stem.

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M20 c
Cylinder head
Valve clearance
Setting under hot running conditions, abt. 15 min after stopping the engine.
Inlet → 0.60 mm
Exhaust → 0.80 mm
After repairs in cold engine condition:
Inlet → 0.60 mm
Exhaust → 0.65 mm
Valve guide
Inlet - Exhaust
Nominal clearance → 0.10 - 0.17 mm
Nominal size outside Ø 26,033 - 0,01

Over size outside Ø 27,033 - 0,01
Measure diameter of the valve shaft in the guide area. Measure guide in cross direction of
engine.
The valve guides are inserted in the cylinder head after cooling them down to -195 ° C
(liquid nitrogen)
The valve stems are used as specified below:

Inlet Exhaust
HFO 1.10.7-22.10.01-01 / -03 / -07 1.10.7-22.10.01-01 / -02
MDO 1.10.7-22.10.01-01 / -03 / -07 1.10.7-22.10.01-01 / -05
From March 2001 on the inlet valve stem 1.10.7-22.10.01-07 is standard equipment for MDO and
HFO operation.
This valve stem has 20° -8´, the valve stems 1.10.7-22.10.01-01 and -03 have 30° -8´.
Valve rotators
MDO - operation: only at the inlet valves
HFO - operation: at inlet and exhaust valves

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M20 c
Cylinder head
Guiding bolts for the valve bridges.
The tightening torque for the guiding bolts is → M = 150 Nm
(Thread M30x2) Loctite 243
The tightening torque for the guiding bolts is → M = 200 Nm
(Thread M36x2) Loctite 243
Oversize for repair purposes
Insert guiding bolts with Loctite 243

and provide the contact faces with
Molykote.
Tighten the sleeve for the fuel injecion valve with → M = 100 Nm
O-ring Viton, green
O-ring Perbunan
Fuel injection valve

The tightening torque for inserting the studs is → M = 40 Nm
Oil
Pretighten nuts with → M = 55 Nm
and loosen again,
then tighten with → M = 30 Nm
Molykote
Tighten nozzle nut with → M = 250 - 20 Nm
Oil lubrication

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M20 c
Cylinder head
Removal
Loosen pressure screws - 1 - and - 2 -.
Loosen transverse thrust piece - 3 - with cover - 4 - by lever effect, then force radial
thrust piece - 5 - out of its end position.
(Important, otherwise damages are inevitable.)
Unscrew nuts from the injection valve. Remove flange - 6 - and mount it again inversely
(180 °).
Screw extractor - 7 - on adjusting screw - 8 - and loosen nozzle holder by turning
against the flange - 6 -.
Withdraw the injection valve from the cylinder head.
5
4
1 3
2
6 Sequence of installation:
1. Insert injection valve, tighten acc. to specification,
and loosen it again.
2. Fit radial thrust piece - 5 - and transverse thrust

piece - 3 -.
3. First tighten pressure screw - 2 -, then pressure

screw - 1 - manually, then tighten pressure
screw - 2 - and after that pressure
screw - 1 - acc. to specification.
4. Tighten injection valve acc. to specification.

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M20 c
Cylinder head
Tighten pressure screw - 1 - and - 2 -
with → M = 85 Nm
Tighten screws - 9 - for connecting

housing with → M = 35 Nm
Molykote
Screws M10x 55 ISO 4762
9
Exhaust gas manifold

Tighten screws to cyl. head alternately.
1st step up to → M = 60 Nm
and
2nd step up to → M = 110 Nm
Dag S5080

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M20 c
Cylinder head
Grinding of inlet and exhaust valves
Apply small dots of the diamond paste Dp 30/10-15 my with a syringe to the new or
remachined valve cone and distribute the
+0.1 -0.3
paste equally. Thereafter the seat ring
surface is to be sprayed with a thinner Ø 62.5 -01
(F25) belonging to the diamond paste, for
Reference dimension 6.93

Ø 59 -02
dilution and in order to increase the grip.
8´
Insert the oiled valve stem into the guide
°-
30
bush. Fasten the device at the valve head
and grind the valve face and seat by hand
applying a moderate pressure, rotating the
4.71
device. The contact reflection „a“ which is
Inlet valve
visible by the smooth grinding process shall
not exceed 30 % of the seat width starting
from the outside diameter. If the
bearing characteristics described
above are not reached,
+0.10
Reference dimension 6.55 -0.30
remachining of both sealing Reference dimension Ø 62.5 -01
surfaces is necessary. Ø 59 -02
After machining both seats
8´
have to be checked with a
°-
20
luminous magnifier. The
fillet must not be refinished.
After machining round 4.71
off the outside edge with a stone.
Inlet valve
The dimensions specified in the 1.10.7-22.10.01-07
sketch are to be observed.
Reference dimension
Ø 62.5 -01
5.71 +0.1 -0.3
Ø 59 -02
29°52´+2’
4.71
Exhaust valve

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M20 c
Cylinder head
Deviations from true running
The deviation from true running on the valve stem must not exceed 0.04 mm on the
measuring distance „S“ of 200 mm.
The deviation from true running on the valve cone must not exceed 0.02 mm.
For both measurements the valve stem must
lie in the measuring device at points A and B.
20 20
A B
Reuse of a valve stem is not possible if:

1. there is severe pitting on the bottom side of the
valve head (formation of so-called „paving stones“),
2. there are corrosion pits and mechanical

damages in the area of the valve stem, stem
transition, and valve head,
s
3. the limit for refinishing is exceeded.
4. In case of corrosive material wear of 2 % from the valve head diameter.

In case of high-temperature corrosion „S“ of 1.50 mm.

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M20 c
Cylinder head
Fitting of valve seat rings
1. Cool valve seat ring down to -195°C
(liquid nitrogen).
2. Insert inlet and exhaust valve seat rings.
3. When the valve seat rings are tight,
press them on with hydraulic device.
4. Check of the bearing surface „Y 2“,
between inlet valve seat ring and
cylinder head no air gap is admissible.
5. Check of the air gap „Y 1“, between
exhaust valve seat ring and cylinder
head. Admissible air gap 0.2+0.3 mm.
Pressure test: Cooling water spaces
Y1
10 bar for 8 min.
Y2
Valve seat rings
Maximum admissible dimension for refinishing the
exhaust valve seat ring: Recess Y must remain
palpable.
inlet valve seat ring: Minimum dimension „Z“ must not be less than 1mm by refinishing.
Refinishing is possible with MaK valve refacer or MaK valve seat milling device.
After grinding there shall be a bearing face of 30-50 % starting from the outside diameter.
’
’+5
Z
5
30°
Ø59 + 0.2
Ø66 + 0.2
5’
5’+
20°
Ø59 + 0.2
Ø66 + 0.2
5’
5’+
30°
Y

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M20 c
Piston
Mahle 1.10.7-26.70.00-01
The tightening torque for inserting the studs in the
piston crown is → M = 10 Nm
Tighten nuts with → M = 35 Nm
loosen nuts again and check the tightening torque for inserting
the studs with → M = 10 Nm
and tighten with → Dw = 50°
Check : At a torque of → M = 35 Nm
the nuts must not turn further.
Mahle 1.10.7-26.70.00-02 / 03 / 04 / 05
The tightening torque for inserting the studs in the
piston crown is → M = 10 Nm
then tighten with → Dw = 80°
loosen nuts again and check the tightening torque for inserting
the studs with → M = 10 Nm

Molykote
Check gap size between piston crown and skirt → 0.04 - 0.09 mm
Screws not tightened.

m
M20 c
Piston
Check : At a torque
of → M = 35 Nm
the nuts must not turn further.
Coat thread and contact surface of the nuts
with Molykote paste G-n.
Attention: In case of reinstallation replace studs if
projecting length of bottom support exceeds
71.3 mm.
71.3
MHW 1.10.7-26.70.00-22 Fitting

specification
Insert fixing pin (spring cotter) into the piston
crown. Coat thread in the piston crown with
motor oil.
Coat thread of the stud with graphite paste,
insert it into the piston crown and tighten
smoothly with → M = 30 Nm
Spray piston crown and skirt with corrosion preventing oil. Grease the joint ring and insert
it torsionless into the piston skirt. Put the piston skirt on the piston crown. Grease the
spherical washers as well as the nut thread with graphite paste and tighten the nut until
you feel the first resistance.
Check gap size between piston crown and skirt at 4 points (each time shifted by 45° in
circumferential direction).
Nominal value → 0.06 ± 0.02 mm
Tighten nuts alternately in steps of → M = 10 Nm
up to → M = 50 Nm
and loosen again.
Check the tightening torque of the stud in the
piston crown with → M = 30 Nm
Tighten nuts until you feel the first resistance
and then alternately in steps of → M = 10 Nm
up to → M = 40 + 5 Nm

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M20 c
Piston
Kolbenschmidt 1.10.7-26.70.00-07
Coat thread and contact surface with Molykote-Paste G-n-plus.
Tighten screws crosswise with → M = 24 Nm
Loosen screws again.

Pretighten screws with → M = 10 Nm
and tighten
with → Dw = 60°
Check: At a torque of → M = 19 Nm
further turning of the screws must not be possible.
Clearance between piston crown and piston skirt → 0.06 - 0.10 mm

Screws not tightened.
Wear limit and clearances

Grooves Groove height Ring height Wear limit Limit clearance
1 5 +0.12 - 0.14 4.95 -0.010 - 0.025 5.60 0.65
2 5 +0.10 - 0.12 4.95 -0.010 - 0.025 5.60 0.65
3 5 +0.06 - 0.08 4.95 -0.010 - 0.025 5.60 0.65
4 6 +0.06 - 0.08 6.00 -0.010 - 0.025 6.50 0.50
1 5 +0.12 - 0.14 4.95 -0.010 - 0.025 5.60 0.65
2 5 +0.10 - 0.12 4.95 -0.010 - 0.025 5.60 0.65
3 6 +0.06 - 0.08 6.00 -0.010 - 0.025 6.50 0.50

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M20 c
Piston
Piston rings gas oil operation
Piston 1.10.7-26.70.00-01 / -02 / -03 / -04
Ring groove ring
1 Rectangular ring 1.10.7-26.17.01-05.1 alternative -04.1
2+3 Compression ring 1.10.7-26.17.01-06.1
4 Oil scraper ring 1.10.7-26.17.01-03.1
Piston 1.10.7-26.70.00-05 / -22

Ring groove ring
1 Rectangular ring 1.10.7-26.17.01-05.1 alternative -04.1
2 Compression ring 1.10.7-26.17.01-06.1
3 Oil scraper ring 1.10.7-26.17.01-03.1
Piston 1.10.7-26.70.00-07
Ring groove ring
1 Rectangular ring 1.10.7-26.17.01-04.1
3 Oil scraper ring 1.10.7-26.17.01-03.1
Piston rings heavy fuel operation

Piston 1.10.7-26.70.00-01 / -02 / -03 / -04
Ring groove ring
1 Rectangular ring 1.10.7-26.17.01-04.1 rpl. -07.1
2+3 Compression ring 1.10.7-26.17.01-06.1
4 Oil scraper ring 1.10.7-26.17.01-03.1
Piston 1.10.7-26.70.00-05 / -22

Ring groove ring
1 Rectangular ring 1.10.7-26.17.01-04.1 rpl. -07.1
3 Oil scraper ring 1.10.7-26.17.01-03.1
Piston 1.10.7-26.70.00-07
Ring groove ring
1 Rectangular ring 1.10.7-26.17.01-07.1
3 Oil scraper ring 1.10.7-26.17.01-03.1
Piston 1.10.7-26.70.00-03 up to 170 kW/cyl. Piston 1.10.7-26.70.00-04/-05 190 kW/cyl.
Piston ring: 1.10.7-26.17.01-07.1 three-sided chromium-plated;
1.10.7-26.17.01.04.1 Chromium ceramic ring
Arrange the ring butts in longitudinal direction of engine alternately opposed. Fit piston
rings with marking upwards.
Removal
In order to avoid loosening of the cylinder liner during removal of the cylinder head or
subsequent turning, the cylinder liner has to be secured always in the crankcase by means of
the retainer. Before removing the piston the fire ring must be removed.

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M20 c
Connecting rod
Big end bearing
1. Tighten bolts 3 and 4 (bottom) with → M = 160 Nm
2. Tighten bolts 1 and 2 (top) with → M = 160 Nm
3. Tighten bolts 1 and 2 once more with → M = 160 Nm
4. Tighten bolts 3 and 4 with → M = 350 Nm
Tighten bolts 1 and 2 with → M = 350 Nm

Molykote
Bolts 1+2 = short + top

Bolts 3+4 = long + bottom
After tightening the big end bolts 1 and 2 to the final torque (350 Nm), tighten big end bolts 3
and 4 once more with the final torque (350 Nm) in order to avoid loss of pretension (settling
effect).
The final tightening torque corresponds to an angle of ratation of:

For bolts 1 + 2 at least 13°- 16°
For bolts 3 + 4 at least 17°- 19°
starting from the pretorque of 160 Nm
4
Big end bearings
Together with the tool kit 2 tightening angle
gauges - one for the big end bolts 1-2 and
one for the big end bolts 3-4 -are supplied.
These tools serve for checking the tightening
angles stated above.
3
If after correct tightening of all big end bolts

the „minimum degrees“ are not reached, the
whole tightening procedure must be
repeated.
Fitting of piston pin bush

Cool the piston pin bush down to ≤ -160° C and push it into piston pin boss, taking care
of the correct position of the oil bores. The lateral projection must be the same on both
sides. After reaching the normal temperature the piston pin bush has to be measured.
The reference dimension after shrinking-in in

cooled state is Ø → 90.09 mm
+ 0.06

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M20 c
Connecting rod
Measurement of the gap
1. Pretighten bolts 3 and 4 with 160 Nm.
2. Measure dimension „X 1“ by means of a slide gauge.
3. Tighten bolts 1 and 2 twice successively in the sequence 1-2/1-2 with 160 Nm.
4. Tighten bolts 3-4/1-2 with 350 Nm.
5. Measure dimension „X 2“
.
„X 1 - X 2“ = gap → 0.45 - 0.65 mm
0.35 mm
Limit value →
1+2
X1 2 Reference size A
X
3+4
Reference size B
Reference dimension of the big end bearings after correct tightening.
Size „ A“ → 152.140 +0.05

mm
Size „ B“ → A + 0.04 +0.06

mm

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M20 c
Liner
Nominal size Ø (original size) → 200.00 +46

mm
Wear limits
Wear and tear value → 0.80 mm
Max. ovality → 0.25 mm
Wedge shape Height → 6.00 mm
Depth * → 0.03 mm
Wedge-shaped indentation across the entire circumference, beginning at TDC 1st piston ring.
Canyon Max. number → 3
Length → 6.00 mm
Total width → 3.00 mm
Individual deep blow-through ducts in the area of the 1st piston ring (TDC).
Score Number → 3
Length → 140.00 mm
Depth → 0.03 mm
Hard vertical, linear friction marks.
Pocket Number → 3
Length → 45.00 mm
Width * * → 15.00 mm
Depth * → 0.02 mm
Areal, irregular indentations.

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M20 c
Liner
Wedge shape Pocket Score TDC 1st ring Canyon
Fire ring
Modern engines are equipped with fire rings in the liners.
In this case the broader joint ring is used between liner and cylinder head.
Old joint ring — 11.8 mm
New joint ring — 15.0 mm
Both joint rings are 5 mm thick, the oversize rings are 6 mm thick.
Dismounting of fire ring

1. Turn piston top edge below the 1
fire ring.
2. Place dismounting device on the

piston so that the recess lies inside
the fire ring.
3. Slightly tighten the dismounting

device by turning spindle nut - 1 -.
4. Press fire ring out by turning the

piston up.

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M20 c
Liner
Removal of the fire ring
1. Clean groove in the
fire ring.
2. Turn piston downwards

until pressure ring - 1 -
of the removing device
with circlip - 2 - can
be inserted. The
circlip must rest
safely in the groove of
the fire ring. 3
3. Put the liner supports

- 3 - on a useless Useless joint
ring as a
joint ring and tighten protection of
by hand with the 2 the sealing
cylinder head nuts. 1 surface.
The useless joint ring
serves as a protction
of the sealing surface in
the liner. The liner must
not be lifted when
turning it out.
4. Turn the piston carefully upwards, permanently observing the fire ring and the liner.
The liner must slide into the cylinder crankcase by its own weight. Attention must be paid to
the correct installation position, i.e. mark - 1 - must point to flywheel side in longitudinal
direction. On the cooling water distributing ring there is a cast lug - 2 - serving as alignment
aid.
X
X

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M20 c
Crankshaft
Tightening torque
The tightening torque for inserting the studs - 1 - is → M = 400 Nm
Molykote
1. Tighten round nuts for main bearings - 2 - steadily by hand.
2. Tighten hexagon screws (lateral screws) - 3 - alternately.
2.1 → M = 100 Nm
2.2 → M = 300 Nm
2.3 → M = 480 Nm
Alternative tightening: (alternately in 3 steps)

2.1 → M = 100 Nm
30°
2.2 → M = 280 Nm
2.3 → Dw = 30°
Molykote
Camshaft side Exhaust gas side
3 3
3. Lengthen main bearing screws with → P = 750 bar

and tighten nuts with a pin.
This corresponds to a tightening angle of → Dw = 135°
or 3 holes (stated for additional checking). Molykote
Check: Reduce pressure to → P = 700 bar
Loosening the nuts must not be possible any more.
The pressure must remain constant if the pump is not operated, otherwise faulty tightening.
Tighten main bearing nuts always in one operation.
Tighten value for hydraulic jack area: 54.8 cm 2

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M20 c
Crankshaft
Marking
Bearing caps and bearing shells are marked on S1 S2
camshaft side with the relative cylinder numbers,
counted from flywheel side. The parts must not
be mixed up. Located and normal main bearings
are identical, for axial fixing on bearing 2 (located
main bearing) thrust washers - 1 - with clamping 1
pins - 2 - are mounted on bearing cap - 3 -. 2
End clearance „S“ →=S1+S2
If the main bearings cannot be loosened with

P = 750 bar, pressure increase by 50 bar to
800 bar is possible. Further increase of pressure
involves the risk that the thread will expand and 3
the nuts will jam. The bottom shells of the normal
main bearings have a guide groove on camshaft
side. The located main bearing cap (bearing 2)
has a fixing pin on exhaust gas side.
The bearings with maximum stress are:

6 cyl. engine bearing 4
Measurement of the gap
1. Remove lateral bolts of the
main bearing and loosen
those of the adjacent main KS KA
bearings by several turns
of thread.
2. Loosen both main bearing
nuts of one bearing pocket
in one operation.
3. Tighten main bearing nuts
by hand alternately and
steadily until the joint
faces of the bearing
shells just touch.
4. Check the projecting
length of the bearing shell by
measuring the gap between
cylinder crankcase and
bearing cap on camshaft and exhaust gas sides.
Gap K = K A + K s

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M20 c
Crankshaft
Normal main bearing
gap → 0.50 - 0.80 mm
limit value → 0.40 mm
Located main bearing

end clearance → 0.23 + 0.165 mm
Crank web deflection

cylinder 1 -9
other cylinders 4 / -6
Counterweight
Tighten screws with → M = 450 Nm
Molykote
6 cyl. engine 12 counterweights

crankpin 1 2pcs.
crankpin 2 1pc., left side *
crankpin 3 1pc., right side *
crankpin 4 2pcs.
crankpin 5 2pcs.
crankpin 6 1pc. left side *
crankpin 7 1pc. right side *
crankpin 8 2pcs.

crankpin 1 2pcs.
crankpin 2 1pc., left side *
crankpin 3 without counterweight
crankpin 4 2pcs.
crankpin 5 2pcs.
crankpin 6 2pcs.
crankpin 7 without counterweight
crankpin 8 1pc., right side *
crankpin 9 2pcs.
* = seen from camshaft side

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M20 c
Gear train
Gear wheel on crankshaft
Mount the gear wheel on the crankshaft cone
by hand.
Increase pressure to → P = 500 bar
with the hydraulic device and press
gear wheel into its final position.
The slide-on distance is :for 1.10.7-25.30.00-01 → 7.2 -2.7 mm.

for 1.10.7-25.30.00-02 → 9.1 -2.95 mm.
Dimension 186 +0.1 mm from front edge gear wheel to the end of crankshaft.
Engine start at the earliest 2 hours after pressure relief.
Hydraulic
connection
186 +0.1

m
M20 c
Gear train
Mounting of crankshaft gear wheel
Turn cylinder 1 into TDC-position (both pressure connections in the crankshaft are upright
one on top of the other). Slide on the crankshaft gear wheel so that the blind hole (without
thread) is located to the left, distorted by approximately 30° (vertically above the
pressure connections is now a taphole). Measure the distance from crankshaft end to
gear wheel. Put on the adapter ring and take care that the positioning pin enters into the
blind hole. Screw in the threaded rod. The two locking screws are inside the holes.
Remove the locking screw of bore „Z“, screw in the pressure pipe and fasten it. Slide on
the pressure ring with the smooth side towards the gear wheel. In the pick-up pocket
there is the pressure pipe. Screw the nut on the threaded rod and tighten it by hand
After connecting the pressure pump apply a pressure of approximately 500 bar.
Slide the gear wheel on the cone up to the limit stop using a ratchet and the nut. The slide-
on distance on old engines (mounting gear wheel on crankshaft variant -01) is
4.5 mm -7.2 mm and on new engines (mounting gear wheel on crankshaft variant -02).
6.1 mm -9.1 mm
Lower the pressure to 0 bar. Do not dismount the hydraulic pump so that the oil may flow
off. After at least 20 minutes the device can be removed.
Fasten the oil splasher on the gear wheel.
Mount the end cover. If there are no dowel pins (old engines) this cover must be centered
with a dial gauge.
Dismounting proceeds in reverse order. Please take care that there is a distance of
approximately 1 mm between pressure nut and pressure ring.
Connection „S“ for the flywheel M8 thread for

Connection „Z“ for the gear wheel fixation of oil
splasher
Blind hole
M30 for the

threaded rod
Connection
„S“
Connection
„Z“

m
M20 c
Gear train
Intermediate gear wheel mounting
Tighten screws - 1 - for the locking plate with → M = 60 Nm
Molykote
Old design New design
Spacer Spacer
1
1
Thrust rings
2
X Gap size
min.:0.30
max.:1.40
Thrust rings
Thrust washers of the new type are glued in.
The adhesion surface areas must be grease-free. Oil
grooves
The oil grooves of the thrust washers must show to the gear wheel.

m
M20 c
Gear drive
Mounting of intermediate gear wheel
The locking plate - 2 - must rest firmly in the groove root of the intermediate gear wheel
axle - 3 -.
Attention! When exchanging the O-ring on the intermediate gear wheel axle take care
that the intermediate gear wheel remains in the meshing of camshaft and crankshaft gear.
Otherwise, there is the risk of misaajusted timing data.
Lub. oil injectors for the gear drive

Tighten hollow screws with → M = 40 Nm
Backlash
Crankshaft gear - intermediate gear wheel → 0.20 - 0.40 mm
intermediate gear wheel - camshaft gear → 0.20 - 0.40 mm
Intermediate gear wheel

End clearance → 0.20 - 0.80 mm

m
M20 c
Gear train
Camshaft gear wheel
Tighten screws - 1 - with → M = 85 Nm
Molykote

Molykote
5.8 +1

m
M20 c
Governor drive
Governor drive gear
Tighten fixing screws - 1 - for → M = 60 Nm
governor drive gear with
Molykote
Tighten castellated nut for fixing the helical gear

wheel - 2 - with → M = 30 Nm
and tighten further to the next split pin hole. Molykote
Backlash
Small governor drive gear (helical gear wheel) -big
governor drive gear (helical gear wheel) → 0.15 - 0.20 mm
End clearance - 3 - between governor console and

coupling bush → 0.20 - 0.30 mm
Between the big governor drive gear (helical gear wheel)

and the end cover there must be a clearance - 4 - of → 0.30 - 0.75 mm

m
M20 c
Camshaft
Camshaft bearing
Tighten fixing screws for the camshaft bearings with → M = 30 Nm
Vibration damper for camshaft

1.10.7-31.40.00-01
Molykote
4 screws M12 x 1,5 X 55 ISO 4762
1.10.7-31.40.00-02 (2 vibration dampers)

Molykote
4 screws M12 x 1,5 X 60 ISO 4762
1.10.7-31.40.00-03 (3 vibration dampers)

Tighten screws - 1 - and - 2 - with → M = 60 Nm
Molykote
1 = 4 Allen screws M12x1,5x130 ISO 4762 8.8-A3C
2 = 2 Allen screws M12x1,5x45 ISO 4762 8.8-A3C
Take care of
the bore
position

m
M20 c
Camshaft
Tighten Allen screws - 1 -
with → M = 100 Nm
Molykote
Tighten screws - 2 - for flange - 3 - with → M = 100 Nm
Molykote
1 1 2
During every assembly of the camshaft take care that a cylindrical pin - 2 - is inserted up
to stop position in the camshaft flanges - 1 -. The cylindrical pin must always be inserted
near the flange code number - 3 - acc. to the following schedule:
6 cyl. Flange code 8 cyl. Flange code 9 cyl. Flange code
Part number Part n u m b e r Part n u m b e r
1 4 1 5 1 1
2 2 2 2 2 1
3 3 3 3 3 2
4 4 4 4 4 3
5 5 5 5 5 4
6 6 6 6 6 4
7 7 7 3
8 8 8 2
9 1

m
M20 c
Lower valve drive
The end clearance between two adjacent bearing
brackets is → 0.10 - 0.20 mm
13 0.10 - 0.20
Mounting instruction
At the junction points of the rocking lever shafts no air is admissible. When the bearing
caps are loosened, the rocking lever shafts must be pushed together from both sides.

m
M20 c
Fuel injection pumps
The tightening torque for inserting
the studs is → M = 40 Nm
Tighten fastening nuts with → M = 50 Nm

Molykote
0.00.6-43.12.00-72 type: DSFP 1M

2 2
Mixed oil drain
Stop
Lub. oil inlet

Regulating
distance 36 mm

m
M20 c
Injection pump 0.00.6-43.12.00-79 type: DSFP 1MW
Tighten screw - 1 - and - 2 - with → M = 45 Nm
Tighten screw - 3 - with → M = 25 Nm
Tighten baffle screw - 4 - with → M = 50 Nm
Insert countersunk screws - 5 - with Loctite 243

and tighten with → M=5 Nm
4 4
Mixed oil drain
Stop
Lub. oil inlet

Regulating
distance 36 mm
5
3

m
M20 c
Injection pump 0.00.6-43.12.00-92 type: DSFP 1MW
Tighten screw - 1 - and - 2 - with → M = 45 Nm
Tighten screw - 3 - with → M = 25 Nm
Tighten baffle screw - 4 - with → M = 90 Nm
Insert countersunk screws - 5 - with Loctite 243

and tighten with → M=5 Nm
This fuel injection pump is replaces the fuel injection pump 0.00.6-43.12.00-79
4 4
Mixed oil drain
Stop
Lub. oil inlet

Regulating
distance 36 mm
5
3

m
M20 c
Fuel distributing and collecting pipe
Old design
Tighten screws - 1 - to fuel injection pump
alternately with → M = 50 Nm
M12x DIN 931
Fuel distributing pipe for fuel injection pump variants -79 and -92.
Circlip - 1 - must be removed before the plug-in pipes can be axially shifted and removed.
1
2

m
M20 c
Dismounting / mounting
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.
The thickness of the distance steel plates for each cylinder is stated in the acceptance test
record. Commencement of Firing TDC
delivery
Check of commencement of fuel
delivery
1. Dismount the injection pump delivery
valve. Position of
2. Mount dial gauge with extension. commencement of
3. Turn engine so that roller rests on delivery
the base circle of cam and the TDC
mark is abt. 45 ° before the dead center indicator.
4. Set dial gauge to „0“, turn engine in direction of rotation
until the indication on the gauge is 5 mm for 170 kW/cyl. and
4 mm for 190 kW/cyl.
5. Check the dimension on the flywheel from TDC mark to dead center indicator.
(1° = 8.8 mm)
As to the commencement of fuel delivery please look into the testbed record.
Setting
1. Place the gauge with measuring device on a level support by means of the
adjusting bush (dimension = 44.2 mm) and set gauge to „0“.
2. Insert measuring device into the injection pump bore in the engine housing
and read value on the dial gauge (roller on cam base circle).
3. Indicated value = thickness of the distance steel plates.
The distance steel plates are used for setting the pre-stroke.
Available sizes:
2.00 mm 2.10 mm 2.20 mm 2.30 mm 2.40 mm 2.50 mm
2.60 mm 2.70 mm 2.80 mm 2.90 mm 3.00 mm
Adjustment of the commencement of fuel injection with built up injection

pump
The roller of the pump drive of cylinder 1 is located on the base circle. Remove the con-
necting piece and the pressure-balancing delivery valve from the injection pump. Fix a dial
gauge on the pump (touches the plunger). Turn the engine in sense of rotation until the
dial gauge indicates 5 mm (old engines; 170 kW/cyl.) (4 mm: new engines; 190 kW/cyl.).
Screw the pressure pipe into the respective taphole of the camshaft and tighten it. Mount
hydraulic pump and apply a pressure of approximately 900 - 1000 bar. Turn the
crankshaft to the respective commencement of fuel injection (see test bed record).
Remark:
If necessary, the camshaft ought to be fixed (is normally not necessary with built up
injection pumps). After mounting crankshaft gear wheel and flywheel check the TDC-
position of the first cylinder in view of correct flywheel markings! If necessary, new
markings must be applied.
m
M20 c
Sundries
Regulating shaft
Setting instruction
1. Connect shaft of the control stand with the regulating shaft by means of coupling.
Do not yet remove assembly pin for the shaft fixing.
2. Shift control rack of the injection pump at cyl. 1 so that coincidence of line mark and
indication is reached.
3. In this position clamp articulated lever fast, keeping the distance of 0.5 mm
between control rack head and articulated lever.
Tightening torque → M = 25 Nm
Molykote
4. Repeat procedure on all remaining cylinders acc. to instructions of points 2 and 3.
5. Remove assembly pin for the shaft fixing in the control stand.
6. Check easy motion of control linkage.
7. Seal articulated lever with lead.
Assembly
During assembly insert the regulating shaft with grease (do not use Molykote).
Regulating shaft
Tighten screw 1 - for the bearing bracket with → M = 60 Nm
Molykote
0.20 Clearance

m
M20 c
Sundries
Tighten screws - 1 - and - 2 -
with → M = 25 Nm
Molykote
Fuel indicator 1
Cam - 1 - must be adjusted in a way that in stop
position the center of the fuel indicator is in line with
the stamped punch mark - 2 -.
2

m
M20 c
Sundries
Cooling water distributing pipe
Molykote
M16 x 100 8.8 -A3C

m
M20 c
Opposite side of couplung
With and without power take-off with Vibration damper
Coat thread and screw head surface with Molykote
Pretighten fixing screws with → M = 100 Nm

Molykote
With the fixing screws pump impeller carrier and gear wheel for lub. oil pump drive are fixed
at the same time.
The vibration damper is connected to the lub. oil system of the engine. Each spring pack
has its own supply bore. When checking the vibration damper the oil bores have to be
checked for free passage.
1
All tightening torques on this page are valid for
the flanged shaft mounting with or without
power take-off.

m
M20 c
Pump carrier
Pump carrier plate
Coat thread and screw head surface with Molykote
Tighten screws M 12 with → M = 60 Nm
Molykote
Tighten screws M 8 with → M = 25 Nm

Molykote
Pump carrier plate

Align pump carrier plate - 1 - over centering
of the pump gear carrier - 2 -, and screw it
at the cylinder crankcase with sealing
compound and pin it.
Cooling water pump

Tighten screw for fastening the
gear wheel with → M = 60 Nm
Molykote
Fuel feed pump

Molykote
Lub. oil pump

Molykote
m
M20 c
Pump carrier
Lub. oil pump mounting, suction and pressure
pump as well as cooling water pump mounting
HT and LT circuit and fuel feed pump mounting
1. Check contact reflection on the
appertaining pump gear wheel cone by
blue paste. Only a contact reflection
displaced to the thick end is admissible.
2. Heat gear wheel up to 120°C - 130°C
above temperature of the cooling water 1
pump shaft and mount it firmly on the
pump cone up to stop position.
The cone faces must be grease-free 2
and dry.
3. Fit and tighten screw - 1 - with washer - 2 -.
Slide-on distance lub.oil pumps — 0.33 - 0.41 mm
Slide-on distance cooling water pumps — 0.29 - 0.32 mm
Slide-on distance fuel feed pumps — 0.44 mm
Lub. oil pump mounting

backlash → 0.20 - 0.47 mm
Fuel feed pump mounting

Cooling water pump mounting


m
M20 c
Flywheel mounting
Flywheel mounting
Turn crankshaft into TDC cyl. 1. Insert flywheel vertically suspended into transport hole
and push it on the crankshaft cone until contact is reached. Mount device, apply a
pressure
of → P = 1300 bar
and press flywheel into the final position.
Final position means flush with end of crankshaft. The slide-on distance is : 15.5 -2.8 mm
and
16.5 -3.05 mm.
1. Turn crankshaft to TDC cyl. 1. (In this position the

projecting screw heads at the gear wheel on
crankshaft are pointing to the respective
pickup pockets on the flywheel).
2. Insert flywheel vertically suspended into

transport hole dia. 50 mm and push it on the
crankshaft cone until contact is reached.
3. Press flywheel into final position by means of

device and oil hydraulic mounting.
4. Final position, as shown, flush with end of

crankshaft.
5. Engine start 20 min after pressure relief at the

earliest.
When dismounting a flywheel, a mark should be applied on

the flywheel and on the crankshaft in order to avoid
incorrect fitting.
Gear rim on flywheel for pneumatic starter.

Molykote

m
M20 c
Flywheel mounting
The following flywheels are in use.
Flywheel 1.10.7-73.10.01-
Var. old slide - on distance replaced by var. slide-on distance

- 03 15.5 -2.8 mm - 09 16.5 - 3.05 mm
- 04 15.5 -2.8 mm - 10 16.5 - 3.05 mm
- 05 15.5 -2.8 mm - 11 16.5 - 3.05 mm
- 06 15.5 -2.8 mm - 12 16.5 - 3.05 mm
- 07 15.5 -2.8 mm - 14 16.5 - 3.05 mm
- 13 16.5 - 3.05 mm
The flywheel variants are stamped at the front side of the flywheels, for instance „1-09“.

m
M20 c
Tighten screws - 1 -
with → M = 60 Nm
Molykote
Tighten screws - 2 -
with → M = 60 Nm
Molykote
1
4
Applicable to coupling side and opposite side.

When mounting the charge air cooler care is to be taken that the screws - 3 -and - 4 - are
alternately tightened in small steps.
First tighten screws - 4 - firmly and only then screws - 3 -.

m
M20 c
Cleaning
In the acceptance test record the differential pressure before / after charge air cooler is
stated. When the value has reached the 1.5-fold, cleaning has to be carried out.
Dismounting
Remove cooling water inlet and outlet pipes. Loosen screws - 1 - and - 3 - and withdraw
the charge air cooler from the casing.
Fitting in reverse order, taking care of perfect fit of the sealing shims.

m
M20 c
Exhaust gas manifold
Tighten all M12 screws
with → M = 60 Nm
Insert all screws with paste DAG S 5080.
Attention !
Take care of the correct screw length.
A projection is inadmissible.
max. 5 mm
Recession
Spray all connecting straps with graphite or High nut
Molybdaen spray before mounting.
No gaskets between expansion joints and exhaust gas
pipes. Mount all expansion joints in direction of arrow.

Paste DAG S 5080
2

m
M20 c
Firing sequences - valve timing values
Firing sequences
6 cyl. engine clockwise 1-3-5-6-4-2
counterclockwise 1-2-4-6-5-3
8 cyl. engine clockwise 1-2-4-6-8-7-5-3
counterclockwise 1-3-5-7-8-6-4-2
9 cyl. engine clockwise 1-2-4-6-8-9-7-5-3
counterclockwise 1-3-5-7-9-8-6-4-2
Valve timing values

Old output 170 KW / cyl.
Exhaust valve opens 60 ° ca. before BDC
Exhaust valve closes 55 ° ca. after TDC
Inlet valve opens 55 ° ca. before TDC
Inlet valve closes 40 ° ca. after BDC
New output 190 KW / cyl.
Exhaust valve opens 40 ° ca. before BDC
Exhaust valve closes 45 ° ca. after TDC
Inlet valve opens 45 ° ca. before TDC
Inlet valve closes 5 ° ca. after BDC
ca. = crankangle

m
M20 c
Designation Length mm Width mm Height mm Weight kg
Crankcase without studs
6 cyl. engine 3190
8 cyl. engine 4040
9 cyl. engine 4530
Crankshaft
6 cyl. engine 2428 Ø 374 730
8 cyl. engine 3088 Ø 374 1000
9 cyl. engine 3415 Ø 374 1100
Counterweight 22
Gear wheel on crankshaft 82 Ø 273 16
Liner 997 Ø 277 68
Piston with connecting rod 60.5
Cyl. head compl. 121
Cyl. head 85.5
Camshaft bearing 72 Ø 190 1.5
Big end bearing 69 Ø 161 1.1
Cooling water distribution

housing 602 328 170 43.5
Injection pump 123 133 342 18
Camshaft element 330 Ø 142 19
Camshaft bearing 40 Ø 160 1.3
Gear wheel on camshaft 65 Ø 533 105
Intermediate gear wheel 23

m
M20 c
Designation Length mm Width mm Height mm Weight kg
Housing for charge air

cooler 210
Charge air cooler 877 540 440 170
Lub. oil cooler 82
Pump carrier plate 78
Starter 34
Flywheel, generator 217 Ø 1005 320
Flywheel, propeller 204 Ø 1005 307
Gear rim on flywheel 38 Ø 1015 44
Vibration damper 151 Ø 620 263
Lub. oil pump 404 230 245 34
Cooling water pump 354 270 335 42


M20

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m

Charge air cooler mounting

Edition Service document of Page

Exhaust gas manifold 52

Fuel injection pump

Edition Service document of Page

Lower valve drive 36

Opposite side of coupling

Pump carrier with attached pumps

Sizes and weights 54 - 55

Edition Service document of Page

The following values serve for judgment on possible failures:

2. Fuel rack reading

3. Lubricating oil t inlet engine t oil cooler inlet

4. Fresh water t inlet engine t outlet engine

t inlet charge air cooler t outlet charge air cooler

5. Charge air temperature t before cooler t before engine

6. Exhaust gas temperature t after cylinder t after turbocharger

7. Lub. oil pressure

8. Fresh water pressure

9. Charge air pressure after charge air cooler

10. Differential pressure at the charge air cooler

Edition Service document of Page

Bore = 200 mm Lub. oil

Speed, rpm = 900 - 1000 Engine inlet 60 - 65 ° C

Main bearing Temperature rise 10 - 14 ° C

Inside Ø = 180 mm Fresh water circulation cooling

Outside Ø = 190 mm Engine outlet 65 - 80 ° C

Big end bearing Temperature rise 7 - 10 ° C

Inside Ø = 152 mm Charge air

Outside Ø = 161 mm Engine inlet 45 - 60 ° C

Valves, inlet and exhaust Pressures

Length = 336 mm Lub. oil 4.0 - 4.5 bar

Shaft Ø = 14.05 mm Fresh water circulation cooling

Valve head Ø = 66 mm With min. 4 mWs 2.5 - 6.0 bar

Valve guide Nozzle cooling 1.5 - 3.0 bar

Length = 175 mm Fuel pressure before injection

HDO-operation 4.0 - 5.0 bar

Details for rated engine output and nominal

Edition Service document of Page

Check: Reduce pressure to → P = 550 bar

At the control bore - 1 - leakages

Edition Service document of Page

Limit clearance → 0.20 mm

Reference size for the bush after pressing-in Ø → 49.99 + 0.109

The bush shall recede after pressing-in by → 0.20 mm

Setting of valve bridges and valve clearances

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

3. Screw in adjusting screws - 2 - until the

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

Edition Service document of Page

Limit clearance → 0.40 mm

Nominal size outside Ø 26,033 - 0,01

The valve stems are used as specified below:

HFO 1.10.7-22.10.01-01 / -03 / -07 1.10.7-22.10.01-01 / -02

MDO 1.10.7-22.10.01-01 / -03 / -07 1.10.7-22.10.01-01 / -05

HFO - operation: at inlet and exhaust valves

Edition Service document of Page

Insert guiding bolts with Loctite 243