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MTU

A comprehensive process

In the MTU factory rebuild process, used engines and assemblies are fully disassembled, cleaned, inspected, then reworked and reassembled using all new genuine wear parts from MTU. Replacement parts are issued for components that are worn, damaged or outdated. When applicable, design and model-related updates are incorporated, making factory overhauled engines comparable to new engines. And before passing final inspection, all factory overhauled engines undergo rigorous acceptance testing using MTU’s state-of-the-art test benches.

1. Disassembly and cleaning

  • Complete engine disassembly
  • Paint and rust removed from all parts and components
  • Verification measurements or damage analysis (provided upon request)

2. Investigation

  • On-site lab analysis of fluids and materials Measurement, inspection and evaluation of all parts against factory-specified tolerance and wear-limits
  • Preparation of dimension sheets, documenting all major components dimensions (crankshafts/crankcases/cylinder heads)
  • Performance of crack testing (on relevant parts)
  • Identification and execution of modernization requirements
  • Documentation of results and findings
  • Customer invitation to evaluate scrapped parts (upon request)

3. Reworking

  • Performance of reworking and machining using series production processes to meet “like-new” tolerance requirements
  • Rebuild of supplier components—such as crankshafts, coolers, heat exchanger inserts, and couplings—conducted in partnership with original manufacturers and/or certified, audited sub-suppliers to ensure maximum quality
  • Additional corrective work, if necessary, depending on engine condition; all factory-proposed solutions are qualified and supported based on factory standards and customer-specific requirements

4. Reassembly

  • Initiation of assembly processes using re-worked/rebuilt parts and components and new wear parts (gaskets, seals, blots, screws, etc.)
  • Utilization of most up-to-date tools, specification documents and layout drawings for series production
  • Adherence to inspection plans developed in agreement with quality management, including documentation of key dimensions (dimensions sheets, templates, push-on dimensions) throughout the assembly process
  • Completion and documentation of order-specific requirements

5. Acceptance testing

  • Test run using specified, order-specific peripheral settings to replicate difficult field conditions (e.g. extreme temperatures)
  • Documentation of engine values, evaluation, and provision of plausibility assessment according to dispatch documentation
  • Customers invitation to participate (if previously agreed)

6. Final preparations

  • Priming and paint-finishing according to customer specifications
  • Packing/preservation (long-life packaging available upon request)

For further details or specific inquiries, please contact your local service sales representative or our Customer Assistance Center at +49 7541 90-77777 or info@mtu-online.com.

Factory Rebuild is valid for Series 183, 396, 493, 538, 595, 652, 956, 1163 and various Defense engines.

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