Detroit diesel 4000 series User manual

Engine exhaust may be harmful to your health if inhaled.

To reduce the chance of personal injury and/or property

damage, the following instructions must be carefully

observed.

Proper service and repair are important to the safety of the

service technician and the safe, reliable operation of the

engine. If part replacement is necessary, the part must

be replaced with one of the same part number or with an

equivalent part number. Do not use a replacement part of

lesser quality.

The service procedures recommended and described in

this manual are effective methods of performing repair.

Some of these procedures require the use of specially

designed tools.

Accordingly, anyone who intends to use a replacement

part, procedure or tool which is not recommended,

must first determine that neither personal safety nor the

safe operation of the engine will be jeopardized by the

replacement part, procedure or tool selected.

It is important to note that this manual contains various

"Cautions" and "Notices" that must be carefully observed

in order to reduce the risk of personal injury during

repair or the possibility that improper repair may damage

the engine or render it unsafe. It is also important to

understand that these "Cautions" and "Notices" are not

exhaustive, because it is impossible to warn personnel of

the possible hazardous consequences that might result

from failure to follow these instructions.

Abstract

This manual provides instruction for construction and industrial and marine applications of

Detroit Diesel Series 4000 Engines.

Specifically, a basic overview of each major component and system along with recommendations

for removal, cleaning, inspection, criteria for replacement, repair and installation and mechanical

troubleshooting are contained in this manual.

Revision Notification

Modification to this manual are announced in the form of Service Information Bulletins.

The bulletins include attachment pages and are posted on the World Wide Web

(www.detroitdiesel.com/svc/sibinex.htm).

Revisions to this manual will be sent marked with a revision bar (see Example 2). Sections

containing revisions will have a third line in the page footer (compare Examples 1 and 2).

Engine Exhaust

Consider the following before servicing engines:

To avoid injury while operating an engine, ensure the work

area is properly ventilated. Engine exhaust is toxic.

Please note this caution and remember:

Always start and operate the engine in a well-ventilated area.

If in an enclosed area, vent the exhaust to the outside.

Do not modify or tamper with the exhaust system.

For accurate dynamometer readings during an engine run-in, the chassis dynamometer

roommust be properly ventilated. See Figure 1.

SERIES 4000 12/16V SERVICE MANUAL

TABLE OF CONTENTS

A GENERAL INFORMATION ................................................ A-1

A 001 IMPORTANT INFORMATION ...................................... A-3

A 002 GENERAL ENGINE INFORMATION ............................... A-11

A 003 TORQUE SPECIFICATIONS ....................................... A-23

A 004 SAFETY PRECAUTIONS .......................................... A-33

A 005 GENERAL DESCRIPTION OF SERIES 4000 OPERATION .......... A-47

A 006 DATA SHEETS .................................................... A-51

A 007 CONVERSION TABLES ........................................... A-65

A 008 REPAIRING THREADED BORES .................................. A-71

B OPERATION SCHEDULES ................................................ B-1

B 001 CHECKING ENGINE CONDITION BEFORE A MAJOR OVERHAUL . B -3

B 002 W5 MAINTENANCE OPERATIONS ................................ B-7

B 003 W6 MAINTENANCE OPERATIONS ................................ B-13

B 004 ENGINE REMOVAL ............................................... B-17

B 005 ENGINE RUN-IN .................................................. B-21

B 006 ENGINE INSTALLATION AND OPERATION ........................ B-29

C MAINTENANCE .......................................................... C-1

C 010 CYLINDER BLOCK ............................................... C-3

C 011.05 CYLINDER BLOCK ....................................... C-5

C 011.05.01 General View .................................. C-7

C 011.05.02 Special Tools .................................. C-11

C 011.05.04 Before-Removal Operations .................... C-12

C 011.05.05 Removal of Cylinder Block and Main Bearings ... C -13

C 011.05.06 Disassembly of Cylinder Block and Main

Bearings ...................................... C-20

C 011.05.08 Inspection and Repair ......................... C-34

C 011.05.10 Assembly of Crankshaft and Main Bearings ..... C-54

C 011.05.11 Installation of Cylinder Block and Main Bearings . C -76

C 011.05.12 After-Installation Operations .................... C-86

C 013.05 CYLINDER LINER ........................................ C-87

C 013.05.01 General View .................................. C-89

C 013.05.02 Special Tools .................................. C-92

C 013.05.04 Before-Removal Operations .................... C-93

C 013.05.05 Removal of Cylinder Liner ...................... C-94

C 013.05.08 Inspection and Repair ......................... C-96

C 013.05.11 Installation of Cylinder Liner .................... C-101

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 013.05.12 After-Installation Operations .................... C-106

C 014.05 OIL PAN ................................................. C-107

C 014.05.01 General View .................................. C-109

C 014.05.02 Special Tools .................................. C-113

C 014.05.04 Before-Removal Operations .................... C-114

C 014.05.05 Removal of Oil Pan ............................. C-115

C 014.05.08 Inspection and Repair ......................... C-118

C 014.05.11 Installation of Oil Pan ........................... C-120

C 014.05.12 After-Installation Operations .................... C-130

C 015.05 LIFTING ATTACHMENTS FOR ENGINE AND RUNNING

GEAR ................................................... C-131

C 015.05.01 General View .................................. C-133

C 015.05.04 Before-Removal Operations .................... C-135

C 015.05.05 Removal of Engine Lifting Attachments .......... C-136

C 015.05.08 Inspection and Repair ......................... C-137

C 015.05.11 Installation of Engine Lifting Attachments ........ C-139

C 015.05.12 After-Installation Operations .................... C-140

C 016.05 FLYWHEEL HOUSING ................................... C-141

C 016.05.01 General View .................................. C-143

C 016.05.02 Special Tools .................................. C-145

C 016.05.04 Before-Removal Operations .................... C-146

C 016.05.05 Removal of Flywheel Housing .................. C-147

C 016.05.06 Disassembly of Flywheel Housing ............... C-150

C 016.05.08 Inspection and Repair ......................... C-152

C 016.05.10 Assembly of Flywheel Housing ................. C-154

C 016.05.11 Installation of Flywheel Housing ................ C-157

C 016.05.12 After-Installation Operations .................... C-160

C 018.11 M CYLINDER BLOCK VENTILATION ........................ C-161

C 018.05.01 M General View ................................. C-163

C 018.05.04 M Before-Removal Operations .................... C-166

C 018.05.05 M Removal of the Marine Cylinder Block Ventilation

System ........................................ C-167

C 018.05.06 M Disassembly of the Marine Cylinder Block

Ventilation System ............................. C-169

C 018.05.08 M Inspection and Repair .......................... C-176

C 018.05.10 M Assembly of the Marine Cylinder Block Ventilation

System ........................................ C-178

C 018.05.11 M Installation of the Marine Cylinder Block

Ventilation ..................................... C-185

C 018.05.12 M After-Installation Operations .................... C-187

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 020 GEAR CASE ..................................................... C-189

C 024.05 GEAR CASE ............................................ C-191

C 024.05.01 General View .................................. C-193

C 024.05.02 Special Tools .................................. C-195

C 024.05.04 Before-Removal Operations .................... C-196

C 024.05.05 Removal Operations for Gear Case ............. C-197

C 024.05.08 Inspection and Repair ......................... C-200

C 024.05.11 Installation of Gear Case ....................... C-203

C 024.05.12 After-Installation Operations .................... C-210

C 025.05 GEAR TRAIN, GEAR CASE END ......................... C-211

C 025.05.01 General View .................................. C-213

C 025.05.04 Before-Removal Operations .................... C-214

C 025.05.05 Removal of Gear Train (Gear Case End) ........ C-215

C 025.05.08 Inspection and Repair ......................... C-218

C 025.05.10 Assembly of Gear Train (Gear Case End) ........ C-222

C 025.05.11 Installation of Gear Train (Gear Case End) ...... C-224

C 025.05.12 After-Installation Operations .................... C-228

C 030 RUNNING GEAR ................................................. C-229

C 031.05 CRANKSHAFT ........................................... C-231

C 031.05.01 General View .................................. C-233

C 031.05.02 Special Tool ................................... C-235

C 031.05.04 Before-Removal Operations .................... C-236

C 031.05.05 Removal of Crankshaft ......................... C-237

C 031.05.06 Disassembly of Crankshaft ..................... C-249

C 031.05.08 Inspection and Repair ......................... C-253

C 031.05.10 Assembly of Crankshaft ........................ C-307

C 031.05.11 Installation of Crankshaft ....................... C-312

C 031.05.12 After-Installation Operations .................... C-319

C 032.05 FLYWHEEL .............................................. C-321

C 032.05.01 General View .................................. C-323

C 032.05.02 Special Tools .................................. C-324

C 032.05.04 Before-Removal Operations .................... C-325

C 032.05.05 Removal of the Flywheel ....................... C-326

C 032.05.06 Disassembly of Flywheel ....................... C-331

C 032.05.08 Inspection and Repair ......................... C-332

C 032.05.10 Assembly of the Flywheel ...................... C-334

C 032.05.11 Installation of the Flywheel ..................... C-337

C 032.05.12 After-Installation Operations .................... C-343

C 035.05 CRANKSHAFT VIBRATION DAMPER ..................... C-345

C 035.05.01 General View .................................. C-347

C 035.05.02 Special Tools .................................. C-349

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 035.05.04 Before-Removal Operations .................... C-350

C 035.05.05 Removal of the Vibration Damper ............... C-351

C 035.05.06 Disassembly of the Vibration Damper ........... C-358

C 035.05.08 Inspection and Repair ......................... C-359

C 035.05.10 Assembly of Vibration Damper .................. C-360

C 035.05.11 Installation of the Vibration Damper ............. C-364

C 035.05.12 After-Installation Operations .................... C-370

C 037.05 PISTONS AND CONNECTING RODS ..................... C-371

C 037.05.01 General View .................................. C-373

C 037.05.02 Special Tools .................................. C-375

C 037.05.04 Before-Removal Operations .................... C-376

C 037.05.05 Removal of Piston with Connecting Rod ......... C-377

C 037.05.06 Disassembly of Piston with Connecting Rod ..... C-384

C 037.05.08 Inspection and Repair ......................... C-388

C 037.05.10 Assembly of Piston with Connecting Rod ........ C-422

C 037.05.11 Installation of Piston with Connecting Rod ....... C-431

C 037.05.12 After-Installation Operations .................... C-453

C 040 CYLINDER HEAD WITH FIXTURES ............................... C-455

C 041.05 CYLINDER HEAD ........................................ C-457

C 041.05.01 General View .................................. C-459

C 041.05.02 Special Tools .................................. C-462

C 041.05.04 Before-Removal Operations .................... C-463

C 041.05.05 Removal of Cylinder Head ...................... C-464

C 041.05.06 Disassembly of Cylinder Head .................. C-468

C 041.05.08 Inspection and Repair ......................... C-478

C 041.05.10 Assembly of Cylinder Head ..................... C-490

C 041.05.11 Installation of Cylinder Head .................... C-506

C 041.05.12 After-Installation Operations .................... C-513

C 050 VALVE OPERATING MECHANISM ................................. C-515

C 051.05 CAMSHAFT .............................................. C-517

C 051.05.01 General View ................................. C-519

C 051.05.02 Special Tools .................................. C-520

C 051.05.04 Before-Removal Operations .................... C-521

C 051.05.05 Removal of Camshaft .......................... C-522

C 051.05.08 Inspection and Repair .......................... C-530

C 051.05.11 Installation of Camshaft ........................ C-533

C 051.05.12 After-Installation Operations .................... C-550

C 052.05 CAMSHAFT DRIVE ...................................... C-551

C 052.05.01 General View ................................. C-553

C 052.05.02 Special Tools .................................. C-554

C 052.05.04 Before-Removal Operations .................... C-555

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 052.05.05 Removal of Camshaft Drive ..................... C-556

C 052.05.08 Inspection and Repair ......................... C-561

C 052.05.11 Installation of Camshaft Drive ................... C-562

C 052.05.12 After-Installation Operations .................... C-573

C 053.05 CAMSHAFT THRUST BEARING .......................... C-575

C 053.05.01 General View ................................. C-577

C 053.05.02 Special Tools .................................. C-578

C 053.05.04 Before-Removal Operations .................... C-579

C 053.05.05 Removal of Camshaft Thrust Bearing ........... C-580

C 053.05.08 Inspection and Repair ......................... C-585

C 053.05.11 Installation of Camshaft Thrust Bearing ......... C-586

C 053.05.12 After-Installation Operations .................... C-597

C 055.05 VALVE OPERATING MECHANISM ........................ C-599

C 055.05.01 General View ................................. C-601

C 055.05.02 Special Tools .................................. C-605

C 055.05.04 Before-Removal Operations .................... C-606

C 055.05.05 Removal of Valve Operating Mechanism ........ C-607

C 055.05.06 Disassembly of Rocker Arm Assembly .......... C-611

C 055.05.08 Inspection and Repair ......................... C-617

C 055.05.10 Assembly of Rocker Arm Assembly ............. C-624

C 055.05.11 Installation of Valve Drive ....................... C-631

C 055.05.12 After-Installation Operations .................... C-644

C 056.05 CYLINDER HEAD COVER ................................ C-645

C 056.05.01 General View .................................. C-647

C 056.05.02 Special Tools .................................. C-648

C 056.05.04 Before-Removal Operations .................... C-649

C 056.05.05 Removal of the Rocker Cover ................... C-650

C 056.05.08 Inspection and Repair ......................... C-651

C 056.05.11 Installation of the Rocker Cover ................. C-652

C 056.05.12 After-Installation Operations .................... C-653

C 070 FUEL SYSTEM - HIGH-PRESSURE ............................... C-655

C 073.05 HIGH-PRESSURE FUEL PUMP .......................... C-663

C 073.05.01 General View .................................. C-665

C 073.05.02 Special Tools .................................. C-667

C 073.05.04 Before-Removal Operations .................... C-668

C 073.05.05 Removal of the High-Pressure Fuel Pump ....... C-669

C 073.05.06 Disassembly of the High-Pressure Fuel Pump ... C -675

C 073.05.08 Inspection and Repair ......................... C-676

C 073.05.11 Installation of the High-Pressure Fuel Pump ..... C-678

C 073.05.12 After-Installation Operations .................... C-685

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 073.05 M FUEL INJECTION PUMP ................................. C-687

C 073.05.01 M General View ................................. C-689

C 073.05.04 M Before-Removal Operations .................... C-690

C 073.05.05 M Removal of the Marine Fuel Injection Pump ..... C-691

C 073.05.08 M Inspection and Repair ......................... C-698

C 073.05.11 M Installation of the Marine Fuel Injection Pump .... C-699

C 073.05.12 M After-Installation Operations .................... C-706

C 075.05 INJECTOR ............................................... C-707

C 075.05.01 General View .................................. C-709

C 075.05.02 Special Tools .................................. C-710

C 075.05.04 Before-Removal Operations .................... C-711

C 075.05.05 Removal of the Injector ......................... C-712

C 075.05.06 Disassembly of the Injector ..................... C-716

C 075.05.08 Inspection and Repair ......................... C-717

C 075.05.10 Assembly of the Injector ........................ C-718

C 075.05.11 Installation of the Injector ....................... C-719

C 075.05.12 After-Installation Operations .................... C-728

C 077.05 HIGH-PRESSURE RAILS AND LINES .................... C-729

C 077.05.01 General View .................................. C-731

C 077.05.02 Special Tools .................................. C-735

C 077.05.04 Before-Removal Operations .................... C-736

C 077.05.05 Removal of the High-Pressure Fuel Rails ........ C-737

C 077.05.06 Disassembly of High-Pressure Rail .............. C-746

C 077.05.07 Inspection and Repair ......................... C-750

C 077.05.10 Assembly of the High-Pressure Rails ............ C-751

C 077.05.11 Installation of the High-pressure Rails ........... C-757

C 077.05.12 After-Installation Operations .................... C-776

C 080 FUEL SYSTEM — LOW-PRESSURE .............................. C-777

C 081.05 FUEL PUMP ............................................. C-779

C 081.05.01 General View ................................. C-781

C 081.05.04 Before-Removal Operations .................... C-782

C 081.05.05 Removal of Low-Pressure Fuel Pump ........... C-783

C 081.05.06 Disassembly of Low-Pressure Fuel Pump ....... C-785

C 081.05.08 Inspection and Repair .......................... C-786

C 081.05.10 Assembly of Low-Pressure Fuel Pump .......... C-787

C 081.05.11 Installation of Low-Pressure Fuel Pump ......... C-788

C 081.05.12 After-Installation Operations .................... C-790

C 083.05 FUEL FILTER ............................................ C-791

C 083.05.01 General View ................................. C-793

C 083.05.04 Before-Removal Operations .................... C-795

C 083.05.05 Removal of Fuel Filter .......................... C-796

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 083.05.06 Disassembly of Fuel Filter ...................... C-800

C 083.05.08 Inspection and Repair ......................... C-802

C 083.05.10 Assembly of Fuel Filter ......................... C-805

C 083.05.11 Installation of Fuel Filter ........................ C-807

C 083.05.12 After-Installation Operations .................... C-810

C 083.05 M FUEL FILTER BRACKET ................................. C-811

C 083.05.01 M General View ................................. C-813

C 083.05.04 M Before-Removal Operations .................... C-814

C 083.05.05 M Removal of the Marine Fuel Filter and Bracket ... C -815

C 083.05.08 M Inspection and Repair ......................... C-817

C 083.05.11 M Installation of the Marine Fuel Filter and Bracket . C -818

C 083.05.12 M After-Installation Operations .................... C-820

C 086.05 FUEL RETURN RAILS AND LINES ....................... C-821

C 086.05.01 General View .................................. C-823

C 086.05.02 Special Tools .................................. C-824

C 086.05.04 Before-Removal Operations .................... C-825

C 086.05.05 Removal of the Fuel Return Rail System ........ C-826

C 086.05.06 Disassembly of the Fuel Return Rails and Lines

System ........................................ C-832

C 086.05.08 Inspection and Repair ......................... C-833

C 086.05.10 Assembly of the Fuel Return Rails and Lines

System ........................................ C-834

C 086.05.11 Installation of Fuel Return Rails and Lines

System ........................................ C-835

C 086.05.12 After-Installation Operations .................... C-839

C 100 TURBOCHARGER ................................................ C-841

C 101.05 TURBOCHARGER ....................................... C-843

C 101.05.01 General View .................................. C-845

C 101.05.04 Before-Removal Operations .................... C-846

C 101.05.05 Removal of the Exhaust Turbocharger ........... C-847

C 101.05.06 Disassembly of the Exhaust Turbocharger ....... C-850

C 101.05.08 Inspection and Repair ......................... C-851

C 101.05.10 Assembly of Turbocharger ...................... C-852

C 101.05.11 Installation of the Turbocharger ................. C-853

C 101.05.12 After-Installation Operations .................... C-856

C 101.05 M TURBOCHARGER (MARINE) ............................. C-859

C 101.05.01 M General View ................................. C-861

C 101.05.04 M Before-Removal Operations (Marine) ............ C-862

C 101.05.05 M Removal of the Turbocharger (Marine) .......... C-863

C 101.05.06 M Disassembly of the Turbocharger (Marine) ....... C-871

C 101.05.08 M Inspection and Repair (Marine) ................. C-872

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 101.05.10 M Assembly of the Turbocharger (Marine) .......... C-873

C 101.05.11 M Installation of the Turbocharger (Marine) ........ C-874

C 101.05.12 M After-Installation Operations .................... C-887

C 103.05 M MARINE TURBOCHARGER ACTUATOR .................. C-889

C 103.05.01 M General View .................................. C-891

C 103.05.04 M Before – Removal Operations ................... C-892

C 103.05.05 M Removal of Turbocharger Actuator (Marine) ..... C-893

C 103.05.08 M Inspection and Repair .......................... C-897

C 103.05.11 M Installation of Turbocharger Actuator (Marine) ... C -898

C 103.05.12 M After – Installation Operations (Marine) ......... C-901

C 104.05 M TURBOCHARGER ACTUATOR CONTROL SOLENOID

VALVE (MARINE) ........................................ C-903

C 104.05.01 M General View (Marine) ......................... C-905

C 104.05.04 M Before – Removal Operations (Marine) .......... C-906

C 104.05.05 M Removal of the Turbocharger Actuator Control

Solenoid Valve (Marine) ....................... C-907

C 104.05.08 M Inspection and Repair (Marine) ................. C-909

C 104.05.11 M Installation of the Turbocharger Actuator Control

Solenoid Valve (Marine) ....................... C-910

C 104.05.12 M After – Installation Operations (Marine) ......... C-913

C 110 CHARGE AIR COOLING .......................................... C-915

C 111.05 CHARGE AIR COOLER .................................. C-917

C 111.05.01 General View ................................. C-919

C 111.05.04 Before-Removal Operations .................... C-920

C 111.05.05 Removal of Charge Air Cooler .................. C-921

C 111.05.06 Disassembly of Charge Air Cooler .............. C-923

C 111.05.08 Inspection and Repair .......................... C-924

C 111.05.10 Assembly of Charge Air Cooler ................. C-929

C 111.05.11 Installation of Charge Air Cooler ................ C-930

C 111.05.12 After-Installation Operations .................... C-934

C 111.05 M CHARGE AIR COOLER .................................. C-935

C 111.05.01 M General View ................................. C-937

C 111.05.04 M Before-Removal Operations .................... C-938

C 111.05.05 M Removal of Marine Charge Air Cooler ........... C-939

C 111.05.08 M Inspection and Repair .......................... C-948

C 111.05.11 M Installation of Marine Charge Air Cooler ......... C-949

C 111.05.12 M After-Installation Operations .................... C-957

C 113.05.01 M Marine Boost Bypass Valve ..................... C-958

C 113.05.04 M Before-Removal Operations .................... C-959

C 113.05.05 M Removal of the Boost Bypass Valve ............. C-960

C 113.05.08 M Inspection and Repair ......................... C-965

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 113.05.11 M Installation of the Boost Bypass Valve ........... C-966

C 113.05.04 M After-Installation Operations .................... C-971

C 120 AIR INTAKE SUPPLY ............................................. C-973

C 121.05 M MARINE AIR FILTER ..................................... C-975

C 121.05.01 M General View ................................. C-977

C 121.05.04 M Before-Removal Operations .................... C-978

C 121.05.05 M Removal of the Air Filter ........................ C-979

C 121.05.08 M Inspection and Repair ......................... C-980

C 121.05.11 M Installation of the Marine Air Filter ............... C-981

C 121.05.12 M After-Installation Operations .................... C-982

C 123.05 M MARINE INTAKE HOUSING .............................. C-983

C 123.05.01 M General View ................................. C-985

C 123.05.04 M Before – Removal Operations ................... C-986

C 123.05.05 M Removal of the Intake Housing ................. C-987

C 123.05.06 M Disassembly of the Intake Housing .............. C-992

C 123.05.08 M Inspection and Repair ......................... C-993

C 123.05.10 M Assembly of the Intake Housing ................ C-994

C 123.05.11 M Installation of the Intake Housing ................ C-996

C 123.05.12 M After – Installation Operations .................. C-1000

C 124.05 AIR INTAKE MANIFOLD .................................. C-1001

C 124.05.01 General View .................................. C-1003

C 124.05.04 Before-Removal Operations .................... C-1004

C 124.05.05 Removal of Air Intake Manifold System .......... C-1005

C 124.05.08 Inspection and Repair ......................... C-1007

C 124.05.11 Installation of the Air Intake Manifold System .... C-1009

C 124.05.12 After-Installation Operations .................... C-1011

C 125.05 AIR INTAKE SYSTEM FROM TURBOCHARGER TO

CHARGE AIR COOLER .................................. C-1013

C 125.05.01 General View .................................. C-1015

C 125.05.04 Before-Removal Operation ..................... C-1016

C 125.05.05 Removal of Air System from Turbocharger to

Charge Air Cooler .............................. C-1017

C 125.05.08 Cleaning, Inspection and Repair ................ C-1020

C 125.05.11 Installation of Air Intake System from Turbocharger

to Charge Air Cooler ........................... C-1022

C 125.05.12 After-Installation Operations .................... C-1025

C 140 EXHAUST SYSTEM .............................................. C-1027

C 141.05 EXHAUST SYSTEM ...................................... C-1029

C 141.05.01 General View .................................. C-1031

C 141.05.04 Before-Removal Operations .................... C-1032

C 141.05.05 Removal of Exhaust System .................... C-1033

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 141.05.06 Disassembly of Exhaust System ................ C-1034

C 141.05.08 Inspection and Repair ......................... C-1036

C 141.05.10 Assembly of the Exhaust System ............... C-1037

C 141.05.11 Installation of Exhaust System .................. C-1038

C 141.05.12 After-Installation Operations .................... C-1040

C 141.05 M MARINE EXHAUST MANIFOLD .......................... C-1041

C 141.05.01 M General View ................................. C-1043

C 141.05.04 M Before-Removal Operations .................... C-1045

C 141.05.05 M Removal of the Exhaust Manifold ............... C-1046

C 141.05.08 M Inspection and Repair ......................... C-1052

C 141.05.11 M Installation of the Exhaust Manifold ............. C-1053

C 141.05.12 M After-Installation Operations .................... C-1060

C 170 STARTING SYSTEM .............................................. C-1061

C 172.05 STARTER ................................................ C-1063

C 172.05.01 General View .................................. C-1065

C 172.05.04 Before-Removal Operations .................... C-1067

C 172.05.05 Removal of Starter ............................. C-1068

C 172.05.06 Disassembly of Starter ......................... C-1070

C 172.05.08 Inspection and Repair ......................... C-1071

C 172.05.10 Assembly of Starter ............................ C-1073

C 172.05.11 Installation of Starter .......................... C-1074

C 172.05.12 After-Installation Operations .................... C-1077

C 172.05 M MARINE STARTER ....................................... C-1079

C 172.05.01 M General View .................................. C-1081

C 172.05.04 M Before-Removal Operations .................... C-1082

C 172.05.05 M Removal of the Marine Starter .................. C-1083

C 172.05.06 M Disassembly of the Marine Starter .............. C-1085

C 172.05.08 M Inspection and Repair ......................... C-1086

C 172.05.11 M Installation of the Marine Starter ................ C-1087

C 172.05.12 M After-Installation Operations .................... C-1089

C 180 LUBE OIL SYSTEM ............................................... C-1091

C 181.05 LUBE OIL PUMP WITH DRIVE ........................... C-1095

C 181.05.01 General View .................................. C-1097

C 181.05.04 Before-Removal Operations .................... C-1098

C 181.05.05 Removal of Lube Oil Pump with Drive ........... C-1099

C 181.05.08 Inspection and Repair ......................... C-1102

C 181.05.11 Installation of Lube Oil Pump with Drive ......... C-1106

C 181.05.12 After-Installation Operations .................... C-1110

C 183.05 OIL FILTER .............................................. C-1111

C 183.05.01 General View .................................. C-1113

C 183.05.02 Special Tools .................................. C-1114

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 183.05.04 Before-Removal Operations .................... C-1115

C 183.05.05 Removal of Oil Filter and Centrifugal Oil Filter ... C -1116

C 183.05.06 Disassembly of Centrifugal Oil Filter Assembly ... C -1124

C 183.05.08 Inspection and Repair ......................... C-1128

C 183.05.10 Assembly of Oil Filter, Centrifugal Oil Filter and Oil

Filter Service Maintenance Alert System ........ C-1133

C 183.05.11 Installation of Oil Filter, Centrifugal Oil Filter and

Oil Filter Service Maintenance Alert System ..... C-1138

C 183.05.12 After-Installation Operations .................... C-1152

C 183.05 M MARINE OIL HEAT EXCHANGER ........................ C-1153

C 183.05.01 M General View .................................. C-1155

C 183.05.04 M Before-Removal Operations .................... C-1156

C 183.05.05 M Removal of the Oil Heat Exchanger ............. C-1157

C 183.05.08 M Inspection, Cleaning and Repair ................ C-1161

C 183.05.11 M Installation of the Oil Heat Exchanger ........... C-1163

C 183.05.12 M After-Installation Operations .................... C-1166

C 184.05 CENTRIFUGAL OIL FILTER .............................. C-1167

C 184.05.01 General View .................................. C-1169

C 184.05.04 Before-Removal Operations .................... C-1171

C 184.05.05 Removal of Centrifugal Oil Filter ................ C-1172

C 184.05.06 Disassembly of Centrifugal Oil Filter ............. C-1174

C 184.05.11 Installation of Centrifugal Oil Filter .............. C-1175

C 184.05.12 After-Installation Operations .................... C-1177

C 185.05 OIL COOLING ........................................... C-1179

C 185.05.01 General View .................................. C-1181

C 185.05.04 Before-Removal Operations .................... C-1182

C 185.05.05 Removal of Oil Cooling System ................. C-1183

C 185.05.08 Inspection and Repair ......................... C-1191

C 185.05.11 Installation of Oil Cooling System ............... C-1197

C 185.05.12 After-Installation Operations .................... C-1207

C 186.05 OIL SYSTEM FOR PISTON COOLING .................... C-1209

C 186.05.01 General View .................................. C-1211

C 186.05.02 Special Tools .................................. C-1213

C 186.05.04 Before-Removal Operations .................... C-1214

C 186.05.05 Removal of Oil System for Piston Cooling ....... C-1215

C 186.05.08 Inspection and Repair ......................... C-1220

C 186.05.11 Installation of Oil System for Piston Cooling ..... C-1225

C 186.05.12 After-Installation Operations .................... C-1234

C 187.05 OIL SUPPLY LINES FOR EXHAUST TURBOCHARGER ... C -1235

C 187.05.01 General View .................................. C-1237

C 187.05.04 Before-Removal Operations .................... C-1238

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 187.05.05 Removal of Oil Supply Hoses for Exhaust

Turbocharger .................................. C-1239

C 187.05.08 Inspection and Repair ......................... C-1241

C 187.05.11 Installation of the Oil Supply Lines for

Turbocharger .................................. C-1243

C 187.05.12 After-Installation Operations .................... C-1244

C 188.05 OIL RETURN LINES FOR TURBOCHARGER ............. C-1245

C 188.05.01 General View .................................. C-1247

C 188.05.04 Before-Removal Operations .................... C-1248

C 188.05.05 Removal of the Oil Return Lines for Turbocharger C -1249

C 188.05.08 Inspection and Repair ......................... C-1251

C 188.05.11 Installation of the Oil Return Lines for

Turbocharger .................................. C-1253

C 188.05.12 After-Installation Operations .................... C-1254

C 185.10.01 M Marine Oil Supply Lines for Turbocharger ........ C-1255

C 185.10.04 M Before-Removal Operations .................... C-1256

C 185.10.05 M Removal of the Oil Supply Lines for Turbocharger C -1257

C 185.10.08 M Inspection and Repair .......................... C-1260

C 185.10.11 M Installation of the Oil Supply Lines for

Turbocharger .................................. C-1261

C 185.10.12 M After-Installation Operations .................... C-1264

C 185.25.01 M Marine Oil Return Lines for Turbocharger ........ C-1265

C 185.25.04 M Before-Removal Operations .................... C-1266

C 185.25.05 M Removal of the Oil Return Lines for Turbocharger C -1267

C 185.25.08 M Inspection and Repair .......................... C-1270

C 185.25.11 M Installation of the Oil Return Lines for

Turbocharger .................................. C-1271

C 185.25.12 M After-Installation Operations .................... C-1274

C 200 COOLING SYSTEM ............................................... C-1275

C 200.05 COOLING SYSTEM ...................................... C-1281

C 200.00 Preliminary Pressure-Testing Cooling System ... C -1283

C 202.05 HIGH–TEMPERATURE WATER PUMP WITH

ATTACHMENTS ......................................... C-1291

C 202.05.01 General View .................................. C-1293

C 202.05.02 Special Tools .................................. C-1296

C 202.05.04 Before-Removal Operations .................... C-1297

C 202.05.05 Removal of High—Temperature Water Pump .... C-1298

C 202.05.06 Disassembly of High-Temperature Pump ........ C-1300

C 202.05.08 Inspection and Repair .......................... C-1307

C 202.05.10 Assembly of High-Temperature Water Pump ..... C-1309

C 202.05.11 Installation of High-Temperature Water Pump .... C-1334

C 202.05.12 After-Installation Operations .................... C-1336

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 203.05 ENGINE COOLANT SYSTEM PIPEWORK ................ C-1337

C 203.05.01 General View .................................. C-1339

C 203.05.04 Before-Removal Operations .................... C-1341

C 203.05.05 Removal of Engine Cooling System Pipework ... C -1342

C 203.05.08 Inspection and Repair .......................... C-1343

C 203.05.11 Installation of Engine Cooling System Pipework .. C -1345

C 203.05.12 After-Installation Operations .................... C-1346

C 204.05 ENGINE COOLANT SYSTEM ............................. C-1347

C 204.05.01 General View .................................. C-1349

C 204.05.04 Before-Removal Operations .................... C-1350

C 204.05.05 Removal of Engine Coolant System ............. C-1351

C 204.05.08 Inspection and Repair .......................... C-1352

C 204.05.11 Installation of Engine Coolant System ........... C-1353

C 204.05.12 After-Installation Operations .................... C-1354

C 205.05 VENT LINES ............................................. C-1355

C 205.05.01 General View .................................. C-1357

C 205.05.04 Before-Removal Operations .................... C-1359

C 205.05.05 Removal of Vent Lines ......................... C-1360

C 205.05.08 Inspection and Repair .......................... C-1361

C 205.05.11 Installation of Vent Lines ........................ C-1362

C 205.05.12 After-Installation Operations .................... C-1363

C 205.05 M COOLANT HEAT EXCHANGER ........................... C-1365

C 205.05.01 M General View .................................. C-1367

C 205.05.04 M Before-Removal Operations .................... C-1368

C 205.05.05 M Removal of the Coolant Heat Exchanger ........ C-1369

C 205.05.08 M Inspection and Repair ......................... C-1380

C 205.05.11 M Installation of the Coolant Heat Exchanger ...... C-1385

C 205.05.12 M After-Installation Operations .................... C-1396

C 206.05 CHARGE AIR COOLING SYSTEM (LOW-TEMPERATURE) C -1397

C 206.05.01 General View .................................. C-1399

C 206.05.02 Special Tools .................................. C-1403

C 206.05.04 Before-Removal Operations .................... C-1404

C 206.05.05 Removal of Charge Air Cooling System

(Low-Temperature) ............................. C-1405

C 206.05.06 Disassembly of Charge Air Cooling System

(Low-Temperature) ............................. C-1408

C 206.05.08 Inspection and Repair ......................... C-1414

C 206.05.10 Assembly of Charge Air Cooling System

(Low-Temperature) ............................. C-1416

C 206.05.11 Installation of Charge Air Cooling System

(Low-Temperature) ............................. C-1441

C 206.05.12 After-Installation Operations .................... C-1445

All information subject to change without notice.

SERIES 4000 12/16V SERVICE MANUAL

C 206.05 M MARINE COOLANT DISTRIBUTION HOUSING AND

THERMOSTAT ........................................... C-1447

C 206.05.01 M General View ................................. C-1449

C 206.05.04 M Before – Removal Operations .................. C-1450

C 206.05.05 M Removal of the Coolant Distribution Housing

Thermostat .................................... C-1451

C 206.05.08 M Inspection and Repair .......................... C-1456

C 206.05.11 M Installation of the Coolant Distribution Housing

Thermostat .................................... C-1458

C 206.05.12 M After – Installation Operations .................. C-1463

C 207.05 CHARGE AIR COOLER COOLING SYSTEM PIPEWORK . C -1465

C 207.05.01 General View .................................. C-1467

C 207.05.04 Before-Removal Operations .................... C-1468

C 207.05.05 Removal of Charge Air Cooler Cooling System

Pipework ...................................... C-1469

C 207.05.08 Inspection and Repair .......................... C-1470

C 207.05.11 Installation of Charge Air Cooler Cooling System

Pipework ...................................... C-1471

C 207.05.12 After-Installation Operations .................... C-1472

C 207.05 M MARINE RAW WATER PUMP WITH CONNECTIONS ...... C-1473

C 207.05.01 M General View ................................. C-1475

C 207.05.04 M Before – Removal Operations .................. C-1477

C 207.05.05 M Removal of the Marine Raw Water Pump with

Connections ................................... C-1478

C 207.05.08 M Inspection and Repair .......................... C-1484

C 207.05.11 M Installation of the Marine Raw Water Pump with

Connections ................................... C-1485

C 207.05.12 M After – Installation Operations .................. C-1490

C 208.05 COOLANT PIPEWORK WITH THERMOSTAT .............. C-1491

C 208.05.01 General View .................................. C-1493

C 208.05.02 Special Tools .................................. C-1495

C 208.05.04 Before-Removal Operations .................... C-1496

C 208.05.05 Removal of Cooling System Thermostat and

Distribution Housings ........................... C-1497

C 208.05.08 Inspection and Repair ......................... C-1504

C 208.05.11 Installation of Cooling System Thermostat and

Distribution Housings ........................... C-1507

C 208.05.12 After-Installation Operations .................... C-1515

C 208.05 M MARINE SURGE TANK ................................... C-1517

C 208.05 M General View ................................. C-1519

C 208.05.04 M Before – Removal Operations .................. C-1520

C 208.05.05 M Removal of the Surge Tank ..................... C-1521

C 208.05.08 M Cleaning, Inspection and Repair ................ C-1526

All information subject to change without notice.

Table of contents

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