Table of Contents
1 Safety
1.1 Important provisions for all products 7
1.2 Personnel and organizational requirements 8
1.3 Transport 9
1.4 Safety regulations for maintenance and
repair work 10
1.5 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 13
1.6 Standards for safety notices in the text 15
2 Product Summary
2.1 Engine Layout 16
2.1.1 Product description 16
2.1.2 Engine layout 28
2.1.3 Sensors, actuators and injectors on 16V
engines – Overview 32
2.2 Engine Side and Cylinder Designations 42
2.2.1 Engine side and cylinder designations 42
2.3 Main Engine Dimensions 43
2.3.1 16V 4000 M63L engines – Main dimensions 43
2.4 Firing Sequence 44
2.4.1 Firing order 44
2.5 Technical Data 45
2.5.1 16V 4000 M63L engine data 45
3 Operation
3.1 Controls 49
3.2 Putting the engine into operation after
extended out-of-service periods (>3 months) 50
3.3 Putting the engine into operation after
scheduled out-of-service-period 51
3.4 Starting the engine 52
3.5 Operational checks 53
3.6 Tasks after extended out-of-service periods
(>3 weeks) 54
3.7 Checks prior to start-up 55
3.8 Fuel treatment system – Putting into
operation 56
3.9 Fuel treatment system – Switching on 59
3.10 Fuel treatment system – Shutdown 60
3.11 Stopping the engine 61
3.12 Emergency engine stop 62
3.13 After stopping the engine 63
3.14 Plant – Cleaning 64
4 Maintenance
4.1 Maintenance task reference table [QL1] 65
5 Troubleshooting
5.1 Troubleshooting 67
5.2 Fuel treatment system – Troubleshooting 70
5.3 Engine governor ADEC (ECU 7) fault
messages for Series 4000 engines, marine
application 71
5.4 Engine governor ADEC (ECU 7) – Fault
codes 72
6 Task Description
6.1 Engine 137
6.1.1 Engine – Barring manually 137
6.1.2 Engine – Barring with starting system 139
6.2 Cylinder Liner 140
6.2.1 Cylinder liner – Endoscopic examination 140
6.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 142
6.3 Crankcase Breather 144
6.3.1 Crankcase ventilation ‒ Overview 144
6.3.2 Crankcase breather – Oil mist fine separator
replacement 145
6.4 Valve Drive 146
6.4.1 Valve gear – Lubrication 146
6.4.2 Valve clearance – Check and adjustment 147
6.4.3 Cylinder head cover – Removal and
installation 150
6.5 Injection Pump / HP Pump 151
6.5.1 HP pump – Filling with engine oil 151
6.5.2 HP pump – Relief bore check 152
6.6 Injection Valve / Injector 153
6.6.1 Injector – Replacement 153
6.6.2 Injector – Removal and installation 154
6.7 Fuel Filter 159
6.7.1 Supplementary fuel filter – Overview 159
6.7.2 Additional fuel filter – Replacement 160
6.7.3 Fuel filter – Replacement 161
6.7.4 Fuel system – Venting 163
6.7.5 Fuel prefilter – Differential pressure check
and adjustment of gauge 164
6.7.6 Fuel prefilter – Draining 165
6.7.7 Fuel prefilter – Flushing 167
6.7.8 Fuel prefilter with water separator – Filter
element replacement 169
6.7.9 Fuel prefilter with water separator – O-ring
replacement in rotary slide valve 171
MS150067/02E 2014-04 | Table of Contents | 5
DCL-ID: 0000005754 - 005
