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Detroit Diesel 4000 Series, Service Manual, Page: 1953 / 2706

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Detroit Diesel 4000 Series Service Manual Download Page 1953

SERIES 4000 12/16V SERVICE MANUAL

J 7557

Timing Gear Installer

53,V53

J 38662

Accessory Drive

50,50G,60

J 21166

Accessory Drive Seal Alignment Tool

71,V71,92

J 36024-C

Accessory Drive Service Set

50,50G,60

J-2901

Abrasive Pads (20)

50,60

J 24542

Block Align Tool (.020 OS,12 & 16V)

149

J 24543

Block Align Tool (.040 OS,12 & 16V)

149

J 41065

Counterbore Cutter Tool Conv. Kit

60

J 43095

Cylinder Sleeve Holding Adapters

40E

PT-2200-83

Depth Collar

50,60

PT-2200-138

Depth Set Collar

50,60

PT-5025

Dial Depth Gauge

50,60

J 41594

Engine Barring Tool

55

J 41997

Engine Barring Tool

55

PT-5020-5SP

Extension Arm Kit

50,60

J 41972

Flex Hone

30G

J 43104

ICP Adapter Plug Kit

40,40E

J 42779

Liner Puller

Cento

J 22490

Liner Remover

53,V53

J 43048

Main Bearing Guide Studs

2000

J 8386-01

Master Ring -Cylinder Block Bore

71,V71

J 8385-01

Master Ring- Liner ID

53,V53

PT-7145-A

Right Angle Drill

50,60

J 38359

Threaded Insert

30G,40,40E,50,50G,53,V53,55,60,71,V71,92,149,8.2

PT-2000-400

X-Long Finish Line

50,60

J 42955

Cylinder Head Alignment Bar

4000

J 41962

Cylinder Head Bolt Bottom Tap

30G

J 42954

Cylinder Head Guide Studs

4000

J 41823

Cylinder Head Lifter Bracket

30G

J 42730

Cylinder Head Lifting Fixture

4000

J 43099

Cylinder Head Magnet Intake Shield

40E

J 42514

Cylinder Headbolt Wrench M12

Cento

J 42637

Cylinder Headbolt Wrench M14

Cento

J 39108

Fuel Line Nut Wrench 11/16"

149

J 43096

Guide Stud Set

40E

PT-7149

Infrared Thermometer (0-1600Deg F)

30G,40,40E,50,50G,53,V53,55,60,71,V71,92,149,8.2

J 24357

Valve Seat Insert Installer

92

J 41573

Bridge Guide Installer

55

All information subject to change without notice.

Copyright © DETROIT DIESEL CORPORATION

C -1807

Summary of Contents for 4000 Series

Page 1: ......

Page 2: ......

Page 3: ...ther 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 import...

Page 4: ... 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 ...

Page 5: ...his caution and remember 3 Always start and operate the engine in a well ventilated area 3 If in an enclosed area vent the exhaust to the outside 3 Do not modify or tamper with the exhaust system 3 For accurate dynamometer readings during an engine run in the chassis dynamometer roommust be properly ventilated See Figure 1 ...

Page 6: ......

Page 7: ...YLINDER 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 ...

Page 8: ...ew 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 VENTILA...

Page 9: ... 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 FLYWHE...

Page 10: ... 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 Cyli...

Page 11: ...ection 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 05...

Page 12: ...5 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...

Page 13: ...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 Remov...

Page 14: ... 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 Co...

Page 15: ...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 FR...

Page 16: ...air 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 ...

Page 17: ...84 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 S...

Page 18: ...ger 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 Operatio...

Page 19: ...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...

Page 20: ...S 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 ...

Page 21: ...05 10 M Assembly of the Alternator C 1569 C 213 05 11 M Installation of the Alternator C 1570 C 213 05 12 M After Installation Operations C 1573 C 220 FAN DRIVE C 1575 C 221 05 FAN DRIVE C 1577 C 221 05 01 General View C 1579 C 221 05 02 Special Tools C 1580 C 221 05 04 Before Removal Operations C 1581 C 221 05 05 Removal of Fan Drive C 1582 C 221 05 06 Disassembly of Fan Drive C 1589 C 221 05 08 ...

Page 22: ... After Installation Operations C 1724 C 250 FLYWHEEL AND FLEX COUPLING C 1725 C 255 05 RESILIENT COUPLING C 1727 C 255 05 01 General View C 1729 C 255 05 04 Before Removal Operations C 1730 C 255 05 05 Removal of Flex Coupling C 1731 C 255 05 06 Disassembly of Flex Coupling C 1732 C 255 05 08 Inspection and Repair C 1735 C 255 05 10 Assembly of Flex Coupling C 1737 C 255 05 11 Installation of Flex...

Page 23: ...ses C 1778 C 502 05 12 M After Installation Operations C 1780 C 503 05 CONSTRUCTION AND INDUSTRIAL ENGINE INJECTOR HARNESSES OPTIONAL ROUTING C 1781 C 503 05 01 General View of B Side Fuel Injector Wiring Harness C 1783 C 503 05 05 Removal of B Side Fuel Injector Wiring Harness C 1785 C 503 05 08 Inspection and Repair of B Side Fuel Injector Wiring Harness C 1788 C 503 05 11 Installation of B Side...

Page 24: ...ESHOOTING E 3 E 011 FAN CLUTCH E 5 E 011 01 General Mechanical Troubleshooting Information E 7 E 011 02 Fault Conditions E 8 E 012 ENGINE MECHANICAL TROUBLESHOOTING E 15 E 012 05 A General E 17 E 012 05 B Engine Does Not Turn E 18 E 012 05 C Engine Turns But Does Not Fire E 19 E 012 05 D Engine Fires Erratically After Start E 20 E 012 05 E Engine Does Not Reach Full Load Speed E 21 E 012 05 F Engi...

Page 25: ...ant Level Rising E 38 E 012 05 AD Engine Coolant Pump Leaking at Weep Hole E 39 E 012 05 AE Preheat Temperature Too Low E 39 E 012 05 AF Charge Air Coolant Temperature Too High E 40 E 012 05 AG Charge Air Coolant Temperature Too Low E 40 E 012 05 AH Charge Air Coolant Pressure Too Low E 41 E 012 05 AI Charge Air Coolant Loss E 42 E 012 05 AJ Charge Air Coolant Level Rising E 42 E 012 05 AK Charge ...

Page 26: ...nction 17 D MAINTENANCE SCHEDULE 19 D000 000 01 Maintenance Schedule Introduction 21 D000 000 03 Maintenance System 21 D000 000 05 Application Group 22 D000 000 07 Maintenance Frequency Chart 22 D000 000 11Maintenance Echelons 23 D000 000 15Maintenance Echelon M6 26 D000 000 17Out of Service Periods 27 D000 000 18Maintenance Schedules Complete System 27 E TROUBLESHOOTING 29 E000 000 01GENERAL 31 I...

Page 27: ...low 49 E202 000 05Engine coolant pressure too low 50 E202 000 07Engine coolant loss 51 E202 000 09Engine coolant level rising 52 E202 051 01Engine coolant pump leaking at weep hole 53 E207 000 01Raw water pressure too low 53 E207 051 01Raw water pump on Weep Hole Leaking 53 G TASK DESCRIPTION 55 G000 000 01Disabling Engine Start 59 G000 000 03Enabling Engine Start 59 G000 000 05Manual Engine Barri...

Page 28: ...Delivery Pump Supply Pressure Check 79 G083 051 01Fuel Duplex Filter Operating Position Check 79 G083 051 03Fuel Duplex Filter Filter Replacement 80 G083 101 01Primary Fuel Filter Priming 81 G083 101 03Primary Fuel Filter Water and Contaminant Draining 82 G083 101 05Primary Fuel Filter Flushing 84 G083 101 07Primary Fuel Filter Draining 86 G083 101 09Primary Fuel Filter Filter Element Replacement ...

Page 29: ... 108 G202 000 05Coolant Sample Extraction and Analysis 109 G202 000 07Engine Coolant Draining 110 G202 000 09Engine Coolant Change 113 G202 051 01Engine Coolant Pump Weep Hole Check 114 G202 400 01Engine Coolant Preheating 114 G202 401 01Engine Coolant Preheating Unit Operation 114 G202 401 03Engine Coolant Preheating Unit Switching On 115 G202 401 05Engine Coolant Preheating Unit Switching Off 11...

Page 30: ...ion and Storage 130 K000 000 07Restore to Service 131 K000 000 09Task Descriptions with 3 Digit Codes 131 001 Clean engine 131 002 Preserve fuel system 131 003 Preserve engine coolant system 132 004 Perform preservation run 132 005 Spray corrosion inhibitor oil into air manifolds 132 006 Spray corrosion inhibitor oil onto turbocharger compressor wheels 132 007 Seal engine exhaust system 133 008 Se...

Page 31: ...50 A000 000 15 Engine Inclinations 151 A000 000 17 General Engine Specifications 152 A050 000 01 Timing Data 154 Firing Order 154 A055 050 01 Valve Clearances 155 A180 000 01 Oil Capacity 155 C OPERATING INSTRUCTIONS 161 C000 000 01 Operating Instructions Introduction 163 C000 000 03 Before Operation Services 164 C000 000 05 Initial Operation 166 C000 000 07 Operational Checks Maintenance Echelon ...

Page 32: ...gine External Cleaning 193 G030 001 01 Engine Barring Tool Installation 195 G030 001 03 Engine Barring Tool Removal 196 G055 000 01 Valve Operating Mechanism Oil Supply Check 196 G055 000 03 Valve Operating Mechanism Lubrication 197 G055 050 01 Valve Clearance 197 G055 101 01 Cylinder Head Rocker Cover Removal 198 G055 101 03 Cylinder Head Rocker Cover Installation 199 G073 051 07 High Pressure Fu...

Page 33: ... Centrifugal Oil Filter Cleaning 216 G202 000 01 Engine Coolant Filling 223 G202 000 03 Engine Coolant Level Check 225 G200 000 05 Coolant Sample Extraction and Analysis 227 G202 000 07 Engine Coolant Draining 227 G202 000 09 Engine Coolant Change 230 G202 051 01 Engine Coolant Pumps Weep Hole Check Relief Bore 231 G202 400 01 Engine Coolant Preheating 231 G202 401 01 Engine Coolant Preheater Oper...

Page 34: ...1 Engine Control System Cut In 246 G500 000 03 Engine Control System Cut Out 246 G500 000 05 Preparation for Welding Operations 247 G500 000 07 DDEC Operation 247 G507 000 01 DDEC Connection Checks 247 G510 000 01 Monitoring System 247 K PRESERVATION 249 K000 000 01 Preservation Introduction 251 K000 000 03 Preservation and Storage 252 K000 000 05 Extended Preservation and Storage 253 K000 000 07 ...

Page 35: ...SERIES 4000 12 16V SERVICE MANUAL 013 Remove seals from engine exhaust system 256 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION xxix ...

Page 36: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice xxx Copyright DETROIT DIESEL CORPORATION ...

Page 37: ...RMATION 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 ...

Page 38: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 2 Copyright DETROIT DIESEL CORPORATION ...

Page 39: ...SERIES 4000 12 16V SERVICE MANUAL A 001 IMPORTANT INFORMATION Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 3 ...

Page 40: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 4 Copyright DETROIT DIESEL CORPORATION ...

Page 41: ...ward the logical structure of the parts list and spare parts manuals Each function group consists of no more than nine parts for example 3 C 011 05 01 General View 3 C 011 05 02 Special Tool 3 C 011 05 04 Before Removal Operations 3 C 011 05 05 Removal 3 C 011 05 06 Disassembly 3 C 011 05 08 Inspection and Repair 3 C 011 05 10 Assembly 3 C 011 05 11 Installation 3 C 011 05 12 After Installation Op...

Page 42: ...ingly 3 Component packaging must only be removed immediately before installation 3 Elastomer components e g rubber parts etc must not be washed with diesel fuel solvents or cold cleaners Parts dirtied with oil and fuel must be cleaned immediately The parts should be wiped with a dry cloth Elastomer components such as engine mounts damping elements couplings and Vee belts must not be painted They c...

Page 43: ... gaskets Sealing compound is to be thinly applied in spots on the flat gaskets or mating faces Immediately after application of the sealing paste the flat gaskets must be fitted to the component and then no more than 20 minutes later the seal components mated together Oil multi purpose grease or other materials must not be used to fix the position 3 Before installing antifriction bearings lightly ...

Page 44: ... unless otherwise specified 3 The assembly surfaces of bolts nuts washers and of parts to be tensioned must be clean and polished or provided with the specified surface protection and free from warping and damage Corrosion inhibitors e g oil grease must be removed Threads and bolt heads must be coated with lubricant before assembly as per tightening specifications Unless otherwise specified the fo...

Page 45: ...e of rotation tightening each bolt head must be color marked so that after tightening it is possible to check that the angle of rotation is correct Exception color marking is not necessary in the case of a self monitoring numerically controlled NC screwdriver 3 Elongation tightening Tightening must be carried out in accordance with tightening specifications taking the tightening tolerance into con...

Page 46: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 10 Copyright DETROIT DIESEL CORPORATION ...

Page 47: ...SERIES 4000 12 16V SERVICE MANUAL A 002 GENERAL ENGINE INFORMATION Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 11 ...

Page 48: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 12 Copyright DETROIT DIESEL CORPORATION ...

Page 49: ...r Drive 10 Intake Manifold 3 Low Temp Coolant LTC Thermostat 11 DDEC ECMs 4 Trunnion Mount 12 Fuel Filters 5 Oil Coolers 13 Air Compressor 6 Centrifugal Oil Filter 14 Oil Filter Cartridges 7 Turbocharger 4 15 Accessory Drive 8 Crankcase Breathers Figure 1 Front View 12V Engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 13 ...

Page 50: ...ler Intake 12 High Temp Water Pump Drive 4 Air Inlet 13 Intake Manifold 5 Crankcase Breathers 14 Dipstick 6 Exhaust Outlet 15 Oil Pan 7 Centrifugal Oil Filter 16 Oil Filler Tube 8 Charge Air Coolant Line 17 Cylinder Head Rocker Cover 9 High Temp Thermostat Housing Figure 2 Back View 12V Engine All information subject to change without notice A 14 Copyright DETROIT DIESEL CORPORATION ...

Page 51: ...Series Cylinders Application Rotation and Type Design Variation Specific Model Number Position 1 Position 2 3 Position 4 Position 5 Position 6 Position 7 8 T 4000 08 0 Incomplete 0 LH K DDEC III IV 00 Basic 12 2 Marine 1 LA 16 3 Industrial and Genset 2 LB 4 Power Base 3 LC 5 Generator 4 LD 5 RA 6 RB 7 RC 8 RF 9 RH Table 1 DDC Model Numbering Format All information subject to change without notice ...

Page 52: ... the right bank B as per DIN ISO 1204 Each cylinder bank is numbered consecutively from No 1 starting at the driving end of the engine Other components and assemblies are also numbered consecutively starting with No 1 at the driving end See Figure 3 Figure 3 Cylinder Designations 12V Engine All information subject to change without notice A 16 Copyright DETROIT DIESEL CORPORATION ...

Page 53: ...and list any optional equipment used on the engine See Figure 4 This label is attached to the charge air cooler housing along with a disclaimer label and a bar code label that contains the engine serial number and customer specification number Figure 4 Option Label All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 17 ...

Page 54: ...ly cover the label to provide a good seal With any order for parts the engine model number and serial number must be given In addition if a type number is shown on the option label covering the equipment required this number should be included on the parts order All groups of parts used on a unit are standard for the model unless otherwise listed on the option label Power take off assemblies torqu...

Page 55: ... 5 Engine Serial Number Location B Bank Side Below Side Cover and Above Oil Pan Bolt Rail Firing Order 3 8V A1 B4 A4 A2 B3 A3 B2 B1 3 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 3 16V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 19 ...

Page 56: ...p Counterclockwise Engine Coolant Pump Counterclockwise Charge Air Coolant Pump Counterclockwise Air Conditioner Compressor Counterclockwise Table 2 Direction of Rotation Valve Clearance with Engine Cold Listed in Table 3 are the valve clearances with engine cold 20 C 68 F Component Description Dimension Inlet 0 20 mm 0 008 in Exhaust 0 50 mm 0 02 in Table 3 Valve Clearance All information subject...

Page 57: ...fter TDC 5 Overlap crank angle 73 degrees 6 Start of delivery map based I TDC top dead center II BDC bottom dead center Figure 6 Valve Timing Diagram Camshaft and Valve Lift Listed in Table 4 are the camshaft and valve lifts for camshaft adjustment Operation Inlet Exhaust Camshaft lift at TDC 1 43 mm 0 056 in 1 43 mm 0 056 in Valve lift at TDC zero valve clearance 2 00 mm 0 07874 in 2 00 mm 0 0787...

Page 58: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 22 Copyright DETROIT DIESEL CORPORATION ...

Page 59: ...SERIES 4000 12 16V SERVICE MANUAL A 003 TORQUE SPECIFICATIONS Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 23 ...

Page 60: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 24 Copyright DETROIT DIESEL CORPORATION ...

Page 61: ...lt Class 9 8 M8 A Standard 31 35 Bolt Class 9 8 M10 A Exhaust Outlet Mounting 42 47 Bolt Class 10 9 M6 A Standard 12 14 Bolt Class 10 9 M8 A Standard 31 35 Bolt Class 10 9 M8 A Top cover of CAC 21 24 Bolt Class 10 9 M10 A Standard 60 66 Bolt Class 10 9 M10 A Oil Pan Block Front 4 Bolts Reference Category F 60 66 Bolt Class 10 9 M10 A Oil Pan Block Reference Category F 30 33 Bolt Class 10 9 M12 A S...

Page 62: ...tandard 35 39 Plug Copper Washer in Steel Cast Iron M16 X 1 5 A Standard 40 44 Plug Copper Washer in Steel Cast Iron M18 X 1 5 A Standard 50 55 Plug Copper Washer in Steel Cast Iron M20 X 1 5 A Standard 55 61 Plug Copper Washer in Steel Cast Iron M22 X 1 5 A Standard 60 66 Plug Copper Washer in Steel Cast Iron M24 X 1 5 A Standard 70 77 Plug Copper Washer in Steel Cast Iron M26 X 1 5 A Standard 80...

Page 63: ...Standard 15 17 Plug Copper Washer in Aluminum M12 X 1 5 A Standard 25 28 Plug Copper Washer in Aluminum M14 X 1 5 A Standard 25 28 Plug Copper Washer in Aluminum M16 X 1 5 A Standard 30 33 Plug Copper Washer in Aluminum M18 X 1 5 A Standard 35 39 Plug Copper Washer in Aluminum M20 X 1 5 A Standard 45 50 Plug Copper Washer in Aluminum M22 X 1 5 A Standard 50 55 Plug Copper Washer in Aluminum M24 X ...

Page 64: ...O 6149 M14 X 1 5 A Standard 15 18 Plug Fitting Sensor ISO 6149 M16 X 1 5 A Standard 18 21 Plug Fitting Sensor ISO 6149 M18 X 1 5 A Standard 23 26 Plug Fitting Sensor ISO 6149 M22 X 1 5 A Standard 33 37 Plug Fitting Sensor ISO 6149 M27 X 2 0 A Standard 57 62 Plug Fitting Sensor ISO 6149 M33 X 2 0 A Standard 103 113 Fitting O ring Face Seal ORFS 9 16 18 4 Hose A Standard 14 16 Fitting O ring Face Se...

Page 65: ...r A Standard 45 56 Plug Fitting NPTF 1 11 X 1 2 3 4 Taper A Standard 102 107 Plug G 1 4 A Plug Hydraulic Expansion Port 25 35 Plug Special M26 X 1 5 A Oil Filter Drain Plug 80 88 Plug Special M42 X 2 0 A Oil Filter Bypass Plug 130 140 Banjo Bolt M12 X 1 5 A Standard 20 22 Banjo Bolt M14 X 1 5 A Standard 25 28 Metal to Metal Cone Seal M12 X 1 5 A Low Pressure Jumper Lines N 15001 30 33 Metal to Met...

Page 66: ... 100 110 Fuel Line M42 X 1 5 A Fuel Rail Nut 550 605 Sensor M18 X 1 5 A Fuel Monitor Marine 25 28 Sensor 1 4 18 NPTF A Coolant Temperature Marine 10 8 16 3 Sensor 1 4 18 NPTF A Pressure Transducer Marine 20 45 Sensor 1 4 18 PTF SAE A Coolant Level Indicator Marine 2 7 4 1 Sensor 1 4 PTF SAE A Coolant Level Industrial 42 45 Sensor 3 8 PTF SAE A Coolant Level Industrial 42 45 Regulator M45 X 1 5 A O...

Page 67: ...valent Verification to minimum torque value Category E Load both high and low critical Process controlled by special torque equipment Verification to equipment capability Category F Joint sensitive to torque sequence See engine build instructions Category G Gasket eliminator used as a sealant Joint sensitive to bolt removal Category H Critical joint Torque plus angle required Table 5 Fastener Torq...

Page 68: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 32 Copyright DETROIT DIESEL CORPORATION ...

Page 69: ...SERIES 4000 12 16V SERVICE MANUAL A 004 SAFETY PRECAUTIONS Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 33 ...

Page 70: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 34 Copyright DETROIT DIESEL CORPORATION ...

Page 71: ...losed space must be adequately vented Some means of providing fresh air into an enclosed space must be ensured Stands Stands must be used in conjunction with hydraulic jacks or hoists Do not rely on a jack or hoist alone When lifting an engine ensure the lifting device is securely fastened Also ensure that the weight of the load being lifted does not exceed the lifting capacity of the device Glass...

Page 72: ... which could lead to fire or an explosion both of which could cause personal injury or property damage or both If a fall should result in the gage end breaking off the sudden release of high pressure gas could turn the cylinder into a dangerous projectile which could cause severe personal injury or property damage or both Observe the following precautions when using oxygen acetylene gas cylinders ...

Page 73: ...sting or servicing an engine To avoid injury when working near the engine do not wear jewelry or loose fitting clothing Any of these items could catch on moving parts and cause serious injury Safety glasses and hearing protection must be worn Power Tools NEVER use defective portable power tools To avoid injury do not use defective portable power tools Check for frayed cords prior to use Ensure all...

Page 74: ...eryone in the work area To avoid injury when blow drying wear adequate eye protection safety glasses or face plate and do not exceed 276 kPa 40 lb in 2 air pressure Transport 3 Lift the engine only with the lifting eyes provided 3 Use only the transport and lifting equipment approved by Detroit Diesel Technical Service 3 The engine must be transported only in an installation position Fuel Lines Re...

Page 75: ...te the skin These fluids can cause a minor cut or opening in the skin If injured by escaping fluid see a doctor immediately Serious infection or adverse reaction to the fluid can result if not treated immediately To avoid injury do not put your hands in front of fluid under pressure Fluids under pressure can penetrate skin and clothing and cause injury All information subject to change without not...

Page 76: ...uel tank This will reduce the likelihood of a dangerous spark To avoid injury do not overfill the fuel tank Overfilling will release flammable liquid and create a fire hazard To avoid injury do not smoke when refueling Do not refuel when the engine is hot or running Failure to follow this caution may result in a fire or explosion caused by fuel ignition All information subject to change without no...

Page 77: ...ng which could result in personal injury disconnect the batteries or disable the air starter if so equipped Fire Keep a charged fire extinguisher within reach Ensure the proper type of extinguisher is on hand Cleaning Agent The following cautions should be followed when using cleaning agents To avoid injury avoid the use of carbon tetrachloride as a cleaning agent It releases harmful vapors Ensure...

Page 78: ...cation of the fan pulleys and belts Avoid making contact across the two terminals of a battery This can cause arcing or battery explosion Start Attempts Observe the following notice during start attempts NOTICE Avoid excessive injection of ether into the engine during start attempts Injection of excessive ether may result in an uncontrolled internal engine explosion that could cause engine damage ...

Page 79: ...fe to handle To avoid injury wear goggles or a faceplate and neoprene or PVC gloves when handling fluoroelastomer O rings or seals that have been degraded by excess heat Make sure engine parts have cooled before handling them If hydrogen fluoride condensate is suspected wash equipment and parts well with lime water calcium hydroxide solution before reusing Discard gloves after handling degraded fl...

Page 80: ...sable for removing heavy accumulations of grease and dirt from the exterior of the engine and its subassemblies Solvent Tank Cleaning Solvent cleaning requires a tank large enough to accommodate the largest part to be cleaned usually the cylinder block To avoid injury burning wear adequate protective clothing eye protection rubber apron rubber boots rubber gloves To prevent splashing carefully low...

Page 81: ... safety glasses or face plate and do not exceed 276 kPa 40 lb in 2 air pressure Parts may be dried with compressed air Heat from the hot tanks will frequently dry the parts making blow drying unnecessary Rust Preventive If parts are not to be used immediately after cleaning dip them in a suitable rust preventive compound Remove the rust preventive coating before installing the parts Service Parts ...

Page 82: ...parts are used at the point where the various specifications apply This requirement applies to references within the text of the manual These wear limits are in general for parts most frequently replaced in engine overhaul work All information subject to change without notice A 46 Copyright DETROIT DIESEL CORPORATION ...

Page 83: ...SERIES 4000 12 16V SERVICE MANUAL A 005 GENERAL DESCRIPTION OF SERIES 4000 OPERATION Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 47 ...

Page 84: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 48 Copyright DETROIT DIESEL CORPORATION ...

Page 85: ...n rail fuel injection system 3 A single casting cylinder block 3 Individual cylinder liners 3 Individual cylinder heads The Series 4000 Application and Installation manual is a compilation of the installation drawings component sketches and technical information required for proper application and installation of the engine General Specifications Listed in Table 6 are the general specifications fo...

Page 86: ...Operator s Guide Marine 8 12 and 16V 6SE4008 Engine Service Fluid and Filter Requirements 7SE273 Coolant Selections 7SE298 Series 4000 Parts Catalog 6SP4011 Series 4000 Generator Set Application and Installation 7SA810 Series 4000 C I Application and Installation 7SA4000 Labor Time Manual 12SE4000 DDEC Multi ECM Troubleshooting Guide 6SE496 Product Support Plan C I 7SE4006 Table 7 Publications All...

Page 87: ...SERIES 4000 12 16V SERVICE MANUAL A 006 DATA SHEETS Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 51 ...

Page 88: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 52 Copyright DETROIT DIESEL CORPORATION ...

Page 89: ...r product support service and DDC or by an external product support service Measurements cannot be below or above the limit values as specified in the Tolerances and Wear Limits List Test data sheets are to be used during engine run in and are as follows see Figure 7 for cylinder block bores See Figure 8 for cylinder block bores See Figure 9 for crankshaft bearing See Figure 10 for cylinder liner ...

Page 90: ...SERIES 4000 12 16V SERVICE MANUAL Figure 7 Test Sheet for Cylinder Block Bores All information subject to change without notice A 54 Copyright DETROIT DIESEL CORPORATION ...

Page 91: ...SERIES 4000 12 16V SERVICE MANUAL Figure 8 Test Sheet for Cylinder Block Bores All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 55 ...

Page 92: ...SERIES 4000 12 16V SERVICE MANUAL Figure 9 Test Sheet for Crankshaft Bearing All information subject to change without notice A 56 Copyright DETROIT DIESEL CORPORATION ...

Page 93: ...SERIES 4000 12 16V SERVICE MANUAL Figure 10 Test Sheet for Cylinder Liner Installed All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 57 ...

Page 94: ...SERIES 4000 12 16V SERVICE MANUAL Figure 11 Test Sheet for Crankshaft Main Bearing All information subject to change without notice A 58 Copyright DETROIT DIESEL CORPORATION ...

Page 95: ...SERIES 4000 12 16V SERVICE MANUAL Figure 12 Test Sheet Connecting Rod Bearing Shells Installed All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 59 ...

Page 96: ...SERIES 4000 12 16V SERVICE MANUAL Figure 13 Test Sheet for Control Times and Injection Timing All information subject to change without notice A 60 Copyright DETROIT DIESEL CORPORATION ...

Page 97: ...SERIES 4000 12 16V SERVICE MANUAL Figure 14 Crankshaft Data Sheet All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 61 ...

Page 98: ...SERIES 4000 12 16V SERVICE MANUAL Figure 15 W6 Component List Sheet 1 All information subject to change without notice A 62 Copyright DETROIT DIESEL CORPORATION ...

Page 99: ...SERIES 4000 12 16V SERVICE MANUAL Figure 16 W6 Component List and Dyno Test Data Sheet 2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 63 ...

Page 100: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 64 Copyright DETROIT DIESEL CORPORATION ...

Page 101: ...SERIES 4000 12 16V SERVICE MANUAL A 007 CONVERSION TABLES Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 65 ...

Page 102: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 66 Copyright DETROIT DIESEL CORPORATION ...

Page 103: ...m 3 Inch3 in 3 16 387 Centimeters3 cm3 Inch3 in 3 0 0164 Liters L Quart qt 0 9464 Liters L Gallon gal 3 785 Liters L Yard3 yd3 0 7646 Meters3 m3 Multiply Mass By To get equivalent number of Pound lb 0 4536 Kilograms kg Ton ton 907 18 Kilograms kg Ton ton 0 907 Tonne t Multiply Force By To get equivalent number of Kilogram kg 9 807 Newtons N Ounce oz 0 2780 Newtons N Pound lb 4 448 Newtons N Multip...

Page 104: ...ilowatt hour kW hr 3 600 000 or 3 6 x 106 Joules J one W s Multiply Light By To get equivalent number of Foot candle fc 10 764 Lumens meter2 lm m2 Multiply Fuel Performance By To get equivalent number of Miles gal mile gal 0 4251 Kilometers liter km L Gallons mile gal mile 2 3527 Liter kilometer L km Multiply Velocity By To get equivalent number of Miles hour mile hr 1 6093 Kilometers hour km hr T...

Page 105: ...5 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1 4 0 250 6 35000 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125 7 14375 25 32 0 78125 19 84375 19 64 0 296875 7 54062 51 64 0 796875 20 24062 5 16 0 3125 7 93750 13 16 0 8125 20 63750 21 64 0 328125 8 33437 53 64 0 828125 21 03437 11 32 0 34375 8 73125 27 32 0 84375 21 43125 23 64 0 359375 9 12812 55 64 0 85...

Page 106: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 70 Copyright DETROIT DIESEL CORPORATION ...

Page 107: ...SERIES 4000 12 16V SERVICE MANUAL A 008 REPAIRING THREADED BORES Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 71 ...

Page 108: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 72 Copyright DETROIT DIESEL CORPORATION ...

Page 109: ...1 8 32 8 04 8 1 8 2 8 25 8 3 M 10 10 40 10 05 10 25 M 12 12 50 12 05 12 25 12 5 M 12 x 1 5 12 43 12 05 12 25 M 14 14 53 14 06 14 25 14 5 M 14 x 1 5 14 43 14 05 14 25 M 15 x 2 15 30 15 20 15 25 M 16 16 53 16 06 16 25 16 5 M 16 x 1 5 16 43 16 05 16 25 M 24 x 1 5 24 43 24 05 24 25 M 26 x 1 5 26 43 24 05 26 25 M 30 x 1 5 30 43 30 05 30 25 Table 10 Data to Repair Threaded Bores All information subject ...

Page 110: ...ve the thread insert from the bore with a suitable tool 2 Bore core hole with suitable twist drill as listed in Table 10 3 Cut thread with special tapped bore NOTE Do not countersink bore 4 Mount spindle 3 and snout 2 corresponding with thread 5 Groove on snout must be aligned with markings on the helix installation tool 4 All information subject to change without notice A 74 Copyright DETROIT DIE...

Page 111: ...ert thread insert 1 into spindle 2 in helix tool 3 See Figure 18 1 Thread insert 3 Helix Installation Tool 2 Spindle Figure 18 Inserting Thread Insert All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 75 ...

Page 112: ...MANUAL 7 Use spindle to turn thread insert through the snout until it is flush at the front See Figure 19 Figure 19 Turning Thread Insert All information subject to change without notice A 76 Copyright DETROIT DIESEL CORPORATION ...

Page 113: ... NOTE Insert thread insert 1 2 to 1 1 2 turns deeper than threaded bore surface Figure 20 Thread Insert Tool 9 Use bolt shearer to remove driver journal to M 14 10 If threaded inserts are over M 14 move the driver journal up and down with pointed pliers and remove All information subject to change without notice Copyright DETROIT DIESEL CORPORATION A 77 ...

Page 114: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice A 78 Copyright DETROIT DIESEL CORPORATION ...

Page 115: ...age 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 ...

Page 116: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 2 Copyright DETROIT DIESEL CORPORATION ...

Page 117: ...VICE MANUAL B 001 CHECKING ENGINE CONDITION BEFORE A MAJOR OVERHAUL Section Page Checking Engine Condition Before a Major Overhaul B 5 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION B 3 ...

Page 118: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 4 Copyright DETROIT DIESEL CORPORATION ...

Page 119: ...fore a major overhaul Before the engine is removed a brief test should be conducted to assist in evaluating its condition and running behavior Deviations from the Engine Acceptance Test Record found during the test run provide valuable information for subsequent overhaul services All information subject to change without notice Copyright DETROIT DIESEL CORPORATION B 5 ...

Page 120: ...l line connections for leaks Remove cylinder head cover Refer to section Removing Rocker CoverRemoving Rocker Cover Check valve gear lubrication visual inspection Extract engine oil sample Operators Guide Analyze engine oil sample spot test water content dilution with fuel Test Kit Extract coolant sample Operators Guide Analyze coolant sample Test Kit Check function of monitoring system and ECU Op...

Page 121: ...SERIES 4000 12 16V SERVICE MANUAL B 002 W5 MAINTENANCE OPERATIONS Section Page W5 Maintenance Operations B 9 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION B 7 ...

Page 122: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 8 Copyright DETROIT DIESEL CORPORATION ...

Page 123: ...move lines clean and replace gaskets Drain exhaust system check security of securing bolts Operators Guide Remove charge air cooler clean and check for leaks Refer to section C 111 05 05C 111 05 05 Check coolant thermostat high temperature circuit replace if necessary Refer to section C 208 05 08C 208 05 08 Check coolant thermostat low temperature circuit replace if necessary Refer to section C 20...

Page 124: ...de Engine mount check security Operators Guide ECU check wiring check security and condition Operators Guide Reinstall mount parts that were removed after they have been assembled according to the engine assembly sequence OEM Guidelines Fill engine coolant vent coolant system Operators Guide Fill oil system with engine oil Operators Guide Switch on battery main switch Operators Guide Switch on mon...

Page 125: ...ons to be Performed Refer to Section Check engine oil level Operators Guide Check engine coolant level Operators Guide Table 2 W5 Maintenance Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION B 11 ...

Page 126: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 12 Copyright DETROIT DIESEL CORPORATION ...

Page 127: ...SERIES 4000 12 16V SERVICE MANUAL B 003 W6 MAINTENANCE OPERATIONS Section Page All information subject to change without notice Copyright DETROIT DIESEL CORPORATION B 13 ...

Page 128: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 14 Copyright DETROIT DIESEL CORPORATION ...

Page 129: ...ect crankshaft assembly 12V engine only 3 Replace crankshaft assembly 16V engine only 3 Inspect camshaft per mandatory inspection instructions 3 Replace cylinder kits 3 Replace connecting rods 3 Replace rod and main bearings 3 Cylinder Heads 3 Replace all 3 Valve operating mechanism 3 Replace all rocker arm assemblies 3 Replace all swing arm assemblies 3 Replace push tubes 3 Gear case assembly 3 I...

Page 130: ... replace with reliabilt 3 Replace high pressure rail sensor 3 Inspect and clean high pressure rail relief valve 3 Replace check valves in junction block 3 Replace flow limiting valves 3 Cooling system 3 Replace all LTC and HTC thermostats 3 Replace both LTC and HTC water pump assemblies with reliabilt 3 For 2700 HP and higher applications only replace the charge air cooler core For all others insp...

Page 131: ...SERIES 4000 12 16V SERVICE MANUAL B 004 ENGINE REMOVAL Section Page Engine Removal B 19 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION B 17 ...

Page 132: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 18 Copyright DETROIT DIESEL CORPORATION ...

Page 133: ...Guide Wash engine without using chemical cleaning agents Disconnect all connections Seal open connections with non linting plugs and covers Release engine securing bolts Remove engine and place on engine stand Using a lifting device attach engine only on suspension brackets provided as shown in installation drawing taking center of gravity and transportation specifications into consideration Refer...

Page 134: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 20 Copyright DETROIT DIESEL CORPORATION ...

Page 135: ...e Engine Run in B 23 Settings B 23 Acceptance Test Marine Applications B 25 Construction and Industrial Applications B 25 Haul Truck Load Bank Test B 25 Inspection Report B 26 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION B 21 ...

Page 136: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 22 Copyright DETROIT DIESEL CORPORATION ...

Page 137: ...gine Factory Test record Listed in Table 4 for the operations to be performed for the engine run in Operations to be Performed Refer to Section Install engine on test stand Connect engine to brake or alternator Connect air intake exhaust engine coolant and fuel lines Connect measuring sensor and measuring lines to the corresponding measuring points to record the measured values for fuel lube oil e...

Page 138: ...e engine for oil consumption measurement Carry out acceptance test in accordance with DDC Engine Acceptance Test Record Refer to section B 005 Enter operational data in engine acceptance test record provided DDC Engine Acceptance Test Record Compare test data with those recorded in DDC Engine Acceptance Test Record DDC Engine Acceptance Test Record Carry out governor test After completing acceptan...

Page 139: ...250 kW at 1800 rpm 2 hour 1493 kW at 1890 rpm Table 5 Acceptance Test Construction and Industrial Applications Listed in Table 6 are the power and propeller curves for the acceptance test construction and industrial applications Running Period Power Propeller Curve Warm up engine 700 1000 rpm 5 min steps 100 rpm from 1000 rpm to 1900 rpm no load 10 min 50 load at 1200 rpm 10 min 50 load at 1500 rp...

Page 140: ...mbar 3 Direction of rotation per ISO 1204 3 Start of fuel delivery BTDC Record the following values when completing the Inspection Report 3 Time hour min 3 Speed n rpm 3 Brake load F N 3 Brake power 3 Test stand Py kW 3 Standard Conditions Pr kW 3 Fuel 3 Quantity V dm3 3 Temperature C 3 Flow measurement t s 3 Specific gravity g cm3 3 Consumption Hourly B kg h and Specific b g kWh 3 Rack setting R ...

Page 141: ...nder C 3 Charge air pressure before 3 Engine mm H2 O 3 Cylinder C 3 Exhaust 3 Temperature after engine C 3 Pressure after engine C 3 Smoke index SI 3 Fuel temperature before engine C 3 Lube oil consumption kg h 3 at Py kW n 3 n rpm 3 Electric starter motor 3 Remarks 3 No evident faults or deficiencies occurred during the acceptance test 3 Signed for DDC 3 Signed for the purchaser All information s...

Page 142: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 28 Copyright DETROIT DIESEL CORPORATION ...

Page 143: ...4000 12 16V SERVICE MANUAL B 006 ENGINE INSTALLATION AND OPERATION Section Page Engine Installation and Operation B 31 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION B 29 ...

Page 144: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 30 Copyright DETROIT DIESEL CORPORATION ...

Page 145: ...arge air coolant system Operators Guide Fill oil system with engine oil Operators Guide Prepare engine for operation Operators Guide Preheat engine Operators Guide Start engine Operators Guide Perform checks while engine is running Operators Guide Carry out test run Measure intake air depression Operators Guide Measure exhaust back pressure Operators Guide Shut down engine Operators Guide Perform ...

Page 146: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice B 32 Copyright DETROIT DIESEL CORPORATION ...

Page 147: ...655 C 080 FUEL SYSTEM LOW PRESSURE C 777 C 100 TURBOCHARGER C 841 C 110 CHARGE AIR COOLING C 915 C 120 AIR INTAKE SUPPLY C 973 C 140 EXHAUST SYSTEM C 1027 C 170 STARTING SYSTEM C 1061 C 180 LUBE OIL SYSTEM C 1091 C 200 COOLING SYSTEM C 1275 C 210 BATTERY CHARGING ALTERNATOR C 1533 C 220 FAN DRIVE C 1575 C 230 ENGINE MOUNT C 1695 C 250 FLYWHEEL AND FLEX COUPLING C 1725 C 500 ELECTRONIC MONITORING S...

Page 148: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 2 Copyright DETROIT DIESEL CORPORATION ...

Page 149: ...nd Repair C 96 C 013 05 11 Installation of Cylinder Liner C 101 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 Operatio...

Page 150: ... 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 ...

Page 151: ...linder 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 5...

Page 152: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 6 Copyright DETROIT DIESEL CORPORATION ...

Page 153: ...ANUAL C 011 05 01 GENERAL VIEW See Figure 1 for a general view of the oil gallery access cover with dipstick tube and oil filling feed pipe All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 7 ...

Page 154: ...ller Tube 4 Hex Head Bolt 12 Access Port Cover 5 Link 13 Oil level Dipstick 6 Blanking Plug 14 Dipstick Tube 7 O ring 15 O ring 8 Washer 16 Access Cover with Dipstick Tube Figure 1 General View of Oil Gallery Access Cover with Dipstick Tube and Oil filler Tube All information subject to change without notice C 8 Copyright DETROIT DIESEL CORPORATION ...

Page 155: ...view of the access port covers 1 Plug 4 Inspection Hole Cover 2 O ring 5 Hex Head Bolt 3 Gasket 6 ECM Mount Inspection Hole Cover Figure 2 General View of Access Port Covers All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 9 ...

Page 156: ...ng Cap Nut 6 Core Plug 2 Main Bearing Cap 7 Washer 3 Main Bearing Cap Stud 8 Main Bearing Cap Cross Bolt 4 Camshaft Bushing 9 Rear Main Thrust Bearing Cap 5 Cylinder Block Figure 3 General View of Cylinder Block All information subject to change without notice C 10 Copyright DETROIT DIESEL CORPORATION ...

Page 157: ...l Number Cylinder block barring tool Stop device for assembly of camshaft bearing Stop device for assembly of camshaft bearing gear case end Installation tool for camshaft bearing Brass drift for cap plug Hydraulic clamping device for main bearing pin Table 1 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 11 ...

Page 158: ...of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 2 Before Removal Operations All information subject to change without notice C 12 Copyright DETROIT DIESEL CORPORATION ...

Page 159: ...r block and main bearings Cylinder Block Removal Perform the following steps to remove the cylinder block and externally mounted components 1 Remove cover 12 access cover with dipstick tube 16 oil filling feed pipe 11 and access port cover 12 See Figure 4 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 13 ...

Page 160: ...inder Block 11 Oil Filler Tube 4 Hex Head Bolt 12 Access Port Cover 5 Link 13 Oil level Dipstick 6 Blanking Plug 14 Dipstick Tube 7 O ring 15 O ring 8 Washer 16 Access Cover with Dipstick Tube Figure 4 Removing of Cylinder Block Components All information subject to change without notice C 14 Copyright DETROIT DIESEL CORPORATION ...

Page 161: ...s 2 Turnover Stand Figure 5 Installing Cylinder Block in Turnover Stand To avoid personal injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 4 Raise cylinder block with a suitable lifting device and place in turnover stand 2 and secure See Figure 5 All information subject to change without notice Cop...

Page 162: ... lube oil filters Take two samples one from the lube oil filters and the other from the engine oil in the pan Drain engine oil from both the oil pan and the gear case 3 Remove oil pan Refer to section C 014 05 05C 014 05 05 4 Wipe down the underside of the engine to remove dripping oil Remove the oil pump to allow clearance to the 9 16V or 7 12V main bearing journal front of engine See Figure 6 1 ...

Page 163: ...the 1 main bearing journal rear of engine There are five bolts two Allen head bolts 2 are removed See Figure 7 1 Filler Spacer 2 Allen Head Bolts Figure 7 Removing Filler Spacer All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 17 ...

Page 164: ...three bolts are accessed from behind the flywheel through the flywheel housing into the filler spacer See Figure 8 Figure 8 Removing Bolts from Filler Spacer All information subject to change without notice C 18 Copyright DETROIT DIESEL CORPORATION ...

Page 165: ...main bearing cap and on the adjacent A bank pan rail Mark each location starting with 1 from the rear working forward 8 Remove all external main bearing stabilizer bolts on both sides of the engine See Figure 9 Figure 9 Removing Main Bearing Stabilizer Bolt All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 19 ...

Page 166: ... necessary mark according to sequence a Punch the main bearing serial number on cylinder block and main bearing cap on left side of engine A side b Punch a 6 mm high number on each main bearing cap c To numerically sequence begin at rear flywheel end of engine with main bearing number 1 NOTE The A side is on the right when the cylinder block is viewed from the bottom See Figure 10 1 Identification...

Page 167: ...t wrench 2 remove all side socket head bolts 1 securing main bearing caps to the cylinder block See Figure 11 1 Main Bearing Cap Stabilizer Bolt 3 Main Bearing Cap Nut 2 Ratchet and Socket Wrench Figure 11 Removing Main Bearing Cap Stabilizer Bolts All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 21 ...

Page 168: ... nut 1 of hydraulic pretensioner on stud 2 of relevant main bearing cap See Figure 12 1 Main Bearing Cap Nut 2 Main Bearing Pretensioner Nut Stud Figure 12 Attaching Main Bearing Cap Stud of Hydraulic Pretensioner All information subject to change without notice C 22 Copyright DETROIT DIESEL CORPORATION ...

Page 169: ...n hydraulic pretensioner by hand until it is in position See Figure 13 1 Hydraulic Stud Pretensioner Figure 13 Hand Tightening Hydraulic Pretensioner All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 23 ...

Page 170: ...essure Hose of Hydraulic Hand Pump 2 Magnetic Dial Indicator Figure 14 Connecting High Pressure Hose of Hydraulic Hand Pump 7 Position magnetic base indicator holder with dial gages on cylinder block support surface for extension measurement of studs All information subject to change without notice C 24 Copyright DETROIT DIESEL CORPORATION ...

Page 171: ...he center on the respective measuring core arrow on the surface of the sleeve measuring pin See Figure 15 Figure 15 Positioning Dial Gage Styluses in Surface of Sleeve of Measuring Pin All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 25 ...

Page 172: ...s at the main bearing cap 12 Relieve the tension on the main bearing cap stud 13 Remove studs mount magnetic base indicator holder with dial gages and hydraulic pretensioner 14 Mount magnetic base indicator holder and hydraulic pretensioner on each adjacent bearing cap in turn and remove all nuts in the same sequence 15 Remove loose nuts from the studs All information subject to change without not...

Page 173: ...ndle components only when wearing protective gloves 16 Screw lifting eye into bearing cap See Figure 17 1 Upper Main Bearing Shell 3 Lifting Eye 2 Main Cylinder Block Bearing Cap Figure 17 Pulling Bearing Cap out of Cylinder Block All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 27 ...

Page 174: ...l bearing cap 2 carefully out of cylinder block taking care not to tilt it NOTE Remove studs only if damaged 19 To remove the studs for main bearing cap use a bearing cap nut 2 which is no longer needed as a locknut See Figure 18 1 Main Bearing Cap Stud 3 Socket Wrench Extension 2 Main Bearing Cap Nut 4 Socket Wrench Figure 18 Removing Studs for Main Bearing Cap All information subject to change w...

Page 175: ...bore Refer to section C 011 05 08 a If limits values are exceeded replace camshaft bushing bore b If limit values are not exceeded continue disassembly 24 To remove camshaft bushing 2 use a suitable extraction tool and remove bushing carefully from bore in cylinder block See Figure 19 1 Camshaft 2 Camshaft Bushing Figure 19 Removing Camshaft Bushing NOTE Remove core plug only if necessary for exam...

Page 176: ...ass drift and hammer carefully knock the edge of one side of the core plug inward until it tilts down into the bore See Figure 20 Figure 20 Removing Core Plug All information subject to change without notice C 30 Copyright DETROIT DIESEL CORPORATION ...

Page 177: ...aling surface of the bore is not damaged 28 To remove blanking plug from oil gallery release hex bolts 2 and link See Figure 21 1 Cylinder Block 5 O ring 2 Hex Bolts 6 Oil Gallery 3 Link 7 Pan Seal 4 Blanking Plug Figure 21 Removing Blanking Plug 29 Using a hex bolt 2 carefully withdraw blanking plug from oil bore See Figure 21 30 Remove O ring 5 from blanking plug 4 See Figure 21 All information ...

Page 178: ... lubricate the studs to be stretched with clean engine oil Place the main bearing stud tensioner 1 on the studs of the main bearing cap Turn the hydraulic pretensioner by hand until it is snug then back off one turn See Figure 22 1 Main Bearing Stud Tensioner Figure 22 Stud Tensioner All information subject to change without notice C 32 Copyright DETROIT DIESEL CORPORATION ...

Page 179: ...the main bearing installation report Elongate the stud only enough to rotate nut loose Using a pin rotate the nuts on the main bearing cap studs until loose three full turns Open the pressure bleed valve on the hydraulic pump and release all pressure Remove the magnetic base dial indicator bridge 4 Remove hydraulic pretensioners and attach a slide hammer to the 12 mm bolt hole in the center of the...

Page 180: ...faces upper and lower bores of the cylinder liners in the cylinder block are not worn damaged or pitted continue inspection 4 Visually inspect thread and shaft of main bearing cap studs for damage a If thread or shaft of main bearing cap studs are damaged replace component as necessary b If thread and shaft of main bearing cap studs are not damaged continue inspection 5 Visually inspect thread sha...

Page 181: ...s To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 2 Clean access cover with oil filler neck with suitable solvent and blow clear with compressed air 3 Visually inspect access cover with oil filler neck for damage and defects a If access cover with oil filler neck is damaged or defected repla...

Page 182: ...defects or previous repairs replace component b If dipstick does not show damage defects or previous repairs continue inspection NOTE When replacing dipstick ensure correct version is used Part number is stamped on grip 2 Ensure that the oil level dipstick is secure in the access cover with dipstick tube 3 Replace O ring NOTE Ensure that parts are perfectly clean All information subject to change ...

Page 183: ...4 1 Hole Brush 2 Oil Gallery Figure 24 Cleaning Oil Bores in Cap with Hole Brush a If mating surface is worn or damaged machine as necessary b If damage is beyond repair replace component as necessary c If mating surface is not worn or damaged continue inspection 2 Thoroughly clean oil bore using a bristle brush if necessary NOTE Never use a wire brush All information subject to change without not...

Page 184: ...e and do not exceed 276 kPa 40 lb in 2 air pressure 3 After cleaning flush oilway under pressure if possible and blow clear with compressed air 4 Protect bore with plastic plugs or suitable adhesive tape against contamination until assembly of engine All information subject to change without notice C 38 Copyright DETROIT DIESEL CORPORATION ...

Page 185: ...il bores in cylinder block 1 Light oil bores with a borescope and cold light sources to ensure they are clean See Figure 25 Figure 25 Viewing Oil Bores to Valve Operating Mechanism with Borescope 2 Visually inspect oil supply bores to valve operating mechanism at cylinder block sides A and B a If oil supply bores are not clean use bristle brush to clean b If oil supply bores are clean continue ins...

Page 186: ...in Oil Supply Bores to Camshaft and Main Bearing with Borescope a If main oil bores to camshaft and main bearings in block valley are not clean use bristle brush to clean b If main oil bores to camshaft and main bearing in block valley are clean continue inspection All information subject to change without notice C 40 Copyright DETROIT DIESEL CORPORATION ...

Page 187: ...1 Oil Bore Figure 27 Inspecting Oil Bores in Camshaft Bushing Bore a If oil bores in camshaft bushing bores are not clean use bristle brush to clean b If oil bores in camshaft bushing bores are clean continue inspection All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 41 ...

Page 188: ...e 28 1 Oil Bores Figure 28 Inspecting Oil Bores To Main Bearing a If oil bores to the main bearings are not clean use bristle brush to clean b If oil bores to the main bearings are clean continue inspection All information subject to change without notice C 42 Copyright DETROIT DIESEL CORPORATION ...

Page 189: ...Bristle Brush a If any other coolant or oil carrying bores are contaminated use a bristle brush to clean b If all other coolant or oil carrying bores are not contaminated continue inspection 7 If necessary clean bores with bristle brush 1 NOTE To avoid scratching cylinder block never use a wire brush All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 43 ...

Page 190: ...276 kPa 40 lb in 2 air pressure 8 After cleaning flush bore under pressure if possible and blow clear with compressed air See Figure 30 Figure 30 Flushing Bore with Compressed Air 9 Protect all bores against contamination with plastic plugs until assembly of the engine All information subject to change without notice C 44 Copyright DETROIT DIESEL CORPORATION ...

Page 191: ...idth 1 Using an outside micrometer 1 measure the main bearing cap width at the bottom and top fits of the bearing cap 2 See Figure 31 1 Outside Micrometer 2 Measurement Area Upper and Lower Figure 31 Measuring Main Bearing Cap Width All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 45 ...

Page 192: ...r adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 2 Visually inspect mating surfaces on main bearing cap and cylinder block to ensure they are clean a If mating surfaces on main bearing cap and cylinder block are not clean blow out with compressed air as necessary b If mating surfaces on main bearing cap and cylinder block are clean continue in...

Page 193: ...max 348 5 mm 13 7 in If L L max replace stud Figure 33 Inspecting Stud for Main Bearing Cap 2 Visually inspect thread and shaft to ensure they are in perfect condition a If thread and shaft are not in perfect condition replace stud b If thread and shaft are in perfect condition continue inspection All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 47 ...

Page 194: ...ides at upper and lower fits See Figure 34 NOTE Do not measure main bearing cap guides with cylinder block installed in turnover stand measured values will be incorrect 1 Bore Gage Figure 34 Measuring Main Bearing Cap Guides For an example of data sheet refer to section A 006A 006 All information subject to change without notice C 48 Copyright DETROIT DIESEL CORPORATION ...

Page 195: ...ore gage 1 Adjust bore gage and dial gage 2 with adjusting ring 1 or micrometer to basic size of respective bore to be measured See Figure 35 1 Adjusting Ring 2 Dial Gage Figure 35 Setting Bore Gage All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 49 ...

Page 196: ...next repair stage a Mark repair stage work on a main bearing bore with numeral punches at least 6 mm 0 23622 in high at stage 1 0 5 mm at stage 2 1 0 mm b Marking location is on the underside of the cylinder block on the B side web of the main bearing affected also refer to section C 011 05 06 NOTE If a new main bearing cap is being installed its position must be marked accordingly See information...

Page 197: ...lowing steps to measure camshaft bushing bore 1 Using a bore gage measure camshaft bushing bore diameter B See Figure 37 1 Cylinder Block 2 Bushing Figure 37 Measuring Camshaft Bushing Bore All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 51 ...

Page 198: ...ring Camshaft Bushing Bore 3 After removing camshaft bushing measure bushing bore diameter A in cylinder block 1 See Figure 38 a If limit values are exceeded recondition bushing bore to next repair size b If limit values are not exceeded continue to next step All information subject to change without notice C 52 Copyright DETROIT DIESEL CORPORATION ...

Page 199: ...ition bores to next repair size b If wear limits are not exceeded continue to next step 2 If reconditioning is necessary only recondition the respective cylinder liner bore in cylinder block top and bottom of bores to next repair stage a Mark repair stage work with numeral punches at least 6 mm high at stage 1 0 5 mm at stage 2 1 0 mm b Marking location is at the top edge of the cylinder block sid...

Page 200: ...se seating surface on core plugs and bore in cylinder block See Figure 40 1 Core Plug 2 Plug Installer Figure 40 Installing Core Plugs 2 Coat sealing surface of plugs with thread locking compound 3 Using a plug installer knock cap plug into the cylinder block plug bore NOTE If necessary because of leaks sealing surface damage the plug can be replaced after it has been knocked out with a brass drif...

Page 201: ...top and camshaft bushing alignment device 1 onto the locating bore of the rocker shafts See Figure 41 1 Fixture for Stop and Alignment of Camshaft Bushing Figure 41 Installing Camshaft Bearings 1 to 6 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 55 ...

Page 202: ...insertion pin 2 onto assembly tool 1 See Figure 42 1 Assembly Tool 3 Spring Loaded Locating Brass Drift 2 Plastic Insertion Brass Drift 4 Oil Bore of Camshaft Bushing Figure 42 Fitting Plastic Insertion Brass Drift onto Assembly Tool All information subject to change without notice C 56 Copyright DETROIT DIESEL CORPORATION ...

Page 203: ... will occur 7 Cool camshaft bushings in liquid nitrogen 8 Fit the cooled camshaft bushing onto the assembly tool so that the spring loaded fixing brass drift 3 of the assembly tool engages in the oil bore 4 of the camshaft bushing See Figure 42 9 Remove insertion brass drift from assembly tool See Figure 43 Figure 43 Removing Insertion Brass Drift from Assembly Tool All information subject to chan...

Page 204: ...44 Removing Brass Drift 12 Using the assembly tool insert camshaft bushing 1 from the outside into the camshaft locating bore as far as it will go See Figure 44 13 At the same time position the assembly tool by the centering and positioning brass drifts which are inserted as the camshaft bushing is fitted in the stop See Figure 44 All information subject to change without notice C 58 Copyright DET...

Page 205: ...ll stop and alignment device 2 for camshaft bushing number 7 from the outside on the front of the cylinder block 1 See Figure 45 1 Front View of Block 2 Stop and Alignment Device Figure 45 Installing Camshaft Bushing Number 7 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 59 ...

Page 206: ...ngs will result in engine damage 16 Insert camshaft bushing in the camshaft bore as far as it will go using the assembly tool See Figure 46 1 Assembly Tool Figure 46 Inserting Camshaft Bushing in Camshaft with Assembly Tool 17 Verify that lube oil bores in bushing and cylinder block are aligned All information subject to change without notice C 60 Copyright DETROIT DIESEL CORPORATION ...

Page 207: ...ith compressed air See Figure 47 Figure 47 Installing Crankshaft Main Bearing Cap Studs 19 Test threaded bore with a new stud for ease of movement up to the threaded end in the cylinder block See Figure 47 a If stud does not show ease of movement replace component b If stud does show ease of movement continue inspection 20 Coat stud thread on the journal side arrow with engine oil See Figure 47 Al...

Page 208: ...Nut 4 Socket Wrench Figure 48 Cylinder Block Stud Insertion 22 Using the installation tool and torque wrench screw stud in until it reaches the limit of travel Torque studs to specification Refer to section A 003A 003 NOTE Cylinder block is upside down with oil pan mating face horizontal All information subject to change without notice C 62 Copyright DETROIT DIESEL CORPORATION ...

Page 209: ... Copper Hammer Figure 49 Installing Main Bearing Cap NOTE Main bearing caps must not be interchanged 24 Insert bearing cap into cylinder block so that the markings on bearing cap and cylinder block are on the same side 25 If the main bearing cap binds tap it on with a soft mallet as necessary All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 63 ...

Page 210: ...1 Main Bearing Stabilizer Bolt 3 Main Bearing Cap Nut 2 Ratchet and Socket Wrench Figure 50 Positioning Main Bearing Stabilizer Bolts 27 Screw in all stabilizer bolts for crankshaft main bearing cap and tighten by hand See Figure 50 All information subject to change without notice C 64 Copyright DETROIT DIESEL CORPORATION ...

Page 211: ...e place the main bearing cap nut 1 on the studs of main bearing cap See Figure 51 1 Main Bearing Cap Nut 2 Main Bearing Pretensioner Nut Stud Figure 51 Placing Hydraulic Pretensioner on Studs of Main Bearing Cap All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 65 ...

Page 212: ...stall hydraulic pretensioner 1 by hand until it is in position See Figure 52 1 Hydraulic Stud Pretensioner Figure 52 Installing Hydraulic Pretensioner All information subject to change without notice C 66 Copyright DETROIT DIESEL CORPORATION ...

Page 213: ...f the hydraulic hand pump to hydraulic pretensioner See Figure 53 1 High Pressure Hose of Hydraulic Hand Pump 2 Magnetic Dial Indicator Figure 53 Connecting High Pressure Hose All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 67 ...

Page 214: ... measurement of the studs 32 Position both dial gage styluses in the center on the respective measuring core arrow on the face of the sleeve measuring pin See Figure 54 Figure 54 Positioning Dial Gage Styluses in Center on Respective Measuring Core All information subject to change without notice C 68 Copyright DETROIT DIESEL CORPORATION ...

Page 215: ...aulic hand pump and elongate studs at same time maximum 1 15 0 05 mm use pin arrow to tighten nuts on main bearing cap arrow See Figure 55 Figure 55 Operating Hydraulic Hand Pump and Elongating Studs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 69 ...

Page 216: ... are completed NOTE Remaining elongation of studs after loosening is 0 9 0 05 mm 38 If remaining elongation of studs is outside tolerance loosen nuts refer to section C 031 05 05C 031 05 05 and repeat nut tightening procedure if necessary replace studs See Figure 56 1 Main Bearing Cap Stabilizer Bolt 3 Main Bearing Cap Nut 2 Ratchet and Socket Wrench Figure 56 Installing Main Bearing Cap All infor...

Page 217: ...ng surface with sealing compound for oil pan extension see Figure 1 at the main bearing thrust cap location See Figure 57 NOTE When coating mating surface for oil pan extension take the front surfaces into consideration 1 Mating Surface of Oil Pan Extension Main Bearing Thrust Cap Location Figure 57 Coating Mating Surface for Oil Pan Extension All information subject to change without notice Copyr...

Page 218: ...nder block 1 and place on the surface of the cylinder block that was coated with sealing compound See Figure 58 1 Cylinder Block 3 Securing Bolt 2 Cylinder Block Filler Strip Figure 58 Aligning Cylinder Block Filler Strip All information subject to change without notice C 72 Copyright DETROIT DIESEL CORPORATION ...

Page 219: ...inder Block Figure 59 Securing Cylinder Block Filler Strip NOTE Using a straightedge verify the alignment of the cylinder block filler strip to the cylinder block The cylinder block filler strip surface must form a single plane with the cylinder block parting line so that the oil pan seals perfectly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 73 ...

Page 220: ...aulic hand pump to hydraulic pretensioner Position magnetic based dial indicator bridge with both indicator pins centered on each main bearing stud 3 Operate the hydraulic hand pump 1 and at the same time elongate each stud 1 15 1 20 mm Using a pin rotate the nuts on the main bearing cap studs until the nuts are snug Remove the magnetic base dial indicator bridge 2 The final elongation of the stud...

Page 221: ...0 250 0 570 mm 0 0098 0 022 6 Clean and apply a light film of RTV reinstall the rear pan rail filler spacer 1 Clean and reinstall the oil pump assembly Torque attaching bolts for each to proper torque specifications Refer to section A 003A003 See Figure 61 1 Filler Spacer 2 Allen Head Bolts Figure 61 Stretching Main Bearing Studs 7 Using a dial indicator measure the oil pump gear backlash Oil pump...

Page 222: ...k 1 Install access cover with oil filler tube dipstick and access cover with dipstick tube and tighten See Figure 1 NOTE Before installation remove the plugs and adhesive tape strips that were used to prevent contamination Ensure parts are perfectly clean NOTE Use new gaskets 2 Install access covers NOTE Ensure a double plate is installed in the proper location for ECM installation All information...

Page 223: ...r block an O ring seal is used instead of the sealing compound 4 Coat new O rings with petroleum jelly and insert into oil transfer bores in cylinder block See Figure 62 5 Insert guide pins 1 in the cylinder block at two diagonally opposite corner points See Figure 62 6 Screw a suitable lifting eye as centrally as possible to the upper edge of the oil gallery All information subject to change with...

Page 224: ...rt surface 8 Tighten the two hex bolts opposite each other in the middle of the oil gallery to specification Refer to section yA 003A 003 See Figure 63 Figure 63 Tightening Hex Bolts 9 Tighten all other hex bolts to specification Refer to section A 003A 003 Torque the bolts by starting in the middle of the oil gallery and working in a continuous spiral or chrisscross pattern proceeding from the ce...

Page 225: ...it on cap plug 6 See Figure 64 1 Cylinder Block 5 O ring 2 Hex Bolt 6 Oil Gallery 3 Link 7 Pan Seal 4 Blanking Plug Figure 64 Installing Blanking Plug NOTE Ensure parts are perfectly clean All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 79 ...

Page 226: ...review all manufacturer s cautionary notes 12 Move suitable lifting device and lifting ropes into position over cylinder block 13 Ensure lifting devices are equally tensioned See Figure 65 1 Supports 2 Turnover Stand Figure 65 Removing Cylinder Block from Turnover Stand 14 Separate cylinder block from turnover stand and lift it out All information subject to change without notice C 80 Copyright DE...

Page 227: ...isalignment during installation 1 Center the crankshaft with reference to its thrust distance Rotate crankshaft until the 1 rod journal is in the down position This will allow for clearance from the crankshaft counterweights for the bearing alignment tool With the flexible bearing pushing tool 1 push out the old upper main bearing shell With a liquid marking pen mark each bearing as to its locatio...

Page 228: ...h Brite is a trademark of 3M Company 3 Clean the new main bearing shells before use Lubricate the main bearings and bearing journals with clean engine oil prior to installation Insert the upper main bearing shell 1 one with a hole in the center onto the crankshaft main bearing journal With part numbers facing towards the A bank install bearing alignment tool 2 onto main bearing cap stud and secure...

Page 229: ...can no longer be moved by hand Using the flexible bearing pusher tool complete the rotation of the upper bearing past the alignment tool 2 See Figure 68 1 Main Bearing Cap Nut 2 Bearing Alignment Tool Figure 68 Installing Bearing Alignment Tool All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 83 ...

Page 230: ...p stud Use the main bearing seating tool 1 to seat the upper main bearing to its proper recessed position See Figure 69 1 Main Bearing Seating Tool Figure 69 Seating Upper Main Bearing to Proper Dimension All information subject to change without notice C 84 Copyright DETROIT DIESEL CORPORATION ...

Page 231: ...ll Place the main bearing alignment tool on the lower main bearing shell with the shell located on the guide slot On the other main bearing cap stud press the bearing shell into place This will require a little pressure to seat the bearing See Figure 70 1 Flexible Bearing Pushing Tool Figure 70 Rotating Upper Main Bearing Shell into Position All information subject to change without notice Copyrig...

Page 232: ...l of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 3 After Installation Operations All information subject to change without notice C 86 Copyright DETROIT DIESEL CORPORATION ...

Page 233: ...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 C 013 05 12 After Installation Operations C 106 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 87 ...

Page 234: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 88 Copyright DETROIT DIESEL CORPORATION ...

Page 235: ... 013 05 01 GENERAL VIEW See Figure 71 for a general view of the cylinder liner 1 Cylinder Liner 2 O rings Figure 71 General View of Cylinder Liner All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 89 ...

Page 236: ... cutaway view of the cylinder liner without scraper ring in cylinder block 1 Cylinder Liner 3 O rings 2 Cylinder Block Figure 72 Cylinder Liner Without Scraper Ring All information subject to change without notice C 90 Copyright DETROIT DIESEL CORPORATION ...

Page 237: ...ew of the cylinder liner with scraper ring marine only in cylinder block 1 Scraper Ring 3 Cylinder Block 2 Cylinder Liner 4 O rings Figure 73 Cylinder Liner With Scraper Ring All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 91 ...

Page 238: ... special tools required for maintenance on the cylinder liner Designation Tool Number Removal tool for liner PT 6400 C Installation tool for liner J 42729 Bore Gage J 5347 B Table 4 Special Tools All information subject to change without notice C 92 Copyright DETROIT DIESEL CORPORATION ...

Page 239: ...line Refer to section C 073 05 05 1 2 3 Disconnect fuel return lines Refer to section C 086 05 05 1 2 3 Remove valve drive Refer to section C 055 05 05 1 2 3 Remove pushrods Refer to section C 055 05 05 1 2 3 Disconnect electric wiring harness Refer to section C 501 05 M 1 2 3 Remove fuel injector Refer to section C 075 05 05 1 2 3 Remove cylinder head Refer to section C 041 05 05 1 2 3 Remove cyl...

Page 240: ... Block 2 Cylinder Liner Figure 74 Removing Cylinder Liner NOTE When examining the engine it is advisable to mark the location of the cylinder liner in reference to the cylinder block at the inboard 12 00 position with a marker pen 2 Mount removal tool PT 6400 C on cylinder liner 1 See Figure 75 All information subject to change without notice C 94 Copyright DETROIT DIESEL CORPORATION ...

Page 241: ... spray nozzle is not damaged 4 Rotate the removal tool spindle until the cylinder liner is released from the cylinder block bore 5 Remove removal tool 6 Remove cylinder liner from cylinder block 7 Remove O rings from cylinder liners All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 95 ...

Page 242: ...faces show wear or damage rub down with emery cloth or oilstone as necessary b If damage is beyond repair replace cylinder as necessary c If sealing and mating surfaces are not damaged or worn continue inspection 5 Replace O rings 6 For cylinder liners with carbon scraper ring marine only visually inspect carbon scraper ring for scores and pitting a If carbon scraper ring shows scores or pitting r...

Page 243: ...place cylinder liner as necessary NOTE When cylinder liners have scraper rings marine only honing is carried out with the scraper ring removed After honing carefully clean the transition from the honing pattern to the mating surface of the scraper ring 2 Visually inspect reversing point of first piston ring for wear a If reversing point of first piston ring shows wear replace ring as necessary All...

Page 244: ...en re using cylinder liners the honing must be recognizable over entire running surface See Figure 77 Figure 77 Inspecting Honing Marks for Consistency Measuring Cylinder Liner I D 1 Adjust dial bore gage 2 and dial gage with micrometer or adjusting gage ring 1 to basic size for cylinder liner See Figure 78 All information subject to change without notice C 98 Copyright DETROIT DIESEL CORPORATION ...

Page 245: ...CE MANUAL 1 Adjusting Gage Ring 2 Dial Bore Gage Figure 78 Adjusting Bore Gage 2 Measure cylinder liner I D with bore gage See Figure79 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 99 ...

Page 246: ...Bore Gage Figure 79 Measuring Cylinder Liner I D a If limit values are exceeded replace cylinder liner b If limit values are not exceeded continue to installation All information subject to change without notice C 100 Copyright DETROIT DIESEL CORPORATION ...

Page 247: ...ecord tolerance and wear limits in cylinder block data sheet 2 Wipe cylinder liner at O ring lands and at chamfer inclination then lightly coat with petroleum jelly See Figure 80 1 O ring Lands 2 Chamfer Inclination Area Figure 80 Coating Cylinder Liner with Petroleum Jelly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 101 ...

Page 248: ...Install O rings with the flat side against the cylinder liner and the rounded side against the cylinder block Ensure that O rings have not twisted during installation After installation of O rings lightly coat O rings with petroleum jelly before installing into cylinder block All information subject to change without notice C 102 Copyright DETROIT DIESEL CORPORATION ...

Page 249: ... Insert cylinder liner in cylinder block See Figure 82 1 Cylinder Block 2 Cylinder Liner Figure 82 Inserting Cylinder Liners into Cylinder Block All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 103 ...

Page 250: ...th installation device J 42729 into cylinder block bore See Figure 83 1 Cylinder Liner Figure 83 Pressing Cylinder Liner with Installation Device into Cylinder Block Bore All information subject to change without notice C 104 Copyright DETROIT DIESEL CORPORATION ...

Page 251: ...rs have carbon scraper rings marine only ensure that the measurement planes are below the fit for the carbon scraper ring Do not insert the carbon scraper ring in the cylinder liner until the pistons have been installed Refer to section C 037 05 01 8 Enter measurement values in data sheet 9 If cylinder liner measures out of round remove liner and measure I D and O D 10 If cylinder liner is confirm...

Page 252: ...section C 075 05 11 1 2 3 Connect electric wiring harness Refer to section C 075 05 11 1 2 3 Install rocker cover Refer to section C 056 05 11 1 2 3 Install charge air manifolds Refer to section C 124 05 11 1 2 3 Install exhaust manifold Refer to section C 141 05 11 1 2 3 Install turbocharger Refer to section C 101 05 11 1 2 3 Install exhaust crossover Refer to OEM Guidelines 1 2 3 Connect electri...

Page 253: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 107 ...

Page 254: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 108 Copyright DETROIT DIESEL CORPORATION ...

Page 255: ...view of the oil pan 1 Oil Pan 8 Spacer 2 Flange 9 Spacer 3 O ring 10 Pan Seal 4 Plug 11 Retainer 5 Bolt 12 O ring 6 Gasket 13 Spacer Block 7 Bolt 14 Suction Basket Figure 85 General View of Oil Pan All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 109 ...

Page 256: ...86 for an overview of the oil pan gear case end 1 Gear Train Cover 3 Washer 2 Hex Bolt 4 Oil Pan 5 Oil Pan Seal Figure 86 Overview of Oil Pan Gear Case End All information subject to change without notice C 110 Copyright DETROIT DIESEL CORPORATION ...

Page 257: ...nts of the oil pan 11 24 diagonally and evenly so that seal seats properly 2 Insert two securing bolts 1 10 in the gear case and pretorque to 60 N m 3 Loosen two securing bolts 1 10 and tighten to a final torque of 30 N m 4 Torque four hex bolts at the corner points 11 24 of oil pan to respective specified final torques diagonally and evenly hex bolts 24 to 60 6 N m hex bolts 11 to 27 3 N m All in...

Page 258: ...11 to 24 to respective final torque 7 Insert securing bolts 2 to 9 in the gear case and tighten to specified torque 8 Ensure that all hex bolts used to secure the oil pan have been tightened to their correct torques Repeat assembly procedure if necessary All information subject to change without notice C 112 Copyright DETROIT DIESEL CORPORATION ...

Page 259: ...n Table 7 is the special tool required for maintenance on the oil pan Designation Tool Number Taper reamer for taper pin 10 x 65 in accordance with DIN 258 Table 7 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 113 ...

Page 260: ... to OEM Guidelines 1 2 3 Remove flange from oil pan gear case end Refer to section C 014 05 05 1 2 3 Remove fuel delivery pump Refer to section C 081 05 05 1 2 3 Release pipe clamp halves of coolant line right engine side Refer to section C 203 05 05 1 2 3 Release or remove access cover with oil filler neck Refer to OEM Guidelines 1 The engine is to be completely disassembled 2 The engine is to be...

Page 261: ...all engine in turnover stand and turn by 180 degrees See Figure 88 1 Lifting Device 3 Oil Pan 2 Eyebolt Figure 88 Removing Oil Pan 2 Remove all hex bolts for oil pan 3 See Figure 88 3 Unscrew plugs at the front and rear surfaces of oil pan and insert two suitable eyebolts 2 in the oil pan All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 115 ...

Page 262: ... 5 Remove eyebolts and flange from front and rear surfaces 6 If necessary remove rubber sealing ring 7 Loosen hex bolts 3 and retainer 5 and at the same time hold suction basket 1 in place See Figure 89 1 Suction Basket 4 Oil Pan 2 Spacer 5 Retainer 3 Hex Bolt 6 O ring Figure 89 Removing Suction Basket 8 Withdraw spacer 2 and suction basket 1 See Figure 89 9 Remove top and bottom O ring from space...

Page 263: ...should be taken to protect the ECMs and harnesses 5 Install a floor jack that has been modified to cradle the oil pan at the center of the oil pan See Figure 90 Figure 90 Installing Floor Jack 6 Remove all oil pan to gear case attaching bolts Remove all remaining oil pan bolts and spacers Slowly lower front end of oil pan allowing remaining oil in the pan to drain NOTE Capture any foreign material...

Page 264: ...re beyond repair replace components as necessary c If mating surfaces do not show irregularities continue inspection 5 Visually inspect all parts for wear and damage a If wear or damage is found replace components as necessary b If wear or damage is not found continue inspection 6 Visually inspect condition of threads in tapped bores a If threads are worn or damaged replace threaded inserts as nec...

Page 265: ...sket spacer block and mating mount flange in oil pan do not show surface irregularities continue inspection 9 Replace gaskets sealing rings and rubber profile All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 119 ...

Page 266: ... top and bottom O rings 6 with petroleum jelly and insert in the top and bottom grooves of the spacer 2 See Figure 91 1 Suction Basket 4 Oil Pan 2 Spacer 5 Retainer 3 Hex Bolt 6 O ring Figure 91 Installing Suction Basket 2 Place suction basket with spacer in position at the flange surface 3 Hold suction basket and spacer in place and screw together with hex bolts 3 and retainer 5 All information s...

Page 267: ...nge 6 Gasket 3 Sealing Ring 7 Pan Strip Seal 4 Plug Figure 92 Installing Oil Pan 5 Apply a bead of RTV Loctite 5900 is preferred at the A and B bank locations were the gear case and block intersect bend of gasket 6 Move flange for plugs into position at both front surfaces of the oil pan All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 121 ...

Page 268: ...g the parting line of cylinder block gear case See Figure 93 1 Cotton Seal 3 Gear Case 2 Cylinder Block Figure 93 Moving Woolen Thread 8 Insert two suitable eyebolts 2 in the plug bores for the oil pan 3 See Figure 94 All information subject to change without notice C 122 Copyright DETROIT DIESEL CORPORATION ...

Page 269: ...ully place on mating surface of cylinder block See Figure 94 1 Lifting Device 3 Oil Pan 2 Eyebolt Figure 94 Placing Oil Pan on Mating Surface 10 At the same time align oil pan to bores in mating surface of cylinder block 11 Tighten oil pan in accordance with tightening diagram Refer to section C 011 05 01 NOTICE Oil pan may break if cylinder block is lowered onto it All information subject to chan...

Page 270: ...e respective surface ends of the oil pan See Figure 95 1 Oil Pan 5 Socket Head Bolt 2 Flange 6 Gasket 3 O ring 7 Pan Strip Seal 4 Plug Figure 95 Installing Flange with Gasket and Plug on Oil Pan All information subject to change without notice C 124 Copyright DETROIT DIESEL CORPORATION ...

Page 271: ...y oil pan is secured to cylinder block on A and B bank side with one taper pin on each side For the position of taper pins see Figure 96 New oil pans do not yet have a bore for the taper pins 14 Install taper pin 10 x 65 with standardized tapering C 1 50 based on DIN 258 as follows All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 125 ...

Page 272: ...gure 97 Installing Taper Pin b At the same time position the drill in the locating bore for the taper pin in the cylinder block c See Figure 97for drilling depth NOTE Ensure parts are perfectly clean All inlets and oil carrying components must be sealed 15 Clean locating bore and ream with a suitable taper reamer All information subject to change without notice C 126 Copyright DETROIT DIESEL CORPO...

Page 273: ...ead projection is A 8 mm 0 31496 in 1 mm 0 03937 in Installing Oil Pan In Chassis Perform the following steps to install oil pan in chassis 1 Clean oil pan block rail and gear case mating surfaces thoroughly 2 Apply a bead of RTV Loctite 5900 is preferred at the A and B bank locations where the gear case and block intersect NOTE This step should be done just before installing the pan the RTV shoul...

Page 274: ...ure the strip seal corners do not rub against the gear case 7 When the pan rail is in position start all oil pan rail bolts 8 Pull up as necessary on the five oil pan bolts closest to the gear case on the left and right bank until the bolts through the gear case and oil pan can be started 9 Torque the gear case oil pan bolts to 65 N m using an alternating torque sequence torque upper most A bank a...

Page 275: ...que oil pan drain plug to 45 N m 50 N m Install new oil filters and refill engine with new engine oil Check oil level with dipstick Clean up tools and area Pressure pre lube with pre filtered oil before start up Remove a rocker cover and ensure oil is getting to the overhead 17 Remove lockout from truck and start engine let run at idle for five minutes while checking for oil leaks Recheck oil leve...

Page 276: ...5 11 1 2 3 Install access cover with oil filler neck Refer to OEM Guidelines 1 2 3 Install pipe clamp halves of coolant line Refer to section C 203 05 11 1 2 3 Fill oil system with engine oil Refer to Operator Guide 1 2 3 Fill engine coolant system Refer to Operator Guide 1 2 3 Enable engine power Refer to Operator Guide 1 2 3 Vent fuel system Refer to Operator Guide 1 The engine is to be complete...

Page 277: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 131 ...

Page 278: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 132 Copyright DETROIT DIESEL CORPORATION ...

Page 279: ...ERAL VIEW See Figure 99 for a general view of the engine lifting attachments 1 Engine Lifting Attachments Figure 99 General View of Engine Lifting Attachments All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 133 ...

Page 280: ...AL See Figure 100 for engine lifting attachments 1 Cylinder Head 3 Mounting Bolt 2 Lifting Eye 4 Washer Figure 100 Engine Lifting Attachment All information subject to change without notice C 134 Copyright DETROIT DIESEL CORPORATION ...

Page 281: ...el of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operator Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 10 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 135 ...

Page 282: ...lts that connect the lifting eye 2 to the cylinder head See Figure 101 1 Cylinder Head 3 Mounting Bolt 2 Lifting Eye 4 Washer Figure 101 Removing Cylinder Head Bolts that Connect Lifting Eye 2 Remove cylinder head bolts 3 and washers 4 See Figure 101 3 Remove lifting eye 2 See Figure 101 All information subject to change without notice C 136 Copyright DETROIT DIESEL CORPORATION ...

Page 283: ...y inspect condition of mating surfaces and or screw down surfaces for damage or wear a If mating surfaces are damaged or worn rub down with an oilstone as necessary b If mating surfaces are not damaged or worn continue inspection 4 Inspect thread in cylinder head for ease of movement a If thread in cylinder head does not show ease of movement rechase threads as necessary b If thread in cylinder he...

Page 284: ...spection of cylinder head bolts 2 Measure shaft length of the cylinder head bolts with depth gage See Figure 102 Figure 102 Inspecting Cylinder Head Bolts 3 For maximum permissible shaft length refer to sectionC 041 05 01 All information subject to change without notice C 138 Copyright DETROIT DIESEL CORPORATION ...

Page 285: ... to sectionA 003 NOTE If at both of the cylinder heads that carry the lifting attachments only the cylinder head bolts at the lifting attachments itself were released then it is sufficient to tighten both of these cylinder head bolts to torque additional angle of rotation to specification Refer to section A 003 Refer to section C 041 05 01 If at both of the cylinder heads that carry the lifting at...

Page 286: ...tachments Level of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 11 After Installation Operations All information subject to change without notice C 140 Copyright DETROIT DIESEL CORPORATION ...

Page 287: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 141 ...

Page 288: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 142 Copyright DETROIT DIESEL CORPORATION ...

Page 289: ...1 GENERAL VIEW See Figure 104 for a general view of the flywheel housing 1 Flywheel Housing 3 Plug 2 Hex Bolt Figure 104 General View of Flywheel Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 143 ...

Page 290: ...ing with attachments 1 Hex Bolt 5 Spring Washer 2 Washer 6 Flywheel Housing 3 Cap Plug 7 O ring 4 Spacer Bushing 8 Dead center Indicator Figure 105 General View of Flywheel Housing with Attachments All information subject to change without notice C 144 Copyright DETROIT DIESEL CORPORATION ...

Page 291: ... the flywheel housing flywheel end Designation Tool Number Flywheel housing alignment tool J 42734 Guide bushing flywheel housing Support Cylinder head bolt Installation tool for radial lip shaft seal Flange Flange Table 12 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 145 ...

Page 292: ...of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 13 Before Removal Operations All information subject to change without notice C 146 Copyright DETROIT DIESEL CORPORATION ...

Page 293: ...e 106 1 Crankshaft End 3 Flywheel Housing 2 Flange 4 Shaft Seal Figure 106 Removing Radial lip Shaft Seal NOTE Engine is turned 180 i e oil pan side is at top 2 Mount flange 2 on crankshaft end See Figure 106 3 Unscrew the two hex bolts arrows in the flywheel housing inner circle All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 147 ...

Page 294: ...usly released and press the support against the flywheel housing as far as it will go See Figure 107 NOTE The TOP mark on the front side of the flywheel housing alignment tool J 42734 must face upwards i e in the direction of the oil pan arrow If the guide bushing jams and does not align in the flywheel housing bore two long guide pins can also be inserted in the bolt bores in order to remove the ...

Page 295: ...ifting device 1 to flywheel housing and suspend load to loosen hex bolts See Figure 108 1 Lifting Device 2 Flywheel Housing Figure 108 Attaching Lifting Device 7 Unscrew all of the hex bolts that secure the flywheel housing to the cylinder block Refer to section C 016 05 01 8 Remove flywheel housing from cylinder block All information subject to change without notice Copyright DETROIT DIESEL CORPO...

Page 296: ...sassemble the flywheel housing 1 Remove cap plug and plugs See Figure 104 1 Flywheel Housing 3 Plug 2 Hex Bolt Figure 109 Removing Cap Plug and Plugs 2 Remove dead center indicator 2 from flywheel housing 1 See Figure 110 All information subject to change without notice C 150 Copyright DETROIT DIESEL CORPORATION ...

Page 297: ...0 12 16V SERVICE MANUAL 1 Flywheel Housing 2 Dead center Indicator Figure 110 Removing Dead center Indicator Marine only All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 151 ...

Page 298: ...place component NOTE Do not straighten dead center indicator if it is damaged or bent but replace with a new part b If dead center indicator is not damaged continue inspection 4 Visually inspect condition of mating surfaces and or bolting surfaces for damage a If mating surface and or bolting surface are damaged rub down with emery cloth or an oilstone as necessary b If mating surfaces are beyond ...

Page 299: ...e 111 1 Adjusting Gage Ring 2 Dial Gage Figure 111 Measuring Crankshaft Bore in Flywheel Housing 2 Using a bore gage measure diameter of crankshaft bore at flywheel housing See Figure 111 3 Enter measurement values in data sheet 4 Replace gear case if necessary All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 153 ...

Page 300: ... dead center indicator 2 to flywheel housing 1 See Figure 112 1 Flywheel Housing 2 Dead center Indicator Figure 112 Mounting Dead center Indicator Marine only 2 Bolt on covers 2 See Figure 113 All information subject to change without notice C 154 Copyright DETROIT DIESEL CORPORATION ...

Page 301: ...lying Gasket Eliminator to Sealing Surface 3 Pre clean sealing surface between flywheel housing and cylinder block with Loctite cleaner 4 Apply Gasket Eliminator 518 to sealing surface evenly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 155 ...

Page 302: ...e sealing surface See Figure 114 1 O ring 2 Gasket Eliminator Figure 114 Smoothing Gasket Eliminator on Sealing Surface 6 Coat O rings with petroleum jelly and insert into bores All information subject to change without notice C 156 Copyright DETROIT DIESEL CORPORATION ...

Page 303: ...ing 1 Clean the sealing surface 1 at cylinder block with cleaner See Figure 115 1 Sealing Surface 2 Flywheel Housing Alignment Tool J 42734 Figure 115 Cleaning Sealing Surface at Cylinder Block 2 Bolt guide bushing onto flange at crankshaft end All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 157 ...

Page 304: ... crane with lifting device 1 and install over the flywheel housing alignment tool J 42734 pushing in direction of cylinder block as far as it will go See Figure 116 5 Screw hex bolts into designated bores hand tight refer section C 016 05 01 6 Tighten two opposing hex bolts in the inner circle of the flywheel housing to specification Refer to section A 003 7 Remove flywheel housing alignment tool ...

Page 305: ...el housing finally tighten the bolts at the outer rim of the flywheel housing Torque all hex bolts clockwise See Figure 105 9 Carefully remove excess gasket eliminator from the parting line between flywheel housing 2 and oil pan mating surface at the cylinder block 1 See Figure 117 1 Cylinder Block 2 Flywheel Housing Figure 117 Removing Excess Gasket Eliminator from Parting Line All information su...

Page 306: ... of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 14 After Installation Operations All information subject to change without notice C 160 Copyright DETROIT DIESEL CORPORATION ...

Page 307: ... 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 Copyright DETR...

Page 308: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 162 Copyright DETROIT DIESEL CORPORATION ...

Page 309: ...entilation assembly for the 12V marine engine see Figure 118 1 Gasket 5 Rubber Sleeve 2 Bolt 6 Guide Sleeve 3 Vent Pipe 7 Oil Separator 4 Clamp Figure 118 General View of Cylinder Block Ventilation Assembly 12V All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 163 ...

Page 310: ...e 119 1 Gasket 5 Rubber Sleeve 2 Bolt 6 Guide Sleeve 3 Vent Pipe 7 Oil Separator 4 Clamp Figure 119 Overview of Cylinder Block Ventilation Assembly 16V Marine Engine For an overview of the cylinder block ventilation piping see Figure 120 All information subject to change without notice C 164 Copyright DETROIT DIESEL CORPORATION ...

Page 311: ...anifold 5 Spacer Bushing 15 Banjo Bolt 6 Clamp 16 Union 7 Clamp 17 Threaded Bushing 8 Rubber Sleeve 18 Pipe Clamp Half 9 Vent Line 19 Mounting Bracket 10 Domed Nut Figure 120 Overview of Cylinder Block Ventilation Piping Marine Engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 165 ...

Page 312: ...Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 15 Before Removal Operations for the Marine Cylinder Block Ventilation System All information subject to change without notice C 166 Copyright DETROIT DIESEL CORPORATION ...

Page 313: ...nect the ventilation lines 7 secured to the cylinder block ventilation supports see Figure 121 1 Sealing Ring 7 Ventilation Lines 2 Adaptor 8 Spacer Bushing 3 Bolt 9 Clamp 4 Bracket 10 Rubber Sleeve 5 Pipe Clamp Half 11 Nut 6 Grommet Figure 121 Disconnecting Marine Cylinder Block Ventilation Lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 167 ...

Page 314: ...s 5 Clamps 3 Cylinder Block Breather Bracket Figure 122 Removing Marine Cylinder Block Ventilation Assembly Bracket 3 Loosen three clamps 5 securing the cylinder block ventilation assembly to the cylinder block vent See Figure 122 4 Remove the cylinder block ventilation system from the cylinder block vent All information subject to change without notice C 168 Copyright DETROIT DIESEL CORPORATION ...

Page 315: ...ntilation system 1 Loosen clamps 2 securing the vent hose to the base of the cylinder block ventilation separator canister See Figure 123 1 Cylinder Block Separator Canister 3 Clamp Hose 2 Clamp Figure 123 Loosening Marine Vent Clamps 2 Remove vent tubing assembly 2 See Figure 124 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 169 ...

Page 316: ...SERIES 4000 12 16V SERVICE MANUAL 1 Vent Tubing 2 Vent Line Assembly Figure 124 Removing Marine Vent Tubing All information subject to change without notice C 170 Copyright DETROIT DIESEL CORPORATION ...

Page 317: ...Remove vent tubing 1 attached to the vent line assembly 2 See Figure 125 1 Vent Tubing 2 Vent Line Assembly Figure 125 Removing Vent Line Assembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 171 ...

Page 318: ...ecuring the mounting bracket to the cylinder block ventilation bracket See Figure 126 1 Mounting Bolt Figure 126 Removing Mounting Bracket to Marine Cylinder Block Ventilation Bracket All information subject to change without notice C 172 Copyright DETROIT DIESEL CORPORATION ...

Page 319: ...ation canister with the cylinder block tubing See Figure 127 1 Clamp Figure 127 Removing Clamps Securing Marine Cylinder Block Ventilation Canister NOTE Repeat step 5 for the remaining cylinder block ventilation canisters All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 173 ...

Page 320: ...ylinder block tubing to the cylinder block ventilation bracket See Figure 128 1 Mounting Bolt 2 Pipe Clamp Half Figure 128 Removing Clamps Securing Marine Cylinder Block Ventilation Canister All information subject to change without notice C 174 Copyright DETROIT DIESEL CORPORATION ...

Page 321: ...ket See Figure 129 1 Clamp 4 Long Spacer 2 Cylinder Block Canister Oil Separator 5 Washer 3 Short Spacer 6 Bolt Figure 129 Removing Marine Cylinder Block Ventilation Canister 8 Remove the cylinder block ventilation canister 2 NOTE Repeat step 6 and step 8 for each cylinder block ventilation canister All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 175 ...

Page 322: ...r damaged continue inspection 4 Visually inspect sealing and mating faces for damage and defects a If sealing and mating surfaces are damaged or defective rub down with oilstone b If damage or defects are beyond repair replace component as necessary c If sealing and mating surfaces are not damaged or defective or can be repaired continue inspection To avoid an eye injury when blow drying parts wea...

Page 323: ...es and safety mask Work in a well ventilated area 7 Visually inspect condition of threads a If threads are not in perfect condition rechase threads b If threads are beyond repair replace threaded inserts as necessary c If threads are in perfect condition continue inspection All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 177 ...

Page 324: ... See Figure 130 1 Clamp 4 Long Spacer 2 Cylinder Block Breather Canisters 5 Washer 3 Short Spacer 6 Bolt Figure 130 Replacing Marine Cylinder Block Ventilation Canister 2 Replace four bolts 6 washers 5 long spacers 4 and short spacers 3 securing the cylinder block ventilation canister 2 to the cylinder block ventilation bracket See Figure 130 All information subject to change without notice C 178 ...

Page 325: ...the cylinder block tubing to the cylinder block ventilation bracket See Figure 131 1 Mounting Bolt 2 Pipe Clamp Half Figure 131 Replacing Bolts and Washers Securing Cylinder Block Tubing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 179 ...

Page 326: ...tion canister with the cylinder block tubing See Figure 132 1 Clamp Figure 132 Tightening Clamps Securing Marine Cylinder Block Ventilation Canister NOTE Repeat step 4 for the remaining cylinder block ventilation canisters All information subject to change without notice C 180 Copyright DETROIT DIESEL CORPORATION ...

Page 327: ...ecuring the mounting bracket to the cylinder block ventilation bracket See Figure 133 1 Mounting Bolt Figure 133 Installing Mounting Bracket to Marine Cylinder Block Ventilation Bracket All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 181 ...

Page 328: ...hat attaches to the vent line assembly 2 See Figure 134 1 Vent Tubing 2 Vent Line Assembly Figure 134 Replacing Vent Tubing 7 Replace vent line assembly 2 See Figure 135 All information subject to change without notice C 182 Copyright DETROIT DIESEL CORPORATION ...

Page 329: ...ine Assembly Figure 135 Replacing Vent Line Assembly 8 Tighten clamps 2 securing the vent hose to the base of the cylinder block ventilation canisters See Figure 136 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 183 ...

Page 330: ...4000 12 16V SERVICE MANUAL 1 Cylinder Block Breather Canister 3 Clamp Hose 2 Clamp Figure 136 Tightening Vent Clamps All information subject to change without notice C 184 Copyright DETROIT DIESEL CORPORATION ...

Page 331: ...hten the cylinder block ventilation hose clamps 3 Install four 35 mm bolts 1 and washers 2 to secure the cylinder block ventilation system to the exhaust manifold Torque bolts to 74 82 N m 55 60 lb ft See Figure 137 1 Bolts 4 Exhaust Manifold 2 Washers 5 Clamps 3 Cylinder Block Breather Bracket Figure 137 Installing Marine Cylinder Block Ventilation Assembly Bracket All information subject to chan...

Page 332: ...ilation Lines 2 Adaptor 8 Spacer Bushing 3 Bolt 9 Clamp 4 Bracket 10 Rubber Sleeve 5 Pipe Clamp Half 11 Nut 6 Grommet Figure 138 Connecting Marine Cylinder Block Ventilation Lines 5 Verify repair of the cylinder block ventilation system All information subject to change without notice C 186 Copyright DETROIT DIESEL CORPORATION ...

Page 333: ...2 3 Enable engine power Refer to Operators Guide 1 2 3 Connect vent lines Refer to section 202 65 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 16 After Installation Operations for Marine Cylinder Block Ventilation All information subject to change without notice Copyright DETROIT DIESEL CORPORA...

Page 334: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 188 Copyright DETROIT DIESEL CORPORATION ...

Page 335: ...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 ...

Page 336: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 190 Copyright DETROIT DIESEL CORPORATION ...

Page 337: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 191 ...

Page 338: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 192 Copyright DETROIT DIESEL CORPORATION ...

Page 339: ... Clamp 14 Plug 3 Grommet 15 Gear Case 4 Oil Line 16 Idler Gear 5 Banjo Bolt 17 Washer 6 Sealing Ring 18 Stud 7 Pressure Regulator 19 Threaded Bushing 8 O ring 20 Oil Pump 9 Intermediate Gear Axle 21 Hex Nut 10 Crankshaft Outboard Bearing 22 Cover All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 193 ...

Page 340: ...lignment tool arrangement for gear case installation 1 Gear Case Alignment Tool J 43634 5 Hex Bolt 2 Top Marking 6 Guide Bushing 3 Gear Case 7 Cotton Seal 2 4 Hex Bolt 8 Oil Pan Seal Figure 140 Alignment Tool Arrangement for Gear Case Installation All information subject to change without notice C 194 Copyright DETROIT DIESEL CORPORATION ...

Page 341: ...l gear case end gear case J 43634 Guide bushing gear case end crankshaft Drift for removing idler gear bushing idler gear axle Installation tool for shaft bushing in gear case Puller for shaft bushing in gear case Guide pin for vibration damper Support bracket for vibration damper Table 17 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 195 ...

Page 342: ...section C 202 05 05 1 2 3 Remove charge air coolant lines Refer to section C 207 05 05 1 2 3 Remove coolant vent lines Refer to section C 205 05 05 1 2 3 Remove charge air coolant vent lines Refer to OEM Guidelines 1 2 3 Remove coolant housing with thermostat Refer to section C 208 05 05 1 2 3 Remove generator Refer to section C 213 05 05 1 2 3 Remove generator drive Refer to section C 213 05 05 1...

Page 343: ...hex bolts 1 and washers 2 for seal carrier See Figure 141 1 Hex Bolt 3 Seal Carrier 2 Washer 4 Gear Case Figure 141 Removing Gear Case 2 Remove seal carrier 3 See Figure 141 3 Mark all bolts 1 differing lengths for gear case and remove See Figure 141 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 197 ...

Page 344: ... using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 5 Attach gear case to crane with lifting device and adjust tension equally See Figure 142 6 Remove oil line Refer to section C 181 05 01 7 Remove pressure regulator valve Refer to section C 181 05 01 All information subject to change without notice C 198 Copyrig...

Page 345: ...avoid injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 9 Carefully push gear case 2 with the lifting device pretensioned in direction of gear case end until it is freed from cylinder block 10 Remove O rings All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 199 ...

Page 346: ...e inspection 4 Check crankshaft outboard bearing for wear scoring and marks a If worn scored or marked replace outboard bearing Refer to section C 024 05 11 b If not worn scored or marked continue inspection 5 Check condition of threads in gear case a If thread condition is not acceptable rechase threads b If threads are in good condition continue inspection 6 Check threads and shaft of hex bolts ...

Page 347: ...g surfaces are not damaged continue inspection 8 Replace O rings 9 Adjust bore gage and dial gage 2 with micrometer or gage ring 1 to basic size for crankshaft outboard bearing bore See Figure 145 1 Adjusting Gage Ring 2 Dial Bore Gage Figure 145 Adjusting Bore Gage and Dial Gage with Micrometer or Gage Ring All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 20...

Page 348: ...ot exceeded continue inspection 11 Enter measurement values in data sheet 12 Check condition of outboard bearing a If the outboard bearing is damaged or out of specification remove with a suitable removal brass drift Refer to section C 024 05 05 b Measure the gear case bore and install a new outboard bearing in the gear case Refer to sectionC 024 05 11 c If the outboard bearing is not damaged cont...

Page 349: ...nufacturer s operator procedures 1 Place gear case on suitable bench or rest to ensure that outboard bearing can be installed flush with the gear case 2 Mark position of oil bores in the outboard bearing on front face arrow See Figure 147 Figure 147 Marking Outboard Bearing in Gear Case for Oil Bores NOTE Position bearing shell markings to face oil bores All information subject to change without n...

Page 350: ...d suffocation will occur 3 Chill outboard bearing in liquid nitrogen To avoid injury while handling HOT components wear protective gloves and clothing 4 Heat gear case to 80 C 176 F 5 Insert chilled outboard bearing flush into gear case ensuring that oil bores arrows are aligned See Figure 147 6 Ensure that oil passages are free of obstruction All information subject to change without notice C 204...

Page 351: ...xles 8 Install delivery valve Refer to section Installation of Delivery Valve 9 Install pressure regulator Refer to section C 181 05 01 10 Install gear case alignment tool J 43634 2 with hex bolt 3 on gear case See Figure 148 NOTE Pay attention to TOP mark Even when cylinder block is rotated the alignment tool marking must be at the top All information subject to change without notice Copyright DE...

Page 352: ...de bushing 2 with hex bolt 1 on crankshaft See Figure 149 1 Hex Bolt 2 Gear Case Alignment Tool Guide Bushing Figure 149 Placing Guide Bushing on Crankshaft All information subject to change without notice C 206 Copyright DETROIT DIESEL CORPORATION ...

Page 353: ...onary notes 12 Install eyebolts 1 in gear case and secure to crane with appropriate lifting device See Figure 150 1 Eyebolt 2 Lifting Device Figure 150 Securing Gear Case to Lifting Device 13 Install the alignment tool with TOP toward the top of the engine in the holes for the seal carrier All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 207 ...

Page 354: ... Figure 151 17 Using crane carefully move gear case over crankshaft guide bushing Refer to section C 024 05 01 18 Ensure that studs are properly aligned NOTE Ensure components are reinstalled in accordance with markings and note that bolts differ in length 19 Install all securing bolts and tighten uniformly 20 Install nuts and washers and tighten 21 Torque securing bolts and nuts to specification ...

Page 355: ...r procedures 22 Remove lifting device and eyebolts NOTE Do not cut off cotton thread projecting over oil pan sealing surface For further procedure refer to section C 014 05 11 23 Remove securing bolts of alignment tool from gear case and guide bushing from crankshaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 209 ...

Page 356: ... 208 05 11 1 2 3 Install charge air coolant pump Refer to section C 206 05 11 1 2 3 Install coolant pump Refer to section C 202 05 11 1 2 3 Install charge air coolant lines Refer to section C 206 05 11 1 2 3 Install coolant vent lines Refer to section C 205 05 11 1 2 3 Install charge air coolant vent lines Refer to OEM Guidelines 1 2 3 Install gear case gear case end Refer to section C 024 05 11 1...

Page 357: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 211 ...

Page 358: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 212 Copyright DETROIT DIESEL CORPORATION ...

Page 359: ...Gear 6 Crankshaft Gear 2 Engine Coolant Pump Drive Gear 7 Gear Case Gear Case End 3 Hub 8 High Pressure Fuel Pump Drive Gear 4 Idler Gear 9 Outboard Bearing Gear Case End 5 Crankshaft 10 Drive Hub Gear Case End Figure 152 General View of Gear Train Gear Case End All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 213 ...

Page 360: ...move charge air coolant lines Refer to section C 207 05 05 1 2 3 Remove coolant vent lines Refer to section C 205 05 05 1 2 3 Remove charge air coolant vent lines Refer to OEM Guidelines 1 2 3 Remove coolant housing with thermostat Refer to section C 208 05 05 1 2 3 Remove generator Refer to section C 213 05 05 1 2 3 Remove generator drive Refer to section C 213 05 05 1 2 3 Remove high pressure pu...

Page 361: ... and remove hex bolts 1 See Figure 153 1 Hex Bolt 3 Hub 2 M 8 Jackscrews Figure 153 Removing Idler Gear Hubs 2 Screw in M 8 jackscrews 2 with continuous thread in thread of hub 3 See Figure 153 3 Using M 8 jackscrews 2 push off hubs evenly See Figure 153 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 215 ...

Page 362: ...Mark respective hub according to installation position and remove from gear case See Figure 154 Figure 154 Removing Idler Gear Hubs from Gear Case All information subject to change without notice C 216 Copyright DETROIT DIESEL CORPORATION ...

Page 363: ...See Figure 154 6 Using a suitable sleeve and manual press remove bushing 2 from idler gear 1 See Figure 155 1 Idler Gear 2 Bushing Figure 155 Removing Bushing from Idler Gear All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 217 ...

Page 364: ...ear continue inspection 4 Visually inspect running surface of idler gear hub bushing in idler gears and bearing surfaces of gears for wear and scores a If wearing or scoring is detected replace component if necessary Refer to section C 025 05 10 b If scoring or wear is not detected continue inspection 5 Check taper seat and bolt on surface of idler gear hubs for scoring and wear a If scored or wor...

Page 365: ...e 156 Figure 156 Cleaning Axle Oil Passages 8 Measure axle oil passages a If wear limit values are exceeded replace components as necessary b If wear limit values are not exceeded continue inspection All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 219 ...

Page 366: ...igure 157 1 Dial Bore Gage 3 Bushing Bore 2 Idler Gear Figure 157 Measuring Bushing Bore in Idler Gear 10 Measure diameter of bore a If limit values are exceeded replace idler gear Refer to section C 025 05 10 All information subject to change without notice C 220 Copyright DETROIT DIESEL CORPORATION ...

Page 367: ...bs at running surface See Figure 158 Figure 158 Measuring Bearing Diameter on Idler Gear Hubs a If limit values are exceeded replace idler gear hub Refer to section C 025 05 10 b If limit values are not exceeded proceed to assembly Refer to section C 025 05 10 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 221 ...

Page 368: ...hing Idler Gear 2 Place idler gear on suitable bench or rest to ensure that when bushing 1 is installed there is no interference See Figure 159 To avoid injury when using liquid nitrogen wear protective clothing gloves and closed shoes Do not allow the liquid nitrogen to come into contact with exposed body parts Danger of freezing body parts and suffocation will occur 3 Cool bushing in liquid nitr...

Page 369: ... injury while handling HOT components wear protective gloves and clothing 4 Heat idler gear to 80 C 176 F 5 Insert cooled bushing flush into idler gear All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 223 ...

Page 370: ...s are clean 1 Coat bushings in idler gear with engine oil See Figure 160 1 Idler Gear 2 Gear Case Figure 160 Installing Idler Gear in Gear Case 2 Insert idler gear 1 via opening in gear case 2 See Figure 160 3 Ensure that idler gear is positioned correctly Refer to section C 025 05 01 All information subject to change without notice C 224 Copyright DETROIT DIESEL CORPORATION ...

Page 371: ...r Case 2 O ring Figure 161 Installing Idler Gear Hubs 5 Insert O ring 2 into groove of gear case 3 See Figure 161 6 Secure O ring 2 in groove in hub base with petroleum jelly See Figure 161 7 Insert hubs in gear case paying attention to fit of idler gear See Figure 161 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 225 ...

Page 372: ...Figure 162 10 Install two eyebolts in gear case To avoid injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 11 Attach gear case to crane with lifting device and adjust tension equally 12 Bring gear case into vertical position All information subject to change without notice C 226 Copyright DETROIT DI...

Page 373: ...o zero See Figure 163 16 Check axial play by moving idler gear back and forth horizontally 17 To measure backlash place dial gage stylus with preload on tooth surface of idler gear 18 Set dial gage with preload to zero 19 Move idler gear back and forth in radial direction to check backlash a If values are exceeded replace idler gears Refer to section C 025 05 05 b If values are not exceeded procee...

Page 374: ...nstall coolant pump Refer to section C 202 05 11 1 2 3 Install charge air coolant lines Refer to section C 207 05 11 1 2 3 Install coolant vent lines Refer to OEM Guidelines 1 2 3 Install charge air coolant vent lines Refer to section C 205 05 11 1 2 3 Install vibration damper Refer to section C 035 05 11 1 2 3 Install and connect electric wiring Refer to section C 501 05 M 1 2 3 Install engine ca...

Page 375: ...ssembly 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 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 Inspectio...

Page 376: ...ir 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 All information subject to change without notice C 230 Copyright DETROIT DIESEL CORPORATION ...

Page 377: ...ations 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 231 ...

Page 378: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 232 Copyright DETROIT DIESEL CORPORATION ...

Page 379: ...Bolt 2 Outboard Bearing Gear Case End 13 Stud 3 Gear Case 14 Nut for Main Bearing Cap 4 Piston 15 Crankshaft Bearing Cap 5 Cylinder Liner 16 Crankshaft Gear 6 O ring 17 O ring 7 Oil Spray Nozzle 18 Crankshaft 8 Connecting Rod 19 O ring 9 Cylinder Block 20 Hex Bolt All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 233 ...

Page 380: ...Drive Hub Figure 164 General View of Crankshaft Installation See Figure 165 for components of the crankshaft 1 Bolt 3 Crankshaft 2 Counterweight 4 Crankshaft Gear Gear Case End Figure 165 Series 4000 Crankshaft 16V All information subject to change without notice C 234 Copyright DETROIT DIESEL CORPORATION ...

Page 381: ...TOOL Listed in Table 22 is the special tool required for maintenance on the crankshaft Designation Tool Number Bearing Alignment Tool J 34199 Table 22 Special Tool All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 235 ...

Page 382: ...Maintenance Operation Reference 1 2 3 Disable engine start Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 23 Before Removal Operations All information subject to change without notice C 236 Copyright DETROIT DIESEL CORPORATION ...

Page 383: ...inder block if necessary mark according to sequence See Figure 166 1 Identification Number Figure 166 Marking of Cylinder Block Bearing Cap Location 2 Starting at flywheel end of the cylinder block stamp number of the main bearing cap with 6 mm 0 2362 in numbers so they can be read from the same direction All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 237 ...

Page 384: ...ap Stabilizer Bolt 3 Main Bearing Cap Nut 2 Ratchet and Socket Wrench Figure 167 Removing Main Bearing Stabilizer Bolts for Main Bearing Cap 4 Remove all main bearing cap stabilizer bolts 1 of main bearing caps from cylinder block with ratchet and socket wrench 2 All information subject to change without notice C 238 Copyright DETROIT DIESEL CORPORATION ...

Page 385: ...lic bolt pretensioner on studs 2 of respective main bearing cap See Figure 168 1 Main Bearing Cap Nut 2 Main Bearing Pretensioner Nut Stud Hydraulic Pretensioner Figure 168 Attaching Main Bearing Cap Nut of Hydraulic Bolt Pretensioner All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 239 ...

Page 386: ...olt pretensioner by hand until contact is made then back off one turn See Figure 169 1 Hydraulic Stud Pretensioner Figure 169 Installing Hydraulic Bolt Pretensioner All information subject to change without notice C 240 Copyright DETROIT DIESEL CORPORATION ...

Page 387: ...al Indicator Figure 170 Connecting High Pressure Hose of Hydraulic Hand Pump to Hydraulic Bolt Pretensioner 8 Mount magnetic dial gage holders with magnetic dial indicator 2 on cylinder block oil jam sealing surface 9 The dial gages are for measuring the elongation of the studs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 241 ...

Page 388: ...ses arrow centrally to respectively measure core on surface of sleeve measuring pin See Figure 171 Figure 171 Positioning Dial Gage Styluses 11 Set dial gages to zero with preload All information subject to change without notice C 242 Copyright DETROIT DIESEL CORPORATION ...

Page 389: ...g Cap with a Pin 13 Loosen nuts on main bearing cap with a pin arrow 14 Relieve tension on studs and move the dial gages with magnetic holders and hydraulic preloading devices to the next adjacent main bearing cap 15 Follow the same procedure to loosen all remaining nuts 16 Remove loose nuts from studs 17 Screw eyebolt into bearing cap All information subject to change without notice Copyright DET...

Page 390: ...e and review all manufacturer s cautionary notes 18 Attach main bearing cap 2 to crane and lifting device apply slight tension to lifting device See Figure 173 1 Upper Main Bearing Bore 3 Lifting Eye 2 Main Bearing Cap Figure 173 Pulling Main Bearing Cap All information subject to change without notice C 244 Copyright DETROIT DIESEL CORPORATION ...

Page 391: ...inder block See Figure 173 20 Mark upper main bearing shell of respective bearing cap with location and remove See Figure 173 NOTICE To avoid damage protect main block bearing shells 21 To protect crankshaft slip four protective sleeves 1 over main bearing cap studs of first and last bearings See Figure 174 1 Protective Sleeves Figure 174 Placing Protective Sleeves over Main Bearing Cap Studs All ...

Page 392: ...review all manufacturer s cautionary notes 22 Using lifting device 2 and crane raise crankshaft 1 clear of cylinder block See Figure 175 1 Crankshaft 2 Lifting Device Figure 175 Lifting Crankshaft from Cylinder Block 23 Take care to keep crankshaft horizontal All information subject to change without notice C 246 Copyright DETROIT DIESEL CORPORATION ...

Page 393: ...4 Lower crankshaft onto a sturdy stand See Figure 176 Figure 176 Lowering Crankshaft onto Sturdy Stand 25 Remove bearing shells from bearing webs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 247 ...

Page 394: ...ing See Figure 177 Figure 177 Marking Bearing Shells toward Drive End NOTE Do not etch bearing surface of the number one bearing which is the thrust washer for the crankshaft 27 Etch the markings or use a non wipe felt marker pen All information subject to change without notice C 248 Copyright DETROIT DIESEL CORPORATION ...

Page 395: ...0 12 16V SERVICE MANUAL C 031 05 06 DISASSEMBLY OF CRANKSHAFT Perform the following steps to disassemble the crankshaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 249 ...

Page 396: ...not remove gear unless damaged 2 Observe proper cutting procedure and take into consideration appropriate cooling periods NOTE To prevent sparks cover crankshaft with heat resistant cloth 3 Determine separation depth B before starting work and check frequently 4 Expand crankshaft gear with suitable wedge and remove 5 Smooth seating surface with emery cloth and remove minor scoring 6 Clean cranksha...

Page 397: ... 179 Figure 179 Determining and Recording Distance Web to Counterweight NOTE Before counterweights are removed after balancing mark relevant counterweight in its installation position with regard to crankshaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 251 ...

Page 398: ...mbers if necessary 9 Remove mounting bolts 2 and counterweight 1 See Figure 180 1 Counterweights 2 Mounting Bolts Figure 180 Removing Bolts and Counterweight NOTE Remove counterweights with crankshaft in a sturdy stand All information subject to change without notice C 252 Copyright DETROIT DIESEL CORPORATION ...

Page 399: ...pection 4 Crack test crankshaft using magnetic test method 5 Visually inspect crankshaft for foreign body indentations a If foreign body indentations are found remove from crankshaft by regrinding to next stage b If no indentations are found continue inspection 6 After grinding perform hardness test 7 Visually inspect bearing journals for scores or thermal fissures a If scores or thermal fissures ...

Page 400: ...y inspect gear tooth surfaces for minor surface cracks hairline cracks a If minor surface cracks are found polish tooth surfaces b If no cracks are found continue inspection 16 Visually inspect crankshaft gear for surface or deeper fissures a If several surface or deeper fissures are found replace crankshaft gear b If no fissures are found continue inspection 17 Visually inspect crankshaft gear fo...

Page 401: ...inspection 3 Inspect oil bores and journal bores 3 counterweight mating surfaces and tapped bores 1 See Figure 181 4 Install crankshaft in longitudinal direction between jaws of test device 5 The specified magnetic field strength of 20 A cm to 60 A cm must be applied at every part of the component 6 Demagnetize crankshaft after crack testing The maximum permissible residual field strength after de...

Page 402: ...ibiting minor thermal cracks can be repaired providing that regrinding to a repair stage or local grinding will remove the damage 6 Carefully regrind the affected bearing journals according to crack depth to a permissible repair size 7 Minor cracks can also be repaired by local grinding 8 Carry out preliminary grinding before the after curing otherwise the thermal cracks could increase in length a...

Page 403: ...ith Grinding Cracks 2 Replace crankshaft with such thermal cracks 3 Grinding cracks occur due to insufficient cooling during grinding or through excessive feed Checking Crankshaft Journal Perform the following steps to inspect the crankshaft journal All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 257 ...

Page 404: ...to next repair stage b If no scoring or damage is found continue inspection 5 Check thrust washer surface of first main bearing for wear a If thrust washer surface is worn regrind to next repair stage b If thrust washer is not worn continue inspection 6 Inspect crankshaft journal for minor scoring or damage a If minor scoring or damage is found polish with emery cloth b If no scoring or damage is ...

Page 405: ...ournal a If limit values are exceeded grind crankshaft to next repair size b If limit values are not exceeded continue inspection Checking Crankshaft Taper Perform the following steps to check the crankshaft taper 1 Check crankshaft taper surfaces arrows for minor scoring and damage a If minor scoring or damage is found polish taper surfaces with emery cloth All information subject to change witho...

Page 406: ...ankshaft Taper 2 Check tapers 1 50 with taper gage a If necessary machine taper to specifications b If taper is to specifications continue inspection Checking Hardness of Journals Perform the following steps to check the hardness of journals All information subject to change without notice C 260 Copyright DETROIT DIESEL CORPORATION ...

Page 407: ...st hardness of each journal at four 90 degree intervals around circumference 3 Specified hardness is from 49 HRC to 53 HRC 4 If a bearing journal has lost its hardness due to bearing scuffing or machining reharden journal Checking Crankshaft Concentricity To check crankshaft concentricity perform the following steps All information subject to change without notice Copyright DETROIT DIESEL CORPORAT...

Page 408: ...8 Checking Crankshaft Concentricity 12V shown 2 Using adjustable dial gage holder and dial gage check concentricity of main bearing journal 3 If wear across circumference of journal is irregular check at transition from cylindrical section of journal to radius 4 Measure journals a If journals are outside specifications grind to next repair stage All information subject to change without notice C 2...

Page 409: ...sition radii and surface finish 4 Record crankshaft serial number main bearing journal and crankpin diameters guide bearing width concentricity values and journal hardness values in the Crankshaft Data Sheet Refer to section 5 Thoroughly clean oil bores after grinding 6 Necessary checks after grinding 3 Check dimensions and surface finish of all bearing journals 3 Check radii at bearing journals 3...

Page 410: ...termine hardness transient across journal see Figure 189 A Main bearing Journals 2 to 7 B Main bearing 1 C Connecting Rod Journals 1 to 6 Figure 189 Hardness Transient Across Journal All information subject to change without notice C 264 Copyright DETROIT DIESEL CORPORATION ...

Page 411: ...nt bearings C 9 mm 0 3545 in Maximum hardened zone depth in radius area D 7 mm 0 2755 in Minimum hardened zone depth in radius area E 2 5 mm 0 0984 in Minimum hardened zone depth in radius area F 5 5 mm 0 2165 in Maximum hardened zone depth in radius area R from 4 9 5 1 mm 0 1929 0 2007 in Maximum peak to valley height at radii 4 µm Figure 190 Hardness Characteristic at Main Bearing Journals 2 to ...

Page 412: ...n Maximum hardened zone depth in radius area D 7 mm 0 2755 in Minimum hardened zone depth in radius area E 21 mm 0 8267 in F 2 5 mm 0 0984 in Minimum hardened zone depth in radius area G 5 5 mm 0 2165 in Maximum hardened zone depth in radius area R from 4 9 5 1 mm 0 1929 0 2007 in Maximum peak to valley height at radii 4 µm Figure 191 Hardness Characteristic at Connecting Rod Journals 1 to 6 All i...

Page 413: ... mm 0 2165 in Maximum hardened zone depth in radius area R from 4 9 5 1 mm 0 1929 0 2007 in Maximum peak to valley height at radii 4 µm Figure 192 Hardness Characteristic at Main Bearing 1 Checking Counterweights To check counterweights of crankshaft perform the following steps 1 Using the magnetic crack testing method with fluorescent magnetic powder check counterweight for cracks a If cracks are...

Page 414: ...ight for Wear 3 Using engineer s blue check contact pattern of mating surface 1 for stress bolt heads See Figure 193 a Remove surface irregularities if found b If no surface irregularities are found continue inspection Checking Bolts for Counterweights To check bolts for counterweights perform the following steps All information subject to change without notice C 268 Copyright DETROIT DIESEL CORPO...

Page 415: ...ic crack testing method with fluorescent magnetic powder check bolts for cracks a If cracks are found replace bolts b If no cracks are found continue inspection 4 Ensure that threads are in perfect condition Checking and Assessing Main Bearing Shells Sputtered Bearing To check and assess the main bearing shells sputtered bearing perform the following steps All information subject to change without...

Page 416: ...ear remains approximately constant at roughly 0 005 mm 0 00275 in See Figure 195 NOTE A magnifying glass is required for a more accurate assessment of the wear condition of the running surface magnification minimum 5x 5 The wear layer is seen as a dark zone and the intermediate layer as a light zone The decisive factor for the wear condition of the grooved bearing is the ratio width of intermediat...

Page 417: ... Listed in Table 24 are types of main bearing damage Type of Damage Inspection Procedure 1 Continued Use Refer to section Continued Use 2 Wear Refer to section Wear 3 Borderline Wear and Leveling Refer to section Borderline Wear and Leveling 4 Wear Layer Fatigue Fractures Refer to section Wear Layer Fatigue Fractures 5 Borderline Case Wear Layer Fatigue Frac ture and Empty Grooves Refer to section...

Page 418: ...Figure 196 Wear Layer View 1 of 2 Figure 197 Wear Layer View 2 of 2 Assessment The ratio wear layer intermediate layer is approximately 25 to 75 All information subject to change without notice C 272 Copyright DETROIT DIESEL CORPORATION ...

Page 419: ...grooves The intermediate layer links show no wear Dark spots are primarily embedded particles of oil carbon See Figure 198 and see Figure 199 Figure 198 Intermediate Layer View 1 of 2 Figure 199 Intermediate Layer View 2 of 2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 273 ...

Page 420: ...16V SERVICE MANUAL Assessment As a result of wear layer removal the intermediate layer links appear slightly wider Condition All information subject to change without notice C 274 Copyright DETROIT DIESEL CORPORATION ...

Page 421: ...o notable alteration of intermediate layer See Figure 200 and see Figure 201 Figure 200 Small Foreign Bodies on Running Surface View 1 of 2 Figure 201 Small Foreign Bodies on Running Surface View 2 of 2 Assessment All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 275 ...

Page 422: ...SERIES 4000 12 16V SERVICE MANUAL Continued use of bearing shell Condition All information subject to change without notice C 276 Copyright DETROIT DIESEL CORPORATION ...

Page 423: ...the intermediate layer links are no longer visible See Figure 202and see Figure 203 Figure 202 Wear Layer Dragged over Intermediate Layer Links View 1 of 2 Figure 203 Wear Layer Dragged over Intermediate Layer Links View 2 of 2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 277 ...

Page 424: ...have reached a ratio of 1 1 The width of the bearing metal links has increased from 25 new condition to 50 There is still some wear layer in the grooves See Figure 204 1 Wear layer groove 2 Intermediate layer link 3 Wear 1 1 Figure 204 Wear Layer Groove Intermediate Links Wear Limits All information subject to change without notice C 278 Copyright DETROIT DIESEL CORPORATION ...

Page 425: ...05 Wear Limits Wear Assessment The bearing is functional If wear is expected before the next inspection the bearing must be replaced as a safety measure Borderline Wear and Leveling Condition All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 279 ...

Page 426: ...ate layer links that are worn locally see Figure 206 1 Intermediate layer links worn 2 Wear 1 1 Figure 206 Locally Worn Intermediate Layer Links Wear Limits All information subject to change without notice C 280 Copyright DETROIT DIESEL CORPORATION ...

Page 427: ...07 Figure 207 Wear Limits Borderline Wear and Leveling Assessment When the above defined wear condition is reached the bearing must be replaced Wear Layer Fatigue Fractures Condition All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 281 ...

Page 428: ...igue fractures in grooves through local overloading see Figure 208 1 Wear layer fatigue fractures Figure 208 Wear Limits Wear Layer Fatigue Fractures Wear Limits All information subject to change without notice C 282 Copyright DETROIT DIESEL CORPORATION ...

Page 429: ...ar Layer Fatigue Fractures Assessment The bearing is functional If wear is expected before the next inspection the bearing must be replaced as a safety measure Borderline Case Wear Layer Fatigue Fracture and Empty Grooves Condition All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 283 ...

Page 430: ...ves are visible In places the intermediate layer links may already be worn See Figure 210 1 Wear layer fatigue fractures 2 Empty grooves 3 Intermediate layer links worn Figure 210 Empty Grooves Wear Limits All information subject to change without notice C 284 Copyright DETROIT DIESEL CORPORATION ...

Page 431: ...ty Grooves Assessment When the above defined condition is reached the bearing must be replaced Dynamically Balancing the Crankshaft To dynamically balance the crankshaft perform the following steps NOTE Prior to dynamically balancing the crankshaft seal all oil passages to prevent foreign matter from entering All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2...

Page 432: ...0 rpm Balancing Speed 150 rpm Permissible Residual Imbalance Per Balancing Plane for Initial Balancing 160 gcm Permissible Residual Imbalance Per Balancing Plane for Comparative Balancing In Different Configuration or Balancing Machine 480 gcm Table 25 Crankshaft Dynamic Balancing Specifications 12V 3 Remove material to balance crankshaft only from counterweights by drilling radially with twist dr...

Page 433: ...ameter E 40 mm 5748 in maximum bore depth Minimum wall strength around balancing bores is 5 mm 1967 in Figure 213 Bore Values at 12V Counterweights Checking Oil Bores To check oil bores perform the following steps 1 Using an borescope inspect all bores with cold light source a Clean bores if they are not perfectly clean All information subject to change without notice Copyright DETROIT DIESEL CORP...

Page 434: ...Inspecting Oil Bores with Borescope Cleaning Oil Bores To clean oil bores perform the following steps 1 Thoroughly clean crankshaft bores with cold cleaner and suitable bristle brush NOTE Never use a wire brush All information subject to change without notice C 288 Copyright DETROIT DIESEL CORPORATION ...

Page 435: ...aring Shells Fit to Main Bearing Bore NOTE The main bearing bore must first be tested without installed main bearings and then with installed main bearings The following describes the test with installed main bearings The procedure is the same for testing the main bearing bore without installed main bearings Installing Main Bearing Shells To install bearing shells perform the following steps NOTE ...

Page 436: ...hells on both sides See Figure 216 1 Oil Bore Figure 216 Installing Main Bearing Shells NOTE Check codes for repair size and journal diameter of new shells and bearing number of used shells These markings must be on sides facing toward flywheel end Compare cylinder block data sheet and crankshaft data sheet All information subject to change without notice C 290 Copyright DETROIT DIESEL CORPORATION...

Page 437: ...n with bearing alignment tool 1 See Figure 217 1 Bearing Alignment Tool Figure 217 Aligning Bearing Shells with Housing Bore 4 Oil bores in bearing shells and cylinder block must be aligned Installing Main Bearing Caps To install main bearing caps perform the following steps All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 291 ...

Page 438: ...plate and do not exceed 276 kPa 40 lb in 2 air pressure 2 Check that mating surfaces on main bearing cap and on bores are clean blow out with compressed air 3 Clean main bearing shell on both sides and insert into main bearing cap according to markings or bearing number 4 Bearing numbers on shells must be aligned and all numbers must be toward flywheel end All information subject to change without...

Page 439: ...re 219 Positioning Tool between Main Bearing Cap Stud and Rear Surface of Bearing Shell 6 Compress main bearing shell 2 until gear case end can be pressed down onto butting surface of main bearing shell See Figure 219 7 Butting joint must be closed 8 Horizontally align bearing shells in center of cap and block bore 9 Install main bearing caps All information subject to change without notice Copyri...

Page 440: ...Bearing Cap NOTE Main bearing caps must not be interchanged 11 Check that thread and shaft are in perfect condition a If thread or shaft are damaged replace stud b If thread or shaft are not damaged continue inspection NOTE Check only those studs that had to be removed for length All information subject to change without notice C 294 Copyright DETROIT DIESEL CORPORATION ...

Page 441: ...nents only when wearing protective gloves 12 Install main bearing cap to respective bearing bore according to cylinder block marking See Figure 221 1 Identification Number Figure 221 Verification of Cylinder Block Main Bearing Cap Markings All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 295 ...

Page 442: ...TICE To avoid damage to main bearing do not drop main bearing cap on main bearing 13 Position the main bearing cap on respective bearing bore in block See Figure 222 1 Upper Main Bearing Bore 3 Lifting Eye 2 Main Bearing Cap Figure 222 Positioning Main Bearing Cap All information subject to change without notice C 296 Copyright DETROIT DIESEL CORPORATION ...

Page 443: ...allet tap main bearing cap lightly to settle it in final position See Figure 223 1 Main Bearing Cap 2 Mallet Figure 223 Tapping Main Bearing Cap with Mallet All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 297 ...

Page 444: ...ne oil and insert main bearing cap stabilizer bolts but do not tighten yet See Figure 224 1 Main Bearing Cap Stabilizer Bolt 3 Main Bearing cap Nut 2 Ratchet and Socket Wrench Figure 224 Installing Main Bearing Cap Stabilizer All information subject to change without notice C 298 Copyright DETROIT DIESEL CORPORATION ...

Page 445: ...el end place main bearing cap nut 1 on studs 2 of respective main bearing cap See Figure 225 1 Main Bearing Cap Nut 2 Main Bearing Pretensioner Nut Stud Figure 225 Attaching Main Bearing Cap Nut All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 299 ...

Page 446: ... pretensioner 1 by hand until contact is made and turn back one turn See Figure 226 1 Hydraulic Stud Pretensioner Figure 226 Installing Hydraulic Bolt Pretensioner All information subject to change without notice C 300 Copyright DETROIT DIESEL CORPORATION ...

Page 447: ...Hydraulic Hand Pump 2 Magnetic Dial Gage Figure 227 Connecting High Pressure Hose of Hydraulic Hand Pump 19 Mount magnetic dial gage 2 holders with dial gages to cylinder block pan rail See Figure 227 20 The dial gages are for measuring the elongation of the studs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 301 ...

Page 448: ...entrally on the respective measuring core arrow on the face of the sleeve measuring pin See Figure 228 Figure 228 Positioning Dial Gage Styluses 22 Set dial gages to zero with preload All information subject to change without notice C 302 Copyright DETROIT DIESEL CORPORATION ...

Page 449: ... 229 Installing Nuts on Main Bearing Cap with a Pin 24 Relieve tension on studs 25 Mount dial gages with magnetic holders and hydraulic preloading devices on studs of next adjacent main bearing cap 26 Install all nuts in same order NOTE Remaining elongation of studs after release 0 95 mm 0 037 in All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 303 ...

Page 450: ...cifications in same sequence as when tightening bearing caps Torque to specification Refer to section A 003 See Figure 230 1 Main Bearing Cap Stabilizer Bolt 3 Main Bearing Cap Nut 2 Ratchet and Socket Wrench Figure 230 Tightening Main Bearing Cap Stabilizer Bolts Measuring Main Bearing I D Perform the following steps to measure main bearing I D All information subject to change without notice C 3...

Page 451: ...r gage ring 1 to basic size for main bearing bore See Figure 231 1 Adjusting Gage Ring 2 Dial Bore Gage Figure 231 Measuring Main Bearing I D 2 Coat wear surfaces of main bearing shells with engine oil All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 305 ...

Page 452: ...hells b If measuring points or limit values are not exceeded continue inspection 4 Enter measurement values in data sheet 5 After measuring main bearing bore I D mark bearing shell according to bearing shell number if necessary NOTE Loosen nuts of one bearing at a time refer to section C 031 05 05 6 Loosen and remove main bearing cap stabilizer All information subject to change without notice C 30...

Page 453: ...ft length of bolts for counterweights for maximum shaft length see Figure 233and refer to section C 031 05 01 Figure 233 Measuring Shaft Length of Cylinder Head Bolts 2 Clean and degrease mating surface on crankshaft and counterweight 1 See Figure 234 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 307 ...

Page 454: ...Coat threads and head mating surface of mounting bolts 2 with engine oil See Figure 234 NOTE Install counterweights 1 in accordance with markings 4 Fit counterweight on crankshaft and tighten slightly with bolts See Figure 234 All information subject to change without notice C 308 Copyright DETROIT DIESEL CORPORATION ...

Page 455: ...235and refer to section C 031 05 02 torque to specification Refer to section A 003 Figure 235 Setting Counterweight to Markings 6 Check that marks applied prior to disassembly and measured distances are correct 7 Mark counterweight bolt heads All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 309 ...

Page 456: ...nstalling counterweights recheck identification marks on counterweights and webs NOTE If new counterweights have been installed dynamically balance crankshaft Beginning at flywheel end apply identification numbers to counterweights using punch numerals 10 Clean and degrease surface of main journal and gear bore All information subject to change without notice C 310 Copyright DETROIT DIESEL CORPORA...

Page 457: ...te force on distance A by measuring distance from end surface of crankshaft to end surface of crankshaft gear with depth gage See Figure 237 14 Force on depth A measured from face of crankshaft to surface of crankshaft gear is 145 2 145 8 mm 5 7165 5 7402 in See Figure 237 15 When the components have cooled lubricate crankshaft gear with engine oil 16 Coat O ring with petroleum jelly and fit in gr...

Page 458: ...are perfectly clean 1 Spray running surfaces of cylinder block main bearing shells with engine oil 2 Clean crankshaft bearing surfaces See Figure 238 Figure 238 Polishing Crankshaft with Emery Cloth 3 Inspect oil bores with lamp and ensure they are perfectly clean All information subject to change without notice C 312 Copyright DETROIT DIESEL CORPORATION ...

Page 459: ...ft slip four protective sleeves 1 over main bearing cap studs of first and last bearings See Figure 239 1 Protective Sleeves Figure 239 Inserting Protective Sleeves All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 313 ...

Page 460: ...nufacturer s cautionary notes 5 Lift crankshaft 1 using lifting device 2 and crane See Figure 240 1 Crankshaft 2 Lifting Device Figure 240 Lowering Crankshaft 6 Align crankshaft horizontally and vertically with line of bores in cylinder block and gradually lower crankshaft All information subject to change without notice C 314 Copyright DETROIT DIESEL CORPORATION ...

Page 461: ...ain combustion residues which are harmful to health To avoid injury wear protective gloves Avoid extended and intensive contact with skin Do not inhale oil vapor 9 Clean the lower main bearing shell and main bearing cap and coat the running surface with engine oil 10 Insert the lower main bearing shells with bearing installation tool NOTE The numbers of the main bearing cap locations must align an...

Page 462: ... Stud Figure 242 Positioning Bearing Installation Tool Between Bearing Cap Stud and Rear Face of Shell 12 To release the tension press the main bearing shell on the side of the cover against the bearing shell on the side of the housing NOTE Butting joint must be closed 13 Bearing shells upper and lower must be centered in the main bearing bore All information subject to change without notice C 316...

Page 463: ... are clean and blow out with compressed air To avoid an eye injury when spraying engine lubrication oil wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 15 Spray main bearing journals with engine oil NOTE Main bearing caps must not be interchanged 16 Repeat the main bearing cap installation procedure All information subject to change withou...

Page 464: ...ar press crankshaft axially as far as it will go 20 Set dial gage with preload to zero 21 Move crankshaft from stop to stop arrows and enter measured value axial clearance in data sheet See Figure 243 a If determined measured value is outside permissible tolerance remove crankshaft and check cause b If measured value is within permissible tolerance continue installation All information subject to ...

Page 465: ...of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 26 After Installation Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 319 ...

Page 466: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 320 Copyright DETROIT DIESEL CORPORATION ...

Page 467: ...ons 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 321 ...

Page 468: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 322 Copyright DETROIT DIESEL CORPORATION ...

Page 469: ...lywheel assembly see Figure 244 1 Flex Coupling 6 Timing Reference Wheel 2 Drive Hub 7 Spring Pin 3 Crankshaft Seal 8 Hex Bolt 4 Washer 9 Scuff Plate 5 Hex Bolt Figure 244 General View of Flywheel All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 323 ...

Page 470: ...ools required for maintenance on the flywheel Designation Tool Number Crankshaft hub installation removal sleeve J 42916 Crankshaft Seal Installer J 42735 Flywheel Guide Studs J 42999 Table 27 Special Tools All information subject to change without notice C 324 Copyright DETROIT DIESEL CORPORATION ...

Page 471: ...ence 1 2 3 Disable engine power Refer to Operator Guidelines 1 2 3 Separate engine from gearbox or alternator 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 28 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 325 ...

Page 472: ... If necessary lock engine on flywheel ring gear of flex coupling with locking device 2 Remove all hex bolts arrow from flex coupling except for one hex bolt See Figure 245 Figure 245 Removing Hex Bolts from Flex Coupling Except One All information subject to change without notice C 326 Copyright DETROIT DIESEL CORPORATION ...

Page 473: ...n two opposite threaded bores of drive hub See Figure 246 1 Flywheel Guide Studs J 42999 Figure 246 Screwing Guide Studs into Drive Hub 4 Screw eyebolt into flex coupling All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 327 ...

Page 474: ...oupling To avoid injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 7 Using crane and lifting device remove flex coupling from flywheel housing via guide pin 8 Remove guide pin and locking device 9 Install the adapter hub onto the crankshaft ensuring that the arrow is aligned with the dowel hole on t...

Page 475: ...el guide studs are removed 1 High Pressure Line of Hand Pump 3 Rear Crankshaft Hub 2 TRS Wheel Figure 248 Crankshaft Hub Installer Sleeve 13 Lubricate the threaded shaft nut and washers with Anti Seize 14 Install the washers and nut onto the shaft Fully tighten then back off a distance equal to that of the push on dimension 15 Install the high pressure line into the drive flange NOTE Do not tighte...

Page 476: ... 249 NOTE Maximum pressure rating is stamped on the drive flange 1 Hydraulic Hand Pump 1 2 Hydraulic Hand Pump 2 Figure 249 Operating Hydraulic Hand Pumps 19 Increase the expansion pressure in increments of 0 1 x pmax Wait two minutes between increases until drive flange is free from the crankshaft NOTICE Do not exceed maximum pressure 20 Remove nut washers and pressure sleeve 21 Remove the high p...

Page 477: ...rankshaft End 3 Flywheel Housing 2 Flange 4 Crankshaft Seal Figure 250 Removing Crankshaft Seal from Flywheel Housing 2 Remove flywheel housing if necessary Refer to section C 016 05 01 3 Using suitable brass drift and hammer remove drive crankshaft sealing ring 4 out of flywheel housing See Figure 250 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 331 ...

Page 478: ... oilstone or emery cloth replace drive hub as necessary c If no wear scoring or indentations are found continue inspection 5 Visually inspect taper surfaces of drive hub for scoring and damage a If minor scoring or damage is found polish with emery cloth b If no scoring or damage is found continue inspection 6 Check taper 1 50 with taper gage a If taper bore is oversized replace drive hub b If tap...

Page 479: ...ring gear is not worn continue inspection 11 Visually inspect ring gear teeth for slight burrs and chipping a If gear teeth have slight burrs or are chipped remove burrs or chips by filing b If gear teeth do not have burrs or chips continue inspection 12 Replace shaft seal during W6 maintenance All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 333 ...

Page 480: ... never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes NOTE The crankshaft seal can only be installed in the flywheel housing with the installer tool if it is mounted on the cylinder block Refer to section C 016 05 01 All information subject to change without notice C 334 Copyright DETROIT DIESEL CORPORATION ...

Page 481: ... Seal Figure 251 Installing Crankshaft Seal into Flywheel Housing 2 Install crankshaft seal 2 with sealing lip facing outwards on press fitting tool See Figure 251 NOTE Denatured ethanol acts as lubricant for the seal 3 Clean and degrease support bore for crankshaft oil seal in flywheel housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 335 ...

Page 482: ...252 Installing Crankshaft Seal in Flywheel Housing 5 Remove pressure spindle with crankshaft adaptor from crankshaft 6 Lightly coat the outside of the seal with engine oil NOTE Do not touch or get oil on the Teflon seal lip or on the drive hub when it is installed All information subject to change without notice C 336 Copyright DETROIT DIESEL CORPORATION ...

Page 483: ...ft and drive hub See Figure 252 2 Coat running surface of drive hub for crankshaft seal with thin film lubricant marine only 3 Coat lip of crankshaft oil seal with petroleum jelly NOTE Do not touch or get oil on the Teflon seal lip or on the drive hub when it is installed 4 Join crankshaft adaptor and flange together and use hex socket bolts to install on front surface of crankshaft paying attenti...

Page 484: ...on position Refer to section C 032 05 01 15 Fill hydraulic hand pumps with SAE 10 engine oil 16 Vent pumps and lines until escaping oil is free of bubbles 17 Tighten high pressure line 18 Before installing coat taper surfaces with expansion fluid by operating hydraulic hand pump 1 until expansion fluid emerges at both sides of the drive hub See Figure 253 1 Hydraulic Hand Pump 1 2 Hydraulic Hand P...

Page 485: ...ons on drive hub for pmax 25 Hydraulic installation is completed when pressure plate is seated against crankshaft 26 Open relief bolt in hydraulic oil pump to relieve expansion pressure 27 Maintain maximum force on pressure pmax for 60 minutes to ensure that the expansion fluid is expelled from the joint and static friction can build up between fixed components 28 Disconnect high pressure lines 29...

Page 486: ...uide pins in two opposite threaded bores of drive flange See Figure 254 1 Flywheel Guide Studs J 42999 Figure 254 Installing Guide Studs in Drive Hub 31 Screw eyebolt into flex coupling All information subject to change without notice C 340 Copyright DETROIT DIESEL CORPORATION ...

Page 487: ...with crane and lifting device See Figure 255 Figure 255 Lifting Flex Coupling by Eyebolt To avoid injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 33 Using crane and lifting device position flex coupling on drive via guide pin All information subject to change without notice Copyright DETROIT DIESE...

Page 488: ...beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 35 Remove guide pins and lifting device 36 Lock engine if necessary on flywheel ring gear with locking device 37 Tighten hex bolts in crossing pattern sequence to specification Refer to section A 003 38 Remove locking device if installed All information subject to change without notice C 342 Copyr...

Page 489: ... Reference 1 2 3 Enable engine power Refer to Operators Guide 1 2 3 Connect engine to gearbox or alternator 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 29 After Installation Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 343 ...

Page 490: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 344 Copyright DETROIT DIESEL CORPORATION ...

Page 491: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 345 ...

Page 492: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 346 Copyright DETROIT DIESEL CORPORATION ...

Page 493: ...eral view of the vibration damper 1 Hex Bolt 5 Damper Hub 2 Washer 6 Seal Carrier 3 Belt Pulley 7 Dust Ring 4 Vibration Damper 8 Dust Felt Figure 257 General View of Crankshaft Vibration Damper All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 347 ...

Page 494: ...e 258 1 Blanking Plug 6 Damper Hub 2 O rings 7 Hex Bolt 3 Vibration Damper 8 Crankshaft Seal 4 O ring 9 Hex Bolt 5 Crankshaft Gear 10 Dust Ring and Felt Figure 258 Cutaway View of Vibration Damper All information subject to change without notice C 348 Copyright DETROIT DIESEL CORPORATION ...

Page 495: ...er Designation Tool Number Guide pin for vibration damper Hydraulic nut M 90 x 2 Support Bushing Hex nut M 36 x 3 Draw spindle Pressure Housing Flange Spacer Socket head bolts M 16 x 100 Hydraulic hand pump 0 3500 SKF hand pump 0 1000 Table 30 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 349 ...

Page 496: ...ion Reference 1 2 3 Disable engine power Refer to Operator Guide 1 2 3 Remove V belt Refer to Operator Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 31 Before Removal Operations All information subject to change without notice C 350 Copyright DETROIT DIESEL CORPORATION ...

Page 497: ...ex bolts 1 together with washers 2 See Figure 259 1 Hex Bolts 3 Belt Pulley 2 Washers 4 Vibration Damper Figure 259 Removal of Vibration Damper 2 Leave one bolt remaining to secure vibration damper All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 351 ...

Page 498: ...remove belt pulley 2 See Figure 260 6 Remove vibration damper 3 with two bolts M 12 x 60 mm 2 3622 in and continuous thread See Figure 260 To avoid injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 7 Attach a suitable lifting device and crane to the vibration damper 3 and remove from guide studs See...

Page 499: ...nk rupture or a sudden air hose failure do not use unregulated air pressure or an accumulator tank with an inadequate pressure rating To avoid injury from failure of a fitting hose or oil cooler core wear a face shield or goggles when conducting a pressure test 9 To remove front drive flange removal procedure install crankshaft adapter to the crankshaft All information subject to change without no...

Page 500: ...Figure 261 1 J 42916 3 High Pressure Hand Pump 2 High Pressure Fuel Line and Connector 4 Front Crankshaft Hub Figure 261 Removing Drive Flange 11 Install spacer bushing 9 onto crankshaft adapter All information subject to change without notice C 354 Copyright DETROIT DIESEL CORPORATION ...

Page 501: ...gh Pressure Fuel Line and Connector 4 Front Crankshaft Hub Figure 262 Removing Drive Hub 13 Hand tighten and back off distance equal to that of the force on dimension NOTE Force on dimension is stamped on the drive flange 14 Install SKF hydraulic pump line to oil hole on drive flange NOTE Do not tighten at this time All information subject to change without notice Copyright DETROIT DIESEL CORPORAT...

Page 502: ...shaft 18 Operate hand pump 2 for hydraulic press and seat press against drive flange by applying minimum pressure start of pressure increase NOTE The hydraulic press acts as a buffer stopping the hub as it slips off its taper seat 19 Operate hydraulic hand pump 1 for expanding the driver flange taper until expansion pressure is half the permitted maximum See Figure 263 1 Hydraulic Hand Pump 1 2 Hy...

Page 503: ...ge free from crankshaft remove draw spindle nut washers draw spindle crankshaft adapter sleeve and adapter 23 Remove hydraulic line To avoid injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 24 Remove drive flange All information subject to change without notice Copyright DETROIT DIESEL CORPORATION ...

Page 504: ...hers See Figure 264 1 Hex Bolt 2 Side Plate Figure 264 Disassembling Vibration Damper 2 Remove side plate 2 See Figure 264 3 Remove O rings NOTE A complete inspection is possible in this condition The spring pack can only be disassembled with the aid of special tools Refer to OEM guidelines All information subject to change without notice C 358 Copyright DETROIT DIESEL CORPORATION ...

Page 505: ...ling surfaces are not worn or rusty continue inspection 4 Visually inspect condition of threads in flange a If threads in flange are damaged rechase threads as necessary b If threads in flange are not damaged continue inspection 5 Ensure that oil bores are particularly clean 6 Visually inspect sealing surface of inner hub to drive hub for wear and scoring a If sealing surface is worn or scored rep...

Page 506: ...essed air and ensure that they are perfectly clean 2 Coat O rings 1 and 2 with petroleum jelly and insert into the side plate grooves 8 See Figure 265 1 O ring 4 Dished Washer 2 O ring 5 Hex Bolt 3 Inner Hub Figure 265 Assembling Vibration Damper 3 Coat inner circumference of side plate 8 and outer circumference of inner hub 3 and driver grooves with thin film lubricant See Figure 265 4 Clean and ...

Page 507: ...t by 90 degrees uniformly in small steps to specification Refer to section A 003 Ensure that side plate does not jam and the plate is not damaged See Figure 265 NOTE Ensure that correct final strength of surface sealant is reached after 72 hours 8 When replacing O rings 1 and 2 a special tool is required See Figure 265 9 After specified torque is reached check measurement levels A B and C See Figu...

Page 508: ...SERVICE MANUAL 10 Install seal carrier 2 on gear case See Figure 267 1 Hex Bolt 2 Seal Carrier Figure 267 Installing Seal Carrier All information subject to change without notice C 362 Copyright DETROIT DIESEL CORPORATION ...

Page 509: ...e 12 Tighten hex bolts 1 with washers diagonally and evenly to specification Refer to sectionA 003 See Figure 268 1 Hex Bolt 5 Damper Hub 2 Washer 6 Seal Carrier 3 Belt Pulley 7 Dust Ring 4 Vibration Damper 8 Dust Felt Figure 268 General View of Crankshaft Vibration Damper All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 363 ...

Page 510: ...ted air pressure or an accumulator tank with an inadequate pressure rating To avoid injury from failure of a fitting hose or oil cooler core wear a face shield or goggles when conducting a pressure test 1 Clean and degrease tapers of crankshaft and vibration damper hub 2 Coat running surface of crankshaft bearing and damper hub with oil NOTE Do not touch or get lubricant on the Crankshaft Teflon s...

Page 511: ...er and crankshaft adapter sleeve 5 Clean crankshaft surface inner hub bore ensuring all dirt and lint is removed 6 Oil both the inner hub bore and the crankshaft 7 Place the drive flange onto the crankshaft and push it as far as it will go The hydraulic pressure created by the oil will cause the drive flange to resist being seated Push until enough oil is released to allow drive flange to seat All...

Page 512: ...Pressure Fuel Line and Connector 4 Front Crankshaft Hub Figure 269 Installing Drive Hub 9 Install washers and nut Hand tighten only until snug See Figure 269 10 Measure distance from the outer edge of the drive flange to the edge of the spacer sleeve NOTE Specifications are stamped on front of hub All information subject to change without notice C 366 Copyright DETROIT DIESEL CORPORATION ...

Page 513: ...e in pressure is possible See Figure 270 1 Hydraulic Hand Pump 1 2 Hydraulic Hand Pump 2 Figure 270 Hydraulic Hand Pumps 14 Tighten nut to draw on the drive flange 15 Repeat steps13and steps 14 until the drive flange is properly seated NOTICE Do not exceed maximum expansion pressure 16 Open bleed screw at pump to release oil pressure 17 Disconnect the pump line at the drive flange 18 Wait one hour...

Page 514: ...installing hex bolt 1 and vibration damper 4 into threaded bore of crankshaft See Figure 271 1 Hex Bolt 3 Belt Pulley 2 Washer 4 Vibration Damper Figure 271 Installing Belt Pulley and Vibration Damper 21 Coat O rings with petroleum jelly and install onto damper hub NOTE Make sure parts are perfectly clean All information subject to change without notice C 368 Copyright DETROIT DIESEL CORPORATION ...

Page 515: ...ttach vibration damper with lifting device and crane and install over guide pins 23 Install belt pulley over guide pins 24 Coat thread and underside of hex bolt heads with engine oil and install 25 Remove guide pins and tighten hex bolts to specification Refer to section A 003 Refer to section C 035 05 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 369 ...

Page 516: ...gine power Refer to Operators guide 1 2 3 Install V belt tension Refer to Operators guide 1 2 3 Release engine start Refer to Operators guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 32 After Installation Operations All information subject to change without notice C 370 Copyright DETROIT DI...

Page 517: ...5 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C ...

Page 518: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 372 Copyright DETROIT DIESEL CORPORATION ...

Page 519: ...d connecting rods 1 Connecting Rod Bolt 4 Upper Connecting Rod Bearing Shell 2 Connecting Rod Cap 5 Connecting Rod 3 Lower Connecting Rod Bearing Shell 6 Piston Figure 272 General View of Pistons and Connecting Rods All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 373 ...

Page 520: ...cting Rod Bolt 7 Piston Pin 2 Connecting Rod Cap 8 Piston 3 Connecting Rod 9 Oil Control Ring 4 Piston Bolt 10 Compression Ring 5 Pressure Plate 11 Fire Ring 6 Snap Ring Figure 273 Piston Components All information subject to change without notice C 374 Copyright DETROIT DIESEL CORPORATION ...

Page 521: ...rings Engine barring tool Assembly sleeve piston connecting rod for carbon scraper ring Assembly sleeve piston connecting rod without carbon scraper ring Installation tool for connecting rod Installation removal of piston with connecting rod Piston ring pliers Ring gage for measuring piston ring and clearance Torque angle tightening device for connecting rod Table 33 Special Tools All information ...

Page 522: ...ant lines as required Refer to section C 204 05 05 1 2 3 Remove high pressure injection line Refer to section C 077 05 05 1 2 3 Remove low pressure fuel return rails and lines Refer to section C 086 05 05 1 2 3 Remove fuel injector Refer to section C 077 05 05 1 2 3 Remove valve drive Refer to section C 055 05 05 1 2 3 Remove pushrods Refer to section C 055 05 05 1 2 3 Remove cylinder head Refer t...

Page 523: ...ombustion residues from cylinder liner NOTE This is not required for cylinder liners with carbon scraper ring 2 For cylinder liner with carbon scraper ring remove carbon scraper ring arrows See Figure 274 NOTE Cylinder liners with carbon scraper rings are applicable to marine engines only Figure 274 Removing Carbon Scraper Ring Marine Engines Only All information subject to change without notice C...

Page 524: ...r TDC 6 Loosen connecting rod bolts arrows through inspection port with socket and large ratchet See Figure 275 Figure 275 Release Connecting Rod Bolts Through Inspection Port Except for the different position of the crankshaft the remainder of the removal procedure is the same as for removing piston with connecting rod on engine stand Removing Piston with Connecting Rod Mounted on Engine Stand Pe...

Page 525: ...necting Rod Bearing Cap 2 Socket Extension Figure 276 Removing Piston with Connecting Rod in Turnover Stand 2 Turn crankpin of respective cylinder on right side 40 before TDC and left side 40 after TDC 3 Loosen connecting rod bolt 1 with socket extension 2 and ratchet See Figure 276 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 379 ...

Page 526: ...ecting Rod Cap and Connecting Rod Markings Figure 277 Check Markings of Connecting Rod Cap to Connecting Rod NOTE Mark parts as necessary NOTE Bearing cap and connecting rod are a single unit and must not be interchanged All information subject to change without notice C 380 Copyright DETROIT DIESEL CORPORATION ...

Page 527: ...necting rod cap mating surfaces must not be damaged If necessary replace connecting rod 7 Check markings from main bearing shell to connecting rod NOTE Mark parts as necessary 8 Turn cylinder block so that piston to be removed with connecting rod is vertical NOTE When removing piston do not damage or warp oil spray nozzle Oil spray nozzles can be removed so that no damage can occur 9 Remove main b...

Page 528: ...e lifting device and review all manufacturer s cautionary notes 10 Secure piston and connecting rod lifting tool J 42781 2 on piston crown 1 See Figure 279 1 Piston Crown Figure 279 Removing Piston with Connecting Rod in Vertical Position All information subject to change without notice C 382 Copyright DETROIT DIESEL CORPORATION ...

Page 529: ...ed load Use a suitable lifting device and review all manufacturer s cautionary notes 11 Remove piston and connecting rod with lifting device and crane from cylinder liner bore 12 Remove lifting device from piston crown All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 383 ...

Page 530: ...g steps 1 Place piston and connecting rod on workbench 2 Check markings on connecting rod piston and piston pin Correct markings if necessary 3 Using snap ring pliers 1 remove snap ring 2 See Figure 280 1 Snap Ring Pliers 2 Snap Ring Figure 280 Removing Snap Ring All information subject to change without notice C 384 Copyright DETROIT DIESEL CORPORATION ...

Page 531: ... 1 Connecting Rod 2 Piston Pin Figure 281 Removing Piston Pin 5 Hold connecting rod 1 and remove piston pin 2 See Figure 281 6 Remove connecting rod from piston NOTICE To avoid breaking piston rings stretch them only until they can be removed from the piston All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 385 ...

Page 532: ...ngs with ring expander pliers arrows in sequence from top to bottom See Figure 282 Figure 282 Removing Piston Rings 8 Install piston on suitable retaining device All information subject to change without notice C 386 Copyright DETROIT DIESEL CORPORATION ...

Page 533: ... piston crown bolt 2 and remove with pressure plate 1 See Figure 283 1 Pressure Plate 2 Piston Crown Bolt Figure 283 Removing Piston Crown Bolt 10 Remove piston crown All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 387 ...

Page 534: ...grooves with decarbonizer 2 Clean area of piston ring grooves with rotating brush 3 Clean oil chamber and compression surfaces with synthetic abrasive MTH 688 rated grain 4 Using the surface crack testing method with fluorescent penetrant dye check piston for cracks a If cracked replace the piston b If not cracked continue inspection 5 Carefully inspect piston ring grooves for cracks a If cracked ...

Page 535: ...tificial depressions which are filled with oil and result in improved lubrication 3 Inspect the piston edge for heavy contact wear pitting scoring or erosion a If piston edge shows signs of heavy contact wear pitting scoring or erosion replace the piston b If piston edge is not worn pitted scored or eroded continue inspection 4 Inspect piston for scoring or scuffing on top land piston crown a Remo...

Page 536: ... If piston skirt shows extensive polishing wear or concentrated scoring replace the piston b If piston skirt does not show extensive polishing wear or concentrated scoring continue inspection 6 Inspect piston skirt for minor localized scuffing a If piston skirt shows localized scuffing replace piston b If piston skirt does not show localized scuffing continue inspection Checking Piston Crown Perfo...

Page 537: ...n crown for cracks a If cracked replace the piston b If not cracked continue inspection 5 Clamp piston crown axially in magnetic crack testing machine 6 When testing turn piston through 180 7 Carefully inspect piston ring grooves for cracks a If cracks are found in piston ring grooves replace complete piston b If not piston ring grooves are not cracked continue inspection 8 Inspect sealing surface...

Page 538: ...g or scuffing on top land of piston crown with an oilstone if localized and does not extend as far as first ring groove b If not scored or scuffed continue with inspection 12 Inspect piston for extensive damage i e if scoring or pitting extends as far as the first annular groove a If damage is extensive replace complete piston b If damage is not extensive continue inspection Checking Piston Crown ...

Page 539: ...a If bolt threads are worn replace bolt b If bolt threads are not worn continue with inspection Measuring Piston Skirt Diameter Perform the following steps to measure the piston skirt diameter 1 Use an outside micrometer to measure outside diameter on wear surfaces a If limit values are not reached replace piston All information subject to change without notice Copyright DETROIT DIESEL CORPORATION...

Page 540: ... in piston skirt for condition and specified torque Refer to section A 003 a If not within specifications replace bolts b If within specifications continue inspection Inspect Piston Ring Grooves Perform the following steps to inspect and repair piston ring grooves All information subject to change without notice C 394 Copyright DETROIT DIESEL CORPORATION ...

Page 541: ...eler Gage 2 Piston Ring Figure 289 Inspecting Piston Ring Grooves 2 If the limit values are exceeded or measurements are below limit values for oil control ring groove replace piston Inspecting Piston Pin Boss Perform the following steps to inspect and repair piston pin boss 1 Adjust bore gage and measure piston pin bore a If limit values are exceeded replace pistons All information subject to cha...

Page 542: ...liding surfaces of bronze bushing for wear and scoring a If sliding surfaces of bronze bushing are worn or scored replace piston b If not worn or scored continue with inspection Inspecting Piston Pin Perform the following steps to inspect and repair piston pin All information subject to change without notice C 396 Copyright DETROIT DIESEL CORPORATION ...

Page 543: ...orn or scored replace piston pin b If not worn or scored continue inspection 4 Inspect piston pin for scuffing indentations and severe wear a If scuffing indentations and severe wear are present replace piston pin b If not scuffed indented or worn continue inspection Inspecting Piston Rings Perform the following steps to inspect and repair the piston rings 1 Replace piston rings during W6 overhaul...

Page 544: ...coloration is found continue with inspection 4 Inspect piston rings for sharp edges a Replace sharp edged piston rings b If piston rings are not sharp edged continue with inspection 5 Inspect upper edge of rectangular section ring for sharp edge a If upper edge of rectangular section ring is sharp edged replace ring b If upper edge of rectangular section ring is not sharp edged continue with inspe...

Page 545: ...fication continue inspection NOTE Piston rings must only be replaced in sets Hone cylinder liners if new piston rings are installed Refer to section C 013 05 08 Inspecting Connecting Rod Perform the following steps to inspect and repair the connecting rod 1 Using magnetic crack testing method with fluorescent magnetic powder check connecting rod connecting rod cap and connecting rod bolts for crac...

Page 546: ...d cap mating surfaces are worn smooth with oilstone b If serrations on connecting rod and connecting rod cap mating surfaces are not worn continue with inspection 5 Check connecting rod for bearing damage a If connecting rod is blue in color due to bearing damage replace connecting rod b If connecting rod is not damaged continue with inspection 6 Check main bore for wear and scoring a If main bore...

Page 547: ...lean a If lube oil bore in connecting rod is not clean clean with bristle brush and blow with compressed air NOTE Never use a wire brush b If lube oil bore in connecting rod is clean continue with inspection Checking Axial Parallelism and Twist of Connecting Rod Bore To check axial parallelism and twist of connecting rod bore perform the following steps All information subject to change without no...

Page 548: ...1 Dial Gage for Axial Parallelism 6 V Block 2 Test Brass Drift Small Connecting Rod Eye 7 Base Plate 3 Dial Gage for Connecting Rod Twist 8 Resilient Stop 4 Connecting Rod 9 Adjustable Dial Gage Holder 5 Test Brass Drift Large Connecting Rod Eye Figure 294 Checking Axial Parallelism and Twist of Connecting Rod Bore 2 Clean large and small connecting rod bore All information subject to change witho...

Page 549: ...ure test brass drift with securing screw NOTE Ensure that test brass drift is properly inserted 7 Insert test brass drift 1 in small connecting rod bore See Figure 295 NOTE Ensure that installation position is correct 8 The wide section of test brass drift arrow must point toward connecting rod shaft narrow section to oil bores of small connecting rod bore See Figure 295 9 Lightly secure test bras...

Page 550: ...cting rod eye 2 on adjustable stop 5 See Figure 296 3 Adjust the rigid stop of adjustable stop 5 so that axle of test brass drift 2 is approximately 2 0 mm 0 0787 in below dial gage stylus 1 See Figure 296 4 Adjust both dial gages at highest point on test brass drift with approximately 2 0 preload set to zero 5 Rotate connecting rod through 180 degrees and carefully place in testing device 6 Move ...

Page 551: ... gages a If limit value is exceeded replace connecting rod b If limit value is not exceeded continue inspection See Figure 297 Figure 297 Calculating Axial Parallelism For example If left dial gage A reads 0 05 mm and right dial gage B reads 0 03 mm calculated value is 0 08 mm Axial parallelism as per example 0 08 mm 0 00315 in 4 0 02 mm 0 007 in Checking Axial Twist Perform the following steps to...

Page 552: ...ing gage 3 via dial gage stylus See Figure 298 1 Testing Device 3 Setting Gage 2 Dial Gages Figure 298 Checking Axial Twist 2 Remove setting gage 3 from testing device 1 See Figure 298 All information subject to change without notice C 406 Copyright DETROIT DIESEL CORPORATION ...

Page 553: ...299 Insert Connecting Rod with Test Brass Drift 4 Set fixed support of adjustable stop so that dial gage stylus travel is approximately 2 mm 0 07874 in 5 Press connecting rod at small connecting rod eye on fixed support 6 Read and record values on dial gages 1 Calculating Axial Twist Perform the following steps to calculate axial twist 1 To determine connecting rod bore axial twist calculate value...

Page 554: ... in 2 Axial twist A 0 10 mm 0039 in 2 0 05 mm 0 0019 in See Figure 300 a If limit value is exceeded replace connecting rod b If limit value is not exceeded continue inspection Checking and Assessing Connecting Rod Bearing Shells Sputtered Bearing Lower Half Perform the following steps to check and assess connecting rod bearing shells sputtered bearing lower half 1 Check rod bearing shells for wear...

Page 555: ...ight zone The decisive factor for the wear condition of the sputtered bearing is the ratio between the width of intermediate layer width of groove and the extent of the worn surface See Figure 301 5 The grooved bearing is still functional if the wear layer is partially missing in the grooves Practice has shown that the sputtered bearing with partially empty grooves can continue in use without nega...

Page 556: ...connecting rod main bearing shells 1 Check rod bearing shells for wear a If worn replace rod bearing shells b If rod bearing shells are not worn continue inspection 2 Replace main bearing shells as part of every W6 overhaul 3 Wear on bearing running surfaces starts at the galvanized wear layer 1 See Figure 302 1 Wear Layer from 12µm 18µm 3 Intermediate Layer Corresponds to Approximately 10 of Bear...

Page 557: ...Connecting Rod Cap Bolt Perform the following steps to check connecting rod cap bolt 1 Check bolt head support and thread for scoring or damage a If scored or damaged replace bolt b If bolt is not scored or damaged continue inspection 2 Measure shaft length of connecting rod bolt with depth gage See Figure 303 Figure 303 Measuring Connecting Rod Cap Bolt 3 For maximum permissible shaft length refe...

Page 558: ...e connecting rod and connecting rod cap mating surfaces for damage a If damaged replace the connecting rod and connecting rod cap b If connecting rod and connecting rod cap are not damaged continue inspection 3 Clean bearing shell mating surfaces on connecting rod and connecting rod cap See Figure 304 Figure 304 Cleaning Bearing Shell Mating Surfaces NOTE New connecting rod bearing shells 1 must b...

Page 559: ...Marking Connecting Rod Bearing Shells According to Cylinder Number on Front Surface NOTE Prior to installing connecting rod bearing shells compare repair stage marking on connecting rod and in crankshaft data sheet 5 Secure connecting rod in assembly fixture or in vice with aluminum jaws with mating surface horizontal All information subject to change without notice Copyright DETROIT DIESEL CORPOR...

Page 560: ...06 8 Carefully press connecting rod cap by hand onto connecting rod 9 Pay attention to locating pin and correct location of bearing shell 10 Coat threads of bolt head mating surfaces and bolt head seating surfaces with engine oil 11 Carefully insert connecting rod bolt into bearing cap bore by hand up to first contact with thread flanks then turn first three rotations without a tool NOTE Do not dr...

Page 561: ...od arm B to specification Refer to sectionA 003 See Figure 307 1 Torque Wrench Figure 307 Inserting Connecting Rod Bolt into Connecting Rod Bearing Cap 15 Adjust bore gage 1 and dial gage with micrometer 2 to basic size for connecting rod bearing bore See Figure 308 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 415 ...

Page 562: ...Gage 2 Micrometer Figure 308 Adjust Gages with Micrometer Measuring Connecting Rod Bore Perform the following steps to measure the connecting rod bore All information subject to change without notice C 416 Copyright DETROIT DIESEL CORPORATION ...

Page 563: ...ved continue inspection 3 Enter measurement values in data sheet 4 Remove connecting rod bolts connecting rod cap and bearing shells NOTE Protect rod bearing shells from damage Measuring Connecting Rod Bearing Bore Perform the following steps to measure connecting rod bearing bore 1 Check connecting rod bore for wear and scoring a If worn or scored machine bore to repair size or replace connecting...

Page 564: ... b If limits are not exceeded continue inspection 4 When reconditioning bore recondition locating pin bore as required and replace locating stud Measuring Connecting Rod Bushing Bore Perform the following steps to measure connecting rod bushing bore 1 Set bore gage to zero dimension of connecting rod bushing bore and measure connecting rod bushing bore See Figure 311 All information subject to cha...

Page 565: ...e 311 Measuring Connecting Rod Bushing Bore NOTE Do not remove connecting rod bushing unless necessary 2 Remove connecting rod bearing See Figure 312 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 419 ...

Page 566: ...imit values are exceeded remove connecting rod bushing and replace connecting rod b If limit values are not exceeded continue inspection Checking Connecting Rod Bushing Axial Seating Perform the following steps to check connecting rod bushing axial seating All information subject to change without notice C 420 Copyright DETROIT DIESEL CORPORATION ...

Page 567: ... See Figure 313 1 Test Brass Drift 2 Connecting Rod Figure 313 Connecting Rod Bushing Axial Seat 2 If test force is not reached use brass drift and hydraulic press to remove connecting rod bushing from connecting rod 2 See Figure 313 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 421 ...

Page 568: ... CONNECTING ROD Perform the following steps to assemble piston with connecting rod Installing Connecting Rod Bushing NOTE Always make sure that all components are perfectly clean All information subject to change without notice C 422 Copyright DETROIT DIESEL CORPORATION ...

Page 569: ... 2 Connecting Rod Bore Figure 314 Installing Connecting Rod Bushing NOTE Ensure that lube oil bores are aligned 2 Check that connecting rod bushing is firmly seated and use a fine drilling tool to machine to specified final dimension 3 After machining cover edges A of connecting rod bushing with felt washer ø 30 40 See Figure 314 4 Stamp connecting rod bushing repair stage diameter on surface B of...

Page 570: ...own on piston skirt NOTE Piston crown 2 and piston skirt 1 form a matched pair and must not be separated See Figure 315 1 Piston Skirt 2 Piston Crown Figure 315 Installing Piston Crown 3 Check that spring pin arrow is correctly seated See Figure 315 All information subject to change without notice C 424 Copyright DETROIT DIESEL CORPORATION ...

Page 571: ...ykote G n Plus 5 Install piston crown bolts in socket 2 to specification Refer to section A 003 See Figure 316 1 Pressure Plate 2 Piston Crown Bolt Figure 316 Installing Piston Crown Bolts All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 425 ...

Page 572: ...p oil control ring first insert piston rings with piston ring pliers into annular grooves on piston a Stretch piston rings only until they can be fitted over the piston Do not overstretch or they may break b Ensure that piston rings are installed in correct sequence c Top marking on piston rings must point in direction of piston crown See Figure 318 and see Figure 319 All information subject to ch...

Page 573: ... Layer 3 Compression Ring 2 Free Ring 4 Oil Control Ring Figure 318 Sequence of Piston Rings Figure 319 Installing Piston Rings with Piston Ring Pliers All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 427 ...

Page 574: ... oil 5 Insert connecting rod 1 into piston 2 according to markings in such a way that the shorter end A of the angle split connecting rod faces piston cooling oil bore hole B See Figure 320 1 Connecting Rod 2 Piston Figure 320 Connecting Rod with Piston 6 Push associated piston pin 2 into piston and connecting rod 1 until seated against snap ring installed beforehand See Figure 321 All information...

Page 575: ...cting Rod 2 Piston Pin Figure 321 Pushing Piston Pin into Piston and Connecting Rod 7 Insert second snap ring 2 with snap ring pliers 1 See Figure 322 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 429 ...

Page 576: ...ERVICE MANUAL 1 Snap Ring Pliers 2 Snap Ring Figure 322 Inserting Snap Ring NOTE Make sure snap ring is perfectly seated in groove All information subject to change without notice C 430 Copyright DETROIT DIESEL CORPORATION ...

Page 577: ...ts are perfectly clean 1 Rotate cylinder block in turnover stand until cylinder liner is vertical 2 Turn crankshaft crankpin of piston to be installed and connecting rod to assembly position 40 before TDC on the right side 40 after TDC on the left side 3 Clean crankpin and running surface of cylinder liner and spray with engine oil Cylinder Liner without Carbon Scraper Ring Perform the following s...

Page 578: ...ure 323 1 Piston 3 Cylinder Block 2 Cylinder Liner Figure 323 Cylinder Liner without Carbon Scraper Ring NOTE Piston crown and piston skirt form a matched pair and must not be interchanged Cylinder Liner with Carbon Scraper Ring Marine Only Perform the following steps to install cylinder liner with carbon scraper ring All information subject to change without notice C 432 Copyright DETROIT DIESEL ...

Page 579: ...er With Carbon Scraper Ring Marine Only 2 Install piston before the carbon scraper ring is installed in the liner NOTE Piston crown and piston skirt form a matched pair and must not be interchanged 3 Spray the piston and piston rings with engine oil 4 Ensure that piston rings are evenly fitted around piston circumference All information subject to change without notice Copyright DETROIT DIESEL COR...

Page 580: ...325 1 Oil Control Ring with Coiled Spring Expander Figure 325 Checking Piston Rings in Grooves 6 The oil control ring with coiled spring expander must be carefully centered to avoid damage All information subject to change without notice C 434 Copyright DETROIT DIESEL CORPORATION ...

Page 581: ...rrows on connecting rod and connecting rod cap with compressed air and check that they are clean See Figure 326 Figure 326 Cleaning Surfaces on Connecting Rod NOTICE Do not damage serrations on mating surfaces 8 If damaged replace connecting rod 9 Clean bearing shell mating surfaces on connecting rod and connecting rod cap All information subject to change without notice Copyright DETROIT DIESEL C...

Page 582: ...ce 1 so that connecting rod bearing recess 3 engages locating pin 2 See Figure 327 1 Locating Pin 2 Bearing Shell Recess Figure 327 Connecting Rod Bearing Shell 11 Coat running surface of bearing shell with engine oil All information subject to change without notice C 436 Copyright DETROIT DIESEL CORPORATION ...

Page 583: ...ith bearing shell half on crankshaft crankpin See Figure 328 Figure 328 Installing Bearing Shell 13 Coat connecting rod bearing sputter top running surface of bearing shell with engine oil All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 437 ...

Page 584: ...according to recess for locating pin on crankpin 2 so that the two recesses are aligned See Figure 329 1 Bearing Shell Half 2 Crankpin Figure 329 Positioning Bearing Shell Half All information subject to change without notice C 438 Copyright DETROIT DIESEL CORPORATION ...

Page 585: ...ing device and review all manufacturer s cautionary notes 15 Attach lifting device 1 for piston 2 See Figure 330 1 Piston Figure 330 Attaching Lifting Tool 16 Place piston ring compressor 2 for piston on appropriate cylinder liner See Figure 330 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 439 ...

Page 586: ... assembly sleeve with chamfered side facing piston into cylinder liner 19 Install piston into oiled cylinder liner so that short arm of connecting rod points outwards to air intake side 20 Gently turn piston when inserting so that the oil spray nozzle is not damaged when the connecting rod is installed or have the oil spray nozzle removed 21 If the oil spray nozzle is damaged remove spray nozzle a...

Page 587: ...craper ring support NOTE In order to avoid damaging piston rings use appropriate assembly sleeve 23 Ensure that assembly sleeve is properly seated See Figure 332 Figure 332 Piston Ring Compressor All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 441 ...

Page 588: ...Use brass drift 2 to push piston into cylinder liner 1 See Figure 333 1 Cylinder Liner 2 Brass Drift Figure 333 Pushing Piston into Cylinder Liner All information subject to change without notice C 442 Copyright DETROIT DIESEL CORPORATION ...

Page 589: ...At same time position assembly device with guide pin See Figure 334 28 Remove bearing installation device and push connecting rod cap by hand onto connecting rod 29 Pay attention to fit of locating pin in recess in connecting rod cap 30 Measure shaft length of connecting rod bolts For maximum shaft length refer to section C 037 05 01 All information subject to change without notice Copyright DETRO...

Page 590: ...il See Figure 335 Figure 335 Measuring Shaft Length 32 Carefully insert connecting rod bolt into bearing cap bore by hand to first contact with thread flanks then turn first three rotations without a tool All information subject to change without notice C 444 Copyright DETROIT DIESEL CORPORATION ...

Page 591: ...ting Connecting Rod Bolt Into Connecting Rod Cap 34 Connecting rod and connecting rod cap serrations must be closed 35 Using torque wrench first tighten connecting rod cap bolt at short connecting rod arm and then on long connecting rod arm to specification Refer to section A 003 For a general view of pistons and connecting rods refer to section C 037 05 01 All information subject to change withou...

Page 592: ...d clear so that the crankshaft will not unexpectedly rotate and cause loss of control of barring tool 37 Bar crankshaft and ensure that there is ease of movement between oil spray nozzle piston and connecting rod or reinstall oil spray nozzle making sure the nozzle is located in the exact center of piston cooling hole Installing Piston With Connecting Rod With Oil Pan Installed Perform the followi...

Page 593: ...ective cylinder on right side 40 before TDC and left side 40 after TDC 4 Remove barring tool 5 Install access port covers left and right sides from respective cylinders Connecting Rod Axial Clearance in Turnover Stand Perform the following steps to check connecting rod axial clearance in turnover stand 1 Rotate cylinder block in turnover stand until oil pan mating surface is horizontal 2 Check dis...

Page 594: ...n long connecting rod arm to specification Refer to section A 003 For a general view of pistons and connecting rods refer to section C 037 05 01 8 Check axial clearance Checking Axial Clearance of Connecting Rods With Oil Pan Installed Perform the following steps to check axial clearance of connecting rods with oil pan installed 1 Apart from altered installation position of cylinder block checking...

Page 595: ...VICE MANUAL 3 Insert carbon scraper ring marine only See Figure 339 1 Carbon Scraper Ring Figure 339 Carbon Scraper Ring Marine Only All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 449 ...

Page 596: ...e engine over stand clear so that the crankshaft will not unexpectedly rotate and cause loss of control of barring tool 5 Install index plate 2 with barring tool on crankshaft gear case end or flex plate coupling and adjust to TDC mark A1 See Figure 340 6 Set piston A1 to firing TDC Refer to section C 037 05 All information subject to change without notice C 450 Copyright DETROIT DIESEL CORPORATIO...

Page 597: ...l Gage 8 Install measuring unit into cylinder head and secure with knurled head bolt 3 See Figure 341 9 Set dial gage to zero 10 Move piston several times up and down through TDC until needle of dial gage registers its highest reading 11 Set dial gage to zero and readjust index plate accordingly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 451 ...

Page 598: ...nt to 5 degrees before TDC 0 36 mm 1 4173 in and the piston went to 5 degrees after TDC 0 32 mm 1 2598 in the total values 0 68 mm 2 6771 in Thus the mean value 0 34 mm 1 3385 in 16 Bar crankshaft to approximately 10 degrees after TDC then bar in direction opposite to normal direction of rotation until dial gage reads mean value i e 0 34 mm 0 0133 in 17 Set pointer of index plate to 5 degrees afte...

Page 599: ... and lines Refer to section C 086 05 11 1 2 3 Install high pressure injection lines Refer to section C 077 05 11 1 2 3 Connect electric cables as required Refer to OEM Guidelines 1 2 3 Install appropriate exhaust line Refer to section C 141 05 11 1 2 3 Install appropriate charge air manifold Refer to section C 124 05 11 1 2 3 Install cylinder head cover Refer to section C 056 05 11 1 2 3 Install a...

Page 600: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 454 Copyright DETROIT DIESEL CORPORATION ...

Page 601: ...ore 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 455 ...

Page 602: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 456 Copyright DETROIT DIESEL CORPORATION ...

Page 603: ...ns 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 457 ...

Page 604: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 458 Copyright DETROIT DIESEL CORPORATION ...

Page 605: ...Figure 342 for a general view of the cylinder head components 1 Gasket 3 Cylinder Head Bolt 2 Washer 4 Sealing Ring Figure 342 General View of Cylinder Head with Attachments All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 459 ...

Page 606: ...E MANUAL See Figure 343 for a view of the cylinder head with valves 1 Cylinder Head 2 Bridge Guide Figure 343 Cylinder Head With Valves All information subject to change without notice C 460 Copyright DETROIT DIESEL CORPORATION ...

Page 607: ...ithout valves 1 Plug 6 Cap Plug DM 24 2 Sealing Cap 7 O ring 3 Cylinder Head 8 Sleeve Injector 4 Cap Plug 9 Valve Guide 5 Spring Pin 10 Plug Figure 344 Overview of Cylinder Head Without Valves All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 461 ...

Page 608: ...tive sleeve Valve installation and removal tool Valve seat rotating unit VDS 2 Brass drift for cap plug Removal brass drift for valve guides Spacer tool valve guide installation Spreader for valve stem seal Plug gage for valve guides Plug gage for valve seats Alignment tool for cylinder head installation Table 36 Special Tools All information subject to change without notice C 462 Copyright DETROI...

Page 609: ...ion C 055 05 05 1 2 3 Remove valve bridges Refer to section C 055 05 05 1 2 3 Disconnect and remove electric cable at injector Refer to OEM Guidelines 1 2 3 Remove fuel injector Refer to section C 075 05 05 1 2 3 Remove charge air manifold bolts Refer to section C 124 05 05 1 2 3 Remove high pressure line between cylinder head and high pressure rail Refer to section C 077 05 05 1 2 3 Disconnect fu...

Page 610: ...ps to remove the cylinder head 1 Use a large ratchet or power assist to unscrew hex bolts from cylinder head evenly See Figure 345 1 Hydraulic Torque Wrench Figure 345 Unscrewing Hex Bolts on Cylinder Head All information subject to change without notice C 464 Copyright DETROIT DIESEL CORPORATION ...

Page 611: ...g device lift cylinder head 1 off of the cylinder block and place it on a suitable base See Figure 346 1 Cylinder Head Figure 346 Lifting Cylinder Head with Lifting Device NOTE With injector installed place cylinder head to the side Injector protrudes at bottom of cylinder head so surface should be flat All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 465 ...

Page 612: ...t 2 from cylinder block mating surface See Figure 347 1 Cylinder Block Mating Surface 3 Cylinder Head Studs 2 Cylinder Head Gasket Figure 347 Removing Cylinder Head Gasket All information subject to change without notice C 466 Copyright DETROIT DIESEL CORPORATION ...

Page 613: ...er sealing ring 1 out of cylinder head lower section See Figure 348 1 Sealing Ring Figure 348 Removing Cylinder Head Sealing Ring 5 For screwdriver contact point arrow see Figure 348 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 467 ...

Page 614: ...he base plate 2 of the valve spring relief device See Figure 349 1 Cylinder Head 2 Base Plate Figure 349 Placing Cylinder Head on Base Plate of Valve Spring Relief Device 2 Align cylinder head on the guide pins so that valve heads lie beside the plastic plate See Figure 349 All information subject to change without notice C 468 Copyright DETROIT DIESEL CORPORATION ...

Page 615: ...e 1 on valve spring retainer and secure to the base plate with hex bolt 2 See Figure 350 1 Pressure Plate 2 Hex Bolt Figure 350 Securing Pressure Plate to Base Plate All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 469 ...

Page 616: ... press the pressure plate onto the spring retainer until valve locks are loose See Figure 351 1 Hand Spindle 2 Valve Lock Figure 351 Removing Valve Locks 5 Using bar magnet take out valve locks 2 6 Release valve spring 7 After all valve locks have been removed remove pressure plate and spindle All information subject to change without notice C 470 Copyright DETROIT DIESEL CORPORATION ...

Page 617: ...ve spring retainer and valve springs See Figure 352 1 Outer Valve Spring 2 Valve Spring Retainer Figure 352 Removing Valve Spring Retainer and Valve Springs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 471 ...

Page 618: ...ICE MANUAL 9 Remove valve rotator See Figure 353 1 Valve Rotators Figure 353 Removing Valve Rotator 10 Lay cylinder head on its side All information subject to change without notice C 472 Copyright DETROIT DIESEL CORPORATION ...

Page 619: ...plate of the valve spring tensioner from the cylinder head See Figure 354 Figure 354 Removing Base Plate from Cylinder Head 12 Remove valves from valve guides All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 473 ...

Page 620: ...n storage frame 1 to protect them from damage See Figure 355 1 Storage Frame Figure 355 Placing Valves in Storage Frame 14 Clamp cylinder head in retaining base All information subject to change without notice C 474 Copyright DETROIT DIESEL CORPORATION ...

Page 621: ...d indicate turn or show unusual wear Replace all bridges that meet these criteria NOTE Count the number of pulls required to remove pin If pin was removed with few pulls or removed with little resistance see step 17 17 Measure bridge pin bore using pin bore digital measuring tool Measure bore at three locations bottom middle and top Record values to a data sheet 18 Preset tool to 12 7 mm 0 50 in p...

Page 622: ...was removed with few pulls or removed with little resistance see step 20 Measure bridge pin bore using pin bore digital measuring tool Measure bore at three locations bottom middle and top Record values to a data sheet 21 Preset tool to 12 7 mm 0 50 in prior to measuring a Replace cylinder heads if any bore is out of tolerance 13 984 14 00 mm 0 550 0 551 in b Reuse cylinder heads if bores are with...

Page 623: ...drift to carefully knock the edge of one side of the cap plug 1 inwards until it tilts in the bore See Figure 358 1 Cap Plug Figure 358 Removing Cap Plug 26 Withdraw cover with pliers 27 When removing take care that cover does not fall into bore and that sealing surface of bore is not damaged NOTICE Never drill cap plug as metal chips in coolant jacket of cylinder head can cause localized overheat...

Page 624: ...ry pretreat oil carbon deposits on valves and cylinder heads with carbon deposit remover 3 After cleaning with carbon deposit remover rinse components in water until there is no further residue 4 Measure cylinder head overall height a If values are below minimum permissible height replace cylinder head b If values are not below minimum permissible height continue inspection 5 Visually inspect cyli...

Page 625: ...ing a If valve seat is worn or pitted recondition as necessary b If valve seat is not worn or pitted continue inspection 9 Visually inspect washers and tapers for wear a If washers or tapers are worn replace as necessary b If washers or tapers are not worn continue inspection 10 Visually inspect all threads in cylinder head for ease of movement a If threads do not show ease of movement rechase thr...

Page 626: ...ylinder Head Bolt Length 3 For maximum permissible shaft length refer to sectionA 003 Inspecting Bridge Guide Perform the following steps to inspect bridge guide 1 Visually inspect bridge guide for damage and wear a If bridge guide is damaged or worn replace as necessary b If bridge guide is not damaged or worn continue inspection All information subject to change without notice C 480 Copyright DE...

Page 627: ...nue inspection 3 Measure protrusion A of bridge guide 4 A 78 mm 3 0708 in 0 5 mm 0 0197 in See Figure 360 Checking Valve Guides Perform the following steps to check valve guides 1 Clean bores of valve guides with valve guide cleaning brush 2 Check all valve guides for wear and damage a If valve guides are worn or damaged replace components as necessary All information subject to change without not...

Page 628: ...e 11 009 0 009 b Length of go end should be 103 mm 4 0551 in 4 Go end plug gage must move easily through the whole valve guide 5 No go side plug gage must not rub Checking Valves Perform the following steps to check valves 1 Visually inspect valves for damage such as pitting scoring and indentations on valve stem 2 head 4 neck 3 and bridge contact area 1 a If valves are damaged replace as necessar...

Page 629: ...lve stems for indentations and scoring a If indentations or scoring are found replace valves stems b If no indentations or scoring is found continue inspection 4 Visually inspect for pitting at transition from valve head to valve stem a If pitting is found at transition from valve head to valve stem replace valves as necessary b If no pitting is found continue inspection NOTE Valve keyways must no...

Page 630: ...oncentricity are found regrind valve sealing area on a valve grinding machine or replace valve as necessary b If no minor deviations in concentricity are found continue inspection NOTE Do not straighten valves Regrinding Valve Sealing Area Perform the following steps to regrind valve sealing area NOTE Do not remove more material than is absolutely necessary to achieve perfect valve sealing All inf...

Page 631: ...rea 2 Set valve grinding angle on valve grinding machine 3 Grind valve with slight advance until valve is smooth and free from chatter marks over the entire circumference 4 Measure height of external edge on valve and valve sealing width a If limit values are exceeded replace valve b If limit values are not exceeded continue inspection All information subject to change without notice Copyright DET...

Page 632: ...t dye check valves for cracks a If cracks are found replace valves as necessary b If no cracks are found continue inspection Inspecting Valve Springs Perform the following steps to inspect the valve springs 1 Visually inspect valve springs for surface cracks or broken coils a If surface cracks or broken coils are found replace valve springs as necessary b If no surface cracks or broken coils are f...

Page 633: ...pring test device 1 See Figure 365 1 Valve Spring Test Device 2 Valve Spring Figure 365 Inspecting Valve Springs 4 Measure valve springs a If limit values are exceeded replace valve spring as necessary b If limit values are not exceeded continue inspection Externally Correcting Valve Seat Perform the following steps to the externally correcting valve seat All information subject to change without ...

Page 634: ... for Stop Pin Figure 366 Externally Correcting Valve Seat 2 Turn rapid adjuster 5 to bring trail edge B of turning tool C into contact with the outer edge A of the valve seat See Figure 366 NOTE Carefully lower rotator onto valve seat edge 3 Gently press stop pin down against the tap pilot and tighten locking bolt All information subject to change without notice C 488 Copyright DETROIT DIESEL CORP...

Page 635: ...ooling system for leaks The coolant must be treated with corrosion inhibitor for pressure testing To avoid personal injury while handling HOT components wear protective gloves and clothing 2 Place cylinder head in an 80 C 176 F hot water bath until cylinder head has warmed To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplate and do not exceed 27...

Page 636: ...e the bridge pin 1 Place bridge pins into dry ice or liquid nitrogen to freeze parts NOTICE Ensure to install bridge pins to specification Improperly seated pins will cause cylinder head damage 2 Place pin into cylinder head bore and install using pin driving tool NOTE Walking the pin may be required along with a couple of hits Count the number of hits Replace pin s requiring excessive hits and re...

Page 637: ...d shoes Do not allow the liquid nitrogen to come into contact with exposed body parts Danger of freezing body parts will occur 2 Cool valve guides 1 with liquid nitrogen See Figure 367 1 Valve Guide 2 Brass Drift Figure 367 Installing Valve Guides 3 Mount warmed up cylinder head on assembly device 4 Using brass drift press chilled valve guides into bore in cylinder head until guide is seated on as...

Page 638: ...asure distance between compression surface and valve guide See Figure 368 Figure 368 Measuring Distance between Compression Surface and Valve Guide All information subject to change without notice C 492 Copyright DETROIT DIESEL CORPORATION ...

Page 639: ... b If diameter is not outside limits continue to next step NOTE Instead of bore gage a plug gage version A may also be used Nominal diameter of plug gage 11 009 0 009 Length of go end 103 mm 4 0551 in Go end plug gage must move easily through the whole valve guide No go side plug gage must not rub Installing Cap Plug Perform the following steps to install cap plug All information subject to change...

Page 640: ...t 3 Using a brass drift insert cap plug flush with bore in cylinder head See Figure 370 Figure 370 Installing Cap Plug NOTE Ensure correct final strength of thread locking agent Refer to section A 003 Installing Injector Sleeves Perform the following steps to install the injector sleeves All information subject to change without notice C 494 Copyright DETROIT DIESEL CORPORATION ...

Page 641: ...er Head 3 O ring 2 Injector Sleeve Figure 371 Installing Injector Sleeves 2 Coat O ring 3 with petroleum jelly and insert into the injector sleeve bore See Figure 371 3 Clamp cylinder head on the assembly plate All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 495 ...

Page 642: ...Refer to section A 003 See Figure 372 1 Sleeve 3 Cylinder Head 2 O ring Figure 372 Tightening Injector Sleeve NOTE Ensure that socket is correctly engaged in sleeve groove Installing Bridge Guide Perform the following steps to install bridge guide All information subject to change without notice C 496 Copyright DETROIT DIESEL CORPORATION ...

Page 643: ...Insertion Brass Drift Figure 373 Installing Bridge Guide 3 Position bridge guide 1 with fitted insertion brass drift 2 as vertically as possible on support bore 4 Drive bridge guide into support bore by gently tapping assembly brass drift with hammer until assembly brass drift is resting on cylinder head All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 497 ...

Page 644: ...uide See Figure 374 A 78 mm 0 031 in 0 5 mm 0 0197 in Figure 374 Measuring Protrusion of Bridge Guide Installing Valves Perform the following steps to install the valves NOTE Ensure parts are perfectly clean All information subject to change without notice C 498 Copyright DETROIT DIESEL CORPORATION ...

Page 645: ...and coat valve stems with engine oil 3 Install valves into valve guides 4 Ensure that valves are correctly installed inlet exhaust NOTE Valve markings at stem end IN inlet and EX exhaust Exhaust valves are nonmagnetic Valve heads and stems are magnetic All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 499 ...

Page 646: ...r head 1 See Figure 376 1 Cylinder Head 2 Base Plate Figure 376 Positioning Cylinder Head on Base Plate 6 Align cylinder head on the guide pins so that valve heads lie beside the plastic plate See Figure 376 All information subject to change without notice C 500 Copyright DETROIT DIESEL CORPORATION ...

Page 647: ...ators between fingers of both hands and with light pressure rotate valve rotator a If there is any resistance or valve rotator stops replace component b If there is no resistance and valve rotator does not stop continue inspection 10 Install outer and inner valve springs NOTE Valve springs have no Top Bottom marking Installation position does not matter 11 Install valve spring retainers 12 Install...

Page 648: ... glasses or faceplate 14 By turning manual spindle direction of arrow press pressure plate onto valve springs until spring retainers expose groove on valve stem end See Figure 378 Figure 378 Rotating Hand Spindle of Valve Spring Pretensioner All information subject to change without notice C 502 Copyright DETROIT DIESEL CORPORATION ...

Page 649: ...ks 16 Release valve springs so that spring retainers are pushed over valve locks 17 Ensure that lip of valve lock is securely seated in groove at valve stem end 18 Remove pressure plate with manual spindle 19 Lift cylinder head out of base plate All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 503 ...

Page 650: ...y on valve stem NOTE Verify that valve locks are in correct position before proceeding Repeat installation of valve locks on any valve which does not appear to be seated properly using additional new valve locks Measuring Valve Clearance to Cylinder Head Perform the following steps to measure valve clearance to cylinder head All information subject to change without notice C 504 Copyright DETROIT ...

Page 651: ...face of cylinder head 3 Set dial gage scale to zero 4 Position stylus on valve heads of inlet valves 2 and exhaust valves 5 and measure valve clearance See Figure 381 a If valve clearances are beyond limits replace valve heads of inlet valves b If valve clearances are not beyond limits continue to next step 5 Valve sealing area on cylinder head and valve head must be checked All information subjec...

Page 652: ...Clean as necessary NOTE Always use new cylinder head gaskets 3 Install cylinder head gaskets 2 See Figure 382 1 Cylinder Block Fire Deck 3 Cylinder Head Studs 2 Cylinder Head Gasket Figure 382 Installing Cylinder Head Gasket 4 Install guide pin for positioning cylinder head gasket and cylinder head to cylinder block See Figure 382 All information subject to change without notice C 506 Copyright DE...

Page 653: ...press sealing ring 1 by 0 5 mm 019685 in to form a slightly oval shape See Figure 383 1 Sealing Ring Figure 383 Installing Sealing Ring 6 Install sealing ring in recess on combustion chamber side of cylinder head See Figure 383 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 507 ...

Page 654: ...NUAL 7 Ensure that sealing ring is fitted correctly See Figure 384 A Cylinder Head Side B Piston Side Figure 384 Ensuring Sealing Ring Fit All information subject to change without notice C 508 Copyright DETROIT DIESEL CORPORATION ...

Page 655: ... when handling and lifting a heavy object use a suitable lifting device and follow the manufacturer s operator procedures 8 Using lifting device and special lifting tool install cylinder head 1 on cylinder block five deck See Figure 385 1 Cylinder Head Figure 385 Installing Cylinder Head on Cylinder Block All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 509 ...

Page 656: ...l Figure 386 Installing Cylinder Head Bolts 10 Install cylinder head bolts 3 with washers manually in cylinder block 11 Install alignment tool 4 on inlets of cylinder heads and tighten See Figure 386 NOTICE To avoid deformation or cracks in exhaust and intake manifolds carry out cylinder head alignment carefully All information subject to change without notice C 510 Copyright DETROIT DIESEL CORPOR...

Page 657: ...hten cylinder head bolts to specification Refer to section A 003 See Figure 387 A Exhaust Side B Inlet Side Figure 387 Cylinder Head Torque Diagram 13 Remove alignment tool 1 See Figure 388 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 511 ...

Page 658: ... 388 Installing Hex Bolts on Cylinder Head NOTE Before tightening cylinder head bolts to additional angle of rotation apply marks to bolt heads to allow angle of rotation check All information subject to change without notice C 512 Copyright DETROIT DIESEL CORPORATION ...

Page 659: ...01 05 M 1 2 3 Install fuel return lines Refer to section C 086 05 11 1 2 3 Install charge air manifolds Refer to section C 124 05 11 1 2 3 Install exhaust manifold bolts Refer to section C 015 05 11 1 2 3 Install turbocharger Refer to section C 101 05 11 1 2 3 Install exhaust Y pipe Refer to section C 141 05 11 1 2 3 Install air filter Refer to section C 221 05 11 1 2 3 Fill engine coolant system ...

Page 660: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 514 Copyright DETROIT DIESEL CORPORATION ...

Page 661: ...ST 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...

Page 662: ... 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 All information subject to change without notice C 516 Copyright DETROIT DIESEL CORPORATION ...

Page 663: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 517 ...

Page 664: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 518 Copyright DETROIT DIESEL CORPORATION ...

Page 665: ...89 for a general view of camshaft components 1 Hex Bolt 5 Thrust Bearing Flange 2 Spacer 6 Dowel Pin 3 SRS Pulse Wheel 7 Camshaft 4 Camshaft Gear Figure 389 General View of Camshaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 519 ...

Page 666: ...uired for maintenance on camshaft Designation Application Number Camshaft guide sleeve Camshaft locating device Camshaft installation removal Piston measuring device Index plate with pointer Table 39 Special Tools All information subject to change without notice C 520 Copyright DETROIT DIESEL CORPORATION ...

Page 667: ... Reference 1 2 3 Disable engine power Refer to Operators Guide 1 2 3 Removal of camshaft not scheduled 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 40 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 521 ...

Page 668: ...f rotation until TDC mark and arrow on flywheel housing are aligned 2 If rocker arms on cylinder A1 are unloaded the piston is in firing TDC See Figure 390 Figure 390 Removing Camshaft Marine only 3 If rocker arms on cylinder A1 are loaded the piston is in overlap TDC 4 Remove valve drive Refer to section C 055 05 05 5 Determine TDC on DDEC engines using a dial gage in cylinder A1 Refer to section...

Page 669: ...SRS sensor 2 slightly to remove from housing bore 9 If shims are installed on the sensor save all shims for re installation Removing Timing Wheel or SRS Wheel Camshaft Gear Perform the following operations to remove the timing wheel or SRS wheel camshaft gear All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 523 ...

Page 670: ...cker shaft flywheel end See Figure 392 1 Camshaft 2 Locating Tool Figure 392 Removing SRS Wheel Camshaft Gear 2 Insert dowel pin of locating tool 2 into camshaft bore 3 Screw locating tool into place All information subject to change without notice C 524 Copyright DETROIT DIESEL CORPORATION ...

Page 671: ...ERVICE MANUAL 4 Find dowel pin hole arrow for locating tool driving end See Figure 393 Figure 393 Locating Bore for Locating Tool All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 525 ...

Page 672: ...4 1 Hex Bolt 3 Camshaft Gear 2 SRS Wheel 4 Spacer Figure 394 Removing Hex Bolts Spacer SRS Wheel and Camshaft Gear NOTICE To prevent gear damage cover bottom of gear case so that no bolts can fall into housing 6 Remove locating tool All information subject to change without notice C 526 Copyright DETROIT DIESEL CORPORATION ...

Page 673: ...Figure 395 NOTICE To prevent gear damage cover bottom of gear case so that no bolts can fall into housing 1 Hex Bolt 2 Thrust Bearing Flange Figure 395 Removing Hex Bolts and Thrust Bearing Flange All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 527 ...

Page 674: ... to rear of cylinder block 2 flywheel end to guide camshaft to be removed with hex bolts 1 See Figure 396 1 Hex Bolts 2 Cylinder Block Figure 396 Securing Camshaft Guide All information subject to change without notice C 528 Copyright DETROIT DIESEL CORPORATION ...

Page 675: ...moving camshaft its weight must be supported by the sliding block To avoid personal injury when handling and lifting a heavy object use a suitable lifting device to lift heavy objects and follow the manufacturer s operator procedures 11 Attach lifting sling 2 midway along camshaft 12 Take up slack and continue carefully withdrawing camshaft from cylinder block 13 Remove insertion sleeve not shown ...

Page 676: ...roller tracks do not show signs of scoring wear or indentations continue inspection 5 Check gear mating surface for wear or damage a If gear mating surface is worn or damaged rub down with oilstone b If gear mating surface is beyond repair replace component c If gear mating surface is not worn or damaged continue inspection 6 Check surface condition of gear teeth with magnifying glass a If gear te...

Page 677: ... of each journal at four points at 90 degree intervals around circumference a If limit values are not achieved machine camshaft to specifications or replace if necessary b If limit values are achieved continue inspection 3 Required hardness is 61 HRC 2 HRC Checking Concentricity and Bearing Journals Perform the following steps to check concentricity and bearing journals All information subject to ...

Page 678: ... journal 3 Measure radial runout of cam base circle journals with dial gage 1 4 Measure cam lift over base circle diameter of valve lobes with dial gage a If limit values are not achieved machine camshaft to DDC specifications b If specified limit values cannot be achieved by machining replace camshaft c If limit values are achieved continue inspection All information subject to change without not...

Page 679: ...g subsections to install camshaft NOTE Ensure all components are perfectly clean 1 Attach camshaft guide 1 flywheel end of cylinder block and center to camshaft bearings See Figure 400 Figure 400 Attaching Camshaft Guide All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 533 ...

Page 680: ...ng sling 2 and clean See Figure 401 1 Camshaft 2 Lifting Sling Figure 401 Withdrawing Camshaft from Cylinder Block 3 Spray camshaft camshaft bearing and guide sleeve with engine oil 4 Install sliding block at outermost cam on camshaft 5 Taking care not to damage bearings slowly install camshaft into cylinder block up to the second to the last bearing All information subject to change without notic...

Page 681: ...re 402 1 Camshaft 2 Assembly Extension Figure 402 Positioning Assembly Extension on Camshaft 7 Remove camshaft guide and assembly extension Installing Camshaft Thrust Bearing Perform the following steps to install camshaft thrust bearing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 535 ...

Page 682: ...lling Hex Bolts and Thrust Bearing Flange 2 Tighten thrust bearing flange 2 with hex bolts 1 NOTICE To prevent gear damage cover bottom of gear case so that no bolts can fall into housing 3 Install spacer 1 with hex bolt 2 on camshaft See Figure 404 All information subject to change without notice C 536 Copyright DETROIT DIESEL CORPORATION ...

Page 683: ...he spacer serves only to secure the camshaft axially and prevent it from falling out during cylinder block transportation 4 Turn camshaft until locating bore flywheel end arrow is visible and at position shown See Figure 405 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 537 ...

Page 684: ...VICE MANUAL Figure 405 Locating Bore for Locating Tool Installing Locating Tool Perform the following steps to install locating tool All information subject to change without notice C 538 Copyright DETROIT DIESEL CORPORATION ...

Page 685: ...rocker shaft flywheel end See Figure 406 1 Camshaft 2 Locating Tool Figure 406 Installing Locating Tool 2 Insert dowel pin of locating tool 2 into camshaft bore 3 and screw locating tool into place All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 539 ...

Page 686: ...Index Plate Figure 407 Installing Pointer on Gear Case 4 Install index plate with barring tool on crankshaft set to TDC marking of A1 and tighten 5 Set piston A1 to firing TDC Refer to section C 037 05 05 All information subject to change without notice C 540 Copyright DETROIT DIESEL CORPORATION ...

Page 687: ...is gear lash in both directions See Figure 408 1 Dowel Pin 3 SRS Wheel 2 Camshaft Gear Figure 408 Installing SRS Wheel via Dowel Pins 7 Install SRS Wheel 3 via dowel pins NOTICE To prevent gear damage cover bottom of gear case so that no bolts can fall into housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 541 ...

Page 688: ...d tighten spacer 1 with hex bolts 2 NOTE Ensure that dowel pin 6 and bolt bores are aligned See Figure 409 1 Spacer 2 Hex Bolt Figure 409 Installing Spacer with Hex Bolts Measuring Backlash Perform the following steps to measure backlash All information subject to change without notice C 542 Copyright DETROIT DIESEL CORPORATION ...

Page 689: ... Backlash 2 Position dial gage stylus with low preload on one tooth flank of camshaft gear 3 Set dial gage to zero 4 Check backlash by moving camshaft gear back and forth 5 For backlash refer to section C 024 05 Measuring Camshaft End Play Perform the following steps to measure camshaft end play All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 543 ...

Page 690: ...n SRS wheel 3 Push camshaft on camshaft gear horizontally as far as it will go 4 Set dial gage with preload to zero 5 Move camshaft from stop to stop and record measured value end play 6 For axial clearance refer to section C 024 05 Installing SRS Sensor Perform the following steps to install SRS sensor All information subject to change without notice C 544 Copyright DETROIT DIESEL CORPORATION ...

Page 691: ... 412 Installing SRS Sensor 2 Turn SRS sensor 1 slightly to install in housing bore 3 If shims had previously been installed re install those shims Checking SRS Sensor Clearance Perform the following steps to check SRS sensor clearance All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 545 ...

Page 692: ...re 413 Figure 413 Checking Speed Sensor Clearance 2 Measure distance small arrows specified value is 0 3 mm to 1 mm 3 If distance is less than 0 3 mm fit appropriate number of adjusting shims of 0 3 mm thickness 4 Measure distance All information subject to change without notice C 546 Copyright DETROIT DIESEL CORPORATION ...

Page 693: ...mshaft Timing 1 Determine TDC position of piston as follows a Install measuring device 1 with dial gage 2 starting at cylinder head A1 b To apply TDC mark index plate on flex coupling flange or crankshaft journal gear case end install suitable TDC pointer on gear case flywheel end or cylinder block All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 547 ...

Page 694: ...ear case end opposite TDC pointer 7 To take up bearing play bar crankshaft in direction of rotation past TDC to approximately 10 degrees 8 Bar crankshaft in direction opposite to normal direction of rotation to 0 3 mm after TDC 9 Apply second mark to index plate flywheel end or to crankshaft journal gear case end NOTE To eliminate bearing clearance the piston must always move in direction of TDC 1...

Page 695: ...ata Sheet 8 Position dial gage stylus on valve bridge of exhaust valve set scale to zero 9 Further turn crankshaft slowly in direction of engine rotation until pointer of dial gage no longer moves 10 Read valve stroke from dial gage and record readings in Data Sheet a If readings are outside limits machine as necessary b If correct limits cannot be obtained by machining replace component c If read...

Page 696: ...of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 41 After Installation Operations All information subject to change without notice C 550 Copyright DETROIT DIESEL CORPORATION ...

Page 697: ...ols C 554 C 052 05 04 Before Removal Operations C 555 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 551 ...

Page 698: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 552 Copyright DETROIT DIESEL CORPORATION ...

Page 699: ...e 415 for a general view of camshaft drive components 1 Hex Bolt 4 Camshaft Gear 2 Spacer 5 Thrust Bearing Flange 3 SRS Wheel Figure 415 General View of Camshaft Drive Components All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 553 ...

Page 700: ...2 are the special tools required for maintenance on the camshaft drive Application Number Piston measuring device Index plate with pointer Camshaft locating device Table 42 Special Tools All information subject to change without notice C 554 Copyright DETROIT DIESEL CORPORATION ...

Page 701: ...rgers Refer to section C 187 05 05 1 2 3 Remove oil return lines for turbochargers Refer to section C 188 05 05 1 2 3 Remove exhaust turbocharger Refer to section C 101 05 05 1 2 3 Remove charge air coolant lines low temperature Refer to section C 207 05 05 1 2 3 Remove engine coolant vent line Refer to section C 205 05 05 1 2 3 Remove charge air coolant vent lines Refer to section C 205 05 05 1 2...

Page 702: ... until TDC mark and arrow on flywheel housing are aligned See Figure 416 Figure 416 Barring Engine to Align TDC A1 and Flywheel Markings Marine only 2 If rocker arms on cylinder A1 are unloaded the piston is in firing TDC 3 If rocker arms on cylinder A1 are loaded the piston is in overlap TDC 4 Remove valve drive Refer to section C 055 05 05 5 On DDEC engines use a dial gage in the A1 cylinder kit...

Page 703: ...ning SRS Sensor 9 If shims are installed on the sensor save all shims for re installation Removing SRS Wheel Camshaft Gear Perform the following steps to remove SRS wheel camshaft gear 1 Position locating tool 2 on bolting surface of rocker shaft flywheel end See Figure 418 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 557 ...

Page 704: ...re 418 Removing SRS Wheel 2 Insert dowel pin of locating tool 2 into camshaft bore and bolt locating tool into place See Figure 419 Figure 419 Locating Bore for Locating Tool All information subject to change without notice C 558 Copyright DETROIT DIESEL CORPORATION ...

Page 705: ...SRS wheel 2 and camshaft gear 3 from camshaft See Figure 420 1 Ring 2 Hex Bolt Figure 420 Removing Hex Bolts SRS Wheel and Camshaft Gear NOTICE To prevent gear damage cover bottom of gear case so that no bolts can fall into housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 559 ...

Page 706: ...e Figure 421 1 Spacer 2 Hex Bolt Figure 421 Installing Spacer with Hex Bolt on Camshaft NOTE The spacer serves only to secure the camshaft axially and prevent if from falling out during cylinder block transportation All information subject to change without notice C 560 Copyright DETROIT DIESEL CORPORATION ...

Page 707: ...r damaged continue inspection 3 Inspect camshaft for minor scoring wear and indentations a If camshaft is damaged polish with emery cloth or machine b If wear or damage is too severe replace camshaft c If no damage is found continue inspection 4 Measure camshaft against limit values a If limit values are exceeded replace components as necessary b If limit values are not exceeded continue inspectio...

Page 708: ...1 Coat thrust surfaces with engine oil See Figure 422 1 Ring 2 Hex Bolt Figure 422 Coating Thrust Surfaces with Engine Oil 2 Tighten thrust bearing flange with hex bolts to specification Refer to section A 003 NOTE Cover bottom of gear case so that no screws can fall into housing 3 Install spacer 1 with hex bolt 2 on camshaft See Figure 423 All information subject to change without notice C 562 Co...

Page 709: ... spacer serves only to secure the camshaft axially and prevent it from falling out during cylinder block transportation 4 Turn camshaft until flywheel end of locating bore arrow is visible and at position shown See Figure 424 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 563 ...

Page 710: ...VICE MANUAL Figure 424 Locating Bore for Locating Tool Installing Locating Tool Perform the following steps to install locating tool All information subject to change without notice C 564 Copyright DETROIT DIESEL CORPORATION ...

Page 711: ... rocker shaft flywheel end See Figure 425 1 Camshaft 2 Locating Tool Figure 425 Installing Locating Tool 2 Insert dowel pin of locating tool into camshaft bore and screw locating tool into place All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 565 ...

Page 712: ...2 with barring tool on crankshaft set to TDC marking of A1 and tighten 5 Set piston A1 to firing TDC Refer to section C 037 05 05 6 Insert camshaft gear 2 into camshaft so that dowel pins 1 engage camshaft gear bore in a vertical line be sure there is gear lash in both directions All information subject to change without notice C 566 Copyright DETROIT DIESEL CORPORATION ...

Page 713: ...re 427 1 Dowel Pin 3 SRS Wheel 2 Camshaft Gear Figure 427 Installing SRS Wheel via Dowel Pins NOTICE To prevent gear damage cover bottom of gear case so that no bolts can fall into housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 567 ...

Page 714: ...rew in ring 1 and tighten with hex bolts 2 See Figure 428 1 Spacer 2 Hex Bolt Figure 428 Screwing in and Tightening Spacer with Hex Bolts NOTE Ensure that dowel pin and bolt bores are aligned Measuring Backlash Perform the following steps to measure backlash All information subject to change without notice C 568 Copyright DETROIT DIESEL CORPORATION ...

Page 715: ...ic Dial Gage Holder 2 Position dial gage stylus with low preload on one tooth flank of camshaft gear 3 Set dial gage to zero 4 Check backlash by moving camshaft gear back and forth 5 For backlash refer to section C 024 05 Measuring Camshaft End Play Perform the following steps to measure camshaft end play All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 569 ...

Page 716: ...ft gear horizontally as far as it will go 4 Set dial gage with preload to zero 5 Move camshaft from stop to stop and record measured value end play 6 For axial clearance refer to section C 024 05 7 For measuring camshaft timing and valve stroke refer to section C 051 05 11 Installing SRS Sensor Perform the following steps to install SRS sensor All information subject to change without notice C 570...

Page 717: ...talling SRS Sensor 2 Turn SRS sensor 1 slightly to install in housing bore if shims had previously been installed re install those shims 3 Screw in hex bolt Checking SRS Sensor Clearance Perform the following steps to check SRS sensor clearance All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 571 ...

Page 718: ... 432 Figure 432 Checking SRS Sensor Clearance 2 Measure distance smaller arrows specified value is 0 3 mm to 1 mm 3 If distance is less than 0 3 mm fit appropriate number of adjusting shims of 0 3 mm thickness 4 Measure distance All information subject to change without notice C 572 Copyright DETROIT DIESEL CORPORATION ...

Page 719: ...es Refer to section C 205 05 11 1 2 3 Install engine coolant vent lines Refer to section C 205 05 11 1 2 3 Install charge air coolant lines low temperature Refer to section C 207 05 11 1 2 3 Install intake air system from turbocharger to charge air cooler Refer to sectionC 125 05 11 1 2 3 Install Y pipe at exhaust outlet housing Refer to section C 141 05 11 1 2 3 Install vibration damper if remove...

Page 720: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 574 Copyright DETROIT DIESEL CORPORATION ...

Page 721: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 575 ...

Page 722: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 576 Copyright DETROIT DIESEL CORPORATION ...

Page 723: ...ure 433 for a general view of camshaft thrust bearing 1 Screw 4 Camshaft Gear 2 Ring 5 Thrust Bearing Flange 3 Metering Wheel Figure 433 General View of Camshaft Thrust Bearing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 577 ...

Page 724: ...e the special tools required for maintenance on the camshaft thrust bearing Application Number Piston measuring device Index plate with pointer Camshaft locating device Table 45 Special Tools All information subject to change without notice C 578 Copyright DETROIT DIESEL CORPORATION ...

Page 725: ... lines for turbochargers Refer to section C 187 05 05 1 2 3 Remove oil return lines for turbochargers Refer to section C 188 05 05 1 2 3 Remove exhaust turbocharger Refer to section C 101 05 05 1 2 3 Remove charge air coolant lines low temperature Refer to section C 207 05 05 1 2 3 Remove engine coolant vent line Refer to section C 205 05 05 1 2 3 Remove charge air coolant vent lines Refer to sect...

Page 726: ... turn engine in normal direction of rotation until TDC mark and arrow on flywheel housing are aligned See Figure 434 Figure 434 Removing Camshaft Thrust Bearing Marine only 2 If rocker arms on cylinder A1 are unloaded the piston is in firing TDC 3 If rocker arms on cylinder A1 are loaded the piston is in overlap TDC 4 Remove valve drive Refer to section C 055 05 05 5 On DDEC engines use a dial gag...

Page 727: ...lightly to remove from housing bore 9 If shims are installed on the sensor save all shims for re installation Removing SRS Wheel Camshaft Gear Perform the following steps to remove SRS wheel camshaft gear 1 Position locating tool 2 on bolting surface of rocker shaft flywheel end See Figure 436 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 581 ...

Page 728: ...re 436 Removing SRS Wheel 2 Insert dowel pin of locating tool 2 into camshaft bore and bolt locating tool into place See Figure 437 Figure 437 Locating Bore for Locating Tool All information subject to change without notice C 582 Copyright DETROIT DIESEL CORPORATION ...

Page 729: ...ear 3 from camshaft See Figure 438 1 Hex Bolt 3 Camshaft Gear 2 SRS Wheel 4 Spacer Figure 438 Removing Hex Bolts Spacer SRS Wheel and Camshaft Gear NOTICE To prevent gear damage cover bottom of gear case so that no bolts can fall into housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 583 ...

Page 730: ... Figure 439 1 Spacer 2 Hex Bolt Figure 439 Installing Spacer with Hex Bolt on Camshaft NOTE The spacer serves only to secure the camshaft axially and prevent it from falling out during cylinder block transportation All information subject to change without notice C 584 Copyright DETROIT DIESEL CORPORATION ...

Page 731: ...or damage or excessive wear a If damage or excessive wear is found replace components b If no damage or excessive wear is found continue inspection 5 Measure camshaft thrust bearing against limit values a If camshaft thrust bearings are outside limits machine as necessary b If correct limits cannot be achieved by machining replace component c If camshaft thrust bearings are not outside limits cont...

Page 732: ... Thrust Bearing Flange Figure 440 Removing Hex Bolts and Thrust Bearing Flange 2 Tighten thrust bearing flange with hex bolts to specification Refer to section A 003 NOTICE To avoid damage to gears cover bottom of gear case so that no bolts can fall into housing 3 Install spacer 1 with hex bolt 2 on camshaft See Figure 441 All information subject to change without notice C 586 Copyright DETROIT DI...

Page 733: ...NOTE The spacer only serves to secure the camshaft axially and prevent it from falling out during cylinder block transportation 4 Turn camshaft until locating bore arrow is visible and at position shown See Figure 442 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 587 ...

Page 734: ...VICE MANUAL Figure 442 Locating Bore for Locating Tool Installing Locating Tool Perform the following steps to install locating tool All information subject to change without notice C 588 Copyright DETROIT DIESEL CORPORATION ...

Page 735: ...he rocker shaft flywheel end See Figure 443 1 Camshaft 2 Locating Tool Figure 443 Installing SRS Wheel 2 Insert dowel pin of locating tool into camshaft bore and screw locating tool into place All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 589 ...

Page 736: ... Plate Figure 444 Installing Pointer on Equipment Carrier 4 Install index plate 2 with barring tool on crankshaft set to TDC marking of A1 and tighten 5 Set piston A1 to firing TDC Refer to section C 037 05 05 All information subject to change without notice C 590 Copyright DETROIT DIESEL CORPORATION ...

Page 737: ...ar lash in both directions See Figure 445 1 Dowel Pin 3 Graduated Disc 2 Camshaft Gear Figure 445 Installing Graduated Disc via Dowel Pins 7 Install SRS wheel 3 via dowel pins NOTICE To avoid gear damage cover bottom of gear case so that no bolts can fall into housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 591 ...

Page 738: ... hex bolts 2 Refer to section C 052 05 01 NOTE Ensure that dowel pin and bolt bores are aligned See Figure 446 1 Spacer 2 Hex Bolt Figure 446 Screwing in and Tightening Spacer with Hex Bolts Measuring Backlash Perform the following steps to measure backlash All information subject to change without notice C 592 Copyright DETROIT DIESEL CORPORATION ...

Page 739: ...g Backlash 2 Position dial gage stylus with low preload on one tooth flank of camshaft gear 3 Set dial gage to zero 4 Check backlash by moving camshaft gear back and forth 5 For backlash refer to section C 024 05 Measuring Camshaft End Play Perform the following steps to measure camshaft end play All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 593 ...

Page 740: ...ft gear horizontally as far as it will go 4 Set dial gage with preload to zero 5 Move camshaft from stop to stop and record measured value end play 6 For axial clearance refer to section C 024 05 7 For measuring camshaft timing and valve stroke refer to section C 051 05 11 Installing SRS Sensor Perform the following steps to install SRS sensor All information subject to change without notice C 594...

Page 741: ...talling Speed Sensor 2 Turn SRS sensor slightly to install in housing bore if shims had previously been installed re install those shims 3 Screw in hex bolt Checking SRS Sensor Clearance Perform the following steps to check SRS sensor clearance All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 595 ...

Page 742: ...e 450 Figure 450 Checking SRS Sensor Clearance 2 Measure distance small arrows specified value is 0 3 mm to 1 mm 3 If distance is less than 0 3 mm fit appropriate number of adjusting shims of 0 3 mm thickness 4 Measure distance All information subject to change without notice C 596 Copyright DETROIT DIESEL CORPORATION ...

Page 743: ...Refer to section C 205 05 11 1 2 3 Install engine coolant vent lines Refer to section C 205 05 11 1 2 3 Install charge air coolant lines low temperature Refer to section C 207 05 11 1 2 3 Install intake air system from turbocharger to intercooler Refer to sectionC 125 05 11 1 2 3 Install Y pipe at exhaust outlet housing Refer to section C 141 05 11 1 2 3 Install vibration damper if removed Refer t...

Page 744: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 598 Copyright DETROIT DIESEL CORPORATION ...

Page 745: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 599 ...

Page 746: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 600 Copyright DETROIT DIESEL CORPORATION ...

Page 747: ... Swing Shaft 7 Snap Ring 2 Swing Arm Intake 8 Adjusting Shim 3 Swing Arm Exhaust 9 Rocker Shaft Bracket 4 Hex Bolt 10 Rocker Arm Exhaust 5 Washer 11 Valve Bridge 6 Rocker Bolt 12 Rocker Arm Intake Figure 451 Valve Operating Mechanism All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 601 ...

Page 748: ...haft Bracket 2 Adjusting Shim 9 Spring Pin 3 Bushing 10 Spring Pin 4 Adjusting Bolt 11 Blanking Plug 5 Intake Rocker Arm 12 Rocker Shaft 6 Nut 13 Exhaust Rocker Arm 7 Grooved Pin 14 Thrust Pad Figure 452 Rocker Shaft Bracket All information subject to change without notice C 602 Copyright DETROIT DIESEL CORPORATION ...

Page 749: ...ure 453 for a general view of swing arm 1 Bushing 5 Roller 2 Ball Socket 6 Bushing 3 Roller Arm Exhaust 7 Pin 4 Roller Arm Intake Figure 453 Swing Arm All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 603 ...

Page 750: ... SERVICE MANUAL See Figure for a general view of valve bridge 1 Adjusting Bolt 3 Hex Nut 2 Valve Bridge Figure 454 Valve Bridge All information subject to change without notice C 604 Copyright DETROIT DIESEL CORPORATION ...

Page 751: ...tools required for maintenance on the valve drive Application Number Valve clearance adjustment gage 0 2 mm 0 5 mm Allen key 8 A F for valve clearance adjustment Engine barring tool Table 48 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 605 ...

Page 752: ... 05 1 2 3 Remove intake air system from turbocharger to intercooler Refer to sectionC 125 05 05 1 2 3 Remove coolant lines high temperature Refer to section C 203 05 05 1 2 3 Remove exhaust turbocharger Refer to section C 101 05 05 1 2 3 Remove charge air coolant vent lines low temperature Refer to section C 205 05 05 1 2 3 Remove engine coolant vent lines high temperature Refer to section C 205 0...

Page 753: ... nuts 3 of adjusting bolts 2 on rocker arm and back off adjusting bolts See Figure 455 1 Pushrod 3 Nut 2 Adjusting Bolt Figure 455 Releasing Adjusting Bolts to Remove Pushrods 2 Remove pushrods 1 from ball sockets of rocker arms NOTE Ensure not to drop pushrod into oil pan 3 Mark pushrods All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 607 ...

Page 754: ...e grooved pin See Figure 456 1 Washer 5 Rocker Arm Exhaust 2 Rocker Shaft Bolt 6 Rocker Shaft Bracket 3 Snap Ring 7 Grooved Pin 4 Adjusting Shim 8 Rocker Arm Intake Figure 456 Removing Rocker Shaft Bolt and Rocker Shaft Bracket from Cylinder Head All information subject to change without notice C 608 Copyright DETROIT DIESEL CORPORATION ...

Page 755: ...nder head See Figure 457 1 Valve Bridges 2 Bridge Pin Figure 457 Marking Valve Bridges and Removing from Bridge Pin 6 Remove pushrods Removing Swing Arms Perform the following steps to remove swing arms All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 609 ...

Page 756: ...458 1 Hex Bolts 3 Swing Arm 2 Swing Shaft Figure 458 Removing Hex Bolts and Swing Arm Shaft from Cylinder Block 2 Remove swing arm shaft 2 with swing arm 3 from cylinder block All information subject to change without notice C 610 Copyright DETROIT DIESEL CORPORATION ...

Page 757: ...r shaft bracket in vice with aluminum jaws See Figure 459 1 Washer 2 Snap Ring Figure 459 Clamping Rocker Shaft Bracket Support in Vice and Removing Snap Ring and Washer from Rocker Shaft 2 Using snap ring pliers remove snap ring 2 from rocker shaft 3 Remove washer 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 611 ...

Page 758: ...rm 3 from rocker shaft See Figure 460 1 Adjusting Bolt 3 Rocker Arm 2 Nut 4 Rocker Shaft Figure 460 Removing Rocker Arm Nut and Adjusting Bolt from Rocker Shaft All information subject to change without notice C 612 Copyright DETROIT DIESEL CORPORATION ...

Page 759: ...Bridge in Vice and Removing Nut and Adjusting Bolt 6 Loosen nut and remove adjusting bolt Removing Swing Arm Bushing Perform the following steps to remove swing arm bushing NOTE Remove swing arm bushing only if necessary Refer to section C 055 05 08 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 613 ...

Page 760: ... Figure 462 1 Swing Arm 2 Swing Arm Bushing Figure 462 Removing Swing Arm Bushing Removing Pin and Roller Perform the following steps to remove pin and roller NOTE Remove pin and roller only if necessary Refer to section C 055 05 08 All information subject to change without notice C 614 Copyright DETROIT DIESEL CORPORATION ...

Page 761: ...m 3 Brass Drift Figure 463 Removing Pin and Roller 2 Use brass drift 3 to remove pin from swing arm 5 3 Remove roller 1 from bore Removing Rocker Arm Bushings Perform the following steps to remove exhaust rocker arm bushings NOTE Remove exhaust rocker arm bushing only if necessary Refer to section C 055 05 08 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 6...

Page 762: ...rift and hydraulic press to remove exhaust rocker arm bushing 2 from rocker arm 1 See Figure 464 Rocker Arm 2 Bushing Figure 464 Removing Rocker Arm Bushing All information subject to change without notice C 616 Copyright DETROIT DIESEL CORPORATION ...

Page 763: ...ons or scoring are found polish with emery cloth or replace components as necessary b If wear indentations or scoring are not found continue inspection 6 Inspect snap rings and washers for damage and wear a If components are damaged or worn replace as necessary b If no damage or wear is found continue inspection 7 Inspect mating surfaces on rocker shaft bracket a If mating surfaces are worn burnis...

Page 764: ...inspection 13 Measure register bores in valve bridges with bore gage a If register bores in valve bridges are outside limits machine as necessary b If correct limits cannot be achieved by machining replace component c If register bores in valve bridges are not outside limits continue inspection 14 Check bridge guides in cylinder heads for wear and protrusion Refer to section C 041 05 08 15 Replace...

Page 765: ...ize of bushing bore and measure diameter of bore a If bushing bores are outside limits replace component b If bushing bore are not outside limits continue inspection 3 Measure bushing bore against limit values 4 If limit values are exceeded replace bushings Measuring Diameter of Rocker Shaft Perform the following steps to measure diameter of rocker shaft All information subject to change without n...

Page 766: ...ft against limit values a If bearing pedestal shafts are outside limits machine as necessary b If correct limits cannot be achieved by machining replace component c If bearing pedestal shafts are not outside limits continue inspection Inspecting Hex Bolts for Rocker Shaft Support Perform the following steps to inspect hex bolts for rocker shaft support All information subject to change without not...

Page 767: ...er to section C 055 05 01 3 Inspect threads and bolt head mating surface a If threads or bolt head mating surface are damaged replace bolt b If threads or bolt head mating surface are not damaged continue inspection Measuring Swing Arm Perform the following steps to measure swing arm All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 621 ...

Page 768: ...t swing arm against limit values a If inlet swing arms are outside limits machine as necessary b If correct limits cannot be achieved by machining replace component c If inlet swing arms are not outside limits continue inspection Measuring Roller Diameter Perform the following steps to measure roller diameter All information subject to change without notice C 622 Copyright DETROIT DIESEL CORPORATI...

Page 769: ... 469 Measuring Roller Diameter 2 Measure roller diameter against limit values a If roller diameter is outside limits machine as necessary b If correct limits cannot be achieved by machining replace component c If roller diameter is not outside limits continue inspection All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 623 ...

Page 770: ...t 3 Rocker Arm 2 Nut 4 Rocker Shaft Figure 470 Assembling Rocker Arm Assembly NOTE Ensure parts are perfectly clean 2 Insert adjusting bolt 1 into rocker arm 3 3 Attach nut 2 to adjusting bolt do not tighten 4 Coat shaft on rocker shaft support bracket and bushings of rocker arm with engine oil 5 Install rocker arm on shaft 6 Install second rocker arm in same way All information subject to change ...

Page 771: ...asses or faceplate 7 Install washer 1 and secure with snap ring 2 See Figure 471 1 Washer 2 Snap Ring Figure 471 Installing Snap Ring and Washer Rocker Shaft 8 Ensure that snap ring is correctly seated 9 Check minimum end play of rocker arm 10 Install second rocker arm in the same way All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 625 ...

Page 772: ...2 Valve Bridge Figure 472 Inserting Adjusting Bolt into Valve Bridge 12 Attach hex nut 3 to adjusting bolt do not tighten Assembling Swing Arms Perform the following steps to assemble swing arms NOTE Ensure parts are perfectly clean All information subject to change without notice C 626 Copyright DETROIT DIESEL CORPORATION ...

Page 773: ...xposed body parts Danger of freezing body parts will occur 1 Chill swing arm bushing 2 in liquid nitrogen and insert flush in swing arm 1 See Figure 473 1 Swing Arm 2 Swing Arm Bushing Figure 473 Assembling Swing Arm Bushing 2 Bushing must not protrude above arm NOTE Check that bore is correctly aligned All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 627 ...

Page 774: ... air pressure NOTE Ensure parts are perfectly clean 3 Blow out bore in swing arm with compressed air See Figure 474 1 Roller 4 Hammer 2 Pin Location 5 Swing Arm 3 Brass Drift Figure 474 Inserting Pin and Roller 4 Heat swing arm to approximately 100 C 5 Insert roller 1 in swing arm 5 All information subject to change without notice C 628 Copyright DETROIT DIESEL CORPORATION ...

Page 775: ...er of freezing body parts and suffocation will occur 6 Chill pin 2 in liquid nitrogen and insert flush in swing arm 5 See Figure 474 7 Use hammer 4 and brass drift 3 to position pin 8 Pin must not protrude above arm Assembling Rocker Arm Perform the following steps to assemble rocker arm NOTE Ensure parts are perfectly clean All information subject to change without notice Copyright DETROIT DIESEL...

Page 776: ...gure 475 1 Rocker Arm 2 Bushing Figure 475 Inserting Rocker Arm Bushing 2 Heat rocker arm to approximately 200 C 3 Insert bushing so that it is flush 4 Bushing must not protrude above arm All information subject to change without notice C 630 Copyright DETROIT DIESEL CORPORATION ...

Page 777: ...6 Clamping Valve Bridge in Vice and Removing Nut and Adjusting Bolt 1 Measure projection of sliding pins with respect to cylinder head Refer to section C 041 05 08 NOTE If valve seats in cylinder head or valves have been machined valve bridges must be adjusted 2 Secure valve bridge 1 in vice with aluminum jaws release locknut and back off adjusting bolt by approximately 3 revolutions 3 Ensure oil ...

Page 778: ...to the markings installation location See Figure 477 1 Adjusting Bolt 3 Allen Wrench 2 Valve Bridge 4 Locknut Figure 477 Installing Adjusting Bolt 6 Adjusting bolt points to charge air manifold 7 Press valve bridge downward arrow and hold Valve bridge must be in contact with valve stem 8 With valve bridge pressed down install adjusting bolt 1 with Allen wrench 3 until adjusting bolt slightly conta...

Page 779: ...3 14 Re install valve bridge on valve head 15 Inspect clearance with 0 1 mm feeler gage under each locknut If equal drag does not occur readjust bridge 16 Coat shaft and bushings of swing arm with engine oil See Figure 478 Figure 478 Installing Swing Roller Arms on Swing Shaft 17 Install swing arms on swing shaft making sure they are positioned correctly arrow 18 Coat rollers and camshaft lobes wi...

Page 780: ...lts Figure 479 Installation Position of Swing Arm Follower 22 Coat ball sockets of pushrods with engine oil and insert pushrods 23 Measure shaft length of hex bolt for maximum shaft length refer to section A 003 All information subject to change without notice C 634 Copyright DETROIT DIESEL CORPORATION ...

Page 781: ...MANUAL 24 Coat thread and mating surface of hex bolts arrows with engine oil See Figure 480 Figure 480 Measuring Shaft Length of Hex Bolt All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 635 ...

Page 782: ...cker Arm Figure 481 Releasing Nuts of Adjusting Bolts on Rocker Arms 26 Fit rocker shaft bracket on cylinder head and check fit of grooved pins 27 Check position of ball joints in pushrods 1 28 Install rocker shaft bolt 4 with washer 5 in cylinder head and tighten to specified torque Refer to section A 003 All information subject to change without notice C 636 Copyright DETROIT DIESEL CORPORATION ...

Page 783: ...f control of barring tool 29 Using the barring tool set piston of cylinder to be checked to firing TDC See Figure 482 Figure 482 Position of Swing Arm Rollers at Firing TDC NOTE At firing TDC both rollers of swing arm of respective cylinder are in base circle arrow of camshaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 637 ...

Page 784: ...ry when barring the engine over stand clear so that the crankshaft will not unexpectedly rotate and cause loss of control of barring tool 1 With barring tool turn engine in normal direction of rotation until TDC A1 mark and arrow on flywheel housing are aligned Adjusting Valve Clearance in Two Crankshaft Positions Perform the following steps to adjust valve clearance in two crankshaft positions Al...

Page 785: ...n overlap TDC 3 Check all valve clearances at two crankshaft positions firing TDC and overlap TDC cylinder A1 in accordance with Figure 4 Turn crankshaft in direction of engine rotation 5 1 Firing TDC at cylinder A1 2 Overlap TDC at cylinder A1 X Exhaust value 0 Inlet valve Adjusting Valve Bridge Perform the following steps to adjust the valve bridge All information subject to change without notic...

Page 786: ...alve bridge must not contact the stem 4 With pressure applied to the valve bridge use an Allen wrench to install the adjusting bolt 1 until the adjusting bolt lightly contacts the valve stem 5 Rotate approximately 20 to 30 degrees to compensate clearance 6 Hold adjusting bolt 1 and tighten locknut slightly 7 Tighten locknut with torque wrench to specification holding valve bridge firmly in place w...

Page 787: ...g Valve Clearance in Two Crankshaft Positions 2 If swing arms on cylinder A1 are loaded the piston is in overlap TDC 3 Check all valve clearances at two crankshaft positions firing TDC and overlap TDC cylinder A1 in accordance with Figure 4 Turn crankshaft in direction of engine rotation 5 1 Firing TDC at cylinder A1 2 Overlap TDC at cylinder A1 X Exhaust value 0 Inlet valve All information subjec...

Page 788: ...clearance on inlet valve long swing arm 0 2 mm cold engine 8 Valve clearance on exhaust valve short swing arm 0 5 mm cold engine NOTE It must still be possible to pull feeler gage through 9 If deviation from specified value is more than 0 1 mm adjust valve clearance All information subject to change without notice C 642 Copyright DETROIT DIESEL CORPORATION ...

Page 789: ...ing Adjusting Bolt 11 Valve clearance on inlet valve long swing arm 0 2 mm cold engine 12 Valve clearance on exhaust valve short swing arm 0 5 mm cold engine 13 Holding adjusting bolt firmly again tighten locknut to specified torque 14 For tightening torque refer to section A 003 15 Again check valve clearance All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C ...

Page 790: ...1 1 2 3 Install charge air coolant vent lines low temperature Refer to section C 205 05 01 1 2 3 Install engine coolant vent lines high temperature Refer to section C 205 05 01 1 2 3 Install intake air system from turbocharger to charge air cooler Refer to sectionC 125 05 11 1 2 3 Install Y pipe at exhaust outlet housing Refer to section C 141 05 11 1 2 3 Add charge air coolant low temperature Ref...

Page 791: ...ols 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 645 ...

Page 792: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 646 Copyright DETROIT DIESEL CORPORATION ...

Page 793: ...gure 489for a general view of rocker cover arrangement 12V 1 Rocker Cover 4 Washer 2 Cylinder Head 5 Hex Bolt 3 Gasket Figure 489 General View of Rocker Cover Arrangement 12V All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 647 ...

Page 794: ...tools required for maintenance on the rocker cover Application Number Valve clearance adjustment gage 0 2 mm 0 5 mm Allen Key 8 A F for valve clearance adjustment Engine barring tool Table 51 Special Tools All information subject to change without notice C 648 Copyright DETROIT DIESEL CORPORATION ...

Page 795: ... Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 52 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 649 ...

Page 796: ...he following steps to remove rocker cover 1 Remove hex bolts See Figure 490 1 Cylinder Head 4 Washer 2 Profile Gasket 5 Rocker Cover 3 Hex Head Bolt Figure 490 Removing Rocker Cover 2 Remove rocker cover and gasket All information subject to change without notice C 650 Copyright DETROIT DIESEL CORPORATION ...

Page 797: ...g particular attention to the mating and sealing surfaces a If rocker cover is worn or damaged rub down with emery cloth or oilstone replace as necessary b If rocker cover is not worn or damaged continue inspection 3 Clean hex bolts and inspect for wear or damage a If hex bolts are worn or damaged replace as necessary b If hex bolts are not worn or damaged continue inspection 4 Inspect threads of ...

Page 798: ...is in perfect condition replace if necessary 3 Place rocker 5 on cylinder head 1 4 Insert hex head bolts 3 with washers and tighten with torque wrench holding valve bridge firmly in place with open end wrench Refer to section A 003 See Figure 491 NOTE Use engine oil as lubricant 1 Cylinder Head 4 Washer 2 Profile Gasket 5 Rocker Cover 3 Hex Head Bolt Figure 491 Installing Rocker Cover 5 Release en...

Page 799: ... Level of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 53 After Installation Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 653 ...

Page 800: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 654 Copyright DETROIT DIESEL CORPORATION ...

Page 801: ...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 1...

Page 802: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 656 Copyright DETROIT DIESEL CORPORATION ...

Page 803: ...ure fuel pump 3 Low pressure fuel lines 3 Remote mounted fuel filter s 3 Engine mounted fuel filter s 3 High pressure fuel pump 3 High pressure fuel rails 3 Fuel injection nozzle assemblies 3 Low pressure return fuel rails 3 Fuel cooler optional 3 Electronic control module ECM 3 All necessary piping Fuel is drawn from the tank and into the fuel junction block by the fuel pump Fuel is then pumped a...

Page 804: ...SERIES 4000 12 16V SERVICE MANUAL Figure 492 Schematic Diagram of the Series 4000 Fuel System All information subject to change without notice C 658 Copyright DETROIT DIESEL CORPORATION ...

Page 805: ...ine 7 High Pressure Line 3 Injector 8 Protective Cover Marine and Hydo Frac Only 4 High Pressure Jumper Line 9 Control Solenoid 5 High Pressure Rail Figure 493 General View of the High Pressure Fuel System See Figure 494 for a cutaway view of the high pressure fuel system All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 659 ...

Page 806: ... 1 Injector Hold Down Clamp 6 High Pressure Jumper Line 2 DDEC Harness Connection 7 Fuel Return Manifold 3 Injector 8 Fuel Flow Limiting Valve All information subject to change without notice C 660 Copyright DETROIT DIESEL CORPORATION ...

Page 807: ...et Filter Element 9 High Pressure Fuel Rail 5 Return Fuel Return Line 10 Injector Hole Tube Figure 494 Cutaway View of the High Pressure Fuel System All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 661 ...

Page 808: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 662 Copyright DETROIT DIESEL CORPORATION ...

Page 809: ...erations 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 Copyright DETROIT DIESEL CORPORATION C 663 ...

Page 810: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 664 Copyright DETROIT DIESEL CORPORATION ...

Page 811: ...w of the high pressure fuel pump 1 Bolt 5 Low Pressure Fuel Transfer 2 High Pressure Fuel Pump 6 Fitting 3 O ring 7 Drive Coupling 4 Drive Adaptor Figure 495 General View of the High Pressure Fuel Pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 665 ...

Page 812: ...sure fuel pump 1 High Pressure Fuel Sensor 4 High Pressure Line to A Bank 2 High Pressure Line to B Bank 5 Control Solenoid 3 Temperature Sensor Figure 496 Cutaway View of the High Pressure Pump All information subject to change without notice C 666 Copyright DETROIT DIESEL CORPORATION ...

Page 813: ...SERIES 4000 12 16V SERVICE MANUAL C 073 05 02 SPECIAL TOOLS Not applicable All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 667 ...

Page 814: ...ove low pressure fuel lines Refer to section C 083 05 05 1 2 3 Remove high pressure fuel lines Refer to section C 083 05 05 1 2 3 Disconnect DDEC Harness Refer to section C 501 05 M 1 2 3 Remove high pressure sensor if necessary Refer to section C 077 05 05 1 2 3 Remove temperature sensor if necessary 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely di...

Page 815: ...iver may not be possible Refer to section C 081 05 05 To avoid personal injury when working on the fuel system do not smoke use open flame or electrical equipment Diesel fuel is a combustible fluid Risk of a fire from sparks is probable Perform maintenance in a well ventilated work area with access to a fire extinguisher 1 Disconnect DDEC Harness connection for solenoid controller at connection Se...

Page 816: ... Sensor 2 DDEC Harness Connector to Controller Solenoid Figure 497 Loosening High Pressure Line Right Side on High Pressure Fuel Pump and Rail 2 Remove DDEC harness connection to temperature sensor See Figure 498 All information subject to change without notice C 670 Copyright DETROIT DIESEL CORPORATION ...

Page 817: ...re Pump Controller Figure 498 Removing DDEC Harness 3 Disconnect low pressure fuel sensor DDEC harness from sensor 4 Remove high pressure line 1 B bank 5 Remove fuel supply 3 and return lines 4 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 671 ...

Page 818: ...e line 1 A bank See Figure 499 1 High Pressure Line A Bank 3 Fuel Supply 2 Pipe Half Clamp 4 Fuel Return Figure 499 Removing High Pressure Line A Bank between High Pressure Pump and Rail All information subject to change without notice C 672 Copyright DETROIT DIESEL CORPORATION ...

Page 819: ...operator procedures 7 Attach high pressure pump 1 with a lifting device to a hoist and remove the attaching Allen head bolts 2 See Figure 500 1 High Pressure Pump 2 Hex Bolt Figure 500 Attaching High Pressure Pump to Lifting Device and Removing Bolts 8 If necessary cover opening in gear case All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 673 ...

Page 820: ...ing 2 Drive Adaptor Figure 501 Removing O ring Drive 10 Remove drive adaptor NOTE When replacing high pressure fuel pump note that replacement pump is delivered without drive adaptor All information subject to change without notice C 674 Copyright DETROIT DIESEL CORPORATION ...

Page 821: ...SURE FUEL PUMP No provision is made for disassembling the high pressure pump on site High pressure pumps are serviced only as an assembly by your authorized Detroit Diesel Distributor All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 675 ...

Page 822: ...inspect condition of threads on high pressure pump for perfect condition and ease of movement a If threads on high pressure pump are worn or damaged or do not show ease of movement rechase threads b If threads on high pressure pump are not worn or damaged and show ease of movement continue inspection 5 Visually inspect drive gear a If drive gear is worn or damaged replace as necessary b If drive g...

Page 823: ... contaminated with oil and fuel discharge continue inspection Figure 502 Visually Inspecting Weep Hole for Oil and Fuel Discharge 8 Replace O ring after each removal All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 677 ...

Page 824: ...r installation of the high pressure fuel pump 1 Coat thread of drive adaptor 1 with Loctite 270 See Figure 503 1 Drive Adaptor Figure 503 Coating Thread of Driver with Loctite 270 2 Screw driver 2 into pump shaft 3 See Figure 504 All information subject to change without notice C 678 Copyright DETROIT DIESEL CORPORATION ...

Page 825: ...504 Screwing Driver into Pump Shaft 3 Coat O ring 1 with petroleum jelly and install on high pressure pump NOTE Ensure that pump drive gear is in its outer most position toward end of shaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 679 ...

Page 826: ...k sealing surface 1 in support bore of gear case See Figure 505 1 Sealing Surface Figure 505 Cleaning and Checking Sealing Surface in Support Bore of Gear Case All information subject to change without notice C 680 Copyright DETROIT DIESEL CORPORATION ...

Page 827: ...efully install high pressure pump 1 in gear case bore See Figure 506 1 High Pressure Pump Figure 506 Installing High Pressure Pump in Gear Case Bore All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 681 ...

Page 828: ...t and extension See Figure 507 1 High Pressure Pump 2 Allen Head Bolt Figure 507 Inserting and Torquing Allen Head Bolts 7 Torque Allen head bolts to specification Refer to section A 003 All information subject to change without notice C 682 Copyright DETROIT DIESEL CORPORATION ...

Page 829: ... lines 2 See Figure 508 1 Fuel Supply Line 3 Pipe Clamp Half 2 Fuel Return Line 4 High Pressure Line Figure 508 Installing Fuel Supply and Return Lines Removing High Pressure Line Left Side All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 683 ...

Page 830: ...ction to Temperature Sensor 2 DDEC Harness Connection to Controller Solenoid Figure 509 Connecting DDEC Harness Connection to Controller Solenoid and Temperature Sensor 10 Connect DDEC harness connection to temperature sensor 3 11 Install high pressure line 1 B bank All information subject to change without notice C 684 Copyright DETROIT DIESEL CORPORATION ...

Page 831: ...C 501 05 M 1 2 3 Connect high pressure sensor if necessary Refer to sectionC 077 05 11 1 2 3 Install temperature sensor if necessary 1 2 3 Install low pressure fuel pump Refer to sectionC 081 05 11 1 2 3 Fill fuel system prime System Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not comple...

Page 832: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 686 Copyright DETROIT DIESEL CORPORATION ...

Page 833: ...moval 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 687 ...

Page 834: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 688 Copyright DETROIT DIESEL CORPORATION ...

Page 835: ...arine high pressure fuel pump see Figure 510 1 Bolt 5 Low Pressure Fuel Transfer 2 High Pressure Fuel Pump 6 Fitting 3 O ring 7 Drive Coupling 4 Drive Adaptor Figure 510 Marine High Pressure Pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 689 ...

Page 836: ...ce Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 56 Before Removal Operations for the Marine High Pressure Fuel Pump All information subject to change without notice C 690 Copyright DETROIT DIESEL CORPORATION ...

Page 837: ...troller See Figure 511 1 High Pressure Fuel Controller 3 B33 High Pressure Fuel Temp Sensor Connector 2 High Pressure Fuel Controller Connector Figure 511 Disconnecting High Pressure Fuel Pump Wiring Harness 2 Disconnect B33 3 high pressure fuel temperature sensor wiring harness from the high pressure fuel pump 1 See Figure 511 All information subject to change without notice Copyright DETROIT DIE...

Page 838: ... from the high pressure fuel pump controller solenoid 2 See Figure 512 1 B34 Low Fuel Pressure Sensor Connector 2 High Pressure Pump Controller Solenoid Figure 512 Disconnecting Low Fuel Pressure Sensor All information subject to change without notice C 692 Copyright DETROIT DIESEL CORPORATION ...

Page 839: ...e high pressure fuel pump See Figure 513 1 F46 Fuel Leakage Monitor Sensor Connector 3 Mount Plate for Leakage Sensor Reservoir 2 Leakage Sensor 4 Fuel Reservoir Figure 513 Removing Fuel Leakage Monitor Sensor F46 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 693 ...

Page 840: ... See Figure 514 1 Mounting Bracket 4 Bolt 2 Pipe Half Clamp 5 High Pressure Fuel Line 3 Grommet 6 Mounting Bracket Figure 514 Disconnecting High Pressure Fuel Lines 12V Marine Engine All information subject to change without notice C 694 Copyright DETROIT DIESEL CORPORATION ...

Page 841: ... Disconnect low pressure fuel lines 1 See Figure 515 1 Low Pressure Fuel Line Figure 515 Disconnecting Low Pressure Fuel Lines 12V Marine Engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 695 ...

Page 842: ...the front cover See Figure 516 1 F46 Fuel Leakage Monitor Sensor Connector 3 Mount Plate for Leakage Sensor Reservoir 2 Leakage Sensor 4 Fuel Reservoir Figure 516 Removing Fuel Leakage Monitor Sensor F46 12V Marine Engine All information subject to change without notice C 696 Copyright DETROIT DIESEL CORPORATION ...

Page 843: ...lt 5 Low Pressure Fuel Transfer 2 High Pressure Fuel Pump 6 Fitting 3 O ring 7 Drive Coupling 4 Drive Adaptor Figure 517 Removing High Pressure Fuel Pump 12V Marine Engine 9 Remove O ring 3 10 Remove the high pressure fuel pump 2 11 If necessary remove the sensors All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 697 ...

Page 844: ... of movement a If threads are not in perfect condition or do not show ease of movement replace component as necessary b If threads are in perfect condition and show ease of movement continue inspection 3 Visually inspect drive gear for wear and damage a If drive gear is worn or damaged replace gear as necessary b If drive gear is not worn or damaged continue inspection 4 Visually inspect wiring fo...

Page 845: ...stall the sensors 2 Coat new O ring 3 with petroleum jelly and fit on high pressure fuel pump See Figure 518 1 Allen Head Bolt 5 Low Pressure Fuel Transfer 2 High Pressure Fuel Pump 6 Fitting 3 O ring 7 Drive Coupling 4 Drive Adaptor Figure 518 Installing High Pressure Fuel Pump 12V Marine Engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 699 ...

Page 846: ...leakage monitor sensor plate 2 and secure with four bolts Torque bolts to 25 30 N m 18 22 lb ft See Figure 519 1 F46 Fuel Leakage Monitor Sensor Connector 3 Mount Plate for Leakage Sensor Reservoir 2 Leakage Sensor 4 Fuel Reservoir Figure 519 Installing Fuel Leakage Monitor Sensor F46 12V Marine Engine All information subject to change without notice C 700 Copyright DETROIT DIESEL CORPORATION ...

Page 847: ...L 5 Connect low pressure fuel lines 1 See Figure 520 1 Low Pressure Fuel Line Figure 520 Connecting Low Pressure Fuel Lines 12V Marine Engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 701 ...

Page 848: ... See Figure 521 1 Mounting Bracket 4 Bolt 2 Pipe Half Clamp 5 High Pressure Fuel Line 3 Grommet 6 Mounting Bracket Figure 521 Connecting High Pressure Fuel Lines 12V Marine Engine All information subject to change without notice C 702 Copyright DETROIT DIESEL CORPORATION ...

Page 849: ...sure fuel pump see Figure 522 1 F46 Fuel Leakage Monitor Sensor Connector 3 Mount Plate for Leakage Sensor Reservoir 2 Leakage Sensor 4 Fuel Reservoir Figure 522 Installing Fuel Leakage Monitor Sensor F46 12V Marine Engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 703 ...

Page 850: ...s 1 to the high pressure fuel pump controller solenoid 2 See Figure 523 1 B34 Low Fuel Pressure Sensor Connector 2 High Pressure Pump Controller Solenoid Figure 523 Connecting Low Fuel Pressure Sensor All information subject to change without notice C 704 Copyright DETROIT DIESEL CORPORATION ...

Page 851: ...essure Fuel Temp Sensor Connector 2 High Pressure Fuel Controller Connector Figure 524 Connecting Marine High Pressure Pump Wiring Harness 10 Connect the 8W wiring harness 2 from the high pressure fuel pump 1 11 Verify repair or replacement of the high pressure fuel pump 12 Prime fuel system See Operators Guide All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C...

Page 852: ...nce 1 2 3 Prime engine Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 57 After Installation Operations for the Marine High Pressure Fuel Pump All information subject to change without notice C 706 Copyright DETROIT DIESEL...

Page 853: ...s 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 707 ...

Page 854: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 708 Copyright DETROIT DIESEL CORPORATION ...

Page 855: ...VIEW See Figure 525 for a general view of the injector 1 Injector Hold Down Clamp 3 Injector 2 Injector Hold Down Clamp Bolt Figure 525 General View of the Injector All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 709 ...

Page 856: ...he special tools required for maintenance on the injector Application Number Ring wrench insert for injection line Removal tool for injector Installation tool for injector Table 58 Special Tools All information subject to change without notice C 710 Copyright DETROIT DIESEL CORPORATION ...

Page 857: ...fer to Operators Guide 1 2 3 Remove rocker cover Refer to section C 056 05 05 1 2 3 Remove high pressure fuel line Refer to section C 083 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 59 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL COR...

Page 858: ...high pressure fuel jumper line replace line 4 Tighten left hand threaded retainer nuts at each end of high pressure fuel jumper line Properly protect seating areas on both ends of high pressure line from damage while removing 5 Remove flow limiter valve inspect and clean Protect seating areas from damage 6 Protect flow limiter opening in high pressure rail from debris or damage during injector rep...

Page 859: ...nch to break bolt torque and note breaking torque Remove bolt from hold down clamp and take off hold down clamp See Figure 527 Figure 527 Removing Hold Down Clamp All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 713 ...

Page 860: ...r removal tool 1 on injector and loosen injector 2 from the bore See Figure 528 1 Injector Removal Tool J 42732 2 Injector Figure 528 Removing Injector from Bore All information subject to change without notice C 714 Copyright DETROIT DIESEL CORPORATION ...

Page 861: ...ctor 3 See Figure 529 1 CE Ring 3 Injector 2 O ring Figure 529 Removing O ring and C E Ring from Injector NOTE After removing injector ensure that no C E support ring remains in bore for injector in cylinder head All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 715 ...

Page 862: ... MANUAL C 075 05 06 DISASSEMBLY OF THE INJECTOR Injectors are serviced only as an assembly by your authorized Detroit Diesel Distributor All information subject to change without notice C 716 Copyright DETROIT DIESEL CORPORATION ...

Page 863: ...y cloth or oilstone b If rubbing down with emery cloth or oilstone does not remove wear or damage replace hold down clamp as necessary c If mating surfaces of hold down clamp are not worn or damaged continue inspection 5 Visually inspect injector O ring surface of injector in cylinder head for wear or damage a If O ring sealing or cylinder head surface of injector is worn or damaged rub down with ...

Page 864: ...E MANUAL C 075 05 10 ASSEMBLY OF THE INJECTOR Injectors are serviced only as an assembly by your authorized Detroit Diesel Distributor All information subject to change without notice C 718 Copyright DETROIT DIESEL CORPORATION ...

Page 865: ...lly and install on injector See Figure 530 1 O ring 2 C E Ring Figure 530 Installing O rings and CE Support Rings on Injector 2 Affix new C E ring with grease on mating surface of injector tip NOTE Ensure that C E support ring is correctly fitted and seated on injector See Figure 531 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 719 ...

Page 866: ... Sealing Surface of C E Ring Figure 531 CE Ring NOTE Ensure that fuel lines and rails are perfectly clean Prior to installation remove all protective covers All information subject to change without notice C 720 Copyright DETROIT DIESEL CORPORATION ...

Page 867: ... injury when barring the engine over stand clear so that the crankshaft will not unexpectedly rotate and cause loss of control of barring tool 3 bar engine several times to blow out any remaining fuel 4 Inspect sealing surface on cylinder head and injector hole tube a Clean sealing surface on cylinder head or hole tube if necessary b If sealing surface on cylinder head or hole tube does not requir...

Page 868: ...o Cylinder Head 6 Using firm pressure press injector 1 into cylinder head 7 Place hold down clamp in position on injector 8 Install injector hold down bolt finger tight for installation of the high pressure fuel line NOTE Hex bolt of hold down clamp is not fully tightened until high pressure line is installed Refer to sectionC 077 05 11 All information subject to change without notice C 722 Copyri...

Page 869: ...il 11 Install high pressure jumper line 4 at injector 2 and connector flow limiting valve 1 NOTE The high pressure jumper line must not be bent Ensure that the installation position is correct NOTE For ease of installation connect both ends of high pressure jumper line before tightening 12 If connector at injector end will not align and start thread engagement re inspect injector C E ring and seat...

Page 870: ...ld down clamp with torque wrench to specification Refer to sectionA 003 See Figure 534 NOTE Use engine oil as lubricant Figure 534 Tightening Bolt of Injector Hold down Clamp All information subject to change without notice C 724 Copyright DETROIT DIESEL CORPORATION ...

Page 871: ... section A 003 See Figure 535 NOTE Use engine oil as lubricant NOTE The high pressure jumper line must not be bent Ensure that the installation position is correct 1 Flow Limiting Valve Connector 2 Injector Figure 535 Tightening Threaded Connection of High Pressure Jumper Line at Injector All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 725 ...

Page 872: ...and tighten Care should be taken not to overtighten Refer to section A 003 See Figure 536 1 Flow Limiting Valve Connector 2 Injector Figure 536 Installing DDEC Injector Harness Terminals under Bolts on Injector Solenoid All information subject to change without notice C 726 Copyright DETROIT DIESEL CORPORATION ...

Page 873: ... Line 3 Cylinder Head 2 Fuel Return Rail Figure 537 Attaching Fuel Return Line Between Cylinder Head and Fuel Return Rail 17 Open fuel supply to engine Prime fuel system Refer to Operators Guide 18 Release engine start 19 Inspect for leaks All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 727 ...

Page 874: ...n C 083 05 11 1 2 3 Install cylinder head cover Refer to section C 056 05 11 1 2 3 Prime engine Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 60 After Installation Operations All information subject to change without not...

Page 875: ...77 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 729 ...

Page 876: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 730 Copyright DETROIT DIESEL CORPORATION ...

Page 877: ...he high pressure rails and lines 1 Mounting Bracket 4 Bolt 2 Pipe Half Clamp 5 High Pressure Fuel Line 3 Grommet 6 Mounting Bracket Figure 538 General View of High Pressure Lines from the High Pressure Rails All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 731 ...

Page 878: ...alve 2 O ring 9 High Pressure Rail 3 Plug in Pipe Marine and HydroFrac only 10 High Pressure Jumper Line 4 Thrust Bolt 11 Sealing Ring 5 Washer 12 Plug 6 Thrust Pad 13 Fuel Flow Limiting Valve 7 Connector 14 Hex Bolt Figure 539 General View of High Pressure Rail and Related Parts All information subject to change without notice C 732 Copyright DETROIT DIESEL CORPORATION ...

Page 879: ...Hydro Frac only 4 Plug in Pipe Marine and Hydro Frac only 12 Drain Plug Marine and Hydro Frac only 5 Plug in Pipe Marine and Hydro Frac only 13 High Pressure Rail 6 Sealing Ring 14 Thrust Pad 7 Fuel Line 15 Washer 8 Banjo Bolt 16 Plug in Pipe Marine and Hydro Frac only Figure 540 General View of High Pressure Rail Left Engine Side All information subject to change without notice Copyright DETROIT ...

Page 880: ...ector 10 Washer Drain Plug 3 O ring 11 Hex Bolt Drain Plug 4 High Pressure Rail 12 Thrust Pad 5 High Pressure Fuel Line 13 Thrust Bolt 6 Thrust Pad 14 Cover 7 Plug in Pipe Marine and Hydro Frac only 15 Plug in Pipe 8 Thrust Bolt Figure 541 General View of High Pressure Rail B Bank All information subject to change without notice C 734 Copyright DETROIT DIESEL CORPORATION ...

Page 881: ...required for the maintenance on the high pressure rails and lines Application Designation Number Retaining device for installing rail Ring insert for high pressure fuel line Alignment tool Table 61 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 735 ...

Page 882: ...e charge air manifolds Refer to section C 124 05 05 1 2 3 Remove rocker cover Refer to section C 056 05 05 1 2 3 Remove part of fuel return line to drain fuel from rails Refer to section C 083 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 62 Before Removal Operations All information subjec...

Page 883: ...ICE MANUAL C 077 05 05 REMOVAL OF THE HIGH PRESSURE FUEL RAILS Perform the following steps for the removal of the high pressure rails All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 737 ...

Page 884: ...o relieve fuel pressure from high pressure rails See Figure 542 2 To remove high pressure line between high pressure pump and high pressure rail remove pipe clamp half 2 1 High Pressure Line A Bank 3 Low Pressure Fuel Supply Line 2 Pipe Half Clamp 4 High Pressure Pump Fuel Return Line Figure 542 Removing High Pressure Line Between High Pressure Pump and High Pressure Rail 3 Unscrew and remove high...

Page 885: ...rail See Figure 543 1 High Pressure Line B Bank 3 DDEC Harness Connection to Temperature Sensor 2 DDEC Harness Connector to Controller Solenoid Figure 543 Loosening High Pressure Line B Bank on High Pressure Pump and Rail All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 739 ...

Page 886: ...gure 544 Loosening Pipe Clamp Halves of High Pressure Line Right Side NOTE When replacing an individual high pressure injector jumper line on an engine that is not disassembled it is not necessary to release the hold down clamps or to remove the high pressure rail All information subject to change without notice C 740 Copyright DETROIT DIESEL CORPORATION ...

Page 887: ...on injector side See Figure 545 Figure 545 Removing Injector High pressure Jumper Lines NOTE The pressure in the high pressure system is reduced automatically However it is advisable to open the high pressure system carefully All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 741 ...

Page 888: ... high pressure rail connector and remove high pressure fuel lines See Figure 546 Figure 546 Loosening High pressure Fuel Jumper Lines between Injector and High pressure Rail 8 Remove O rings All information subject to change without notice C 742 Copyright DETROIT DIESEL CORPORATION ...

Page 889: ...e on A bank high pressure rail flywheel end See Figure 547 1 Fuel Return Line Fuel Relief Line 2 High pressure Rail Relief Valve Figure 547 Removing Fuel Relief Line on High Pressure Rail Flywheel End All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 743 ...

Page 890: ...iting valves 1 from high pressure rail connectors See Figure 548 1 Flow Limiting Valve Figure 548 Removing Flow Limiting Valves from High pressure Rail Connectors All information subject to change without notice C 744 Copyright DETROIT DIESEL CORPORATION ...

Page 891: ... Bolts from Cylinder Block 12 Remove plug in pipes 13 Remove connector from high pressure rails 14 Remove O rings from connectors 15 Remove protective covers Marine and Hydro Frac only 16 Clean exterior of rails thoroughly NOTE Sand rails to remove corrosion and pain if necessary All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 745 ...

Page 892: ...o disassemble high pressure rail use special tool J 42731 to clamp high pressure rail in vise See Figure 550 Figure 550 Clamping High Pressure Rail in Vise 2 Remove thrust bolts See Figure 551 All information subject to change without notice C 746 Copyright DETROIT DIESEL CORPORATION ...

Page 893: ...ICE MANUAL Figure 551 Removing Thrust Bolts Thrust Pad and Pressure Relief Valve 3 Remove thrust ring from thrust pad See Figure 552 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 747 ...

Page 894: ...ICE MANUAL 1 Thrust Ring 2 Thrust Pad Figure 552 Removing Thrust Ring from Thrust Pad 4 Remove O ring from thrust pad See Figure 553 All information subject to change without notice C 748 Copyright DETROIT DIESEL CORPORATION ...

Page 895: ...00 12 16V SERVICE MANUAL 1 O ring 3 Thrust Pad 2 Thrust Bolt Figure 553 Removing O ring and Thrust Bolt from Thrust Pad All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 749 ...

Page 896: ...damaged continue inspection 5 Visually inspect sealing taper of high pressure rail for wear and damage a If sealing taper of high pressure rail is worn or damaged replace component as necessary b If sealing taper of high pressure rail is not worn or damaged continue inspection 6 Using the magnetic crack testing method with fluorescent magnetic powder inspect high pressure rail for cracks a If high...

Page 897: ...rails 1 Install thrust ring on thrust pad See Figure 554 1 Thrust Ring 2 Thrust Pad Figure 554 Installing Thrust Ring on Thrust Pad NOTE Ensure that thrust pads are provided with through bore 2 Coat cone area of the thrust pad with grease See Figure 555 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 751 ...

Page 898: ...5 Coating Cone Area of Thrust Pad with Grease 3 Coat thread of the thrust bolt with oil See Figure 556 Figure 556 Coating Thread of Thrust Bolt with Oil All information subject to change without notice C 752 Copyright DETROIT DIESEL CORPORATION ...

Page 899: ...ly and install on thrust pad See Figure 557 1 O ring 3 Thrust Pad 2 Thrust Bolt Figure 557 Installing O ring and Thrust Bolt onto Thrust Pad 5 Slide thrust ring onto thrust pad All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 753 ...

Page 900: ...Pressure Rail B Bank 7 Insert prepared thrust pad in the bore 8 Install thrust bolt and tighten to specification Refer to section A 003 9 Install pressure relief valve in opposite end bore of high pressure rail 10 Install thrust bolt and tighten to specification Refer to section A 003 All information subject to change without notice C 754 Copyright DETROIT DIESEL CORPORATION ...

Page 901: ...re 559 Figure 559 Preassembling High Pressure Rail A Bank 12 Install prepared thrust pad in the bore 13 Install thrust bolt and tighten to specification Refer to section A 003 14 Install seal in opposite end bore of high pressure rail All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 755 ...

Page 902: ...ction A 003 16 To prepare connectors for marine or Hydro Frac coat O rings with petroleum jelly and insert in grooves on connector See Figure 560 1 O ring Figure 560 Inserting O ring in Grooves on Connector All information subject to change without notice C 756 Copyright DETROIT DIESEL CORPORATION ...

Page 903: ...nd Connectors to Cylinder Block 2 Install connectors and plug in pipes together in alternating sequence 3 Install protective covers over O rings on the connectors NOTE Ensure that mating surface of connector is correctly positioned with regard to cylinder block corresponding to left or right engine side 4 To secure connector on cylinder block install hex bolts in first and last connector on each e...

Page 904: ...ssembled connector and plug in pipe assembly See Figure 562 Figure 562 Inserting High Pressure Rail in Connector and Plug In Pipe NOTE Ensure that high pressure rail is correctly positioned All information subject to change without notice C 758 Copyright DETROIT DIESEL CORPORATION ...

Page 905: ...ngine side See Figure 563 1 Alignment Tool Figure 563 Positioning Alignment Tools in Tightened Connectors 8 Align high pressure rail until alignment tool taper is centered in bore of high pressure rail 9 Carefully tighten alignment tool All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 759 ...

Page 906: ...t openings of all connectors in which no alignment tool is installed See Figure 564 1 Flow Limiting Valve Figure 564 Installing Flow Limiting Valve in Outlet Openings of all Connectors All information subject to change without notice C 760 Copyright DETROIT DIESEL CORPORATION ...

Page 907: ... and then loosen to allow proper alignment of high pressure lines See Figure 565 Refer to sectionC 077 05 11 1 Injector 2 Injector Crab Figure 565 Pretightening Injectors All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 761 ...

Page 908: ...6 Figure 566 Pretightening and then Loosening Line at Injectors 13 Tighten on injector side to specification Refer to section A 003 NOTE Tighten only high pressure fuel lines on which flow limiting valves have already been installed All information subject to change without notice C 762 Copyright DETROIT DIESEL CORPORATION ...

Page 909: ...Figure 567 Installing High Pressure Fuel Lines between Injector and High Pressure Rail 15 Install all hex bolts securing connector to cylinder block See Figure 568 Figure 568 Installing Plug In Pipes and Connectors from Cylinder Block All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 763 ...

Page 910: ... injectors to high pressure lines that are fitted to specification Refer to sectionA 003 See Figure 569 Figure 569 Tightening High Pressure Line Injectors All information subject to change without notice C 764 Copyright DETROIT DIESEL CORPORATION ...

Page 911: ...ctor on injector side to specification Refer to section A 003 See Figure 570 Figure 570 Installing Injection Lines NOTE Tighten only high pressure fuel lines on which flow limiting valves have already been installed All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 765 ...

Page 912: ...e to specification Refer to section A 003 See Figure 571 Figure 571 Tightening High Pressure Fuel Lines between Injector and High Pressure Rail NOTE Tighten only high pressure fuel lines on which flow limiting valves have already been installed All information subject to change without notice C 766 Copyright DETROIT DIESEL CORPORATION ...

Page 913: ...ng high pressure fuel lines between high pressure rail and injector 22 Tighten injectors to high pressure lines that are fitted to specification Refer to sectionA 003 23 Tighten all high pressure fuel lines on injector side to specification Refer to section A 003 24 Tighten all high pressure fuel lines on high pressure rail side to specification Refer to section A 003 All information subject to ch...

Page 914: ... pressure rail of B bank See Figure 573 1 Plug in Pipe Figure 573 Installing Thrust Bolt at End of B Bank Flywheel End 26 Install thrust bolt at flywheel end of high pressure rail of A bank All information subject to change without notice C 768 Copyright DETROIT DIESEL CORPORATION ...

Page 915: ...olts securing connector to cylinder block to specification Refer to sectionA 003 See Figure 574 Figure 574 Tightening Hex Bolts Securing Connector to Cylinder Block All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 769 ...

Page 916: ...See Figure 575 1 Fuel Return Line Fuel Relief Line 2 High Pressure Rail Relief Valve Figure 575 Installing Plug In Pipe End Section and Fuel Return Line 29 Install fuel return line 1 on high pressure rail of A bank end All information subject to change without notice C 770 Copyright DETROIT DIESEL CORPORATION ...

Page 917: ...essure Fuel Supply Line 2 Pipe Half Clamp 4 High Pressure Pump Fuel Return Line Figure 576 Installing High Pressure Line between High Pressure Pump and High Pressure Rail 31 Fully tighten high pressure fuel line 1 left side on high pressure pump and high pressure rail to specification Refer to section A 003 32 Install pipe clamp half 2 All information subject to change without notice Copyright DET...

Page 918: ...ne 3 Temperature Sensor 2 DDEC Harness Connector to Controller Solenoid B bank Figure 577 Installing High Pressure Line B Bank on High Pressure Pump and Rail 34 Tighten high pressure fuel line 1 B bank on high pressure pump and high pressure rail to specification Refer to section A 003 All information subject to change without notice C 772 Copyright DETROIT DIESEL CORPORATION ...

Page 919: ...p halves 1 of high pressure line 2 B bank See Figure 578 1 Pipe Clamp Half 2 High Pressure Line Figure 578 Installing Pipe Clamp Halves of High Pressure Line B Bank All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 773 ...

Page 920: ... 579 Leak Checking Common Rail System To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 37 Install high pressure line and apply pressure to system 38 Check all threaded connections in system for leaks All information subject to change without notice C 774 Copyright DETROIT DIESEL CORPORATION ...

Page 921: ... tighten to specification Refer to sectionA 003 See Figure 580 1 High Pressure Fuel Sensor 4 High Pressure Line to A Bank Side 2 High Pressure Line to B Bank Side 5 Control Solenoid 3 Temperature Sensor Figure 580 Installing High Pressure Sensor to High Pressure Pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 775 ...

Page 922: ...arge air manifolds Refer to sectionC 124 05 11 1 2 3 Install fuel return line if necessary Refer to sectionC 083 05 11 1 2 3 Fill fuel system Refer to Operators Guide 1 2 3 Prime system Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain inst...

Page 923: ...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...

Page 924: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 778 Copyright DETROIT DIESEL CORPORATION ...

Page 925: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 779 ...

Page 926: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 780 Copyright DETROIT DIESEL CORPORATION ...

Page 927: ...ENERAL VIEW See Figure 581 for a general view of the fuel pump assembly 1 O ring 3 Fuel Pump 2 Drive Adaptor 4 Socket Head Bolt Figure 581 Fuel Pump Assembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 781 ...

Page 928: ...e 1 2 3 Remove charge air manifold Refer to section C 124 05 05 1 2 3 Remove fuel supply line Refer to section C 083 05 05 1 2 3 Remove plug in pipes Refer to section C 083 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 64 Before Removal Operations All information subject to change without ...

Page 929: ...r electrical equipment Diesel fuel is a combustible fluid Risk of a fire from sparks is probable Perform maintenance in a well ventilated work area with access to a fire extinguisher 1 Remove Allen head bolts 1 See Figure 582 1 Allen Head Bolt Figure 582 Removing Allen Head Bolts 2 Remove fuel delivery pump 1 from gear case See Figure 583 All information subject to change without notice Copyright ...

Page 930: ...ing 2 Coupling Figure 583 Removing Fuel Delivery Pump 3 Remove coupling 2 from the drive shaft of the fuel delivery pump 1 See Figure 583 4 Remove O ring 3 See Figure 583 All information subject to change without notice C 784 Copyright DETROIT DIESEL CORPORATION ...

Page 931: ...1 05 06 DISASSEMBLY OF LOW PRESSURE FUEL PUMP Low pressure fuel pumps are serviced only as an assembly by your authorized Detroit Diesel Distributor All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 785 ...

Page 932: ...y b If bolts are not damaged or worn continue inspection 3 Inspect threads of securing bolts for ease of movement a If bolt threads do not show ease of movement replace bolts as necessary b If bolt threads show ease of movement continue inspection 4 Visually inspect coupling for wear and damage a If coupling is worn or damaged replace coupling element b If coupling is not worn or damaged continue ...

Page 933: ...81 05 10 ASSEMBLY OF LOW PRESSURE FUEL PUMP Low pressure fuel pumps are serviced only as an assembly by your authorized Detroit Diesel Distributor All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 787 ...

Page 934: ...an 1 Coat O ring 3 with petroleum jelly and install onto fuel delivery pump 1 See Figure 584 1 Fuel Delivery Pump 3 O ring 2 Coupling Figure 584 Installing Low Pressure Fuel Pump 2 Install coupling 2 onto driver of high pressure pump See Figure 584 3 Install high pressure pump driver into the coupling 2 See Figure 584 All information subject to change without notice C 788 Copyright DETROIT DIESEL ...

Page 935: ... withdraw the pump and check the position of the driver with regard to the coupling 5 Secure with Allen head bolts and torque socket head bolts 1 to specification Refer to sectionA 003 See Figure 585 1 Allen Head Bolts Figure 585 Installation of Allen Head Bolts All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 789 ...

Page 936: ...ration Reference 1 2 3 Enable engine power Refer to Operators Guide 1 2 3 Vent fuel system Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 65 After Installation Operations All information subject to change without notice C 790 Copyright DETROIT DIESEL CORPORATION ...

Page 937: ...3 05 05 Removal of Fuel Filter C 796 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 791 ...

Page 938: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 792 Copyright DETROIT DIESEL CORPORATION ...

Page 939: ...See Figure 586 for a general view of the fuel lines 1 Fuel Return Line Figure 586 General View of Fuel Lines See Figure 587 for general view of the fuel line components All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 793 ...

Page 940: ...ex Bolt 13 Pressure Regulator 2 bar 4 Adaptor 14 Valve 1 7 bar 5 Bolt 15 Connector 6 Plug in Pipe 16 Fuel Line 7 O ring 17 Fuel Hose 8 Flange 18 Valve 0 1 bar 9 Nut 19 Bracket 10 Stud Figure 587 Fuel Line Components All information subject to change without notice C 794 Copyright DETROIT DIESEL CORPORATION ...

Page 941: ...3 Remove charge air manifold Refer to section C 124 05 05 1 2 3 Remove fuel supply line Refer to section C 083 05 05 1 2 3 Remove plug in pipes Refer to section C 083 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 66 Before Removal Operations All information subject to change without notice...

Page 942: ...ted work area with access to a fire extinguisher Perform the following steps to remove fuel filter 1 Remove fuel line bracket 1 See Figure 588 1 Bracket 3 Fuel Line at ECM 2 Fuel Lines Figure 588 Removing Fuel Lines at Fuel Distribution Housing and ECM NOTE When releasing the threaded connections of the fuel lines catch any fuel that emerges in suitable containers 2 Remove the fuel line 3 at ECM A...

Page 943: ...2 and O rings See Figure 589 1 Fuel Filter 3 Hex Bolt 2 Plug in Pipes Figure 589 Removing Plug In Pipes and O rings 4 Remove hex bolts 3 and flanges 5 Remove fuel filter 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 797 ...

Page 944: ...UAL 6 Remove nuts 1 and hex bolts 2 See Figure 590 1 Nut 2 Hex Bolt Figure 590 Removing Nuts and Hex Bolts and Removing Fuel Junction Block All information subject to change without notice C 798 Copyright DETROIT DIESEL CORPORATION ...

Page 945: ...only if necessary See Figure 591 1 Studs Figure 591 Removing Studs 8 Install nut on stud and lock with locknut 9 Remove stud 10 Install a protective cover over inspection hole in cylinder block All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 799 ...

Page 946: ...lter head 1 from junction block 3 See Figure 592 1 Filter Head 3 Junction Block 2 Hex Bolt Figure 592 Removing Hex Bolts and Separating Filter Head from Junction Block 2 Remove the blanking plug 4 and threaded connection 3 from filter head 1 and junction block 2 See Figure 593 All information subject to change without notice C 800 Copyright DETROIT DIESEL CORPORATION ...

Page 947: ...ng Plug Figure 593 Removing Blanking Plug and Threaded Connection from Filter Head and Junction Block 3 Remove pressure regulator valve from bore on junction block 4 Remove delivery valve from filter base All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 801 ...

Page 948: ...ck Figure 594 Examining All Channels with Cold Light Source NOTE Ensure fuel carrying components are perfectly clean 2 Clean fuel line with cleaner 3 Visually inspect fuel line for general condition and damage a If fuel line is in poor condition or is damaged replace fuel line as necessary b If fuel line is in good condition and is not damaged continue inspection All information subject to change ...

Page 949: ... single ended adaptors do not show ease of movement recondition or replace parts as necessary b If threads of adaptor nuts and single ended adaptors show ease of movement continue inspection 11 Inspect securing bolts for general condition and bolt threads for ease of movement a If securing bolts are not in good condition or threads do not show ease of movement replace bolts as necessary b If secur...

Page 950: ... If sealing tapers are damaged or indented replace as necessary b If sealing tapers are not damaged or indented continue inspection 15 Replace sealing rings 16 Replace hose lines as part of every W6 overhaul All information subject to change without notice C 804 Copyright DETROIT DIESEL CORPORATION ...

Page 951: ...95 Installing Blanking Plug and Threaded Connection into Filter Head or Junction Block 2 Install blanking plug 6 and threaded connection 3 into filter head 1 and junction block 2 3 Tighten to specification Refer to section A 003 4 Install delivery valve into filter base 5 Tighten to specification Refer to section A 003 6 Coat O rings 5 with petroleum jelly and install in filter head 1 7 Coat O rin...

Page 952: ...1 Filter Head 3 Junction Block 2 Hex Bolt Figure 596 Installing Hex Bolts and Filter Head onto Junction Block 9 Install hex bolts 2 tighten diagonally and evenly to specification Refer to section A 003 All information subject to change without notice C 806 Copyright DETROIT DIESEL CORPORATION ...

Page 953: ...See Figure 597 1 Studs Figure 597 Cylinder Block Studs 1 Remove protective cover over inspection hole in cylinder block 2 Install nut on stud and lock with locknut 3 Rotate stud 1 into cylinder block as far as it will go 4 Tighten studs to specification Refer to section A 003 5 Remove nut and locknut All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 807 ...

Page 954: ...tall fuel junction block onto studs on cylinder block See Figure 598 1 Nut 2 Hex Bolt Figure 598 Installing Fuel Junction Block 7 Install hex bolts 2 All information subject to change without notice C 808 Copyright DETROIT DIESEL CORPORATION ...

Page 955: ...L 8 Tighten nuts and hex bolts to specification Refer to section A 003 9 Install fuel filter See Figure 599 Figure 599 Installing Fuel Filter All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 809 ...

Page 956: ...ine start Refer to Operators Guide 1 2 3 Prime fuel system Refer to Operators Guide 1 2 3 Vent fuel system Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 67 After Installation Operations All information subject to change ...

Page 957: ...l 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 811 ...

Page 958: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 812 Copyright DETROIT DIESEL CORPORATION ...

Page 959: ...el filters and bracket assembly see Figure 600 1 Plug 5 Mounting Bracket 2 Fuel Filter 6 Collecting Trough 3 Washer 7 Sealing Ring 4 Bolt Figure 600 Fuel Filters and Bracket Assembly 12V Marine Engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 813 ...

Page 960: ...nance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 68 Before Removal Operations for the Marine Fuel Filter Bracket All information subject to change without notice C 814 Copyright DETROIT DIESEL CORPORATION ...

Page 961: ...l lines drain into a suitable container 2 Disconnect the fuel lines See Figure 601 1 Low Pressure Fuel Line Figure 601 Disconnecting Low Pressure Fuel Supply Line from the Filter to the Injection Pump 12V Marine Engine 3 Remove fuel filters and dispose of them in accordance with local specifications All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 815 ...

Page 962: ...ar coolant plate See Figure 602 1 80 mm Bolts 2 30 mm Bolts Figure 602 Removing Marine Filter Bracket Bolts 5 Remove two 30 mm bolts 2 securing the bracket to the front cover 6 Remove the fuel bracket assembly All information subject to change without notice C 816 Copyright DETROIT DIESEL CORPORATION ...

Page 963: ...ow drying parts wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 2 Clean all components with compressed air 3 Visually inspect all components for damage and defects a If components are damaged or defective replace as necessary b If components are not damaged or defective proceed to installation All information subject to change without noti...

Page 964: ...mm bolts 2 securing the bracket to the front cover See Figure 603 1 80 mm Bolts 2 30 mm Bolts Figure 603 Marine Filter Bracket Bolts 3 Tighten bolts to specification Refer to section A 003 4 Install two 80 mm bolts 1 securing the bracket assembly to the rear coolant plate 5 Tighten bolts to specification Refer to section A 003 All information subject to change without notice C 818 Copyright DETROI...

Page 965: ... Connect the fuel lines See Figure 604 1 Low Pressure Fuel Line Figure 604 Connecting Low Pressure Fuel Supply Line from the Filter to the Injection Pump 12V Marine Engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 819 ...

Page 966: ...e Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 69 After Installation Operations for Marine Fuel Filter and Bracket All information subject to change without notice C 820 Copyright DETROIT DIESEL CORPORATION ...

Page 967: ...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 All information subject to change without notice Copyright DETROIT DIESE...

Page 968: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 822 Copyright DETROIT DIESEL CORPORATION ...

Page 969: ... 1 Fuel Return Line 6 Banjo Bolt 2 Fuel Return Rail 7 Pipe Half Clamp 3 Sealing Ring 8 Hex Bolt 4 Adaptor 9 T piece 5 Fuel Return Line Figure 605 Return Rails and Lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 823 ...

Page 970: ...SERIES 4000 12 16V SERVICE MANUAL C 086 05 02 SPECIAL TOOLS Not applicable All information subject to change without notice C 824 Copyright DETROIT DIESEL CORPORATION ...

Page 971: ...e 1 2 3 Remove charge air manifold Refer to section C 124 05 05 1 2 3 Remove fuel supply line Refer to section C 083 05 05 1 2 3 Remove plug in pipes Refer to section C 083 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 70 Before Removal Operations All information subject to change without ...

Page 972: ...e fluid Risk of a fire from sparks is probable Perform maintenance in a well ventilated work area with access to a fire extinguisher NOTE When removing the fuel lines catch any fuel that emerges in suitable containers 1 Remove fuel return line 1 See Figure 606 1 Fuel Return Line Figure 606 Removing Fuel Return Line High Pressure Pump Body to Junction Block 2 Remove adaptor nut 1 See Figure 607 All...

Page 973: ...1 Adaptor Nut 2 Fuel Return Rail Figure 607 Removing Adaptor Nut and Blanking Plug Fuel Return Rail 3 Remove blanking plug from fuel return rail All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 827 ...

Page 974: ...l return line 1 at T piece See Figure 608 1 Fuel Return Line 3 Fuel Return Rail 2 T piece Figure 608 Removing Fuel Return Line at T Piece 5 Remove T piece 2 All information subject to change without notice C 828 Copyright DETROIT DIESEL CORPORATION ...

Page 975: ... See Figure 609 1 Fuel Return Line 3 Pipe Clamp Half 2 Connecting Line Figure 609 Removing Fuel Line from Connecting Line 7 Remove fuel return line 1 at connecting element All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 829 ...

Page 976: ... pressure rail of A Bank See Figure 610 1 Fuel Return Line Fuel Relief Line 2 High pressure Rail Relief Valve Figure 610 Removing Fuel Return Line on High Pressure Rail of A Bank All information subject to change without notice C 830 Copyright DETROIT DIESEL CORPORATION ...

Page 977: ... Pipe Clamp Half 3 Fuel Return Line 2 Fuel Return Rail Figure 611 Removing Fuel Return Lines Between Cylinder Head and Fuel Return Rail 10 Remove pipe clamp halves 1 11 Release fuel collecting lines 2 at connecting points All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 831 ...

Page 978: ...00 12 16V SERVICE MANUAL C 086 05 06 DISASSEMBLY OF THE FUEL RETURN RAILS AND LINES SYSTEM This section not applicable All information subject to change without notice C 832 Copyright DETROIT DIESEL CORPORATION ...

Page 979: ...aks are found replace fuel lines as necessary b If leaks are not found continue inspection 4 Coolant temperature is 30 C minimum components must also be at this temperature 5 If component must be held in hands coolant temperature is 40 C maximum 6 Test pressure is 0 5 bar 7 Visually inspect condition of banjo bolts and threads for wear and damage a If banjo bolts or threads are worn or damaged rep...

Page 980: ...4000 12 16V SERVICE MANUAL C 086 05 10 ASSEMBLY OF THE FUEL RETURN RAILS AND LINES SYSTEM This section not applicable All information subject to change without notice C 834 Copyright DETROIT DIESEL CORPORATION ...

Page 981: ...r Head 2 Fuel Return Rail Figure 612 Installing Fuel Return Lines between Cylinder Head and Fuel Return Rail 2 Loosely install hex bolts on pipe clamp halves so that fuel collecting line can still be turned See Figure 612 3 Install fuel return lines 2 between cylinder head 1 and fuel return rail and tighten to specification Refer to section A 003 See Figure 612 4 Tighten hex bolts of pipe clamp ha...

Page 982: ...ail and install them on engine with pipe clamp half and bolt 2 See Figure 613 1 Fuel Return Line 2 Pipe Clamp Half and Bolt Figure 613 Installing Fuel Return Line at Connecting Element All information subject to change without notice C 836 Copyright DETROIT DIESEL CORPORATION ...

Page 983: ...ce 2 to fuel return line 1 and fuel return rail 3 See Figure 614 1 Fuel Return Line 3 Fuel Return Rail 2 T Piece Figure 614 Installing Fuel Return Line at T Piece All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 837 ...

Page 984: ...r Nut 2 Fuel Return Rail Figure 615 Installing Blanking Plugs and Adaptor Nuts 8 Install adaptor nut and tighten to specification Refer to section A 003 9 Install fuel return line on high pressure rail A Bank end All information subject to change without notice C 838 Copyright DETROIT DIESEL CORPORATION ...

Page 985: ...peration Reference 1 2 3 Vent fuel system Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 71 After Installation Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 839 ...

Page 986: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 840 Copyright DETROIT DIESEL CORPORATION ...

Page 987: ... 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...

Page 988: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 842 Copyright DETROIT DIESEL CORPORATION ...

Page 989: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 843 ...

Page 990: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 844 Copyright DETROIT DIESEL CORPORATION ...

Page 991: ...GENERAL VIEW See Figure 616 for a general view of the turbocharger 1 A Bank Turbocharger 2X 2 B Bank Turbocharger 2X Figure 616 General View of Turbocharger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 845 ...

Page 992: ...nt of charge air manifold on exhaust turbocharger Refer to section C 124 05 05 C 124 05 05 1 2 3 Remove oil supply lines for turbocharger Refer to section C 187 05 05 C 187 05 05 1 2 3 Remove oil return lines for turbochargers Refer to section C 188 05 05 C 188 05 05 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but ...

Page 993: ...emove turbocharger remove hex nuts 1 from flange on both turbochargers 2 See Figure 617 1 Hex Nut 3 Spacer Bushing 2 Turbocharger 4 Exhaust Manifold Figure 617 Exhaust Turbocharger 2 Remove spacer sleeves 3 NOTE Two different length of spacers are used All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 847 ...

Page 994: ...ilitate removal of exhaust outlet Y pipe from turbocharger NOTE Secure exhaust outlet Y pipe with brackets to prevent it from falling 5 Remove exhaust outlet Y pipe 6 Remove gasket from exhaust manifold turbocharger flange 7 Remove hex bolt and washer 2 from exhaust outlet Y pipe 3 and bracket 4 See Figure 618 1 Hex Nut 3 Exhaust Outlet Y pipe 2 Washer 4 Bracket Figure 618 Removing Hex Bolt and Wa...

Page 995: ...SERIES 4000 12 16V SERVICE MANUAL 8 Remove bracket 4 9 Remove piston rings from exhaust outlet Y pipe 3 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 849 ...

Page 996: ...VICE MANUAL C 101 05 06 DISASSEMBLY OF THE EXHAUST TURBOCHARGER At present no provision is made for turbocharger disassembly on site All information subject to change without notice C 850 Copyright DETROIT DIESEL CORPORATION ...

Page 997: ... 4 Visually inspect turbocharger for external damage in particular in area of turbine and compressor wheels a If turbocharger shows damage replace component as necessary b If turbocharger does not show damage continue inspection 5 Visually inspect all sealing and seating surfaces for damage and irregularities a If sealing or seating surfaces show damage or irregularities rub down with an oilstone ...

Page 998: ...SERIES 4000 12 16V SERVICE MANUAL C 101 05 10 ASSEMBLY OF TURBOCHARGER Refer to section C 101 05 06 All information subject to change without notice C 852 Copyright DETROIT DIESEL CORPORATION ...

Page 999: ...urbocharger 1 Install piston rings in groove 1 provided on exhaust outlet Y pipe See Figure 619 1 Groove Figure 619 Installing Piston Ring in Groove on Exhaust Outlet Y pipe 2 Coat outer surface of piston rings with sealing compound All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 853 ...

Page 1000: ...utlet 4 Bolt bracket 4 and Y pipe 3 together with hex bolt 1 and washer 2 Refer to section A 003 NOTE Join retainers on exhaust outlet Y pipe and bracket at central bores Final alignment on exhaust outlet Y pipe with vehicle exhaust system can be carried out after installation NOTE Secure exhaust outlet Y pipe to prevent from falling All information subject to change without notice C 854 Copyright...

Page 1001: ...registered trademark of Garlock Helicoflex a subsidiary of B F Goodrich Aerospace 5 Attach turbocharger 1 to crane and together with bracket carefully install on the studs See Figure 621 1 Turbocharger 3 Spacer Bushing 2 Hex Nut 4 Exhaust Manifold Figure 621 Tightening Turbocharger Diagonally with Hex Nuts 6 Install spacer bushings 3 and nuts 7 Tighten hex nuts 2 on the turbocharger flange diagona...

Page 1002: ...tion C 188 05 11 C 188 05 11 1 2 3 Install intermediate charge air element of manifold on exhaust turbocharger Refer to section C 124 05 11 C 124 05 11 1 2 3 Install exhaust system after exhaust outlet Y pipe Refer to section C 141 05 11 C 141 05 11 1 2 3 Install air system before exhaust turbocharger Refer to section C 101 05 11 1 The engine is to be completely disassembled 2 The engine is to be ...

Page 1003: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 857 ...

Page 1004: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 858 Copyright DETROIT DIESEL CORPORATION ...

Page 1005: ...e 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 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 859 ...

Page 1006: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 860 Copyright DETROIT DIESEL CORPORATION ...

Page 1007: ...of the turbocharger marine 1 Sealing Ring 6 Exhaust Line 2 Plug 7 Cover 3 Washer 8 O ring 4 Bolt 9 Carrier Housing 5 Carrier Housing Cover 10 Hex Nut Figure 622 General View of Turbocharger Parts Location All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 861 ...

Page 1008: ... intermediate element of charge air manifold on exhaust turbocharger Refer to section C 124 05 05 1 2 3 Remove oil supply lines for turbocharger Refer to section C 187 05 05 1 2 3 Remove oil return lines for turbochargers Refer to section C 188 05 05 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely di...

Page 1009: ...o remove the turbocharger 1 Remove the exhaust pyrometer 1 from the turbocharger housing See Figure 623 1 Exhaust Pyrometer Figure 623 Removing Exhaust Pyrometer 2 Disconnect the turbocharger oil drain line See Figure 624 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 863 ...

Page 1010: ... 3 Bolt 9 Pipe 4 Hose 10 Hex Nut 5 O ring 11 Adaptor 6 Mounting Bracket Figure 624 Removing Oil Drain and Feed Lines Marine 3 Disconnect the turbocharger oil feed lines See Figure 624 All information subject to change without notice C 864 Copyright DETROIT DIESEL CORPORATION ...

Page 1011: ...securing the exhaust bellow to the turbocharger and remove the exhaust bellow 1 See Figure 625 1 Exhaust Pipe Bellow 3 Washer 2 Bolt Figure 625 Removing Exhaust Bellows Marine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 865 ...

Page 1012: ... 626 NOTE Label bolts for length for assembly 1 Bolt 4 Left Rear Turbocharger Carrier Housing 2 Right Front Turbocharger Carrier Housing 5 Right Rear Turbocharger Carrier Housing 3 Left Front Turbocharger Carrier Housing Figure 626 Removing Left Rear Turbocharger Carrier Housing Marine All information subject to change without notice C 866 Copyright DETROIT DIESEL CORPORATION ...

Page 1013: ...Carrier Housing 8 Washer 3 Snap Ring 9 Hex Nut 10 mm 6 4 Turbine Housing 10 Hex Nut 8 mm 8 5 Stud 11 Tapered Washers 6 O ring Figure 627 Removing Turbocharger Housing O rings Marine 7 Remove eight 8 mm nuts 10 from the turbocharger compressor housing 7 See Figure 627 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 867 ...

Page 1014: ... 628 Removing Turbine Housing Marine 9 Remove two bolts 2 securing the out flange for the compressor to the turbocharger carrier housing 3 See Figure 628 10 Remove six 10 mm nuts from the turbocharger carrier housing 11 Slide the turbocharger assembly 4 forward to remove from the turbocharger carrier housing 3 See Figure 628 All information subject to change without notice C 868 Copyright DETROIT ...

Page 1015: ...ings 7 Turbocharger Compressor Housing 2 Rear Carrier Housing 8 Washer 3 Snap Ring 9 Hex Nut 10 mm 6 4 Turbine Housing 10 Hex Nut 8 mm 8 5 Stud 11 Tapered Washers 6 O ring Figure 629 Removing Turbocharger Housing O rings Marine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 869 ...

Page 1016: ...bocharger Carrier Housing 7 Crossover 4 O rings Figure 630 Removing Housing from Exhaust Manifold Marine 14 Remove four 10 mm nuts 1 securing the left turbocharger housing to the crossover 7 See Figure 630 15 Remove O rings 4 between the left turbocharger carrier housing 3 and the exhaust manifold See Figure 630 All information subject to change without notice C 870 Copyright DETROIT DIESEL CORPOR...

Page 1017: ...6 M DISASSEMBLY OF THE TURBOCHARGER MARINE Disassemble the turbocharger compressor housing as follows 1 Refer to OEM guidelines for disassembly procedures All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 871 ...

Page 1018: ...for damage in particular in the area of the turbine and compressor wheels replace the turbocharger if damage is found 4 Clean and visually check all components for damage and defects replace as necessary 5 Visually check all sealing and seating surfaces for damage and surface irregularities rub down with an oilstone or emery cloth as necessary 6 Visually check studs for damage replace studs as nec...

Page 1019: ...UAL C 101 05 10 M ASSEMBLY OF THE TURBOCHARGER MARINE Assemble the turbocharger as follows 1 Refer to OEM guidelines for assembly procedures All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 873 ...

Page 1020: ...Washer 6 Bolt 3 Left Turbocharger Carrier Housing 7 Crossover 4 O rings Figure 631 Installing Carrier Housing Components Marine 2 Coat the left turbocharger carrier housing to the crossover with Loctite adhesive sealant See Figure 631 3 Install four 10 mm nuts 1 and washers 2 to secure the left turbocharger housing 3 to the crossover 7 Torque nuts to 72 84 N m 53 62 lb ft See Figure 631 All inform...

Page 1021: ...view all manufacturer s cautionary notes 4 Install the left turbocharger carrier housing 3 to the exhaust manifold and secure with bolts 6 and washers 2 Torque bolts to 72 84 N m 53 62 lb ft See Figure 631 5 Coat the turbine housing surface with Loctite adhesive sealant All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 875 ...

Page 1022: ...7 Turbocharger Compressor Housing 2 Rear Carrier Housing 8 Washer 3 Snap Ring 9 Hex Nut 10 mm 6 4 Turbine Housing 10 Hex Nut 8 mm 8 5 Stud 11 Tapered Washers 6 O ring Figure 632 Installing Turbocharger Compressor Housing O ring Marine All information subject to change without notice C 876 Copyright DETROIT DIESEL CORPORATION ...

Page 1023: ...e lifting device see Figure 633 install the turbocharger compressor assembly 2 into the turbocharger carrier housing 1 and secure with washers 8 and nuts 9 Torque nuts to 42 N m 31 lb ft See Figure 632 1 Turbocharger Carrier Housing 2 Turbocharger Compressor Assembly Figure 633 Installing Turbocharger Compressor Assembly Marine All information subject to change without notice Copyright DETROIT DIE...

Page 1024: ...er carrier housing 3 Torque bolts to 21 24 N m 15 17 lb ft See Figure 634 1 Turbine Housing 3 Turbocharger Carrier Housing 2 Bolt 4 Turbocharger Compressor Housing Figure 634 Installing Compressor out Flange Marine All information subject to change without notice C 878 Copyright DETROIT DIESEL CORPORATION ...

Page 1025: ...rine 10 Rotate the turbine plate in clockwise direction to stopped position mark the position Turn turbine plate to the center of the marked positions See Figure 635 NOTICE Ensure that the tapered washers are positioned correctly per the installation instructions to avoid damage to the turbocharger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 879 ...

Page 1026: ...er carrier housing and secure with nuts 8 and washers 2 Torque nuts to 24 N m 18 lb ft See Figure 636 1 Nut 8 mm 3 Center Housing 2 Tapered Washers Figure 636 Installing Turbine Housing Marine All information subject to change without notice C 880 Copyright DETROIT DIESEL CORPORATION ...

Page 1027: ...1 O rings 7 Turbocharger Compressor Housing 2 Rear Carrier Housing 8 Washer 3 Snap Ring 9 Hex Nut 10 mm 6 4 Turbine Housing 10 Hex Nut 8 mm 8 5 Stud 11 Tapered Washers 6 O ring Figure 637 Installing O rings Marine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 881 ...

Page 1028: ...arrier Housing 2 Right Front Turbocharger Carrier Housing 5 Right Rear Turbocharger Carrier Housing 3 Left Front Turbocharger Carrier Housing Figure 638 Installing Turbocharger Carrier Housing Marine 14 Coat the left front turbocharger carrier housing with Loctite adhesive sealant All information subject to change without notice C 882 Copyright DETROIT DIESEL CORPORATION ...

Page 1029: ...e and review all manufacturer s cautionary notes 15 Using a suitable lifting device install the left front turbocharger carrier housing 3 to the left rear turbocharger carrier housing 4 and secure with bolts 1 Torque bolts to 42 47 N m 31 35 lb ft See Figure 638 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 883 ...

Page 1030: ...rbocharger and secure with washers 3 and bolts 2 Torque bolts to 42 47 N m 31 35 lb ft See Figure 639 1 Exhaust Pipe Bellow 3 Washer 2 Bolt Figure 639 Installing Exhaust Bellows Marine All information subject to change without notice C 884 Copyright DETROIT DIESEL CORPORATION ...

Page 1031: ... 47 N m 31 35 lb ft See Figure 640 1 Gasket 7 Pipe Clamp Half 2 Washer 8 Grommet 3 Bolt 9 Pipe 4 Hose 10 Hex Nut 5 O ring 11 Adaptor 6 Mounting Bracket Figure 640 Installing Oil Drain and Feed Lines Marine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 885 ...

Page 1032: ...e bolts to 42 47 N m 31 35 lb ft See Figure 640 19 Install the exhaust pyrometer 1 to the turbocharger housing See Figure 641 1 Exhaust Pyrometer Figure 641 Installing Exhaust Pyrometer Marine All information subject to change without notice C 886 Copyright DETROIT DIESEL CORPORATION ...

Page 1033: ...bochargers Refer to section C 188 05 11 1 2 3 Install intermediate charge air element of manifold on exhaust turbocharger Refer to section C 124 05 11 1 2 3 Install exhaust system after Y pipe Refer to section C 141 05 11 1 2 3 Install air system before exhaust turbocharger Refer to section C 101 05 11 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely d...

Page 1034: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 888 Copyright DETROIT DIESEL CORPORATION ...

Page 1035: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 889 ...

Page 1036: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 890 Copyright DETROIT DIESEL CORPORATION ...

Page 1037: ...1 Bushing 9 Washer 2 Bolt 10 Lever 3 Shaft 11 Spacer 4 Exhaust Flap 12 Actuator Rod 5 Shaft 13 Spring Pin 6 Sealing Ring 14 Mounting Bracket 7 Sealing Flange 15 Actuator Cylinder 8 Nut Figure 642 General View of Turbocharger Actuator Marine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 891 ...

Page 1038: ...evel of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 76 Before Removal Operation All information subject to change without notice C 892 Copyright DETROIT DIESEL CORPORATION ...

Page 1039: ...sconnect the pyrometer wiring harness See Figure 643 1 Exhaust Pyrometer Figure 643 Removing Exhaust Pyrometer and Supply Line Marine 2 Remove the exhaust pyrometer 1 from the turbocharger See Figure 643 3 Disconnect the oil supply lines refer to section C 186 05 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 893 ...

Page 1040: ...ure 644 1 Bushing 9 Washer 2 Bolt 10 Lever 3 Shaft 11 Spacer 4 Exhaust Flap 12 Actuator Rod 5 Shaft 13 Spring Pin 6 Sealing Ring 14 Mounting Bracket 7 Sealing Flange 15 Actuator Cylinder 8 Nut Figure 644 Removing Turbocharger Actuator Marine All information subject to change without notice C 894 Copyright DETROIT DIESEL CORPORATION ...

Page 1041: ...15 See Figure 644 6 Remove bolts 2 securing mounting bracket 14 to the turbocharger and remove the mounting bracket See Figure 644 7 Remove bolts 2 securing the actuator cylinder 15 to the mounting bracket 14 and remove the actuator See Figure 645 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 895 ...

Page 1042: ... Spacer 4 Exhaust Flap 12 Actuator Rod 5 Shaft 13 Spring Pin 6 Sealing Ring 14 Mounting Bracket 7 Sealing Flange 15 Actuator Cylinder 8 Nut Figure 645 Removing Turbocharger Actuator Marine All information subject to change without notice C 896 Copyright DETROIT DIESEL CORPORATION ...

Page 1043: ...esel fuel and blow dry with compressed air 2 Visually inspect mounting bracket for wear cracks and damage a If mounting bracket shows wear cracks or damage recondition or replace as necessary b If mounting bracket does not show wear cracks or damage continue inspection 3 Visually inspect actuating cylinder for function and condition a If actuating cylinder does not function or is in poor condition...

Page 1044: ...the following steps to install the turbocharger actuator 1 Install the actuator cylinder 15 to the mounting bracket 14 and secure with bolts 2 Torque bolts to specification Refer to section A 003 See Figure 646 All information subject to change without notice C 898 Copyright DETROIT DIESEL CORPORATION ...

Page 1045: ...talling Turbocharger Actuator Marine 2 Install the mounting bracket 14 to the turbocharger and secure using bolts 2 Torque bolts to specification Refer to section A 003 See Figure 646 3 Install actuator rod 12 to lever 10 and secure with bolts 2 spacer 11 washers 9 and nuts 8 Torque bolts to specification Refer to sectionA 003 See Figure 646 All information subject to change without notice Copyrig...

Page 1046: ...on Refer to section A 003 See Figure 646 5 Connect oil supply lines refer to section C 187 05 11 6 Install the pyrometer 1 to the turbocharger See Figure 647 1 Exhaust Pyrometer Figure 647 Installation of Pyrometer Marine 7 Install the pyrometer wiring harness See Figure 647 All information subject to change without notice C 900 Copyright DETROIT DIESEL CORPORATION ...

Page 1047: ...arine Level of Maintenance Operation Reference 1 2 3 Enable engine start Refer to Operator s Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 77 After Installation Operation All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 901 ...

Page 1048: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 902 Copyright DETROIT DIESEL CORPORATION ...

Page 1049: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 903 ...

Page 1050: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 904 Copyright DETROIT DIESEL CORPORATION ...

Page 1051: ...uator control solenoid valve parts location 1 Bolt 5 Bolt 2 Washer 6 Mounting Bracket 3 Turbocharger Actuator Control Solenoid Valve 7 Nut 4 Mounting Plate Figure 648 General View of Turbocharger Actuator Control Solenoid Valve Marine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 905 ...

Page 1052: ...enoid valve Level of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 78 Before Removal Operation All information subject to change without notice C 906 Copyright DETROIT DIESEL CORPORATION ...

Page 1053: ...the turbocharger actuator control solenoid valve oil feed lines 1 See Figure 649 1 Oil Feed Lines Figure 649 Removing Turbocharger Actuator Control Solenoid Valve Oil Feed Lines Marine 2 Remove bolt 1 and washers 2 securing the turbocharger actuator control solenoid valve 3 and mounting plate 4 to the mounting bracket 6 See Figure 650 All information subject to change without notice Copyright DETR...

Page 1054: ...ing Plate Figure 650 Removing Bolt and Washer from Turbocharger Actuator Control Solenoid Valve Marine 3 Remove bolts 5 and washers 2 securing the mounting bracket 6 to the exhaust crossover housing and remove the mounting bracket See Figure 650 All information subject to change without notice C 908 Copyright DETROIT DIESEL CORPORATION ...

Page 1055: ...e 1 Use clean diesel fuel to remove dirt and debris from the turbocharger actuator control solenoid valve and blow dry with compressed air 2 Visually inspect components for damage a If any components are damaged replace as necessary b If no components are damaged continue inspection All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 909 ...

Page 1056: ...NSTALLATION OF THE TURBOCHARGER ACTUATOR CONTROL SOLENOID VALVE MARINE Perform the following steps to install the turbocharger actuator control solenoid valve All information subject to change without notice C 910 Copyright DETROIT DIESEL CORPORATION ...

Page 1057: ...Turbocharger Actuator Control Solenoid Valve 7 Nut 4 Mounting Plate Figure 651 Installation of Turbocharger Actuator Control Solenoid Valve Marine 2 Install the mounting plate 4 and turbocharger actuator control solenoid valve 3 to mounting bracket 6 and secure with washers 2 and bolts 1 Torque bolts to specification Refer to section A 003 See Figure 651 All information subject to change without n...

Page 1058: ...ed lines 1 See Figure 652 1 Oil Feed Lines Figure 652 Installing Turbocharger Actuator Control Solenoid Valve Oil Feed Lines Marine 4 Verify repair of the turbocharger actuator control solenoid valve All information subject to change without notice C 912 Copyright DETROIT DIESEL CORPORATION ...

Page 1059: ...olenoid valve Level of Maintenance Operation Reference 1 2 3 Enable Engine Power Refer to Operator s Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 79 After Installation Operation All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 913 ...

Page 1060: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 914 Copyright DETROIT DIESEL CORPORATION ...

Page 1061: ...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 0...

Page 1062: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 916 Copyright DETROIT DIESEL CORPORATION ...

Page 1063: ...emoval 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 917 ...

Page 1064: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 918 Copyright DETROIT DIESEL CORPORATION ...

Page 1065: ...1 Nut M12 3 Hex Bolt 12 Bolt M12 X 65 4 Washer 13 Right Bracket 5 Bottom Outlet Housing 14 Bolt M16 X 110 6 Rubber Seal Ring 15 Left Bracket 7 Charge Air Cooler 16 Dowel Pin 8 Top Inlet Housing 17 Spacer 9 Bolt M12 X 47 Figure 653 General View of Charge Air Cooler All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 919 ...

Page 1066: ...05 M 1 2 3 Remove charge air manifolds Refer to section C 124 05 05 1 2 3 Remove coolant vent line Refer to section C 205 05 05 1 2 3 Drain engine coolant Refer to Operators Guide 1 2 3 Remove coolant lines Refer to section C 204 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 80 Before Remo...

Page 1067: ...the charge air cooler 1 Remove hex bolts 2 from bracket 1 See Figure 654 1 Bracket 4 Hex Bolt 2 Hex Bolt 5 Outlet Elbow 3 Nut Figure 654 Removing Charge Air Cooler 2 Remove nuts 3 from hex bolts 4 and remove outlet elbow 5 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 921 ...

Page 1068: ...n charge air cooler and bracket To avoid personal injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 5 Attach charge air cooler to crane with lifting device and carefully raise from engine NOTE After removing charge air cooler seal all connections on engine with suitable plugs and covers All informat...

Page 1069: ...g Charge Air Cooler from Connecting Housing Bottom 2 Lift off inlet housing 3 Remove hex bolts between outlet housing bottom 2 and charge air cooler 1 4 Remove charge air cooler from outlet housing bottom 5 Remove rubber seal ring from inlet and outlet housings NOTICE Protect charge air cooler in particular the cooling fins from mechanical damage e g jolts etc by covering fins with firm cardboard ...

Page 1070: ... seal and inspect for damage and unevenness a If sealing contact or mating surfaces is damaged or uneven smooth with oilstone or emery cloth as necessary b If sealing contact or mating surface is not damaged or uneven continue inspection 4 Inspect threads in charge air cooler and inlet housing for ease of movement a If threads in charge air cooler and inlet housing do not show ease of movement rec...

Page 1071: ...40 lb in 2 air pressure 2 If greasy or oily deposits have formed cooler must be cleaned with steam cleaner 3 Use nozzle for multi point water jet Operating pressure of high pressure cleaning unit should be approximately 80 bar Use clear water at a temperature of approximately 70 C to prevent steam 4 Flow direction for vapor blast cleaning should be in the opposite direction to the cooling air flow...

Page 1072: ... can be used for flushing purposes 6 Ensure that charge air cooler is clean a If charge air cooler is not clean repeat procedure for cleaning coolant side b If charge air cooler is clean continue cleaning coolant side 7 If cooler is not put into operation immediately afterward the water side must be dried and preserved after this cleaning 8 Dry in a drying oven between 110 C and 120 C for approxim...

Page 1073: ...ine 3 Soak charge air cooler in test basin filled with water heated to 80 C 4 Open compressed air supply and set pressure reducer 3 to 0 5 bar To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 5 Pressure test charge air cooler for leaks with air in water bath a If bubbles emerge replace charge...

Page 1074: ... protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 6 After inspecting blow through cooling air ducts with compressed air in vertical direction Refer to section C 111 05 10 All information subject to change without notice C 928 Copyright DETROIT DIESEL CORPORATION ...

Page 1075: ...utlet and inlet housings 2 See Figure 658 NOTE Insert dry rubber seal ring Insert T shaped seal ring with wide slot into groove NOTE Before installation remove all plugs and verify that air carrying components are perfectly clean 1 Rubber Seal Ring 2 Groove in Outlet and Inlet Housing Figure 658 Preparing Connecting Housing All information subject to change without notice Copyright DETROIT DIESEL ...

Page 1076: ... air cooler on the outlet housing See Figure 659 1 Charge Air Cooler 2 Outlet Housing Bottom Figure 659 Installing Charge Air Cooler on Outlet Housing Bottom 2 Install two hex bolts 1 in center of front and rear of charge air cooler i e immediately to left and right of bore for dowel pin 2 and hand tighten See Figure 660 All information subject to change without notice C 930 Copyright DETROIT DIES...

Page 1077: ...torque 6 Install inlet housing on charge air cooler align on dowel pins 7 Ensure inlet cover seal ring remains in place 8 Apply Loctite to attaching bolts 9 Install hex bolts with spacers all around 10 Proceed as with installing outlet housing 11 Start in center on both front and rear of charge air cooler and secure four hex bolts from center in both directions tightening in several stages to spec...

Page 1078: ...ler To avoid personal injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 14 Attach charge air cooler to crane with lifting device and place on engine 15 Install hex bolts 2 in bracket 1 16 Secure outlet elbow 5 with hex bolts 4 and nuts 3 on charge air cooler All information subject to change without...

Page 1079: ...gure 662 1 Securing Bolts 2 Pipe Clamps Figure 662 Installing Securing Bolts between Charge Air Cooler and Bracket 18 Install inlet and outlet coolant couplings seals and clamps 19 Tighten clamps for coolant couplings All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 933 ...

Page 1080: ...t lines Refer to section C 205 05 11 1 2 3 Install DDEC sensors and harness Refer to section C 501 05 M 1 2 3 Fill engine coolant system Refer to Operators Guide 1 2 3 Inspect for leaks Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain inst...

Page 1081: ...tion 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 C 113 05 11 M Installation of the Boost Bypass Valve C 966 C 113 05 04 M After Installation Operations C 971 All informatio...

Page 1082: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 936 Copyright DETROIT DIESEL CORPORATION ...

Page 1083: ...ts location 1 Bolt 5 Right B Bank Charge Air Cooler 2 Left A Bank Charge Air Cooler 6 Elbow B Bank side only 3 Bolt 7 Bolt 4 O ring 8 Vent Line Location Figure 663 Exploded View of Marine Charge Air Cooler Assembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 937 ...

Page 1084: ...3 Remove charge air manifolds Refer to C 124 05 05 1 2 3 Remove coolant vent line Refer to C 206 05 05 M 1 2 3 Drain engine coolant Refer to Operators Guide 1 2 3 Remove coolant lines Refer to C 203 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 82 Before Removal Operations for the Marine C...

Page 1085: ...tand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 1 Attach a suitable lifting device to the charge air cooler 1 See Figure 664 1 Charge Air Cooler 2 Lifting Sling Figure 664 Removing Charge Air Cooler from Engine 2 Disconnect water vent line 7 See Figure 665 All information subject to change without notice Copyright DETROIT DIESEL CORPORATIO...

Page 1086: ...ooler 2 Left A Bank Charge Air Cooler 6 Elbow B Bank side only 3 Bolt 7 Bolt 4 O ring 8 Vent Line Location Figure 665 Disconnecting Water Vent Line on Charge Air Cooler Assembly All information subject to change without notice C 940 Copyright DETROIT DIESEL CORPORATION ...

Page 1087: ...ct connection tube 2 from the compressor housing to the charge air cooler See Figure 666 1 O ring 2 Connection Tube Figure 666 Charge Air Cooler Assembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 941 ...

Page 1088: ...lange 8 Elbow 2 Washer 9 Pipe Half Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adaptor 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 667 Removing Bolts and Washers Securing Crossover Tube All information subject to change without notice C 942 Copyright DETROIT DIESEL CORPORATION ...

Page 1089: ...r 2 Left A Bank Charge Air Cooler 6 Elbow B Bank side only 3 Bolt 7 Bolt 4 O ring 8 Vent Line Location Figure 668 Removing Bolts Securing Charge Air Cooler Assembly to Flywheel Housing 6 Remove three 55 mm 2 2 in bolts 3 securing the charge air cooler to the flywheel housing See Figure 668 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 943 ...

Page 1090: ...ng Threaded Bushing or Air Intake Temperature Sensor Location 3 Washer 7 Sealing Ring Threaded Bushing or Turbocharger Boost Sensor Location 4 Bolt Figure 669 Removing Bolts Securing Charge Air Cooler Assembly to Flywheel Housing All information subject to change without notice C 944 Copyright DETROIT DIESEL CORPORATION ...

Page 1091: ...ge 6 Sealing Ring Threaded Bushing or Air Intake Temperature Sensor Location 3 Washer 7 Sealing Ring Threaded Bushing or Turbocharger Boost Sensor Location 4 Bolt Figure 670 Removing Bolts Securing Intake Manifold Flange to Charge Air Cooler 9 Remove the charge air cooler All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 945 ...

Page 1092: ...ing Threaded Bushing or Air Intake Temperature Sensor Location 3 Washer 7 Sealing Ring Threaded Bushing or Turbocharger Boost Sensor Location 4 Bolt Figure 671 Removing O rings from Flywheel Housing NOTE Perform step 11 through step 13 only for the B bank All information subject to change without notice C 946 Copyright DETROIT DIESEL CORPORATION ...

Page 1093: ...Right B Bank Charge Air Cooler 2 Left A Bank Charge Air Cooler 6 Elbow B Bank Side only 3 Bolt 7 Bolt 4 O ring 8 Vent Line Location Figure 672 Removing Bolts Securing Elbow to Charge Air Cooler 12 Remove the elbow 5 13 Remove O ring 4 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 947 ...

Page 1094: ...epaired continue inspection To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 3 Using compressed air clean all components 4 Visually inspect all components for damage and defects a If damage or defects are found replace components as necessary b If no damage or defects are found continue inspe...

Page 1095: ...LLATION OF MARINE CHARGE AIR COOLER Perform the following steps for the installation of the charge air cooler NOTE Perform step 1 through step3 only for the B bank All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 949 ...

Page 1096: ... only 3 Bolt 7 Bolt 4 O ring 8 Vent Line Location Figure 673 Installing New O ring to Elbow 2 Install charge air cooler to turbocharger elbow 6 and secure with two bolts 3 Torque bolts to 21 24 N m 15 18 lb ft 3 Install two new O rings 4 to the flywheel housing NOTE A bank only All information subject to change without notice C 950 Copyright DETROIT DIESEL CORPORATION ...

Page 1097: ... Tube 2 Flange 6 Sealing Ring Threaded Bushing or Air Intake Temperature Sensor Location 3 Washer 7 Sealing Ring Threaded Bushing or Turbocharger Boost Sensor Location 4 Bolt Figure 674 Installing Intake Manifold Flange to Charge Air Cooler All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 951 ...

Page 1098: ...suitable lifting device and review all manufacturer s cautionary notes 5 Using a suitable lifting device 2 install the charge air cooler 1 See Figure 675 1 Charge Air Cooler 2 Lifting Device Figure 675 Installing Charge Air Cooler to Engine All information subject to change without notice C 952 Copyright DETROIT DIESEL CORPORATION ...

Page 1099: ... Bolt 5 Right B Bank Charge Air Cooler 2 Left A Bank Charge Air Cooler 6 Elbow B side only 3 Bolt 7 Bolt 4 O ring 8 Vent Line Location Figure 676 Securing Charge Air Cooler with Bolts 7 Install two 70 mm 2 8 in bolts 3 Torque bolts to 74 82 N m 55 60 lb ft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 953 ...

Page 1100: ... See Figure 677 1 Flange 8 Elbow 2 Washer 9 Pipe Half Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adapter 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 677 Installing Crossover Tube and Securing with Bolts All information subject to change without notice C 954 Copyright DETROIT DIESEL CORPORATION ...

Page 1101: ...ousing to charge air cooler See Figure 678 1 O ring 2 Connection Tube Figure 678 Installing Connection Tube between Compressor Housing and Charge Air Cooler 10 Connect vent lines 7 See Figure 679 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 955 ...

Page 1102: ...ht B Bank Charge Air Cooler 2 Left A Bank Charge Air Cooler 6 Elbow B side only 3 Bolt 7 Bolt 4 O ring 8 Vent Line Location Figure 679 Connecting Vent Lines All information subject to change without notice C 956 Copyright DETROIT DIESEL CORPORATION ...

Page 1103: ...Refer to C 206 05 11 M 1 2 3 Install monitoring system Refer to C 501 05 M 1 2 3 Fill engine coolant system Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 83 After Installation Operations for the Marine Charge Air Cooler ...

Page 1104: ...e location 1 Flange 8 Elbow 2 Washer 9 Pipe Half Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adaptor 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 680 Boost Bypass Valve Assembly All information subject to change without notice C 958 Copyright DETROIT DIESEL CORPORATION ...

Page 1105: ...enance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 84 Before Removal Operations for the Boost Bypass Valve All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 959 ...

Page 1106: ...6V SERVICE MANUAL C 113 05 05 M REMOVAL OF THE BOOST BYPASS VALVE Perform the following steps to remove the boost bypass valve All information subject to change without notice C 960 Copyright DETROIT DIESEL CORPORATION ...

Page 1107: ...r 9 Pipe Half Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adaptor 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 681 Removing Boost Bypass Valve and Crossover Tube 2 Remove crossover tube 4 3 Remove O ring 5 from crossover tube 4 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 961 ...

Page 1108: ...er 9 Pipe Half Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adaptor 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 682 Removing Boost Bypass Valve and Crossover Tube 5 Disconnect oil feed lines from boost bypass valve 7 All information subject to change without notice C 962 Copyright DETROIT DIESEL CORPORATION ...

Page 1109: ...ssembly See Figure 683 1 Flange 8 Elbow 2 Washer 9 Pipe Half Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adaptor 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 683 Removing Boost Bypass Valve and Crossover Tube 8 Remove O ring 5 See Figure 683 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 963 ...

Page 1110: ... MANUAL 9 Remove four bolts 3 and four washers 2 securing actuating cylinder 6 to elbow 8 See Figure 683 10 Remove elbow See Figure 683 All information subject to change without notice C 964 Copyright DETROIT DIESEL CORPORATION ...

Page 1111: ...ure 1 Using compressed air clean all components and visually inspect for damage and defects a If components are damaged or defective replace as necessary b If components are not damaged or defective continue inspection 2 Check thread in connecting housing for ease of movement a If thread does not show ease of movement recondition as necessary b If thread does show ease of movement continue inspect...

Page 1112: ... Figure 684 for the boost bypass valve location 1 Flange 8 Elbow 2 Washer 9 Pipe Half Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adaptor 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 684 Installing Boost Bypass Valve All information subject to change without notice C 966 Copyright DETROIT DIESEL CORPORATION ...

Page 1113: ...ure 684 2 Install boost bypass valve 7 to turbocharger crossover tube and secure with four bolts 3 Tighten bolts to specified torque in accordance with specifications Refer to section A 003 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 967 ...

Page 1114: ...lf Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adaptor 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 685 Installing Boost Bypass Valve 5 Tighten bolts to specified torque in accordance with specification Refer to section A 003 See Figure 685 All information subject to change without notice C 968 Copyright DETROIT DIESEL CORPORATION ...

Page 1115: ... to crossover tube 4 neck See Figure 686 1 Flange 8 Elbow 2 Washer 9 Pipe Half Clamp 3 Bolt 10 Grommet 4 Crossover Tube 11 Oil Feed Line 5 O ring 12 Adaptor 6 Actuating Cylinder 13 Sealing Ring 7 Boost Bypass Valve Figure 686 Installing Boost Bypass Valve All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 969 ...

Page 1116: ... and secure with four bolts 3 and washers 2 10 Tighten bolts to specified torque in accordance with Torque Specifications 028T4000 11 Verify repair of boost bypass valve All information subject to change without notice C 970 Copyright DETROIT DIESEL CORPORATION ...

Page 1117: ...tenance Operation Reference 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 85 After Installation Operations for the Marine Boost Bypass Valve All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 971 ...

Page 1118: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 972 Copyright DETROIT DIESEL CORPORATION ...

Page 1119: ...ion 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 Operation...

Page 1120: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 974 Copyright DETROIT DIESEL CORPORATION ...

Page 1121: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 975 ...

Page 1122: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 976 Copyright DETROIT DIESEL CORPORATION ...

Page 1123: ...M GENERAL VIEW For a general view of the marine air filter see Figure 687 1 Intake Housing 3 Air Filter 2 Clamp Figure 687 General View of Marine Air Filter All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 977 ...

Page 1124: ...ce Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 86 Before Removal Operations for the Marine Air Filter All information subject to change without notice C 978 Copyright DETROIT DIESEL CORPORATION ...

Page 1125: ...lement 1 Loosen the V band clamp 2 securing the air filter 3 to the intake housing 1 see Figure 688 1 Intake Housing 3 Air Filter 2 V band Clamp Figure 688 Loosening V band Clamp 2 Remove the air filter 3 and V band clamp 2 see Figure 688 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 979 ...

Page 1126: ...lace component as necessary b If bolts show ease of movement continue inspection 4 Visually inspect air filter for contamination a If air filter is contaminated replace component b If air filter is not contaminated continue inspection NOTE Replace air filter at appropriate maintenance intervals To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplat...

Page 1127: ...ir filter 1 Install the marine air filter element and V band clamp 2 Finger tighten the V band clamp 2 securing the air filter 3 to the intake housing 1 see Figure 689 1 Intake Housing 3 Air Filter 2 V band Clamp Figure 689 Installing V band Clamp All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 981 ...

Page 1128: ...vel Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 87 After Installation Operations for the Marine Air Filter All information subject to change without notice C 982 Copyright DETROIT DIESEL CORPORATION ...

Page 1129: ...oval 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 983 ...

Page 1130: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 984 Copyright DETROIT DIESEL CORPORATION ...

Page 1131: ...690 for a general view of the intake housing 1 Turbocharger 5 Bolt 2 Clamp 6 Washer 3 O ring 7 Intake Housing 4 Retainer 8 Mounting Bracket Figure 690 General View of Intake Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 985 ...

Page 1132: ...n Table 88 are the Before Removal Operations for the intake housing Level of Maintenance Operation Reference 3 Disable engine power Refer to Operators Guide Table 88 Before Removal Operations All information subject to change without notice C 986 Copyright DETROIT DIESEL CORPORATION ...

Page 1133: ...lamp 2 and remove the air filter element from the air intake housing 1 See Figure 691 1 Intake Housing 3 Air Filter 2 Clamp Figure 691 Removing Air Filter Element from Air Intake Housing 2 Disconnect the B3 air temperature sensor wiring harness See Figure 692 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 987 ...

Page 1134: ...urbocharger Speed Sensor Figure 692 Disconnecting the B3 Air Temperature Sensor Wiring Harness 3 Disconnect the B44 turbocharger speed sensor wiring harness See Figure 692 All information subject to change without notice C 988 Copyright DETROIT DIESEL CORPORATION ...

Page 1135: ... breather system See Figure 693 1 Air Intake Vent Tube 3 Clamps 2 Intake Housing 4 Vent Tube Fitting Figure 693 Removing Air Intake Vent Tube 5 Remove the air intake vent tube 1 from the intake housing 2 See Figure 693 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 989 ...

Page 1136: ...ing 4 Retainer 8 Mounting Bracket Figure 694 Removal of Intake Housing Components 7 Remove bolts 5 and washers 6 securing the air intake housing 7 to the exhaust manifold mounting bracket 8 and remove the intake housing See Figure 694 8 Remove bolts 5 and washers 6 securing the mounting bracket to the exhaust manifold See Figure 694 All information subject to change without notice C 990 Copyright ...

Page 1137: ...2 16V SERVICE MANUAL 9 Remove the air temperature sensor if necessary 10 Remove the turbocharger speed sensor if necessary All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 991 ...

Page 1138: ...5 and washer 6 securing retainer 4 to the intake housing and remove the retainer See Figure 695 1 Turbocharger 5 Bolt 2 Clamp 6 Washer 3 O ring 7 Intake Housing 4 Retainer 8 Mounting Bracket Figure 695 Disassembling Intake Housing 2 Remove O ring 3 from the intake housing 7 All information subject to change without notice C 992 Copyright DETROIT DIESEL CORPORATION ...

Page 1139: ...ue inspection 5 Visually inspect sealing mating and seating surfaces on intake housing for damage and surface irregularities a If sealing mating and seating surfaces on intake housing show damage or surface irregularities rub down with oilstone as necessary b If damage is beyond repair replace component c If sealing mating and seating surfaces on intake housing do not show damage or surface irregu...

Page 1140: ... See Figure 696 1 Turbocharger 5 Bolt 2 Clamp 6 Washer 3 O ring 7 Intake Housing 4 Retainer 8 Mounting Bracket Figure 696 Assembling Intake Housing 2 Install retainer 4 to the intake housing and secure with washers 6 and bolt 5 Torque bolts to specification Refer to section A 003 See Figure 697 All information subject to change without notice C 994 Copyright DETROIT DIESEL CORPORATION ...

Page 1141: ...UAL 1 Turbocharger 5 Bolt 2 Clamp 6 Washer 3 O ring 7 Intake Housing 4 Retainer 8 Mounting Bracket Figure 697 Assembling Left Intake Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 995 ...

Page 1142: ...e sensor if removed 3 Install the intake housing mounting bracket 8 to the exhaust manifold and secure with bolts 5 and washers 6 Torque bolts to specification Refer to section A 003 See Figure 698 1 Turbocharger 5 Bolt 2 Clamp 6 Washer 3 O ring 7 Intake Housing 4 Retainer 8 Mounting Bracket Figure 698 Installing Intake Housing Components All information subject to change without notice C 996 Copy...

Page 1143: ...stall the air intake vent tube 1 to the intake housing 2 and secure with clamps 3 Torque clamp nut to specification Refer to section A 003 See Figure 699 1 Air Intake Vent Tube 3 Clamps 2 Intake Housing 4 Vent Tube Fitting Figure 699 Installing Air Intake Vent Tube All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 997 ...

Page 1144: ... harness See Figure 700 1 Air Temperature Sensor 2 Turbocharger Speed Sensor Figure 700 Connecting B3 and B44 Wiring Harness 7 Connect B3 air temperature sensor 1 wiring harness See Figure 700 All information subject to change without notice C 998 Copyright DETROIT DIESEL CORPORATION ...

Page 1145: ...e housing 1 and secure with clamp 2 See Figure 701 1 Intake Housing 3 Air Filter 2 Clamp Figure 701 Removing Air Filter Element from Air Intake Housing 9 Verify repair of the intake housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 999 ...

Page 1146: ...ble 89 are the After Installation Operations for the intake housing Level of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide Table 89 After Installation Operations All information subject to change without notice C 1000 Copyright DETROIT DIESEL CORPORATION ...

Page 1147: ...emoval 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1001 ...

Page 1148: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1002 Copyright DETROIT DIESEL CORPORATION ...

Page 1149: ... a general view of the air intake manifolds 1 Bolt 5 Air Intake Manifold 2 Washer 6 Sealing Ring 3 O ring 7 Adapter 4 Gasket 8 Plug Figure 702 General View of Air Intake Manifold System All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1003 ...

Page 1150: ...Refer to Operators Guide 1 2 3 Remove DDEC harness and sensors Refer to section C 501 05 M 1 2 3 Remove retainer for CA connector on elbow Refer to section C 501 05 M 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 90 Before Removal Operations All information subject to change without notice C 100...

Page 1151: ... and hex nuts 3 joining charge air cooler and outlet elbow See Figure 703 1 Outlet Elbow 3 Hex Nut 2 Hex Bolt Figure 703 Removing Hex Bolts and Nuts Joining Charge Air Cooler and Outlet Elbow 2 Remove outlet elbow 1 from air intake manifold See Figure 703 3 Remove O rings from outlet elbow All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1005 ...

Page 1152: ...old End Section 2 Hex Bolt with Washer Figure 704 Removing Hex Bolts from Charge Air Manifold and Removing Bracket for Injector Control Cable 5 Remove bracket for injector control cable 2 6 Remove charge air manifold If necessary withdraw from adjacent charge air manifold 7 Remove gasket All information subject to change without notice C 1006 Copyright DETROIT DIESEL CORPORATION ...

Page 1153: ...r and damage a If sealing and mating surfaces are worn or damaged rub down the component with an oilstone b If wear or damage is beyond repair replace the component c If sealing and mating surfaces are not worn or damaged continue inspection 5 Inspect threads for wear and damage a If threads are worn or damaged rechase threads b If damage is beyond repair replace threaded inserts c If threads are ...

Page 1154: ... plugs are worn or damaged replace blanking plugs b If blanking plugs are not worn or damaged continue inspection 9 Replace seals sealing rings and gaskets All information subject to change without notice C 1008 Copyright DETROIT DIESEL CORPORATION ...

Page 1155: ... Washer Figure 705 Installing Charge Air Manifold 2 Place gear case end air intake manifold end section 4 on sealing surface of cylinder head NOTE Before tightening hex bolts check that gasket is correctly positioned 3 Install hex bolt with washer 3 and retainer 2 and tighten 4 Before installing adjacent air intake manifold 1 coat O ring with petroleum jelly and install on air intake manifold 5 Co...

Page 1156: ...rge Air Cooler 4 Outlet Elbow 2 Hex Bolt 5 O ring 3 Hex Nut Figure 706 Installing Outlet Elbow in Charge Air Cooler Outlet Flange 8 Coat O ring 5 with petroleum jelly and insert in outlet elbow flange to charge air cooler 1 9 Install outlet elbow in charge air intake manifold so that outlet elbow flange is flush with outlet flange on charge air cooler 10 Install and tighten hex bolts 2 and hex nut...

Page 1157: ... to OEM Guidelines 1 2 3 Install DDEC harness and sensors Refer to OEM Guidelines 1 2 3 Install DDEC harness and sensors Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 91 After Installation Operations All information subj...

Page 1158: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1012 Copyright DETROIT DIESEL CORPORATION ...

Page 1159: ...ration 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1013 ...

Page 1160: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1014 Copyright DETROIT DIESEL CORPORATION ...

Page 1161: ...Air Manifold A Bank Side Y Pipe 8 Charge Air Manifold A Bank Side 3 Nut 9 Clamp 4 Bracket 10 Adaptor 5 Retaining Plate 11 Charge Air Manifold B Bank Side 6 Hex Bolt 12 Charge Air Manifold B Bank Side Y Pipe Figure 707 General View of Air Intake System from Turbocharger to Charge Air Cooler All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1015 ...

Page 1162: ...harge air cooler Level of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 92 Before Removal Operations All information subject to change without notice C 1016 Copyright DETROIT DIESEL CORPORATION ...

Page 1163: ...nd push back adaptor 5 toward turbocharger See Figure 708 1 Retaining Plate 4 Clamp 2 Charge Air Manifold 5 Adaptor 3 Hex Bolt 6 Bracket Figure 708 Removing Clamps on Turbocharger and Pushing Back Adaptor Toward Exhaust Turbocharger 2 Remove hex bolts 3 from retaining plate 1 3 Remove charge air manifold 2 4 Remove O rings from charge air manifold All information subject to change without notice C...

Page 1164: ... Bracket Figure 709 Removing Rocker Cover and Bracket 6 Remove retaining plate 2 along with bracket 7 If necessary separate bracket from retaining plate by removing hex nuts 3 8 If rocker covers are not to be removed reinstall hex bolts 1 to keep out dirt All information subject to change without notice C 1018 Copyright DETROIT DIESEL CORPORATION ...

Page 1165: ...rge Air Manifold Y pipe 2 Y pipe Inlet Housing of Charge Air Cooler Figure 710 Removing Charge Air Manifold 10 Remove O rings 11 After removing charge air manifold Y pipes protect all openings on the inlet housing with suitable plugs or covers All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1019 ...

Page 1166: ... Visually inspect all sealing and mating surfaces for wear and damage a If sealing and mating surfaces are worn or damaged rub down with an oilstone b If wear or damage is beyond repair replace component c If sealing and mating surfaces are not worn or damaged continue inspection 5 Visually inspect retaining plates and brackets for cracks a If cracks are found replace retaining plates and brackets...

Page 1167: ...d blanking plugs for wear and damage a If hex bolts or blanking plugs are worn or damaged replace as necessary b If hex bolts or blanking plugs are not worn or damaged continue inspection 10 Replace seals sealing rings and gaskets All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1021 ...

Page 1168: ...See Figure 711 1 Y Pipe Charge Air Manifold 3 Inlet Housing of Charge Air Cooler 2 Cast on Arrows Figure 711 Installing Charge Air Manifold Y Pipes 2 Coat O rings with petroleum jelly and install on charge air manifolds Y pipes 1 3 Insert charge air manifold Y pipes in openings on upper inlet housing 3 of charge air cooler 4 At same time align charge air manifold Y pipes with inlet housing in acco...

Page 1169: ...ge Air Manifolds with Triangular Flange Side on Forked Charge Air Manifold Y Pipe 6 Install pipe clamps 4 on round flange ends 7 Coat O rings with petroleum jelly and install on adaptors 5 8 Install adaptors in turbocharger 9 Position adaptors on charge air manifold ends and secure with pipe clamps 4 10 Install retaining plate 1 and bracket with hex bolt 3 on charge air manifold All information su...

Page 1170: ...d hex nut 3 See Figure 1 Hex Bolt 3 Hex Nut 2 Retaining Plate 4 Bracket Figure 713 Securing Retaining Plate and Bracket on Rocker Cover 12 Secure retaining plate 2 and bracket 4 with hex bolts 1 on rocker cover All information subject to change without notice C 1024 Copyright DETROIT DIESEL CORPORATION ...

Page 1171: ...aintenance Operation Reference 1 2 3 Inspect for leaks Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 93 After Installation Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION ...

Page 1172: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1026 Copyright DETROIT DIESEL CORPORATION ...

Page 1173: ...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 ...

Page 1174: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1028 Copyright DETROIT DIESEL CORPORATION ...

Page 1175: ...emoval of Exhaust System C 1033 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1029 ...

Page 1176: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1030 Copyright DETROIT DIESEL CORPORATION ...

Page 1177: ...ust system 12V 1 Gasket 8 Piston Ring 2 Spacer 9 Y pipe 3 Bolt 10 Washer 4 Stud 11 Hex Bolt 5 Support Bracket 12 Spacer Washer 6 Hex Nut 13 Exhaust Manifold 7 Hex Nut Figure 714 General View of Exhaust System 12V All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1031 ...

Page 1178: ...C 141 05 05 1 2 3 Remove adaptor of charge air manifold on turbocharger Refer to section C 124 05 05 1 2 3 Remove oil supply lines for turbochargers Refer to section C 187 05 05 1 2 3 Remove oil return lines for turbochargers Refer to section C 188 05 05 1 2 3 Remove turbocharger Refer to section C 101 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not comple...

Page 1179: ...See Figure 715 1 Gasket 3 Spacer 2 Hex Bolt 4 Exhaust Manifold Figure 715 Removing Gasket 12V 2 Remove all hex bolts 2 securing exhaust manifolds 4 and spacers 3 3 Lift exhaust manifolds from engine and separate from each other by pulling and twisting at same time All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1033 ...

Page 1180: ... from exhaust manifold only if necessary 1 To remove studs 1 from exhaust manifold install hex nut on stud and lock with second hex nut See Figure 716 1 Stud 2 Exhaust Manifold Figure 716 Removing Studs 12V 2 Place open end wrench on locked hex nut and remove stud All information subject to change without notice C 1034 Copyright DETROIT DIESEL CORPORATION ...

Page 1181: ... components wear protective gloves and clothing NOTE If stud cannot be loosened with open end wrench slightly heat stud in area of thread Ensure that only bottom of the adapter is heated All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1035 ...

Page 1182: ...o 20 to help cleaning 6 Visually inspect exhaust manifolds for cracks using the surface crack testing method with red penetrant dye a If exhaust manifold is cracked replace component b If exhaust manifold is not cracked continue inspection 7 Visually inspect exhaust manifolds for warping a If exhaust manifolds are warped replace component b If exhaust manifolds are not warped continue inspection 8...

Page 1183: ... the exhaust pipework after cylinder head 1 Install nonlubricated stud 1 in flange of exhaust manifold 2 and tighten to stop by means of locked hex nuts See Figure 717 1 Stud 2 Exhaust Manifold Figure 717 Installing Studs 12V All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1037 ...

Page 1184: ...ust manifolds 4 dry together See Figure714 2 Install exhaust manifolds with gaskets 1 dry on mating surfaces on exhaust outlet of cylinder heads See Figure 718 1 Gasket 3 Spacer Bushing 2 Hex Bolt 4 Exhaust Manifold Figure 718 Installing Exhaust Manifold 12V All information subject to change without notice C 1038 Copyright DETROIT DIESEL CORPORATION ...

Page 1185: ...hten diagonally to specification Torque bolts to specification Refer to section A 003 4 Install gaskets 1 dry on turbocharger flange See Figure 719 1 Gasket Figure 719 Installing Gaskets Dry on Turbocharger Flange 12V All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1039 ...

Page 1186: ...188 05 11 1 2 3 Install adaptors of charge air manifold on turbocharger Refer to section C 124 05 11 1 2 3 Install exhaust pipework after Y pipe Refer to section C 141 05 11 1 2 3 Install air system before turbocharger Refer to section C 101 05 11 1 2 3 Check for leaks Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The en...

Page 1187: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1041 ...

Page 1188: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1042 Copyright DETROIT DIESEL CORPORATION ...

Page 1189: ...gure 720and see Figure 721 for a general view of the exhaust manifold 1 Turbocharger 3 Tube 2 Cross over Tube 4 Charge Air Cooler Figure 720 Top View of Marine Exhaust Manifold All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1043 ...

Page 1190: ...ousing 8 Cover 3 Bolt 120 mm 9 Plug in Pipe 4 Washer 10 Stop 5 Bolt 30 mm 11 Adaptor 6 Exhaust Line 12 Bolt 8 mm Figure 721 General View of Marine Exhaust Manifold Parts Location All information subject to change without notice C 1044 Copyright DETROIT DIESEL CORPORATION ...

Page 1191: ...emove air filters Refer to OEM Guidelines 1 2 3 Remove A bank intake housing Refer to OEM Guidelines 1 2 3 Remove B bank intake housing Refer to OEM Guidelines 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 96 Before Removal Operations for Exhaust Manifold All information subject to change withou...

Page 1192: ...fold 1 Disconnect vent lines as required 2 Disconnect the B6 exhaust coolant temperature sensor A bank See Figure 722 1 Exhaust Coolant Temperature Sensor 2 Exhaust Manifold Cover Figure 722 Disconnecting B6 Exhaust Coolant Temperature Sensor All information subject to change without notice C 1046 Copyright DETROIT DIESEL CORPORATION ...

Page 1193: ...re 723 NOTE Repeat step 3 for each cylinder head 1 Nut 7 O ring 2 Exhaust Manifold Housing 8 Cover 3 Bolt 120 mm 9 Plug in Pipe 4 Washer 10 Stop 5 Bolt 30 mm 11 Adaptor 6 Exhaust Line 12 Bolt 8 mm Figure 723 Removing Exhaust Manifold Components All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1047 ...

Page 1194: ...8 mm bolts 12 and nuts 1 securing the exhaust manifold sections See Figure 723 NOTE Repeat step 5 for each manifold section as necessary NOTE Perform step 6 and step 7 for the A bank exhaust manifold 6 Disconnect the marine control box wiring harness All information subject to change without notice C 1048 Copyright DETROIT DIESEL CORPORATION ...

Page 1195: ...e marine control box to the A bank exhaust manifold 1 See Figure 724 1 A Bank Exhaust Manifold 4 Nut 2 Spacer 5 Marine Control Box 3 Mounting Bolt Figure 724 Removing Marine Control Box All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1049 ...

Page 1196: ...iew all manufacturer s cautionary notes 8 Install a suitable lifting device and remove the exhaust manifolds 2 from the cylinder heads See Figure 725 1 Lifting Device 2 Exhaust Manifold Figure 725 Removing Exhaust Manifold NOTE Perform step 9 through step 12 as required All information subject to change without notice C 1050 Copyright DETROIT DIESEL CORPORATION ...

Page 1197: ...move bolts 5 and stop 10 securing cover 8 to the exhaust manifold 2 See Figure 723 11 Remove cover 8 and O rings 7 from the exhaust manifold See Figure 723 12 Remove pipe in plug 9 and O rings 7 from the cover 8 See Figure 723 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1051 ...

Page 1198: ...s for cracks using the surface crack testing method a If exhaust lines are cracked replace component as necessary b If exhaust lines are not cracked continue inspection 4 Visually inspect exhaust manifolds for warping a If exhaust manifolds are warped replace component b If exhaust manifolds are not warped continue inspection 5 Visually inspect sealing and mating faces for damage or wear a If seal...

Page 1199: ...5 11 M INSTALLATION OF THE EXHAUST MANIFOLD Perform the following steps to install the exhaust manifold NOTE Perform step 1 though step 3 as necessary All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1053 ...

Page 1200: ...pe 4 Washer 10 Stop 5 Bolt 30 mm 11 Adaptor 6 Exhaust Line 12 Bolt 8 mm Figure 726 Installing Exhaust Manifold Components 2 Install cover 8 and new O rings 7 to the exhaust manifold 2 and secure with stops 10 and bolts 5 Torque bolts to specification Refer to section A 003 See Figure 726 All information subject to change without notice C 1054 Copyright DETROIT DIESEL CORPORATION ...

Page 1201: ...st manifold 2 and secure with 8 mm bolts 12 and nuts 1 Torque bolts to specification Refer to section A 003 See Figure 726 4 Coat the exhaust manifold machined surfaces with Loctite adhesive sealant All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1055 ...

Page 1202: ...ting device and review all manufacturer s cautionary notes 5 Secure a suitable lifting device 1 and install the exhaust manifold sections 2 to the cylinder heads See Figure 727 1 Lifting Device 2 Exhaust Manifold Figure 727 Installing Exhaust Manifold All information subject to change without notice C 1056 Copyright DETROIT DIESEL CORPORATION ...

Page 1203: ...t Manifold Housing 8 Cover 3 Bolt 120 mm 9 Plug in Pipe 4 Washer 10 Stop 5 Bolt 30 mm 11 Adaptor 6 Exhaust Line 12 Bolt 8 mm Figure 728 Installing Exhaust Manifold Components 7 Install 8 mm bolts 12 and nuts 1 to secure the exhaust manifold sections 2 to the cylinder head Torque bolts to 74 82 N m 55 60 lb ft See Figure 728 All information subject to change without notice Copyright DETROIT DIESEL ...

Page 1204: ...nd secure with bolts 3 and spacers 2 Torque bolts to 35 40 N m 26 30 lb ft See Figure 729 1 A Bank Exhaust Manifold 4 Nut 2 Spacer 5 Marine Control Box 3 Mounting Bolt Figure 729 Installing Marine Control Box All information subject to change without notice C 1058 Copyright DETROIT DIESEL CORPORATION ...

Page 1205: ...re sensor See Figure 730 1 Exhaust Coolant Temperature Sensor 2 Exhaust Manifold Cover Figure 730 Installing B6 Exhaust Coolant Temperature Sensor 10 Connect the vent lines as necessary All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1059 ...

Page 1206: ...s 1 2 3 Install A bank intake housing Refer to OEM Guidelines 1 2 3 Install B bank intake housing Refer to OEM Guidelines 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 97 After Installations Operations All information subject to change without n...

Page 1207: ... 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 ...

Page 1208: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1062 Copyright DETROIT DIESEL CORPORATION ...

Page 1209: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1063 ...

Page 1210: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1064 Copyright DETROIT DIESEL CORPORATION ...

Page 1211: ...e Figure 731 for a general view of the starter A bank and B bank 1 A Bank Starter 3 B Bank Starter 2 Hex Socket Bolt Figure 731 General View of Starter A Bank and B Bank All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1065 ...

Page 1212: ...r 1 Commutator Cover 4 Housing for Engagement Lever 2 Access Port Cover for Inspecting Carbon Brushes 5 Bendix Driver Housing 3 Solenoid 6 Starter Housing Figure 732 General View of Starter All information subject to change without notice C 1066 Copyright DETROIT DIESEL CORPORATION ...

Page 1213: ...isable engine power Refer to Operators Guide 1 2 3 Remove charge air manifold if necessary Refer to section C 124 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 98 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1067 ...

Page 1214: ...e that the battery ground cable is disconnected 1 Remove the lower hex socket nut 1 See Figure 733 1 Hex Socket Nut Figure 733 Removing Lower Hex Socket Nut 2 Remove hex socket bolt 1 See Figure 734 NOTE Secure starter to prevent it from falling out All information subject to change without notice C 1068 Copyright DETROIT DIESEL CORPORATION ...

Page 1215: ...V SERVICE MANUAL 1 Hex Socket Bolt Figure 734 Removing Hex Socket Bolt 3 Lift starter out through opening in flywheel housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1069 ...

Page 1216: ...SERIES 4000 12 16V SERVICE MANUAL C 172 05 06 DISASSEMBLY OF STARTER See OEM Guidelines All information subject to change without notice C 1070 Copyright DETROIT DIESEL CORPORATION ...

Page 1217: ... b If individual parts are not damaged continue inspection 2 Visually inspect tooth flanks of pinion for wear indentations and chipping a If tooth flanks of pinion are worn indented or chipped recondition component b If tooth flanks of pinion are worn indented or chipped beyond repair replace component c If tooth flanks of pinion are not worn indented or chipped continue inspection 3 Visually insp...

Page 1218: ...ne or emery cloth as necessary b If mating surface on flywheel is beyond repair replace component as necessary c If mating surface on flywheel is not worn continue inspection 7 Visually inspect threads for damage or wear a If threads are damaged or worn rechase threads as necessary b If threads are not damaged or worn continue inspection All information subject to change without notice C 1072 Copy...

Page 1219: ...S 4000 12 16V SERVICE MANUAL C 172 05 10 ASSEMBLY OF STARTER For assembly of starter Refer to section C 172 05 08 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1073 ...

Page 1220: ...dling and lifting a heavy object use a suitable lifting device and follow the manufacturer s operator procedures 1 Install starter in opening of flywheel housing and align bores in starter flange to support bores See Figure 736 1 Hex Socket Bolt Figure 736 Installing Starter in Opening of Flywheel Housing 2 Install hex socket bolts All information subject to change without notice C 1074 Copyright ...

Page 1221: ...nuts 1 See Figure 737 1 Hex Socket Nut Figure 737 Installing Lower Hex Socket Nut 4 Tighten all hex socket bolts diagonally and evenly to specification Refer to section A 003 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1075 ...

Page 1222: ...tly See Figure 738 1 Oil Pump 2 Hex Bolts Figure 738 Connecting Electric Starter NOTE When connecting to ground ensure that the electric circuit has the correct polarity 6 Connect battery ground strap 7 Ensure that starter rotates in proper direction All information subject to change without notice C 1076 Copyright DETROIT DIESEL CORPORATION ...

Page 1223: ... Install charge air manifold if necessary Refer to section C 124 05 11 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 99 After Installation Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1077 ...

Page 1224: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1078 Copyright DETROIT DIESEL CORPORATION ...

Page 1225: ...082 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1079 ...

Page 1226: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1080 Copyright DETROIT DIESEL CORPORATION ...

Page 1227: ... GENERAL VIEW For location of the marine starter see Figure 739 1 A Bank Starter 3 Mounting Bolt 2 B Bank Starter Figure 739 General View of Marine Starter All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1081 ...

Page 1228: ...ce Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 100 Before Removal Operations for the Marine Starter All information subject to change without notice C 1082 Copyright DETROIT DIESEL CORPORATION ...

Page 1229: ...ee Figure 740 1 A Bank Starter 3 Mounting Bolt 2 B Bank Starter Figure 740 Removing Marine Starter 1 Disconnect the engine electrical system 2 Tag starter leads for assembly 3 Disconnect the 1 A bank starter leads See Figure 740 4 Remove three bolts 3 securing the starter to the flywheel housing See Figure 740 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C ...

Page 1230: ...system 7 Tag starter leads for assembly 8 Disconnect the 2 B bank starter leads See Figure 740 9 Remove three bolts 3 securing the starter to the flywheel housing See Figure 740 10 Remove starter 2 B bank by lifting out through the opening in the flywheel housing See Figure 740 All information subject to change without notice C 1084 Copyright DETROIT DIESEL CORPORATION ...

Page 1231: ...E STARTER Refer to OEM guidelines At the present time no provision is made for electric starter disassembly on site If necessary send the high pressure pump to an authorized dealer All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1085 ...

Page 1232: ...nspection 3 Visually inspect nuts and studs for damage a If nuts or studs are damaged replace as necessary b If nuts or studs are not damaged continue inspection 4 Inspect threads for ease of movement a If threads do not show ease of movement replace as necessary b If threads show ease of movement continue inspection 5 Visually inspect mating surface on the flywheel housing for wear a If mating su...

Page 1233: ...o install the starter A and B bank See Figure 741 1 A Bank Starter 3 Mounting Bolt 2 B Bank Starter Figure 741 Installing Marine Starter 1 Disconnect the engine electrical system 2 Insert starter 1 A bank in the opening in the flywheel housing aligning bores in the starter flange to support bores See Figure 741 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C...

Page 1234: ...ank is installed If starter B bank was also removed continue with this procedure 6 Insert starter 2 B bank in the opening in the flywheel housing aligning bores in the starter flange to support bores See Figure 741 7 Replace three bolts 3 securing the starter to the flywheel housing See Figure 741 8 Connect the B bank starter leads 9 Connect the engine electrical system All information subject to ...

Page 1235: ...ance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 101 After Installation Operations for the Marine Starter All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1089 ...

Page 1236: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1090 Copyright DETROIT DIESEL CORPORATION ...

Page 1237: ...1 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 ...

Page 1238: ...ions 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 Suppl...

Page 1239: ...l Cooler 2 Gear Case Containing Oil Pump and Oil Pressure Valves 6 Centrifugal Oil Filter 3 Vibration Damper 7 Oil Filter Housing 4 Distribution Housing Containing Oil Circuits 8 Oil Filters Figure 742 General View of Lube Oil System All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1093 ...

Page 1240: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1094 Copyright DETROIT DIESEL CORPORATION ...

Page 1241: ...fore 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1095 ...

Page 1242: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1096 Copyright DETROIT DIESEL CORPORATION ...

Page 1243: ...ube oil pump with drive 1 Hex Bolt 6 Banjo Bolt 2 Pipe Clamp Half 7 Sealing Ring 3 Grommet 8 Pressure Regulator 4 Bracket 9 Washer 5 Oil Line 10 Hex Bolt Figure 743 General View of Lube Oil Pump with Drive All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1097 ...

Page 1244: ...uide 1 2 3 Drain or draw off engine oil Refer to Operators Guide 1 2 3 Remove oil pan Refer to section C 014 05 05 1 2 3 Remove engine mount gear case end Refer to section C 231 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 102 Before Removal Operations All information subject to change wi...

Page 1245: ... To remove oil pump with relief valve remove hex bolts 1 for oil pump 2 and remove oil pump from gear case See Figure 744 1 Hex Bolts Figure 744 Removing Oil Pump with Relief Valve 2 To remove high pressure oil line remove hex bolt 4 and pipe clamp half See Figure 745 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1099 ...

Page 1246: ...ure Oil Line 3 Remove banjo bolt 1 for high pressure oil line 2 from gear case and banjo bolt 3 from pressure regulator valve 4 Remove high pressure oil line NOTE For a clearer view the vibration damper has been removed See Figure 745 All information subject to change without notice C 1100 Copyright DETROIT DIESEL CORPORATION ...

Page 1247: ... Remove gaskets 6 To remove pressure regulator valve remove regulator from gear case See Figure 746 Figure 746 Removing Pressure Regulator Valve All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1101 ...

Page 1248: ...no wear or damage is found continue inspection 4 Visually inspect sealing surfaces for irregularities with ink check plate a If irregularities are found machine sealing surfaces b If no irregularities are found on sealing surfaces continue inspection 5 Visually inspect banjo bolts for wear or damage and threads for ease of movement a If banjo bolts are worn or damaged or threads do not show ease o...

Page 1249: ...spection 3 Visually inspect teeth of drive gear for wear indentations and chipping a If teeth of drive gear are worn indented or chipped rub down with oilstone or emery cloth as necessary b If damage is beyond repair replace drive gear c If teeth of drive gear are not worn indented or chipped continue inspection 4 Visually inspect oil pump for minor wear scoring and indentations a If minor wear sc...

Page 1250: ...or damaged and threads show ease of movement continue inspection NOTE Ensure that parts are perfectly clean NOTE Opening pressure of relief valve is 15 bar Pressure Regulator Valve Perform the following steps for the inspection and repair of the pressure regulator valve NOTE Do not disassemble the oil pressure regulator valve 1 Visually inspect pressure regulator valve for damage a If pressure reg...

Page 1251: ... injured by escaping fluid see a doctor immediately Serious infection or adverse reaction to the fluid can result if not treated immediately 3 Visually inspect pressure regulator valve opening pressure NOTE The valve limits the oil flow so that a constant pressure of 5 5 bar 1 bar is maintained at the last main bearing Medium temperature is 90 C to 100 C Design pressure at n min n max of oil pump ...

Page 1252: ...es on gear case See Figure 749 NOTE When performing any task ensure that components are perfectly clean 1 Hex Bolts Figure 749 Installing Oil Pump with Relief Valve 2 Insert oil pump into gear case ensuring that gears engage correctly 3 Install hex bolts 1 for oil pump but not do tighten fully 4 For torque limits refer to section A 003 All information subject to change without notice C 1106 Copyri...

Page 1253: ...n pressure regulator valve See Figure 750 NOTE Ensure that parts are perfectly clean 1 Groove Figure 750 Installing Pressure Regulator Valve 6 Install pressure regulator valve into gear case and tighten to specification Refer to sectionA 003 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1107 ...

Page 1254: ...rough with compressed air and ensure that it is perfectly clean See Figure 751 1 High Pressure Oil Line 3 Banjo Bolt 2 Pipe Half Clamp Figure 751 Installing High Pressure Oil Line 8 Install new copper sealing rings 9 Install banjo bolt 3 on pressure regulator valve and gear case 10 Do not tighten banjo bolts fully 11 Mount bracket free of tension See Figure 743 All information subject to change wi...

Page 1255: ...3 13 Install banjo bolts 3 free of tension See Figure 743 NOTE On some engines two copper sealing rings are installed When reinstalling regulator valves two copper seals should be used All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1109 ...

Page 1256: ... 11 1 2 3 Install engine mount gear case end Refer to section C 231 05 11 1 2 3 Fill oil system with engine oil Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 103 After Installation Operations All information subject to c...

Page 1257: ...ssembly 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 All information subject to cha...

Page 1258: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1112 Copyright DETROIT DIESEL CORPORATION ...

Page 1259: ...ing 9 Oil Filter Housing Assembly 3 O ring 10 Oil Filter Cartridge 4 Centrifugal Oil Filter 11 Oil Filter Mounting Bracket 5 Hex Bolt 12 Hex Bolt 6 O ring 13 Hex Bolt 7 Washer 14 Maintenence Alert System Figure 752 General View of Oil Filter All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1113 ...

Page 1260: ...required for maintenance of the oil filter and centrifugal filter Application Number Strap wrench for oil filter Rotor disassembly tool 23540262 6906A Tube extraction tool 23540261 6909A Table 104 Special Tools All information subject to change without notice C 1114 Copyright DETROIT DIESEL CORPORATION ...

Page 1261: ...ne lockout Refer to Operators Guide 1 2 3 Drain engine coolant Refer to Operators Guide 1 2 3 Drain engine oil from centrifugal oil filter Refer to section C 184 05 05 C 184 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 105 Before Removal Operations All information subject to change withou...

Page 1262: ...ench to a filter cartridge 2 Turn filter with strap wrench in a counterclockwise direction to remove 3 After emptying oil filter cartridge remove with strap wrench See Figure 753 Figure 753 Removing Oil Filter Cartridges with Strap Wrench 4 Repeat step 1through step 2 until all four 4 oil filter cartridges are removed All information subject to change without notice C 1116 Copyright DETROIT DIESEL...

Page 1263: ...il Pressure Sensor 6 Remove cable clamps 3 and separate plug in connection to lube oil pressure sensor 4 NOTE Make photographic record of cable clamp fixture point for reference to avoid incorrect reinstallation which could cause engine malfunction 7 Unscrew lube oil pressure sensor 4 8 After removal seal all openings with suitable plugs All information subject to change without notice Copyright D...

Page 1264: ...Pressure Sensor 10 Remove cable straps and separate plug in connection to lube oil temperature sensor and crankcase pressure sensor 3 NOTE Make photographic record of cable clamp fixture point for reference to avoid incorrect reinstallation which could cause engine malfunction 11 Remove lube oil temperature sensor 4 and cylinder block pressure sensor 3 12 After removal seal all openings with suita...

Page 1265: ...r housing See Figure 756 1 Centrifugal Oil Filter Assembly 3 Hex Bolts for Oil Filter Housing 2 Hex Bolts for Centrifugal Oil Filter Figure 756 Removing Centrifugal Oil Filter Assembly from Oil Filter Housing 14 Remove hex bolts for oil filter housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1119 ...

Page 1266: ... bolts and washers 2 from oil filter housing and bracket 1 See Figure 757 1 Bracket 2 Hex Bolts and Washers Figure 757 Removing Oil Filter Housing Assembly All information subject to change without notice C 1120 Copyright DETROIT DIESEL CORPORATION ...

Page 1267: ...tribution housing 1 with suitable blanking plugs See Figure 758 1 Openings in Coolant Distribution Housing Figure 758 Sealing Openings in Coolant Distribution Housing with Blanking Plugs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1121 ...

Page 1268: ...ng steps for removal of the oil filter and by pass valve and spring from the oil filter housing assembly See Figure 759 1 Plug Figure 759 By Pass Location 1 Remove threaded plug with O ring from filter housing All information subject to change without notice C 1122 Copyright DETROIT DIESEL CORPORATION ...

Page 1269: ...t 3 O ring 10 Hex Bolt 4 Washer 11 Plug By Pass Valve 5 Hex Bolt 12 O ring 6 Oil FIlter Housing Assembly 13 By Pass Valve 7 Oil Filter Cartridge 14 By Pass Valve Spring Figure 760 General View of Oil Filter 3 Remove by pass valve from oil filter housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1123 ...

Page 1270: ...il filter assembly 1 Stop engine and enable engine lockout NOTE Clean around centrifugal oil filter area before disassembly See Figure 761 1 Cover Nut 4 Oil Filter Housing Assembly 2 Centrifugal Oil Filter 5 Oil Filter Cartridge 3 T bolt Clamp Figure 761 Centrifugal Oil Filter Location All information subject to change without notice C 1124 Copyright DETROIT DIESEL CORPORATION ...

Page 1271: ...ound on the outside of the centrifugal oil filter cover See Figure 762 1 Cover Nut 3 Cover Assembly 2 Service Instructions 4 Band Clamp T Bolt Figure 762 Removing Band Clamp and Cover Nut 2 Unscrew the cover nut remove the band clamp 3 Remove the centrifugal oil filter cover assembly See Figure 762 4 Drain oil from the rotor assembly Raising the rotor on the spindle may assist draining All informa...

Page 1272: ...0262 are mandatory to prevent damage during disassembly of the rotor assembly 6 Secure the rotor assembly and disassembly tool P N 23540262 6906A Unscrew the rotor assembly cover nut and seperate the rotor cover from the body See Figure 763 Figure 763 Disassembly and Extraction Tools 7 Remove the stand tube using the stand tube extraction tool P N 23540261 6909A See Figure 764 All information subj...

Page 1273: ...be 16 Band Clamp 5 Snap Ring 17 O ring 6 O ring 18 Body Assembly 7 Rotor Cover 19 Locating Pin 8 Nozzle 20 Shuttle 9 Bearing Tube Assembly 21 Spring 10 Pin 22 Washer 11 Cover Nut Tube 23 Plug 12 Pin Figure 764 Exploded View of Centrifugal Oil Filter All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1127 ...

Page 1274: ...aded bores 3 3 Sealing surfaces 2 3 Sealing surface for bracket 3 Threaded adaptor 1 a If sealing mating and sliding surfaces are worn scored or indented rub down with an emery cloth or an oilstone b If damage is beyond repair replace components as necessary c If sealing mating and sliding surfaces are not worn scored or indented continue inspection 1 Threaded Adaptor 3 Threaded Bores 2 Sealing Su...

Page 1275: ...scoring or indentations continue inspection See Figure 766 1 Sealing Surface for Bracket 3 Threaded Bores 2 Seating Surfaces of O rings 4 Plug By Pass Valve Figure 766 Inspecting Oil Filter Housing Assembly 3 Inspect in particular 3 Threaded bores 3 3 Sealing surface 3 Seating surface of O rings 2 3 Sealing surfaces for bracket 1 4 Inspect components for minor wear scoring and indentations a If we...

Page 1276: ...form the following steps to inspect and repair the centrifugal oil filter 1 Remove sludge deposits from the inside of the rotor cover using a spatula Sludge deposits should not exceed 35 mm 1 4 in See Figure 764 To avoid an eye injury when blow drying parts wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 2 Ensure that all rotor components ...

Page 1277: ...be 16 Band Clamp 5 Snap Ring 17 O ring 6 O ring 18 Body Assembly 7 Rotor Cover 19 Locating Pin 8 Nozzle 20 Shuttle 9 Bearing Tube Assembly 21 Spring 10 Pin 22 Washer 11 Cover Nut Tube 23 Plug 12 Pin Figure 767 Exploded View of Centrifugal Oil Filter All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1131 ...

Page 1278: ... and Repair of Oil Filter By Pass Valve and Spring Perform the following steps for inspection and repair of oil filter by pass valve and spring 1 Inspect opening pressure of the valve The opening pressure should be 1 79 28 bars 25 96 4 06 lb in 2 a If opening pressure does not correspond to specified value disassemble valve and readjust by fitting appropriate adjusting shims until correct value is...

Page 1279: ...CE Care should be taken to properly assemble the centrifugal oil filter to prevent external oil leaks External oil leaks could result in an engine fire 1 To install centrifugal filter assembly coat O rings with petroleum jelly and insert into groove of oil filter housing See Figure 768 1 Groove 2 Oil Filter Housing Figure 768 Inserting O rings into Groove of Oil Filter Housing 2 Install a new filt...

Page 1280: ...ther units as pin alignments may vary resulting in uneven operation and leakage NOTICE Omittion of stifferner plate during assembling will result in improper component stackup resulting in an external oil leak 4 Install stiffener plate If the stiffener plate is missing replace with new stiffener plate 5 Install the rotor cover nut and torque to 6 to 7 N m 4 43 to 5 16 lb ft All information subject...

Page 1281: ...of Safety Chain for Lock Pin 2 Pipe 1 in x 8 5 long 5 Rotor Shaft 3 Hole 9 32 Drilled Through Pipe 1 2 from Bottom on Center to Align wIth Hole in Rotor Shaft Figure 769 Fabricated Tool 7 Replace the rotor on the spindle and check that the rotor spins freely 8 Examine the centrifuge body O ring for damage and replace if necessary NOTE At 2500 hours replace the O ring All information subject to cha...

Page 1282: ...eplace the band clamp and torque to 5 to 6 N m 3 69 to 4 43 lb ft maximum The band clamp must fit securely during operation to prevent oil leaks 13 Repeat step 11and step 12 to ensure cover nut and band clamp remain tight 14 Using a tie strap place a service tag with date and hour of service around both sides of the band clamp bolt and secure tightly This tie strap will act as a safety tie to insu...

Page 1283: ...nd check for leaks or unusual noise For oil filter operation see Figure 771 1 Cover Nut 4 Body Assembly 2 Cover Assembly 5 Cut Off Valve 3 Rotor Assembly Figure 771 Centrifugal Oil Filter Operation All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1137 ...

Page 1284: ...ssages are perfectly clean NOTE Prior to installation remove all blanking plugs and or covers 1 To install oil filter housing coat O rings with petroleum jelly before installing See Figure 772 1 Coolant Distribution Housing 2 Oil Filter Housing Figure 772 Installing Oil Filter Housing 2 Fit O rings See Figure 752 3 Install oil filter housing with washers and hex bolts on coolant distribution housi...

Page 1285: ...ring with petroleum jelly and insert in groove on lube oil pressure sensor and cylinder block pressure sensor See Figure 773 1 O ring Figure 773 Inserting O ring into Groove on Oil Pressure Sensor All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1139 ...

Page 1286: ...h petroleum jelly and insert in groove on lube oil temperature sensor See Figure 774 1 Groove Figure 774 Inserting O ring into Groove on Oil Temperature Sensor All information subject to change without notice C 1140 Copyright DETROIT DIESEL CORPORATION ...

Page 1287: ...ure Sensor Figure 775 Installing Oil Line Threaded Adaptor into Oil Filter Housing 7 Install new O ring on threaded adaptor 1 and coat with petroleum jelly 8 Install threaded adaptor 1 into oil filter housing 9 Hold threaded adaptor 1 firmly with open end wrench and install oil line 10 Attach cable connector and secure with cable clamps 3 All information subject to change without notice Copyright ...

Page 1288: ...o Oil Filter Housing 12 Install cylinder block pressure sensor 3 into oil filter housing and tighten to specification Refer to section A 003 13 Coat O ring with petroleum jelly and insert in groove on threaded adaptors 4 and 5 14 Install threaded adaptor into oil filter housing 15 Hold threaded adaptors 4 and 5 firmly with open end wrench and install oil lines 1 NOTE Use only DDC branded oil filte...

Page 1289: ...sealing ring of new oil filter cartridge clean as necessary and coat with oil See Figure 777 Figure 777 Installing New Oil Filter Cartridge NOTE Coat O rings with petroleum jelly before installing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1143 ...

Page 1290: ...ually as necessary b If the oil filters are not leaking continue installation 19 Install tie strap 2 so that connector grommet and harness are connected by a tight loop See Figure 778 1 Harness 3 Crankcase Pressure 2 Tie Strap Figure 778 Installing Harness Tie Strap NOTE The harness must not slip out through the connector during engine operation All information subject to change without notice C 1...

Page 1291: ...ll the centrifugal oil filter 1 To install centrifugal filter assembly coat O rings with petroleum jelly and insert into groove of oil filter housing See Figure 779 1 Groove 2 Oil Filter Housing Figure 779 Inserting O rings into Groove of Oil Filter Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1145 ...

Page 1292: ...e with washers and hex bolts See Figure 780 Refer to section A 003 1 Hex Bolts 2 Centrifugal Oil Filter Assembly Figure 780 Assembly of Centrifugal Oil Filter Assembly to the Oil Filter Housing All information subject to change without notice C 1146 Copyright DETROIT DIESEL CORPORATION ...

Page 1293: ...l the oil filter service maintenance alert system NOTE The engine must be shut down with the safety lockout in place 1 Remove the plug 1 and 2 from oil filter adaptor See Figure 781 1 Plug 2 Plug Figure 781 Oil Filter Adaptor Plug Locations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1147 ...

Page 1294: ...ing in location 1 loose Install 1 adaptor assembly into location 2 and torque to 110 121 N m 81 89 lb ft See Figure 782 1 Fitting Elbow Assembly 5 Nut 2 Sensor 6 Adaptor 3 Seal Ring 7 Oil Feed Tube Assembly 4 Washer Figure 782 Oil Filter Service Maintenance Alert System All information subject to change without notice C 1148 Copyright DETROIT DIESEL CORPORATION ...

Page 1295: ... the black wire from the sensor harness to the 953 ground circuit 8 Connect the red wire from the sensor harness to 419 default circuit This will differ depending on the OEM s control circuit 9 Test to insure proper installation of switch as follows Reconnect battery power Then using a small screwdriver depress the delta pressure switch through the base of the adaptor 10 With the ignition on and t...

Page 1296: ...alve spring into oil filter housing See Figure 783 1 O ring 8 Oil Filter Mounting Bracket 2 O ring 9 Hex Bolt 3 O ring 10 Hex Bolt 4 Washer 11 Plug 5 Hex Bolt 12 O ring 6 Oil FIlter Housing Assembly 13 By Pass Valve 7 Oil Filter Cartridge 14 By Pass Valve Spring Figure 783 Installation of Oil Filter By Pass Valve and Spring All information subject to change without notice C 1150 Copyright DETROIT ...

Page 1297: ...all by pass valve spring 14 into by pass valve opening 4 Coat O ring on thread plug 11 and coat O ring 12 with petroleum jelly 5 Install threaded plug from oil filter housing 6 Torque threaded plug to 130 140 N m 95 88 103 26 lb ft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1151 ...

Page 1298: ...o section C 184 05 11C 184 05 11 1 2 3 Inspect for leaks or unusual noise 1 2 3 Fill engine coolant system Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 106 After Installation Operations All information subject to change...

Page 1299: ...e 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1153 ...

Page 1300: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1154 Copyright DETROIT DIESEL CORPORATION ...

Page 1301: ...the oil heat exchanger components 1 O ring 6 Cover Plate 2 Guide Bushing 7 Bolt 3 End Plate 8 Washer 4 Oil Cooler Plate 9 Spacer Bushing 5 First Plate Figure 784 General View of Oil Heat Exchanger Components All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1155 ...

Page 1302: ...ance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 107 Before Removal Operations for Oil Heat Exchanger All information subject to change without notice C 1156 Copyright DETROIT DIESEL CORPORATION ...

Page 1303: ...See Figure 785 1 Sealing Ring 7 Grommet 2 Adapter 8 Hex Nut 3 Bleed Line 9 Pipe 4 Bracket 10 Adaptor 5 Half Clamp 11 Distributor 6 Bolt 12 Distributor Bracket Figure 785 Disconnecting Vent Lines 2 Install guide studs 4 to aid in the removal of the oil heat exchanger plates See Figure 786 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1157 ...

Page 1304: ...r 5 Oil Heat Exchanger 3 Bolt Figure 786 Installing of Guide Studs NOTICE Remove the bolts in a uniform manner to avoid bolt binding and damage to the heat exchanger plates All information subject to change without notice C 1158 Copyright DETROIT DIESEL CORPORATION ...

Page 1305: ...the cover plate 6 to the front cover See Figure 787 1 O ring 6 Cover Plate 2 Guide Bushing 7 Bolt 3 End Plate 8 Washer 4 Oil Cooler Plate 9 Spacer Bushing 5 First Plate Figure 787 Removing Cover Plate All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1159 ...

Page 1306: ...l heat exchanger plates on a clean flat surface to avoid bending and gasket damage 5 Remove the oil cooler plates 4 and place on a clean flat surface See Figure 786 6 Remove the guide studs All information subject to change without notice C 1160 Copyright DETROIT DIESEL CORPORATION ...

Page 1307: ...kPa 40 lb in 2 air pressure 2 Dry the parts with compressed air Perform the following steps to inspect the oil heat exchanger 1 Visually inspect oil cooler plates and front cover with red penetrant dye or fluorescent penetrant dye for cracks a If oil cooler plates or front cover is cracked replace component as necessary b If oil cooler plates and front cover are not cracked continue inspection 2 V...

Page 1308: ...00 12 16V SERVICE MANUAL 3 Visually inspect the oil plate seals for damage replace as necessary 4 Replace all O rings All information subject to change without notice C 1162 Copyright DETROIT DIESEL CORPORATION ...

Page 1309: ...r 1 Install new O rings 1 to the base of the coolant heat exchanger See Figure 788 1 O ring 6 Cover Plate 2 Guide Bushing 7 Bolt 3 End Plate 8 Washer 4 Oil Cooler Plate 9 Spacer Bushing 5 First Plate Figure 788 Installing O rings to Coolant Heat Exchanger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1163 ...

Page 1310: ...TE Ensure order of oil cooler plates is correct 3 Install the cover plate 6 See Figure 788 4 Install spacer bushing 9 washers 8 and bolts 7 to secure the oil heat exchanger assembly to the coolant heat exchanger See Figure 788 5 Tighten bolts from the center of the plate cover to the ends in a uniform pattern to compress the plates to the required torque specification 180 N m 133 lb ft All informa...

Page 1311: ... 2 Adapter 8 Hex Nut 3 Bleed Line 9 Vent Lines 4 Bracket 10 Adaptor 5 Clamp Half 11 Distributor 6 Bolt 12 Distributor Bracket Figure 789 Connecting the Vent Lines 7 Verify repair of the oil heat exchanger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1165 ...

Page 1312: ...el of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 108 After Installations Operations All information subject to change without notice C 1166 Copyright DETROIT DIESEL CORPORATION ...

Page 1313: ...moval 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1167 ...

Page 1314: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1168 Copyright DETROIT DIESEL CORPORATION ...

Page 1315: ...al oil filter assembly 1 Cover Nut 3 Cover Assembly 2 Service Instructions 4 Band Clamp T Bolt Figure 790 General View of Centrifugal Oil Filter Assembly See Figure 791 for a general view of the centrifugal oil filter All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1169 ...

Page 1316: ...Clamp 5 Snap Ring 17 O ring 6 O ring 18 Body Assembly 7 Rotor Cover 19 Locating Pin 8 Nozzle 20 Shuttle 9 Bearing Tube Assembly 21 Spring 10 Pin 22 Washer 11 Cover Nut Tube 23 Plug 12 Pin Figure 791 General View of the Centrifugal Oil Filter All information subject to change without notice C 1170 Copyright DETROIT DIESEL CORPORATION ...

Page 1317: ...2 3 Disable engine power Refer to Operators Guide 1 2 3 Drain engine oil from centrifugal oil filter Refer to section C 184 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 109 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 11...

Page 1318: ...hex bolts 2 for centrifugal oil filter 1 and remove centrifugal oil filter from oil filter housing See Figure 792 1 Centrifugal Oil Filter 2 Hex Bolts Figure 792 Removing Centrifugal Oil Filter 2 Seal openings arrow in oil filter housing with suitable plugs See Figure 793 All information subject to change without notice C 1172 Copyright DETROIT DIESEL CORPORATION ...

Page 1319: ... MANUAL Figure 793 Sealing Openings in Oil Filter Housing with Suitable Plugs NOTE Plugs are used to keep contamination out of opening All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1173 ...

Page 1320: ...SERIES 4000 12 16V SERVICE MANUAL C 184 05 06 DISASSEMBLY OF CENTRIFUGAL OIL FILTER See OEM Guidelines All information subject to change without notice C 1174 Copyright DETROIT DIESEL CORPORATION ...

Page 1321: ...fugal oil filter 1 Remove plugs 2 Coat O ring with petroleum jelly and insert into groove 1 of oil filter housing 2 See Figure 794 1 Groove 2 Oil Filter Housing Figure 794 Coating O ring with Petroleum Jelly and Inserting into Groove of Oil Filter Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1175 ...

Page 1322: ...e with washers and hex bolts 2 See Figure 795 1 Centrifugal Oil Filter 2 Hex Bolts Figure 795 Installing Centrifugal Oil Filter 4 Tighten hex bolts to specification Refer to section A 003 All information subject to change without notice C 1176 Copyright DETROIT DIESEL CORPORATION ...

Page 1323: ...ference 1 2 3 Fill engine oil as necessary Refer to section C 184 05 11 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 110 After Installation Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1177 ...

Page 1324: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1178 Copyright DETROIT DIESEL CORPORATION ...

Page 1325: ...fore 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1179 ...

Page 1326: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1180 Copyright DETROIT DIESEL CORPORATION ...

Page 1327: ...e oil cooling system 1 O ring 7 Oil Cooler Housing 2 Cooler Core 8 O ring 3 Sealing Washer 9 Nut 4 O ring 10 Bracket 5 Hex Bolt 11 Plug in Pipe 6 Nut for Coolant Figure 796 General View of Oil Cooling System All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1181 ...

Page 1328: ... power Refer to Operators Guide 1 2 3 Drain engine coolant Refer to Operators Guide 1 2 3 Drain charge air coolant Refer to section C 206 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 111 Before Removal Operations All information subject to change without notice C 1182 Copyright DETROIT DI...

Page 1329: ...ant lines disconnect vent lines 3 See Figure 797 1 Charge Air Cooler Pipe 4 Charge Air Cooler Pipe Support Bracket 2 Coupling 5 Oil Cooler Housing 3 Vent Lines Connection 6 Vent Lines Figure 797 Removing Pipe to Charge Air Cooler 2 Unscrew hex nuts 2 for pipe connections See Figure 797 3 Remove V clamps and reattach pipe connections to respective remaining pipe See Figure 797 4 Remove hex bolt 2 a...

Page 1330: ...end See Figure 798 1 Charge Air Cooler Pipe 4 Bracket 2 Bracket Bolts 5 Clamp Seal and Coupling 3 Return Pipe 6 Charger Air Cooler Figure 798 Removing Clamps and Bracket 7 Remove clamps 8 Remove hex bolt 2 from bracket and remove bracket All information subject to change without notice C 1184 Copyright DETROIT DIESEL CORPORATION ...

Page 1331: ...Air Cooler Pipe Support Bracket 2 Coupling 5 Oil Cooler Housing 3 Vent Lines Connection 6 Vent Lines Figure 799 Removing Vent Line 10 Reattach rubber sleeve over remaining pipe end 1 11 Remove clamps 2 12 Remove vent line 3 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1185 ...

Page 1332: ... Coupling 5 Oil Cooler Housing 3 Vent Lines Connection 6 Vent Lines Figure 800 Removing Vent Lines and Pipe 14 Reattach pipe connection on pipe from charge air cooler 3 15 Separate vent line at connecting points and remove 16 Remove pipe from charge air cooler All information subject to change without notice C 1186 Copyright DETROIT DIESEL CORPORATION ...

Page 1333: ...ntercooler 2 Retainer Figure 801 Removing Pipe from Charge Air Cooler 18 Remove V clamps 1 and reattach pipe connection to respective remaining pipe 3 19 Remove hex bolt with bracket 2 and spacer washer 20 Remove pipe 3 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1187 ...

Page 1334: ...acket See Figure 802 1 Fan Control Solenoid and Bracket 3 DDEC Harness Connector 2 Hex Bolts Figure 802 Removing Fan Control Solenoid and Bracket From Cooler Housing 22 Lay 1 fan control solenoid back from oil cooler housing All information subject to change without notice C 1188 Copyright DETROIT DIESEL CORPORATION ...

Page 1335: ...ting eye 3 into left and right oil cooler housing To avoid personal injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 25 Using crane and suitable lifting device remove oil cooler housing from coolant distribution housing All information subject to change without notice Copyright DETROIT DIESEL CORPO...

Page 1336: ... 1 Oil Cooler Cores 2 Sealing Washers Figure 804 Lifting Oil Cooler Cores out of Distribution Housing Bore 27 Carefully lift oil cooler cores vertically out of distribution housing bore All information subject to change without notice C 1190 Copyright DETROIT DIESEL CORPORATION ...

Page 1337: ...ction 6 Visually inspect all sealing mating and sliding surfaces for wear scoring and indentations a If sealing mating and sliding surfaces are worn scored or indented remove minor damage by rubbing down with an emery cloth or an oilstone b If damage is beyond repair replace components as necessary c If sealing mating and sliding surfaces are not worn scored or indented continue inspection 7 Visua...

Page 1338: ...ution and the nature and type of the deposits To avoid personal injury when working near a high pressure hydraulic hose during installation and removal of components wear protective gloves safety mask and safety glasses 3 The cleaning process is completed when loosened contaminants can be flushed away with a powerful water jet 5 After cleaning flush cooler with water until pH values of clean water...

Page 1339: ...ective gloves safety mask and safety glasses 5 After cleaning oil side must be flushed with water until pH values of fresh water and flushing water are roughly equal within a difference of 1 pH NOTE Contaminants are released particularly particles from wearing parts and are flushed away with the water NOTE Flushing pressure should be within 3 bars 43 51 lb inch2 to 4 bars 58 01 lb inch2 with a flo...

Page 1340: ...ven drying time of approximately 3 hours 7 Spray preservation agent into cooler The preservation agent condenses and falls to form a protective layer over the inner surfaces NOTE Ensure dosages are correct Inspection of Cooler Core for Leaks Perform the following steps to inspect cooler core for leaks All information subject to change without notice C 1194 Copyright DETROIT DIESEL CORPORATION ...

Page 1341: ...Plug with Connection Figure 805 Inspecting Cooler Core for Leaks 2 At plug with connection 2 seal compressed air line See Figure 805 To avoid personal injury while handling HOT components wear protective gloves and clothing 3 Soak cooler core 1 in test basin filled with water heated to 80 C 176 F See Figure 805 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C...

Page 1342: ...and inspect for emerging bubbles indicating leaks a If bubbles emerge replace cooler core b If no bubbles emerge continue inspection 6 After testing remove compressed air line sleeves and plugs To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 7 Blow out cooling fins of cooler core 1 with comp...

Page 1343: ... first ensure that oil chambers and oil bores 1 are perfectly clean See Figure 806 1 Oil bores Figure 806 Inspecting Oil Chambers and Bores NOTE Prior to installation remove all blanking plugs and or covers 2 Before installing oil cooler core coat O rings 1 with petroleum jelly See Figure 807 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1197 ...

Page 1344: ...with Petroleum Jelly 3 If necessary remove blanking plugs and or covers in cooler core 4 Install oil cooler core in coolant distribution housing See Figure 808 Figure 808 Installing Oil Cooler Core All information subject to change without notice C 1198 Copyright DETROIT DIESEL CORPORATION ...

Page 1345: ...r core See Figure 809 1 O Ring 3 Elbow Groove 2 Sealing Washers Figure 809 Placing Sealing Washers over Thread of Oil Cooler Core 6 Coat O ring 1 with petroleum jelly and insert in elbow groove All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1199 ...

Page 1346: ... Cooler Housing 8 Coat O ring 2 with petroleum jelly and insert in groove on oil cooler housing 3 NOTE Early engine sealed oil cooler housing with gasket assembly sequence is the same as with O ring 9 Ensure that sealing surface of distribution housing is perfectly clean All information subject to change without notice C 1200 Copyright DETROIT DIESEL CORPORATION ...

Page 1347: ...th bracket 3 on oil cooler housing See Figure 811 Also See Figure 796for general view To avoid personal injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 12 Attach oil cooler housing with lifting eyes 3 suitable lifting device and install on coolant distribution housing with hex bolts 1 All informat...

Page 1348: ...g Eye 2 Nut Figure 812 Torquing Bolts and Nuts on Oil Cooler Housing 14 Tighten hex bolts 1 to specification Refer to section A 003 15 Install nuts 2 and tighten to specification Refer to section A 003 All information subject to change without notice C 1202 Copyright DETROIT DIESEL CORPORATION ...

Page 1349: ...for elbow 1 of coolant pipework to specification Refer to section A 003 See Figure 813 1 Elbow 2 Hex Bolts Figure 813 Torquing Hex Bolts for Elbow of Coolant Pipework All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1203 ...

Page 1350: ...ner Figure 814 Installing Pipe from Charge Air Cooler 18 Coat seal arrow with petroleum jelly 19 Install and center V clamps 1 and pipe connection 3 on pipe 20 Install hex bolts for V clamps but do not tighten 21 Install bracket 2 with hex bolt and nut but do not tighten All information subject to change without notice C 1204 Copyright DETROIT DIESEL CORPORATION ...

Page 1351: ...rt Bracket 2 Coupling 5 Oil Cooler Housing 3 Vent Lines Connection 6 Vent Lines Figure 815 Installing Vent Line 23 Install and center V clamps 1 and pipe connection 5 on pipe 3 24 Install hex nuts 4 for V clamps but do not tighten 25 Install vent line 2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1205 ...

Page 1352: ... Vent Lines Figure 816 Installing Pipe to Charge Air Cooler 27 Coat seal with petroleum jelly 28 Install and center V clamps 5 and pipe connection 6 on pipe 29 Install hex nuts for V clamps 5 but do not tighten 30 Install vent lines 3 tension free 31 Install bracket with spacer shim 1 and hex bolt but do not tighten All information subject to change without notice C 1206 Copyright DETROIT DIESEL C...

Page 1353: ...olant system Refer to section C 206 05 11 1 2 3 Fill engine coolant system Refer to Operators Guide 1 2 3 Enable engine start Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 112 After Installation Operations All information subject to change without notice Copyright DETROI...

Page 1354: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1208 Copyright DETROIT DIESEL CORPORATION ...

Page 1355: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1209 ...

Page 1356: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1210 Copyright DETROIT DIESEL CORPORATION ...

Page 1357: ... ring 6 Hex Bolt 2 Snap Ring 7 Pipe 3 Delivery Valve 8 Bracket 4 Gear Case Cover 9 Oil Spray Nozzle 5 Washer Figure 817 General View of Oil System for Piston Cooling See Figure 818 for a cross section view of the oil system for piston cooling All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1211 ...

Page 1358: ...MANUAL 1 Oil Spray Nozzle 4 Pipe 2 Bracket 5 Washer 3 O ring 6 Delivery Valve Figure 818 Cross Section of Oil System for Piston Cooling All information subject to change without notice C 1212 Copyright DETROIT DIESEL CORPORATION ...

Page 1359: ...le 113 are the special tools required for maintenance on the oil system in for piston cooling Application Number Gage for oil spray nozzle Engine barring tool Table 113 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1213 ...

Page 1360: ...2 3 Remove coolant lines high temperature Refer to section C 204 05 05 1 2 3 Remove charge air coolant lines low temperature Refer to section C 207 05 05 1 2 3 Mark and disconnect DDEC harness Refer to section C 501 05 M 1 2 3 Remove front drive hub gear case end from crankshaft Refer to section C 035 05 05 1 2 3 Remove SRS wheel Refer to section C 032 05 05 1 2 3 Remove gear case Refer to section...

Page 1361: ...riate access port cover 2 Turn crankshaft until oil spray nozzle 1 to be removed is accessible See Figure 819 1 Oil Spray Nozzle 3 Hex Bolt Location 2 Bracket 4 Oil Pipe Figure 819 Removing Oil Spray Nozzle 3 Starting at cylinder A1 or B1 remove hex bolts 3 4 Remove oil spray nozzle 1 from bracket 2 5 Remove bracket from oil pipe 4 All information subject to change without notice Copyright DETROIT...

Page 1362: ...emove oil pipe from bracket 3 See Figure 820 1 Aligning Pins 3 Bracket 2 Oil Pipe 4 Oil Pipe Figure 820 Removing Oil Pipe from Release Bracket Removal of Seal Washer Perform the following steps to remove the seal washer All information subject to change without notice C 1216 Copyright DETROIT DIESEL CORPORATION ...

Page 1363: ...n Cylinder Block 2 Remove O rings on seal washer Removal of Delivery Valve Perform the following steps to remove the delivery valve NOTE For removal of fan drive refer to section C 221 05 05 NOTE For removal of trunnion mounts gear case end refer to section C 231 05 05 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1217 ...

Page 1364: ...s 2 See Figure 822 1 Plug 3 Pipe Clamp Half 2 Hex Bolt Figure 822 Removing Hex Bolts 2 Remove pipe clamp halves 3 3 Remove plugs 1 under high pressure fuel line All information subject to change without notice C 1218 Copyright DETROIT DIESEL CORPORATION ...

Page 1365: ...ve snap ring 1 from housing See Figure 823 1 Snap Ring 3 Delivery Valve 2 O ring Figure 823 Removing Snap Ring 5 Remove delivery valve 3 from housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1219 ...

Page 1366: ...lace component as necessary b If oil spray nozzle does not show damage or defects continue inspection 3 Visually inspect oil spray nozzle for surface cracks using red penetrant dye a If oil spray nozzle is cracked replace nozzle as necessary b If oil spray nozzle is not cracked continue inspection To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or facep...

Page 1367: ... component as necessary c If threads are not damaged or worn continue inspection 7 Visually inspect sealing and mating surfaces of oil spray nozzle for wear and damage a If sealing and mating surfaces of oil spray nozzle are worn or damaged rub down with emery cloth or oilstone as necessary b If damage is beyond repair replace oil spray nozzle c If sealing and mating surfaces are not damaged reuse...

Page 1368: ...pe is not bent continue inspection Inspection and Repair Perform the following steps to inspect and repair the seal washer 1 Clean seal washer 2 Visually inspect seal washer for wear cracks and damage a If seal washer is worn cracked or damaged replace as necessary b If seal washer is not worn cracked or damaged continue inspection 3 Visually inspect bore in cylinder block for wear a If bore in cy...

Page 1369: ...ace component b If delivery valve is not damaged continue inspection 2 Visually inspect sealing surface 1 for unevenness See Figure 825 a If sealing surface is uneven smooth with oilstone as necessary b If sealing surface is not uneven continue inspection 1 Sealing Surface Figure 825 Visually Inspecting Sealing Surface NOTE A is 49 8 mm 0 1 mm 0 3 mm All information subject to change without notic...

Page 1370: ...ction or adverse reaction to the fluid can result if not treated immediately 3 Ensure that delivery valve opening pressure is 2 50 bar 0 25 bar a If values are outside specified limits replace delivery valve b If values are within specified limits continue inspection NOTE Opening pressure is marked in valve seat NOTE Earlier engines had delivery valves without O rings and opened at 1 50 bar 0 25 b...

Page 1371: ... of the oil system for piston cooling 1 Bracket Figure 826 Installing Oil Spray Nozzle NOTE Distance A from bracket 1 is to cylinder block 2 Ensure that bracket 1 is correctly positioned See Figure 826 Also see Figure 817for a general view of the oil system for piston cooling NOTE Ensure that all components are perfectly clean 3 Coat O rings with petroleum jelly and insert into grooves on oil pipe...

Page 1372: ... spray nozzle brackets 3 and secure with hex bolts 1 through cylinder block See Figure 827 1 Hex Bolts 3 Oil Spray Nozzle Bracket 2 Oil Pipe Figure 827 Installing Oil Pipes All information subject to change without notice C 1226 Copyright DETROIT DIESEL CORPORATION ...

Page 1373: ...nd do not exceed 276 kPa 40 lb in 2 air pressure 5 Blow out oil bore 1 for oil spray nozzle with compressed air and ensure that it is perfectly clean and not obstructed See Figure 828 1 Oil Bore Figure 828 Blowing Out Oil Bore with Compressed Air All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1227 ...

Page 1374: ...the crankshaft will not unexpectedly rotate and cause loss of control of barring tool 8 After installing bar engine and ensure that there is clearance between oil spray nozzle and piston and that oil nozzle is perfectly centered in oil bore of piston 9 Install access port cover Installation of Seal Washer Perform the following steps to install the seal washer NOTE Ensure that all components are pe...

Page 1375: ... insert them into grooves 1 on seal washer See Figure 830 1 Groove Figure 830 Installing O rings on Seal Washer 2 Align oil pipe 1 so that inner O ring is not damaged See Figure 831 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1229 ...

Page 1376: ...o cylinder block NOTE For further steps refer to section C 186 05 12 Installation of Delivery Valve Perform the following steps to install the delivery valve NOTE Ensure parts are perfectly clean 1 Coat O ring with petroleum jelly and insert into groove 1 See Figure 832 All information subject to change without notice C 1230 Copyright DETROIT DIESEL CORPORATION ...

Page 1377: ...L 1 Groove Figure 832 Installing Delivery Valve 2 Coat O ring 1 with petroleum jelly and insert into groove on delivery valve See Figure 833 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1231 ...

Page 1378: ...SERIES 4000 12 16V SERVICE MANUAL 1 O ring Figure 833 Installing O rings on Delivery Valve All information subject to change without notice C 1232 Copyright DETROIT DIESEL CORPORATION ...

Page 1379: ...and mating surfaces of plug for cleanness a If sealing and mating surfaces are not clean clean as necessary b If sealing and mating surfaces are clean continue inspection 6 Tighten plug with new sealing ring to specification Refer to section A 003 NOTE For installation of trunnion mounts refer to section C 231 05 11 NOTE For installation of fan drive refer to section C 221 05 11 All information su...

Page 1380: ...ant lines high temperature Refer to section C 204 05 11 1 2 3 Install charge air coolant line low temperature Refer to section C 207 05 11 1 2 3 Install oil pan Refer to section C 014 05 11 1 2 3 Install fan drive Refer to section C 221 05 11 1 2 3 Fill engine coolant system Refer to Operators Guide 1 2 3 Fill charge air coolant system Refer to section C 206 05 11 1 2 3 Fill oil system with engine...

Page 1381: ...emoval Operations C 1238 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1235 ...

Page 1382: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1236 Copyright DETROIT DIESEL CORPORATION ...

Page 1383: ...ly lines for exhaust turbocharger 1 Adapter 4 Adapter Fitting 2 A Bank Oil Supply Lines 5 O rings for A Bank 3 B Bank Oil Supply Lines 6 O rings for B Bank Figure 835 General View of Oil Supply Lines for Turbocharger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1237 ...

Page 1384: ...arger Level of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 116 Before Removal Operations All information subject to change without notice C 1238 Copyright DETROIT DIESEL CORPORATION ...

Page 1385: ...upply hose 1 See Figure 836 1 Turbocharger Oil Supply Hose 3 Adaptor Fitting 2 Box Wrench Figure 836 Removing Turbocharger Oil Supply Hose 2 Use box wrench 2 and extension to loosen connector from turbocharger oil supply hose NOTE Adapter fitting must not rotate Use a suitable tool to hold the adapter fitting in position All information subject to change without notice Copyright DETROIT DIESEL COR...

Page 1386: ... See Figure 837 1 Adaptor 2 Oil Supply Hose Figure 837 Loosening Threaded Adaptor and Removing Turbocharger Oil Supply Hose 4 Protect connections with suitable blanking plugs 5 Protect oil line from damage All information subject to change without notice C 1240 Copyright DETROIT DIESEL CORPORATION ...

Page 1387: ...a If oil supply lines for turbocharger show leaks replace lines as necessary b If oil supply lines for turbocharger do not show leaks continue inspection NOTE Test pressure is 0 5 bar To avoid an eye injury when blow drying parts wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 4 Blow dry oil supply lines for turbocharger after pressure tes...

Page 1388: ... not show damage or wear continue inspection 7 Visually inspect threads of components for damage or wear a If threads of components are damaged or worn machine as necessary b If threads of components are beyond repair replace component as necessary c If threads of components are not damaged continue inspection 8 Replace sealing rings and gaskets All information subject to change without notice C 1...

Page 1389: ...r faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 1 Blow out oil supply lines for turbocharger with compressed air and ensure that they are perfectly clean 2 Replace sealing O rings on adaptor fitting 3 Install oil supply lines for exhaust turbocharger and plugs with new sealing rings and gaskets Align and tighten to specification Refer to section A 003 4 Install brackets Align and tig...

Page 1390: ...enance Operation Reference 1 2 3 Inspect for leaks Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 117 After Installation Operations All information subject to change without notice C 1244 Copyright DETROIT DIESEL CORPORAT...

Page 1391: ...rations 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 Retu...

Page 1392: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1246 Copyright DETROIT DIESEL CORPORATION ...

Page 1393: ...for a general view of the oil return lines for turbocharger 1 Gasket 4 Hex Bolt 2 Hex Nut 5 Right Pipework 3 Left Pipework Figure 838 General View of Oil Return Lines for Turbocharger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1247 ...

Page 1394: ...r Level of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 118 Before Removal Operations All information subject to change without notice C 1248 Copyright DETROIT DIESEL CORPORATION ...

Page 1395: ...CHARGER For removal of the oil return lines for turbocharger perform the following steps 1 Remove hex nut 1 See Figure 839 1 Hex Nut Figure 839 Removing Hex Nut 2 Remove hex bolt 1 See Figure 840 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1249 ...

Page 1396: ... 1 Hex Bolts 2 Oil Return Hose Figure 840 Removing Hex Bolts 3 Remove oil return hose 2 with gaskets 4 Protect connections with suitable plugs All information subject to change without notice C 1250 Copyright DETROIT DIESEL CORPORATION ...

Page 1397: ...r for leaks with compressed air in water bath as necessary a If oil return lines for turbocharger show leaks replace lines as necessary b If oil return lines for turbocharger do not show leaks continue inspection NOTE Test pressure is 0 5 bar To avoid an eye injury when blow drying parts wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 4 Bl...

Page 1398: ...ing surfaces for damage or wear a If sealing and mating surfaces show damage or wear rub down with an oilstone or emery cloth as necessary b If sealing and mating surfaces do not show damage or wear continue inspection 7 Replace gaskets sealing rings and gaskets All information subject to change without notice C 1252 Copyright DETROIT DIESEL CORPORATION ...

Page 1399: ...e eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 1 Blow out oil lines with compressed air and ensure that they are perfectly clean 2 Install oil return lines for turbocharger with new gaskets and sealing rings Align properly and tighten to specification Refer to section A 003 NOTE After engine start visually inspect oil return lines for turbocharger fo...

Page 1400: ...harger Level of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 119 After Installation Operations All information subject to change without notice C 1254 Copyright DETROIT DIESEL CORPORATION ...

Page 1401: ...the oil supply lines parts location 1 Gasket 7 Pipe Half Clamp 2 Washer 8 Grommet 3 Bolt 9 Oil Supply Line 4 Oil Return Line 10 Hex Nut 5 O ring 11 Adaptor 6 Mounting Bracket Figure 841 General View of Oil Supply Lines for Turbocharger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1255 ...

Page 1402: ... of Maintenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 120 Before Removal Operations for Oil Supply Lines All information subject to change without notice C 1256 Copyright DETROIT DIESEL CORPORATION ...

Page 1403: ...ICE MANUAL C 185 10 05 M REMOVAL OF THE OIL SUPPLY LINES FOR TURBOCHARGER Perform the following steps to remove the oil supply lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1257 ...

Page 1404: ...alf Clamp 2 Washer 8 Grommet 3 Bolt 9 Oil Supply Line 4 Oil Return Line 10 Hex Nut 5 O ring 11 Adaptor 6 Mounting Bracket Figure 842 Removing Oil Supply Lines 2 Repeat step for the B bank turbocharger See Figure 842 3 Remove O rings 5 from the A bank turbocharger All information subject to change without notice C 1258 Copyright DETROIT DIESEL CORPORATION ...

Page 1405: ...ure 842 5 Remove gasket 1 from the A bank turbocharger 6 Repeat step for the B bank turbocharger See Figure 842 7 Remove mounting brackets 6 and pipe half clamps 7 as necessary See Figure 842 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1259 ...

Page 1406: ...f oil lines are damaged replace as necessary b If oil lines are not damaged continue inspection To avoid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 3 Pressure test oil supply lines at 0 5 bar 7 lb in 2 with compressed air in a water bath to check for leaks a If leaks are found replace oil line s...

Page 1407: ... MANUAL C 185 10 11 M INSTALLATION OF THE OIL SUPPLY LINES FOR TURBOCHARGER Perform the following steps to install the oil supply lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1261 ...

Page 1408: ...il Supply Line 4 Oil Return Line 10 Hex Nut 5 O ring 11 Adaptor 6 Mounting Bracket Figure 843 Installing Oil Supply Lines 2 Install a new gasket 1 for the A bank turbocharger 3 Repeat step for B bank turbocharger See Figure 843 4 Install new O rings 5 for the A bank turbocharger All information subject to change without notice C 1262 Copyright DETROIT DIESEL CORPORATION ...

Page 1409: ...2 and bolts 3 to secure oil supply line 9 to the A bank turbocharger 7 Repeat step for B bank turbocharger See Figure 843 8 Tighten bolt to specified torque in accordance with specifications Refer to section A 003 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1263 ...

Page 1410: ...el of Maintenance Operation Reference 1 2 3 Enable engine start Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 121 After Installation Operations for Oil Supply Lines All information subject to change without notice C 1264 Copyright DETROIT DIESEL CORPORATION ...

Page 1411: ...ew of the oil return lines parts location 1 Gasket 7 Pipe Half Clamp 2 Washer 8 Grommet 3 Bolt 9 Oil Supply Line 4 Oil Return Line 10 Hex Nut 5 O ring 11 Adaptor 6 Mounting Bracket Figure 844 General View of the Oil Return Lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1265 ...

Page 1412: ...l of Maintenance Operation Reference 1 Disable engine power Refer to Operator s Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 122 Before Removal Operations for Oil Return Lines All information subject to change without notice C 1266 Copyright DETROIT DIESEL CORPORATION ...

Page 1413: ...ICE MANUAL C 185 25 05 M REMOVAL OF THE OIL RETURN LINES FOR TURBOCHARGER Perform the following steps to remove the oil return lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1267 ...

Page 1414: ...e 845 1 Gasket 7 Pipe Half Clamp 2 Washer 8 Grommet 3 Bolt 9 Oil Supply Line 4 Oil Return Line 10 Hex Nut 5 O ring 11 Adaptor 6 Mounting Bracket Figure 845 Removing Oil Return Lines 2 Repeat step for the B bank turbocharger See Figure 845 All information subject to change without notice C 1268 Copyright DETROIT DIESEL CORPORATION ...

Page 1415: ...move bolts 3 washers 2 and O ring 5 connecting oil return line to the A bank turbocharger 4 Repeat step for the B bank turbocharger See Figure 845 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1269 ...

Page 1416: ...oid an eye injury when using compressed air wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 2 Visually inspect oil return lines for damage a If oil lines are damaged replace as necessary b If oil lines are not damaged continue inspection 3 Pressure test oil return lines at 0 5 bar 7 lb in 2 with compressed air in a water bath to check for ...

Page 1417: ... MANUAL C 185 25 11 M INSTALLATION OF THE OIL RETURN LINES FOR TURBOCHARGER Perform the following steps to install the oil return lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1271 ...

Page 1418: ...ipe Half Clamp 2 Washer 8 Grommet 3 Bolt 9 Oil Supply Line 4 Oil Return Line 10 Hex Nut 5 O ring 11 Adaptor 6 Mounting Bracket Figure 846 Installing Oil Return Lines 2 Repeat step for the B bank turbocharger See Figure 846 3 Tighten bolt to specified torque Refer to section A 003 All information subject to change without notice C 1272 Copyright DETROIT DIESEL CORPORATION ...

Page 1419: ... to cylinder block and secure with washers 2 and bolts 3 See Figure 846 5 Repeat step for the B bank turbocharger See Figure 846 6 Tighten bolt to specified torque Refer to section A 003 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1273 ...

Page 1420: ...el of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 123 After Installation Operations for Oil Return Lines All information subject to change without notice C 1274 Copyright DETROIT DIESEL CORPORATION ...

Page 1421: ... 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 13...

Page 1422: ...oolant 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 Coo...

Page 1423: ... 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 C 208 05 11 M Installation of the Surge Tank C 1527 C 208 05 12 M After Installation Operations C 1532 All information su...

Page 1424: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1278 Copyright DETROIT DIESEL CORPORATION ...

Page 1425: ...njury when using any chemical substances it is essential to observe the manufacturer s instructions for use safety instructions and waste disposal specifications All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1279 ...

Page 1426: ... KW Decalcifying agent Porodox or Euron 1308 Hydrochloric acid Corrosion preventive Pfinder AP 11 F Denatured ethanol Thin film lubricant Molycote g N plus Multipurpose grease Shell Retinax A Kerosene or diesel fuel Sealing Paste Elastosil N 189 Engineer s blue blue Antifriction bearing grease Texando F020 Corrosion preventive Caramba Express Dry compressed air Magnetic crack testing equipment wit...

Page 1427: ... 12 16V SERVICE MANUAL C 200 05 COOLING SYSTEM Section Page C 200 00 Preliminary Pressure Testing Cooling System C 1283 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1281 ...

Page 1428: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1282 Copyright DETROIT DIESEL CORPORATION ...

Page 1429: ...ith water and check for leaks See Figure 847 1 Supply Hose Line 2 Vent Line Figure 847 Pressure Testing Cooling System 1 To allow for the checking of internal components remove plugs from the following components 3 Inspection port cover 3 Charge air manifold A Bank and B Bank engine side 3 Exhaust elbow A Bank and B Bank engine side 2 Connect supply hose line 1 of coolant pressure testing device t...

Page 1430: ...MANUAL 4 Connect vent line 1 to elbow of engine high temperature water pump 2 See Figure 848 1 Vent Line Figure 848 Connecting Vent Line All information subject to change without notice C 1284 Copyright DETROIT DIESEL CORPORATION ...

Page 1431: ...t line 1 to thermostat housing coolant outlet flange See Figure 849 1 Vent Line Figure 849 Connecting Vent Line to Thermostat Housing Coolant Outlet Flange All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1285 ...

Page 1432: ...ent line 1 of coolant pressure testing device to engine vent See Figure 850 1 Vent Line Figure 850 Connecting Vent Line to Coolant Pressure Testing Device All information subject to change without notice C 1286 Copyright DETROIT DIESEL CORPORATION ...

Page 1433: ...in cylinder block A bank engine side flywheel end See Figure 851 1 Drain Hose Line 2 Coolant Port in Cylinder Block Figure 851 Connecting Drain Hose Line of Hydraulic Pressure Testing Device to Coolant Port in Block A Bank All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1287 ...

Page 1434: ... See Figure 852 1 Drain Hose Line 2 Coolant Port in Cylinder Block B Bank Figure 852 Connecting Drain Hose Line of Pressure Testing Device to Coolant Port in Black B Bank 9 Connect pressure unit and fill engine cooling system with treated coolant 10 Pressure cooling system All information subject to change without notice C 1288 Copyright DETROIT DIESEL CORPORATION ...

Page 1435: ... treated immediately 11 Pressure test cooling system with water at 80 C for one hour NOTE Test pressure with water is 5 bar test pressure with air is 1 3 bar 12 Inspect all coolant retaining components for leaks a If leaks are found replace components as necessary b If no leaks are found continue inspection 13 Release test pressure 14 Drain system 15 Remove removal tool 16 Reinstall plugs 17 Reins...

Page 1436: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1290 Copyright DETROIT DIESEL CORPORATION ...

Page 1437: ...02 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 Copyright DETROIT DIESEL COR...

Page 1438: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1292 Copyright DETROIT DIESEL CORPORATION ...

Page 1439: ...al view of the coolant high temperature water with attachments 1 Hex Bolt 6 Plug in Pipe 2 Washer 7 Nut 3 O ring 8 Thermostat Housing 4 High Temperature Water Pump 9 Bracket 5 Flange 10 Elbow Figure 853 General View of High Temperature Water Pump with Attachments All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1293 ...

Page 1440: ...aring 3 Thrust Ring 13 Washer 4 Sealing Ring 14 Bearing Housing 5 Plug 15 Spacer Sleeve 6 Metal Ring 16 Circlip 7 Impeller 17 Cylindrical Roller Bearing 8 Impeller 18 Gear 9 Rotary Seal 19 Water Pump Shaft 10 Shaft Seal Figure 854 Cutaway View of High Temperature Water Pump All information subject to change without notice C 1294 Copyright DETROIT DIESEL CORPORATION ...

Page 1441: ...ousing 12 Gear 4 Impeller 13 Cylindrical Roller Bearing 5 Metal Ring 14 Water Pump Shaft 6 O Ring 15 Spacer Sleeve 7 Thrust Ring 16 Angular Contact Ball Bearing 8 Hex Bolt 17 Shaft Seal 9 Seal Carrier 18 Rotary Seal Figure 855 Three Dimensional Overview of High Temperature Water Pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1295 ...

Page 1442: ...ntenance of the high temperature water pump Application Number Removal tool for impeller Underlay sleeve for shaft Underlay sleeve for housing Installation tool for shaft Installation tool for drive gear Table 125 Special Tools All information subject to change without notice C 1296 Copyright DETROIT DIESEL CORPORATION ...

Page 1443: ...ion Reference 1 2 3 Disable engine power Refer to Operators Guide 1 2 3 Drain engine coolant Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 126 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1297 ...

Page 1444: ...856 1 Water Pump Outlet Elbow 5 High Temperature Thermostat Housing 2 High Temperature Water Pump 6 Bolt 3 Water Pump Inlet Elbow 7 Low Temperature Thermostat Housing 4 Bolt 8 Low Temperature Water Pump Figure 856 Removing Charge Air Cooler Pipe 2 Remove charge cooler pipe flange hex bolts and remove charge air cooler pipe 6 All information subject to change without notice C 1298 Copyright DETROIT...

Page 1445: ...0 12 16V SERVICE MANUAL 3 Remove flange hex bolts at pump inlet 4 4 Remove flange hex bolts on elbow 1 5 Remove elbow 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1299 ...

Page 1446: ... 1 Hex Bolt 4 O ring 2 Washer 5 Hex Nut 3 Pump Housing Figure 857 Removing High Temperature Water Pump from Gear Case 2 Use prybar to remove high temperature water pump from gear case 3 Remove O ring from high temperature water pump All information subject to change without notice C 1300 Copyright DETROIT DIESEL CORPORATION ...

Page 1447: ...t 2 Coolant Pump Housing Figure 858 Removing Attaching Bolts from Pump Housing to Seal Carrier and Removing Pump Housing 5 Using a pry bar carefully remove pump housing 2 6 Using a jack screw remove the impeller from the pump shaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1301 ...

Page 1448: ...ring and metal ring from groove on back of impeller See Figure 859 1 Metal Ring Figure 859 Removing Thrust Ring with Inserted O ring and Metal Ring from Groove on Back of Impeller All information subject to change without notice C 1302 Copyright DETROIT DIESEL CORPORATION ...

Page 1449: ...emove thrust ring with inserted O ring and metal ring from groove on back of impeller NOTE Due to the interference fit of gear hub and shaft the shaft will be heavily scored when the gear is removed 10 Remove securing bolt 1 between seal carrier 2 and bearing housing 3 See Figure 860 11 Using a pry bar carefully remove bearing housing from seal carrier All information subject to change without not...

Page 1450: ...ure 861 Figure 861 Removing Pump Shaft with Roller Bearing Spacer Sleeve and Bearing Inner Race from Seal Carrier 13 Remove O rings from seal carrier 14 Use a suitable tool to remove bearing inner race spacer sleeve and roller bearing from pump shaft All information subject to change without notice C 1304 Copyright DETROIT DIESEL CORPORATION ...

Page 1451: ...ICE MANUAL 15 Remove snap ring 1 from bearing housing See Figure 862 1 Snap Ring Figure 862 Removing Snap Ring from Bearing Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1305 ...

Page 1452: ...ng from bearing housing 17 Remove rotary seal 3 and shaft seal behind it from seal carrier 2 See Figure 863 1 O ring 3 Rotary Seal 2 Seal Carrier Figure 863 Removing Rotary Seal and Shaft Seal from Seal Carrier All information subject to change without notice C 1306 Copyright DETROIT DIESEL CORPORATION ...

Page 1453: ...ted or pitted rub down with emery cloth or an oilstone b If damage is beyond repair replace component c If sealing surfaces and or annular grooves are not worn or damaged continue inspection 5 Visually inspect elbow housing impeller and inlet adaptor for pitting a If pitting is over 1 mm in depth replace component b If pitting is under 1 mm in depth continue inspection To avoid an eye injury when ...

Page 1454: ... is beyond repair replace component c If threads are not worn or damaged continue inspection 10 Adjust bore gage and measure bearing bores in housing a If bearing bores are not within specified limits replace components as necessary b If bearing bores are within specified limits continue inspection 11 Using micrometer measure bearing seat on shaft a If limit values are exceeded replace components ...

Page 1455: ...oller bearing See Figure 864 1 Inner Race 3 Angular Contact Ball Bearing 2 Spacer Sleeve 4 Pump Shaft Figure 864 Pressing Angular Contact Ball Bearing Spacer Sleeve and Inner Race of Cylindrical Roller Bearing on Pump Shaft 2 Place shaft contact washer in manual press 3 Place pump shaft so that mating surface for angular contact ball bearing surfaces up 4 Press the angular contact ball bearing spa...

Page 1456: ...eal arrow with Molykote See Figure 865 Figure 865 Coating Pump Shaft with Molykote 6 To prepare bearing housing degrease contact surfaces of cylindrical roller bearing in bearing housing All information subject to change without notice C 1310 Copyright DETROIT DIESEL CORPORATION ...

Page 1457: ...VICE MANUAL 7 Install cylindrical roller bearing evenly to the stop See Figure 866 Figure 866 Installing Cylindrical Roller Bearing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1311 ...

Page 1458: ... roller bearing in bearing housing See Figure 867 1 Snap Ring Figure 867 Inserting Snap Ring into Bearing Housing 9 To prepare seal carrier degrease contact surfaces of shaft seal All information subject to change without notice C 1312 Copyright DETROIT DIESEL CORPORATION ...

Page 1459: ... 1 evenly in seal carrier 2 See Figure 868 1 Shaft Seal 2 Seal Carrier Figure 868 Inserting Shaft Seal in Seal Carrier 11 Clean bore bearing surfaces with ethanol All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1313 ...

Page 1460: ...NUAL 12 Coat outer surface of rotary seal with sealant See Figure 869 Figure 869 Coating Outer Surface of Rotary Seal with Surface Sealant All information subject to change without notice C 1314 Copyright DETROIT DIESEL CORPORATION ...

Page 1461: ...rier See Figure 870 1 Rotary Seal 3 O ring 2 Seal Carrier Figure 870 Inserting Rotary Seal in Seal Carrier 14 Coat O ring 3 with petroleum jelly and insert into groove in seal carrier 2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1315 ...

Page 1462: ...nsure that bore of seal carrier comes to rest over an opening in working plate so that pump shaft is not obstructed during subsequent installation 16 Coat O ring 2 with petroleum jelly and insert into groove provided on seal carrier 1 See Figure 871 17 Screw in guide pin 3 See Figure 871 All information subject to change without notice C 1316 Copyright DETROIT DIESEL CORPORATION ...

Page 1463: ...ft in seal carrier See Figure 872 Figure 872 Installing Pump Shaft 19 Insert part of shaft coated with Molykote arrow first 20 Ensure that lip of shaft seal is not damaged All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1317 ...

Page 1464: ...ball bearing is correctly positioned in seal carrier 1 See Figure 873 1 Seal Carrier 2 Ball Bearing Figure 873 Checking Pump Shaft Positioning 22 Angular contact ball bearing 2 must be flat All information subject to change without notice C 1318 Copyright DETROIT DIESEL CORPORATION ...

Page 1465: ... place loosely on sealing ring flange 2 See Figure 874 1 Bearing Housing 2 Sealing Ring Flange Figure 874 Installing Bearing Housing on Guide Pin and Placing Loosely on Sealing Ring Flange All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1319 ...

Page 1466: ...press See Figure 875 1 Brass Drift Adapter 3 Seal Carrier 2 Bearing Housing Figure 875 Pressing Bearing Housing onto Seal Carrier 25 Use press to press bearing housing 2 onto seal carrier 3 to the stop All information subject to change without notice C 1320 Copyright DETROIT DIESEL CORPORATION ...

Page 1467: ...ainst seal carrier 3 See Figure 876 1 Hex Bolt 3 Seal Carrier 2 Bearing Housing Figure 876 Locating Bearing Housing with Hex Bolt against Seal Carrier 27 Tighten hex bolt to specification Refer to section A 003 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1321 ...

Page 1468: ...77 Figure 877 Degreasing Drive Gear To avoid personal injury while handling HOT components wear protective gloves and clothing 29 Preheat drive gear uniformly to 180 C 30 Degrease contact surfaces on drive gear and pump shaft All information subject to change without notice C 1322 Copyright DETROIT DIESEL CORPORATION ...

Page 1469: ...ress See Figure 878 Figure 878 Installing Drive Gear 32 Place installed pump shaft on adapter so that bearing housing faces up 33 Place preheated gear on pump shaft and press into place to the stop All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1323 ...

Page 1470: ... is firm See Figure 879 Figure 879 Press Fitting Drive Gear 35 Turn pump assembly over to complete the installation 36 To install impeller first degrease contact surface between pump shaft and impeller All information subject to change without notice C 1324 Copyright DETROIT DIESEL CORPORATION ...

Page 1471: ...anual press with drive gear facing down See Figure 880 Figure 880 Installing Impeller and Cleaning Rotary Seal Surface 38 Clean rotary seal surface with ethanol All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1325 ...

Page 1472: ...tall on thrust ring 2 See Figure 881 1 O ring 2 Thrust Ring Figure 881 Coating O ring and Fitting on Thrust Ring NOTE Ensure that O ring is perfectly seated against shoulder of thrust ring All information subject to change without notice C 1326 Copyright DETROIT DIESEL CORPORATION ...

Page 1473: ...urface of thrust ring See Figure 882 Figure 882 Degreasing Impeller To avoid personal injury while handling HOT components wear protective gloves and clothing 41 Preheat impeller uniformly to 210 C All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1327 ...

Page 1474: ...2 Install metal ring 1 in groove on back of impeller See Figure 883 1 Metal Ring Figure 883 Installing Metal Ring in Groove on Back of Impeller All information subject to change without notice C 1328 Copyright DETROIT DIESEL CORPORATION ...

Page 1475: ...to groove on back of impeller 1 See Figure 884 1 Impeller 2 Thrust Ring Figure 884 Pressing Thrust Ring into Groove on Back of Impeller 44 Clean inside surface of thrust ring with ethanol All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1329 ...

Page 1476: ...e 885 Placing Preheated Impeller on Pump Shaft 46 Use manual press to press impeller to stop and maintain pressure until shaft to gear shrink on connection is secure See Figure Figure 886 Securing Impeller All information subject to change without notice C 1330 Copyright DETROIT DIESEL CORPORATION ...

Page 1477: ...ump housing with petroleum jelly at contact surface to O ring arrow See Figure 887 Figure 887 Coating Pump Housing 48 Carefully place seal carrier with impeller side on pump housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1331 ...

Page 1478: ...housing on bearing housing tapping lightly with hammer or by means of light press pressure See Figure 888 Figure 888 Positioning Pump Housing on Bearing Housing All information subject to change without notice C 1332 Copyright DETROIT DIESEL CORPORATION ...

Page 1479: ...is not damaged 51 Install pump housing to seal carrier with hex bolts 1 See Figure 889 1 Hex Bolt 2 Coolant Pump Housing Figure 889 Installing Pump Housing to Seal Carrier All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1333 ...

Page 1480: ...sert in groove on bearing housing of high temperature water pump See Figure 890 1 Hex Bolt 4 O ring 2 Washer 5 Hex Nut 3 Pump Housing Figure 890 Installing High Temperature Water into Bore in Gear Case 2 Position water pump correctly and install into bore in gear case ensuring that gear engages 3 Check gear lash All information subject to change without notice C 1334 Copyright DETROIT DIESEL CORPO...

Page 1481: ...891 1 Water Pump Outlet Elbow 5 High Temperature Thermostat Housing 2 High Temperature Water Pump 6 Bolt 3 Water Pump Inlet Elbow 7 Low Temperature Thermostat Housing 4 Bolt 8 Low Temperature Water Pump Figure 891 Installing Charge Air Cooler Pipe Flange to Elbow and Bracket to Elbow All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1335 ...

Page 1482: ...ne coolant system Refer to Operators Guide 1 2 3 Inspect for leaks Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 127 After Installation Operations All information subject to change without notice C 1336 Copyright DETROIT...

Page 1483: ...e 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1337 ...

Page 1484: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1338 Copyright DETROIT DIESEL CORPORATION ...

Page 1485: ...GENERAL VIEW NOTE Refer to section before beginning any work in the cooling system See Figure 892 for a general view of the engine cooling system pipework All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1339 ...

Page 1486: ... Pipe 4 Hex Bolt 14 Connector 5 Thermostat Housing 15 Manifolds 6 Restrictor 16 Elbow 7 Gasket 17 Gasket 8 Oil Cooler Core 18 Washer 9 Washer 19 Distribution Housing 10 Nut Figure 892 General View of Engine Cooling System Pipework All information subject to change without notice C 1340 Copyright DETROIT DIESEL CORPORATION ...

Page 1487: ...ation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 2 3 Drain engine coolant Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 128 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1341 ...

Page 1488: ...it is advisable to photograph the engine from all sides or attach metal tags to the lines and fixtures so that they can be reinstalled in their original positions 1 Remove all monitoring units installed in coolant lines 2 After removing lines seal all open connections by installing suitable plugs All information subject to change without notice C 1342 Copyright DETROIT DIESEL CORPORATION ...

Page 1489: ...yond repair replace components as necessary c If no wear or damage is found continue inspection 4 Visually inspect sealing cones and banjo adaptors for damage indentations or corrosion a If sealing cones or banjo adaptors show damage indentations or corrosion replace components as necessary b If sealing cones or banjo adaptors are not damaged indented or corroded continue inspection 5 Replace rubb...

Page 1490: ...ochloric acid always wear protective clothing protective gloves goggles and safety mask Work in a well ventilated area 12 Pickle pipework in hydrochloric acid solution 9 parts water and 1 part hydrochloric acid Do not use on aluminum lines 13 Pickle up to 2 hours depending on layer of scale or rust 14 After pickling wash lines with hot water To avoid an eye injury when blow drying parts wear adequ...

Page 1491: ...id an eye injury when blow drying parts wear adequate eye protection safety glasses or faceplate and do not exceed 276 kPa 40 lb in 2 air pressure 2 Blow coolant lines clear with compressed air 3 Before assembling coat O rings with petroleum jelly 4 Install coolant lines with new gaskets sealing rings and O rings with fixtures free of tension All information subject to change without notice Copyri...

Page 1492: ...ce 1 2 3 Fill engine coolant system Refer to Operators Guide 1 2 3 Inspect for leaks 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 129 After Installation Operations All information subject to change without notice C 1346 Copyright DETROIT DIESEL...

Page 1493: ...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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1347 ...

Page 1494: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1348 Copyright DETROIT DIESEL CORPORATION ...

Page 1495: ...ooling system See Figure 893 for a general view of engine coolant pipework after cylinder head 1 Connector 3 Hex Bolt 2 O ring 4 Coolant Collecting Line Figure 893 General View of Engine Coolant Pipework after Cylinder Head All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1349 ...

Page 1496: ... 05 04 BEFORE REMOVAL OPERATIONS Refer to section C 203 05 04 for the Before Removal Operations for the engine coolant pipework after cylinder head All information subject to change without notice C 1350 Copyright DETROIT DIESEL CORPORATION ...

Page 1497: ...AL C 204 05 05 REMOVAL OF ENGINE COOLANT SYSTEM Refer to section C 203 05 05 for removal of the engine coolant pipework after cylinder head All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1351 ...

Page 1498: ...L C 204 05 08 INSPECTION AND REPAIR Refer to section C 203 05 08 for inspection and repair of the engine coolant pipework after cylinder head All information subject to change without notice C 1352 Copyright DETROIT DIESEL CORPORATION ...

Page 1499: ...204 05 11 INSTALLATION OF ENGINE COOLANT SYSTEM Refer to section C 203 05 11 for installation of the engine coolant pipework after cylinder head All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1353 ...

Page 1500: ...12 AFTER INSTALLATION OPERATIONS Refer to section C 203 05 12 for the After Installation Operations for the engine coolant pipework after cylinder head All information subject to change without notice C 1354 Copyright DETROIT DIESEL CORPORATION ...

Page 1501: ...5 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1355 ...

Page 1502: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1356 Copyright DETROIT DIESEL CORPORATION ...

Page 1503: ...ew of the high temperature cooling system vent lines 1 Hex Bolt 6 Reduction Adaptor 2 Pipe Clamp Half 7 Washer 3 Grommet 8 Distributor Block 4 T piece 9 Angled Bracket 5 Vent Line 10 Straight Bracket Figure 894 General View of High Temperature Cooling System Vent Lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1357 ...

Page 1504: ...ture cooling system vent lines 1 Reduction Washer 5 Hex Bolt 2 Washer 6 Angled Bracket 3 Pipe Clamp Half 7 Vent Line 4 Grommet Figure 895 General View of Low Temperature Cooling System Vent Lines All information subject to change without notice C 1358 Copyright DETROIT DIESEL CORPORATION ...

Page 1505: ... 04 BEFORE REMOVAL OPERATIONS Refer to section C 203 05 04 for the Before Removal Operations for the high and low temperature cooling system vent lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1359 ...

Page 1506: ...AL C 205 05 05 REMOVAL OF VENT LINES Refer to section C 203 05 05 for the removal of the high and low temperature cooling system vent lines All information subject to change without notice C 1360 Copyright DETROIT DIESEL CORPORATION ...

Page 1507: ...5 05 08 INSPECTION AND REPAIR Refer to section C 203 05 08 for the inspection and repair of the high and low temperature cooling system vent lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1361 ...

Page 1508: ...205 05 11 INSTALLATION OF VENT LINES Refer to section C 203 05 11 for the installation of the high and low temperature cooling system vent lines All information subject to change without notice C 1362 Copyright DETROIT DIESEL CORPORATION ...

Page 1509: ...AFTER INSTALLATION OPERATIONS Refer to section C 203 05 12 for the After Installation Operations for the high and low temperature cooling system vent lines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1363 ...

Page 1510: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1364 Copyright DETROIT DIESEL CORPORATION ...

Page 1511: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1365 ...

Page 1512: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1366 Copyright DETROIT DIESEL CORPORATION ...

Page 1513: ...Plate 2 Cover 11 Plate B 3 Washer 12 Plate A 4 Bolt 13 Intermediate Plate 5 Sealing Ring 14 End Plate 6 Plug 15 Mounting Bracket 7 Rubber Ring 16 Plug 8 Cover Plate 17 Base Plate 9 Guide Ring 18 Guide Sleeve Figure 896 General View of Coolant Heat Exchanger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1367 ...

Page 1514: ...Guidelines 1 2 3 Remove fuel filter assembly Refer to OEM Guidelines 1 2 3 Remove the electronic control unit Refer to OEM Guidelines 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 130 Before Removal Operations All information subject to change without notice C 1368 Copyright DETROIT DIESEL CORPO...

Page 1515: ...ove fuel lines 1 connected to and from the heat exchanger See Figure 897 1 Fuel Line 6 Sealing Ring 2 Half clamp 7 Bracket 3 Bolt 8 Check Valve 4 Grommet 9 Washer 5 Adaptor 10 Hex Nut Figure 897 Removing Fuel Lines 2 Remove the coolant level sensor 1 See Figure 898 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1369 ...

Page 1516: ...SERIES 4000 12 16V SERVICE MANUAL 1 Coolant Level Sensor Figure 898 Removing Coolant Level Sensor All information subject to change without notice C 1370 Copyright DETROIT DIESEL CORPORATION ...

Page 1517: ...6V SERVICE MANUAL 3 Install the guide studs 1 See Figure 899 1 Guide Studs 2 Heat Exchanger Figure 899 Installing Guide Studs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1371 ...

Page 1518: ...ll line 2 See Figure 900 1 Heat Exchanger 3 Surge Tank 2 Static Fill Line Figure 900 Removing Static Fill Line 5 Mark the coolant heat exchanger bolts for reassembly All information subject to change without notice C 1372 Copyright DETROIT DIESEL CORPORATION ...

Page 1519: ...olant Heat Exchanger Plate NOTE Back bolts off evenly during removal When removing the front coolant heat exchanger plate ensure that the removal tool is securely in place to avoid dropping the plate and causing personal injury NOTICE Use care when removing the coolant plates to avoid damaging the coolant plate gaskets All information subject to change without notice Copyright DETROIT DIESEL CORPO...

Page 1520: ... Plate Figure 902 Removing Front Coolant Heat Exchanger Plate 8 Remove coolant plates and place on a flat surface See Figure 903 NOTE Do not damage coolant plate gaskets 1 during removal See Figure 904 All information subject to change without notice C 1374 Copyright DETROIT DIESEL CORPORATION ...

Page 1521: ...12 Plate A 4 Bolt 13 Intermediate Plate 5 Sealing Ring 14 End Plate 6 Plug 15 Mounting Bracket 7 Rubber Ring 16 Plug 8 Cover Plate 17 Base Plate 9 Guide Ring 18 Guide Sleeve Figure 903 Removing Base Plate All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1375 ...

Page 1522: ...ES 4000 12 16V SERVICE MANUAL 1 Coolant Plate Gasket Figure 904 Removing Coolant Plates 9 Remove the guide studs All information subject to change without notice C 1376 Copyright DETROIT DIESEL CORPORATION ...

Page 1523: ...e 10 Coolant Plate 2 Cover 11 Plate B 3 Washer 12 Plate A 4 Bolt 13 Intermediate Plate 5 Sealing Ring 14 End Plate 6 Plug 15 Mounting Bracket 7 Rubber Ring 16 Plug 8 Cover Plate 17 Base Plate 9 Guide Ring 18 Guide Sleeve Figure 905 Removing Mounting Bracket All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1377 ...

Page 1524: ...bolts 1 and washers securing the base plate 2 to the front cover and remove the base plate See Figure 906 1 Bolts 80 mm 2 Base Plate Figure 906 Removing Base Plate All information subject to change without notice C 1378 Copyright DETROIT DIESEL CORPORATION ...

Page 1525: ...se Plate 5 Thermostat Housing Flange 3 Fresh Water Elbow Figure 907 Removing Base Plate Components 13 Remove thermostat housing flange O ring 14 Remove the thermostat housing flange 5 See Figure 907 15 Remove the O ring 16 Remove the base plate option plate 4 and O ring if necessary See Figure 907 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1379 ...

Page 1526: ...nd refer to section Stream Jet Cleaning Mechanical Cleaning Perform the following step for the mechanical cleaning of the coolant cooler NOTICE Use soft brushes to avoid damage to plates 1 Clean cooler plates only with a soft brush and flowing water See Figure 908 Figure 908 Cleaning Cooler Plate Stream Jet Cleaning Perform the following step to stream jet clean the coolant cooler All information ...

Page 1527: ...a 40 lb in 2 air pressure NOTICE Maintain specified service pressure and minimum spraying distance to avoid damaging plates Observe Operator Guide of equipment manufacturer 1 Remove deposits with a high pressure spraying jet See Figure 909 Figure 909 Removing Deposits Chemical Cleaning the Coolant Cooler Perform the following steps for the chemical cleaning of the coolant cooler All information su...

Page 1528: ...dium bicarbonate 3 Nitric acid 3 Citric acid 3 Phosphoric acid 3 Sodium polyphosphate 3 Parafin or naphtha NOTE Do not use the following solutions Ketone ester halogenized hydrocarbon e g chlorothene carbon tetrachloride freon aromatic compounds benzine toluene 1 To clean biological growth and sludge use alkaline cleaning agent a Caustic soda All information subject to change without notice C 1382...

Page 1529: ...and sediment calcium bicarbonate calcium sulphate corrosion products and metallic oxides use a Nitric acid b Citric acid c Phosphoric acid d Sodium polyphosphate NOTE Remove scale with a descaling product NOTE After chemical cleaning flush cooling plates with water and dry with a cloth See Figure 910 3 To clean carbon hydrogen deposits use a solution with 3 Parafin basis All information subject to...

Page 1530: ...SERVICE MANUAL 3 Naphtha basis See Figure 910 NOTE After chemical cleaning flush cooling plates with water and dry with a cloth All information subject to change without notice C 1384 Copyright DETROIT DIESEL CORPORATION ...

Page 1531: ...late 2 Base Plate 5 Thermostat Housing Flange 3 Fresh Water Elbow Figure 911 Installing Base Plate Option Plate 2 Install the thermostat housing flange 5 and O rings to the base plate See Figure 911 3 Install the fresh water elbow 3 to the base plate and secure with 3 bolts Torque bolts to 21 25 N m 15 18 lb ft 4 Install new O rings onto the base plate 2 See Figure 911 All information subject to c...

Page 1532: ...ate 2 Cooler Plates Figure 912 Placing Base Plate on Blocks of Wood 6 Install guide studs to the base plate NOTICE When assembling the coolant heat exchanger ensure that the coolant plate gaskets are properly aligned to avoid coolant leaks All information subject to change without notice C 1386 Copyright DETROIT DIESEL CORPORATION ...

Page 1533: ...all the cooler plates onto the base plate in the order in which they were removed See Figure 913 Figure 913 Installing Cooler Plates onto Base Plate All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1387 ...

Page 1534: ...r Plate 9 Install the spacers 2 washers 3 and bolts 4 to secure the front coolant heat exchanger plate 5 to the base plate See Figure 914 NOTE Finger tighten bolts Do not torque bolts NOTICE Ensure that the front coolant heat exchanger bolts are torqued in a uniform pattern This will ensure that the coolant plates are properly seated together preventing coolant leaks All information subject to cha...

Page 1535: ...plate bolts from the center of the plate to the edges in a crossing pattern to specification Refer to section A 003 See Figure 915 Figure 915 Torquing Coolant Heat Exchanger Bolts All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1389 ...

Page 1536: ...rer s cautionary notes 11 Install a lifting device 2 to the coolant heat exchanger 1 See Figure 916 1 Coolant Heat Exchanger 2 Lifting Device Figure 916 Supporting Coolant Heat Exchanger Assembly 12 Lift the coolant heat exchanger assembly and align for installation onto the front cover All information subject to change without notice C 1390 Copyright DETROIT DIESEL CORPORATION ...

Page 1537: ...assembly to the front cover and secure with six bolts Torque bolts to specification Refer to section A 003 See Figure 917 Figure 917 Torquing Sequence for Base Plate to Front Cover All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1391 ...

Page 1538: ...ssembly bracket 2 to the front cover Torque bolts to specification Refer to section A 003 See Figure 918 1 Bolts 2 Fuel Filter Assembly Bracket Figure 918 Torquing Location for Fuel Filter Assembly All information subject to change without notice C 1392 Copyright DETROIT DIESEL CORPORATION ...

Page 1539: ...re 919 1 Fuel Filter Assembly Bracket Figure 919 Torquing Location and Values for the Fuel Filter Bracket 16 Install the coolant heat exchanger mounting bracket 15 and secure with two bolts 4 and washers 3 to the front cover See Figure 920 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1393 ...

Page 1540: ...4 Bolt 13 Intermediate Plate 5 Sealing Ring 14 End Plate 6 Plug 15 Mounting Bracket 7 Rubber Ring 16 Plug 8 Cover Plate 17 Base Plate 9 Guide Ring 18 Guide Sleeve Figure 920 Installing Coolant Heat Exchanger Bracket All information subject to change without notice C 1394 Copyright DETROIT DIESEL CORPORATION ...

Page 1541: ...Line 6 Sealing Ring 2 Half clamp Pipe 7 Bracket 3 Bolt 8 Check Valve 4 Grommet 9 Washer 5 Adapter 10 Hex Nut Figure 921 Connecting Fuel Lines 18 Verify repair of the coolant heat exchanger All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1395 ...

Page 1542: ...nce Operation Reference 1 2 3 Install the electronic control unit Refer to OEM Guidelines 1 2 3 Install the surge tank Refer to OEM Guidelines 1 2 3 Install fuel filter Assembly Refer to OEM Guidelines 1 2 3 Enable engine power Refer to Operators Guide Table 131 After Installation Operations All information subject to change without notice C 1396 Copyright DETROIT DIESEL CORPORATION ...

Page 1543: ...ooling 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 notic...

Page 1544: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1398 Copyright DETROIT DIESEL CORPORATION ...

Page 1545: ...ICE MANUAL C 206 05 01 GENERAL VIEW NOTE Refer to section before beginning any work in the charge air cooling system low temperature All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1399 ...

Page 1546: ...rature 1 Washer 7 O ring 2 Mounting Bolt 8 Washer 3 Washer 9 Nut 4 Bolt 10 Washer 5 Low Temperature Thermostat Housing 11 Bolt 6 Charge Air Coolant Pump Figure 922 General View of Charge Air Coolant Pump with Attachments Charge Air Cooling System Low Temperature All information subject to change without notice C 1400 Copyright DETROIT DIESEL CORPORATION ...

Page 1547: ...Cylindrical Roller Bearing 13 Rotary Seal 4 Snap Ring 14 Countering 5 O ring 15 Impeller 6 Washer 16 Impeller Housing 7 Spacer Sleeve 17 Metal Ring 8 Bearing Housing 18 Sealing Ring 9 Hex Bolt 19 Plug 10 Angular contact Ball Bearing Figure 923 Cutaway View of Charge Air Cooling System Low Temperature All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1401 ...

Page 1548: ...ing 12 Cylindrical Roller Bearing 4 Metal Ring 13 Pump Shaft 5 O ring 14 Spacer Sleeve 6 Countering 15 Angular Contact Ball Bearing 7 Hex Bolt 16 Shaft Seal 8 Seal Carrier 17 Rotary Seal 9 Bearing Housing 18 Plug Figure 924 Three Dimensional Overview of Charge Air Cooling System Low Temperature All information subject to change without notice C 1402 Copyright DETROIT DIESEL CORPORATION ...

Page 1549: ...nce on the charge air cooling system low temperature Application Number Removal tool for impeller Washer for shaft Washer for housing Press fit sleeve for pump shaft Installation tool for drive gear impeller Table 132 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1403 ...

Page 1550: ... 05 05 1 2 3 Separate coolant supply from cooler Refer to section C 204 05 05 1 2 3 Separate coolant return from cooler Refer to section C 204 05 05 1 2 3 Release flange coolant pipe to pump inlet Refer to section C 202 05 05 1 2 3 Release flange coolant pipe to pump outlet Refer to section C 202 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely d...

Page 1551: ...ections on charge air coolant outlet 1 and return 2 See Figure 925 1 Pump Outlet Pipe 3 Coolant Supply 2 Coolant Return 4 Pump Inlet Pipe Figure 925 Loosening Pipe Connections on Charge Air Coolant Supply and Return 2 Loosen coolant pipes at pump inlet 4 and supply 3 and couplings on charge air coolant pipes All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 14...

Page 1552: ... of thermostat housing 2 and remove thermostat housing with thermo element and thermostat seal See Figure 926 1 Thermostat Housing Figure 926 Removing Thermostat Housing All information subject to change without notice C 1406 Copyright DETROIT DIESEL CORPORATION ...

Page 1553: ... Thermostat Housing 2 Bolt Figure 927 Removing Charge Air Coolant Pump from Gear Case 5 Carefully loosen charge air coolant pump 3 from gear case and remove 6 Remove O ring from charge air coolant pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1407 ...

Page 1554: ...sen securing bolts 1 from pump housing 2 to seal carrier See Figure 928 1 Securing Bolts 2 Pump Housing Figure 928 Removing Securing Bolts from Pump Housing to Seal Carrier 2 Carefully remove pump housing with pry bar 3 Use a suitable removal tool to remove impeller from charge air coolant pump shaft All information subject to change without notice C 1408 Copyright DETROIT DIESEL CORPORATION ...

Page 1555: ...tal Ring Figure 929 Removing Metal Ring from Groove on Back of Impeller 5 Use a suitable removal tool to remove gear from charge air coolant pump shaft NOTE Due to interference fit of gear hub and shaft shaft will be heavily scored when gear is removed All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1409 ...

Page 1556: ...3 See Figure 930 1 Securing Bolt 3 Bearing Housing 2 Seal Carrier Figure 930 Removing Securing Bolt between Seal Carrier and Bearing Housing 7 Using a pry bar carefully remove bearing housing 3 from seal carrier All information subject to change without notice C 1410 Copyright DETROIT DIESEL CORPORATION ...

Page 1557: ...l carrier See Figure 931 Figure 931 Removing Pump Shaft from Seal Carrier 9 Remove O rings from seal carrier 10 Use a suitable tool to remove bearing inner race spacer sleeve and roller bearing from charge air coolant pump shaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1411 ...

Page 1558: ... housing See Figure 932 1 Snap Ring Figure 932 Removing Snap Ring from Bearing Housing 12 Remove bearing cage with outer race of cylindrical roller bearing from bearing housing All information subject to change without notice C 1412 Copyright DETROIT DIESEL CORPORATION ...

Page 1559: ... behind it from seal carrier 2 See Figure 933 1 O ring 3 Rotary Seal 2 Seal Carrier Figure 933 Removing Rotary Seal and Shaft Seal from Seal Carrier 14 Remove O ring 1 from outer collar All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1413 ...

Page 1560: ... show wear indentations or pitting rub down with emery cloth or an oilstone b If damage is beyond repair replace component as necessary c If sealing surfaces and or annular grooves on elbow and housing impeller and inlet connection do not show wear indentations or pitting continue inspection 5 Visually inspect elbow housing impeller and inlet adapter for pitting a If pitting is over 1 mm in depth ...

Page 1561: ...components b If damage is beyond repair replace component c If threads are not worn or damaged continue inspection 10 Adjust bore gage and measure bearing bores in housing a If bearing bores are not within specified limits replace components as necessary b If bearing bores are within specified limits continue inspection 11 Using micrometer measure bearing seat on shaft a If limit values are exceed...

Page 1562: ...al roller bearing See Figure 934 1 Inner Race 3 Angular Contact Ball Bearing 2 Spacer Sleeve 4 Pump Shaft Figure 934 Pressing Angular Contact Ball Bearing Spacer Sleeve and Inner Race of Cylindrical Roller Bearing on Pump Shaft 2 Place shaft contact washer in manual press 3 Place pump shaft 4 so that mating surface for angular contact ball bearing faces up See Figure 934 4 Press the angular contac...

Page 1563: ...eal arrow with Molykote See Figure 935 Figure 935 Coating Pump Shaft with Molykote 6 To prepare bearing housing degrease contact surfaces of cylindrical roller bearing in bearing housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1417 ...

Page 1564: ...VICE MANUAL 7 Install cylindrical roller bearing evenly to the stop See Figure 936 Figure 936 Installing Cylindrical Roller Bearing All information subject to change without notice C 1418 Copyright DETROIT DIESEL CORPORATION ...

Page 1565: ... roller bearing in bearing housing See Figure 937 1 Snap Ring Figure 937 Inserting Snap Ring into Bearing Housing 9 To prepare seal carrier degrease contact surfaces of shaft seal All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1419 ...

Page 1566: ... evenly in seal carrier 2 See Figure 938 1 Shaft Seal 2 Seal Carrier Figure 938 Inserting Shaft Seal in Seal Carrier 11 Clean bore and bearing surfaces with ethanol All information subject to change without notice C 1420 Copyright DETROIT DIESEL CORPORATION ...

Page 1567: ...E MANUAL 12 Coat outer surface of rotary seal with sealant See Figure 939 Figure 939 Coating Outer Surface of Rotary Seal with Sealant All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1421 ...

Page 1568: ...rier See Figure 940 1 Rotary Seal 3 O ring 2 Seal Carrier Figure 940 Inserting Rotary Seal in Seal Carrier 14 Coat O ring 3 with petroleum jelly and install into groove in seal carrier 2 All information subject to change without notice C 1422 Copyright DETROIT DIESEL CORPORATION ...

Page 1569: ...ier Over NOTE Ensure that bore of seal carrier comes to rest over an opening in working plate so that pump shaft is not obstructed during subsequent installation 16 Coat O ring 2 with petroleum jelly and insert into groove provided on seal carrier 1 17 Screw in guide pin 3 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1423 ...

Page 1570: ...t in seal carrier See Figure 942 Figure 942 Installing Pump Shaft 19 Install part of shaft coated with Molykote arrow first 20 Ensure that lip of shaft seal is not damaged All information subject to change without notice C 1424 Copyright DETROIT DIESEL CORPORATION ...

Page 1571: ...ball bearing is correctly positioned in seal carrier 1 See Figure 943 1 Seal Carrier 2 Ball Bearing Figure 943 Verifying Pump Shaft Positioning 22 Angular contact ball bearing 2 must be flat All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1425 ...

Page 1572: ... housing 1 on guide pins and place loosely on sealing ring flange 2 See Figure 944 1 Bearing Housing 2 Sealing Ring Flange Figure 944 Installing Bearing Housing All information subject to change without notice C 1426 Copyright DETROIT DIESEL CORPORATION ...

Page 1573: ... press See Figure 945 1 Brass Drift Adapter 3 Seal Carrier 2 Bearing Housing Figure 945 Pressing Bearing Housing onto Seal Carrier 25 Use press to press bearing housing 2 onto seal carrier 3 to the stop All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1427 ...

Page 1574: ...ainst seal carrier 3 See Figure 946 1 Hex Bolt 3 Seal Carrier 2 Bearing Housing Figure 946 Locating Bearing Housing with Hex Bolt against Seal Carrier 27 Tighten hex bolt to specification Refer to section A 003 All information subject to change without notice C 1428 Copyright DETROIT DIESEL CORPORATION ...

Page 1575: ...47 Figure 947 Degreasing Drive Gear To avoid personal injury while handling HOT components wear protective gloves and clothing 29 Preheat drive gear uniformly to 180 C 30 Degrease contact surfaces on drive gear and pump shaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1429 ...

Page 1576: ...ress See Figure 948 Figure 948 Installing Drive Gear 32 Place installed pump shaft on adapter so that bearing housing faces up 33 Place preheated gear on pump shaft and press into place to the stop All information subject to change without notice C 1430 Copyright DETROIT DIESEL CORPORATION ...

Page 1577: ... is firm See Figure 949 Figure 949 Press Fitting Drive Gear 35 Turn pump assembly over to complete the installation 36 To install impeller first degrease contact surface between pump shaft and impeller All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1431 ...

Page 1578: ...7 Place pump on manual press with drive gear facing down See Figure 950 Figure 950 Installing Impeller 38 Clean rotary seal surface with ethanol All information subject to change without notice C 1432 Copyright DETROIT DIESEL CORPORATION ...

Page 1579: ...jelly and install on thrust ring 2 See Figure 951 1 O ring 2 Thrust Ring Figure 951 Coating O ring NOTE Ensure that O ring is perfectly seated against shoulder of thrust ring All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1433 ...

Page 1580: ...urface of thrust ring See Figure 952 Figure 952 Degreasing Impeller To avoid personal injury while handling HOT components wear protective gloves and clothing 41 Preheat impeller uniformly to 210 C All information subject to change without notice C 1434 Copyright DETROIT DIESEL CORPORATION ...

Page 1581: ...2 Install metal ring 1 in groove on back of impeller See Figure 953 1 Metal Ring Figure 953 Installing Metal Ring in Groove on Back of Impeller All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1435 ...

Page 1582: ...to groove on back of impeller 1 See Figure 954 1 Impeller 2 Thrust Ring Figure 954 Pressing Thrust Ring into Groove on Back of Impeller 44 Clean inside surface of thrust ring with ethanol All information subject to change without notice C 1436 Copyright DETROIT DIESEL CORPORATION ...

Page 1583: ...55 Placing Preheated Impeller on Pump Shaft 46 Use manual press to press impeller to stop and maintain pressure until shaft to gear shrink on connection is secure See Figure 956 Figure 956 Installing Impeller All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1437 ...

Page 1584: ...ump housing with petroleum jelly at contact surface to O ring arrow See Figure 957 Figure 957 Coating Pump Housing 48 Carefully place seal carrier with impeller side on pump housing All information subject to change without notice C 1438 Copyright DETROIT DIESEL CORPORATION ...

Page 1585: ...housing on bearing housing tapping lightly with hammer or by means of light press pressure See Figure 958 Figure 958 Positioning Pump Housing on Bearing Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1439 ...

Page 1586: ...g arrow is not damaged 51 Install pump housing to seal carrier with hex bolts 1 See Figure 959 1 Securing Hex Bolt Figure 959 Install Pump Housing to Seal Carrier All information subject to change without notice C 1440 Copyright DETROIT DIESEL CORPORATION ...

Page 1587: ...e on pump housing of charge air coolant pump 2 Install charge air coolant pump 2 into bore in gear case ensuring that gear engages See Figure 960 1 Bolt 2 Charge Air Coolant Pump 2 Washer Figure 960 Installing Charge Air Coolant Pump into Gear Case 3 Inspect gear lash 4 Install hex bolts 2 with washers and tighten uniformly to specification Refer to sectionA 003 All information subject to change w...

Page 1588: ...ermostat element dry in thermostat housing See Figure 961 1 Thermostat Housing 3 Thermostat 2 Sealing Ring 4 Mounting Bolt Figure 961 Installing Sealing Ring and Thermostat Element in Thermostat Housing All information subject to change without notice C 1442 Copyright DETROIT DIESEL CORPORATION ...

Page 1589: ...gure 962 1 Washer 3 Thermostat Housing 2 Bolt Figure 962 Installing Thermostat Housing on Charge Air Coolant Pump Housing 7 Align with charge air coolant piping 8 Ensure that thermostat element is properly seated All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1443 ...

Page 1590: ...t pump housing See Figure 963 1 Low Temperature Thermostat Housing 2 Bolt Figure 963 Securing Thermostat Housing to Charge Air Coolant Pump Housing 10 Tighten hex bolts to specification Refer to section A 003 All information subject to change without notice C 1444 Copyright DETROIT DIESEL CORPORATION ...

Page 1591: ...mperature switch Refer to section C 208 05 11 1 2 3 Connect coolant supply to cooler Refer to section C 204 05 11 1 2 3 Connect coolant return from cooler Refer to section C 204 05 11 1 2 3 Fill engine coolant system Refer to Operators Guide 1 2 3 Inspect for leaks Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine...

Page 1592: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1446 Copyright DETROIT DIESEL CORPORATION ...

Page 1593: ...moval 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1447 ...

Page 1594: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1448 Copyright DETROIT DIESEL CORPORATION ...

Page 1595: ...system See Figure 964 for a general view of the marine coolant distribution housing thermostat assembly 1 Bolts 3 Input Tube Fresh Water Pump 2 Coolant Pressure Sensor Figure 964 General View of Thermostat Housing for Marine Engines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1449 ...

Page 1596: ...intenance Operation Reference 1 2 3 Disable engine power Operator s Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 135 Before Removal Operations for the Marine Thermostat All information subject to change without notice C 1450 Copyright DETROIT DIESEL CORPORATION ...

Page 1597: ...g thermostat 1 Drain the coolant system 2 Disconnect the coolant pressure sensor 2 See Figure 965 1 Bolts 3 Input Tube Fresh Water Pump 2 Coolant Pressure Sensor Figure 965 Disconnecting the Coolant Pressure Sensor 3 Remove the fresh water supply line input 4 and connector See Figure 965 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1451 ...

Page 1598: ...2 Plug in Pipe 6 Sealing Ring 3 Flange 7 Thermostat 4 Bolt 8 Distribution Housing Figure 966 Removing O rings 5 Remove two 40 mm bolts securing the fresh water distribution housing flange 3 to the fresh water pump All information subject to change without notice C 1452 Copyright DETROIT DIESEL CORPORATION ...

Page 1599: ...mostat housing to the water distribution housing See Figure 967 1 Bolts 3 Input Tube Fresh Water Pump 2 Coolant Pressure Sensor Figure 967 Removing Bolts Securing Thermostat Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1453 ...

Page 1600: ...in Pipe 6 Sealing Ring 3 Flange 7 Thermostat 4 Bolt 8 Distribution Housing Figure 968 Removing Thermostat Housing and O rings 8 Remove the four thermostats 7 and sealing rings 6 from the thermostat housing 5 See Figure 968 NOTE Perform step 9 and step10 only if required All information subject to change without notice C 1454 Copyright DETROIT DIESEL CORPORATION ...

Page 1601: ...or securing the flange 3 and O ring 1 to the thermostat housing 5 See Figure 968 10 Remove the plug in pipe 2 and O rings 1 connected to flange 3 See Figure 968 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1455 ...

Page 1602: ...e 4 If necessary pressure test the coolant and oil chambers of the coolant distribution housing with air in water bath with corrosion inhibitor for leaks except cooling system to cooling system NOTE Test Pressure 0 5 bar a If bubbles emerge replace component as necessary b If bubbles do not emerge continue inspection 5 Visually inspect all mating surfaces for wear and damage a If wear or damage is...

Page 1603: ...elding torch or a blow torch to heat the coolant thermostat To avoid personal injury while handling HOT components wear protective gloves and clothing 4 Visually inspect coolant thermostat for start of opening with heat supply uniform and water constantly circulated a If results of inspection are not desired replace thermostat b If results are desired continue inspection 5 Reheat coolant to 85 C 1...

Page 1604: ...OF THE COOLANT DISTRIBUTION HOUSING THERMOSTAT Perform the following steps to install the coolant distribution thermostats NOTE Perform step 1 and step 2 only if required All information subject to change without notice C 1458 Copyright DETROIT DIESEL CORPORATION ...

Page 1605: ...ipe and O rings 2 Install bolts 4 to secure the flange 3 and O ring 1 to the thermostat housing 5 Torque bolts to specification Refer to section A 003 See Figure 969 3 Install the four thermostats 7 and sealing rings 6 to the thermostat housing 5 See Figure 4 Install the thermostat housing and new O rings 1 to the coolant heat exchange housing 8 See Figure 969 All information subject to change wit...

Page 1606: ... to the water distribution housing 4 Torque bolts to specification Refer to section A 003 See Figure 970 1 Bolts 3 Input Tube Fresh Water Pump 2 Coolant Pressure Sensor Figure 970 Installing Bolts All information subject to change without notice C 1460 Copyright DETROIT DIESEL CORPORATION ...

Page 1607: ...ng 3 Flange 7 Thermostat 4 Bolt 8 Distribution Housing Figure 971 Installing O rings 7 Install two 40 mm bolts to secure the fresh water distribution housing flange to the fresh water pump Torque bolts to specification Refer to section A 003 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1461 ...

Page 1608: ... See Figure 972 1 Mounting Bracket 3 Input Tube Fresh Water Pump 2 Coolant Pressure Sensor Figure 972 Connecting Coolant Pressure Sensor 9 Connect the fresh water supply line input 4 All information subject to change without notice C 1462 Copyright DETROIT DIESEL CORPORATION ...

Page 1609: ...r Installation Operations for the marine thermostat housing Level of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operator s Guide Table 136 After Installation Operations for the Marine Thermostat All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1463 ...

Page 1610: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1464 Copyright DETROIT DIESEL CORPORATION ...

Page 1611: ...oval 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1465 ...

Page 1612: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1466 Copyright DETROIT DIESEL CORPORATION ...

Page 1613: ...for a general view of the charge air cooler cooling system pipework 1 Gasket 6 Bracket 2 Bolt 7 Nut 3 Pipe 8 Bracket 4 Hex Bolt 9 Return Line 5 Coupling Assembly 10 Thermostat Housing Figure 973 General View of Charge Air Cooler Cooling System Pipework All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1467 ...

Page 1614: ...7 05 04 BEFORE REMOVAL OPERATIONS Refer to section C 203 05 04 for the Before Removal Operations for the charge air cooler cooling system pipework All information subject to change without notice C 1468 Copyright DETROIT DIESEL CORPORATION ...

Page 1615: ... 05 REMOVAL OF CHARGE AIR COOLER COOLING SYSTEM PIPEWORK Refer to section C 203 05 05 for the removal of the charge air cooler cooling system pipework All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1469 ...

Page 1616: ... C 207 05 08 INSPECTION AND REPAIR Refer to section C 203 05 08for the inspection and repair of the charge air cooler cooling system pipework All information subject to change without notice C 1470 Copyright DETROIT DIESEL CORPORATION ...

Page 1617: ...INSTALLATION OF CHARGE AIR COOLER COOLING SYSTEM PIPEWORK Refer to section C 203 05 11for the installation of the charge air cooler cooling system pipework All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1471 ...

Page 1618: ... 12 AFTER INSTALLATION OPERATIONS Refer to section C 203 05 12 for the After Installation Operations for the charge air cooler cooling system pipework All information subject to change without notice C 1472 Copyright DETROIT DIESEL CORPORATION ...

Page 1619: ... 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1473 ...

Page 1620: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1474 Copyright DETROIT DIESEL CORPORATION ...

Page 1621: ... 12 16V SERVICE MANUAL C 207 05 01 M GENERAL VIEW NOTE Refer to section before beginning any work in the cooling system All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1475 ...

Page 1622: ... Raw Water Pump Elbow 11 Cover 4 Raw Water Pump Intake Elbow 12 Restrictor 5 O ring 13 Raw Water Supply Tube 6 Gasket 14 Raw Water Supply Connector 7 Sealing Ring 15 Raw Water Supply Elbow 8 Plug 16 Elbow Figure 974 General View of Marine Water Pump Connections All information subject to change without notice C 1476 Copyright DETROIT DIESEL CORPORATION ...

Page 1623: ...ce Operation Reference 1 2 3 Disable engine power Refer to Operator s Guide 1 2 3 Cut out raw water supply Refer to Operator s Guide 1 2 3 Raw water draining Refer to Operator s Guide 1 2 3 Disconnect electric wiring Table 137 Before Removal Operations of the Marine Raw Water Pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1477 ...

Page 1624: ...M REMOVAL OF THE MARINE RAW WATER PUMP WITH CONNECTIONS Perform the following steps to remove the raw water pump 1 Drain the coolant system See Figure 975 All information subject to change without notice C 1478 Copyright DETROIT DIESEL CORPORATION ...

Page 1625: ...Raw Water Supply Tube 6 Gasket 14 Raw Water Supply Connector 7 Sealing Ring 15 Raw Water Supply Elbow 8 Plug 16 Elbow Figure 975 Draining the Cooling System 2 Remove four bolts 1 and half clamps 2 securing the raw water pump intake elbow 4 to the raw water pump elbow 3 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1479 ...

Page 1626: ...ter Pump Elbow 11 Cover 4 Raw Water Pump Intake Elbow 12 Restrictor 5 O ring 13 Raw Water Supply Tube 6 Gasket 14 Raw Water Supply Connector 7 Sealing Ring 15 Raw Water Supply Elbow 8 Plug 16 Elbow Figure 976 Removing Four Bolts Securing the Raw Water Pump Elbow to the Raw Water Pump All information subject to change without notice C 1480 Copyright DETROIT DIESEL CORPORATION ...

Page 1627: ...ve five bolts 1 securing the raw water pump to the raw water supply tube elbow 15 6 Remove three bolts 1 securing the raw water pump to the front cover 11 7 Remove the raw water pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1481 ...

Page 1628: ...Raw Water Pump Intake Elbow 12 Restrictor 5 O ring 13 Raw Water Supply Tube 6 Gasket 14 Raw Water Supply Connector 7 Sealing Ring 15 Raw Water Supply Elbow 8 Plug 16 Elbow Figure 977 Removing the Raw Water Pump Gasket 9 Remove the raw water supply tube See Figure 977 All information subject to change without notice C 1482 Copyright DETROIT DIESEL CORPORATION ...

Page 1629: ... 12 16V SERVICE MANUAL 10 Remove the raw water supply connector 14 See Figure 977 11 Remove two O rings 5 See Figure 977 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1483 ...

Page 1630: ... rubber sleeves for damage a If rubber clamps are worn or damaged replace component b If rubber clamps are not worn or damaged continue inspection 6 Replace O rings gaskets and sealing rings Perform these steps to clean and inspect the raw water pump 1 Clean all components 2 Visually inspect the spiral housing impeller intermediate element and bearing housing for cracks using the surface crack tes...

Page 1631: ...AL C 207 05 11 M INSTALLATION OF THE MARINE RAW WATER PUMP WITH CONNECTIONS Perform the following steps to install the marine raw water pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1485 ...

Page 1632: ... Intake Elbow 12 Restrictor 5 O ring 13 Raw Water Supply Tube 6 Gasket 14 Raw Water Supply Connector 7 Sealing Ring 15 Raw Water Supply Elbow 8 Plug 16 Elbow Figure 978 Installing Two New O rings 2 Install the raw water supply connector 14 See Figure 978 3 Install the raw water supply tube 13 See Figure 978 All information subject to change without notice C 1486 Copyright DETROIT DIESEL CORPORATIO...

Page 1633: ...ng 13 Raw Water Supply Tube 6 Gasket 14 Raw Water Supply Connector 7 Sealing Ring 15 Raw Water Supply Elbow 8 Plug 16 Elbow Figure 979 Installing Raw Water Pump Gasket 5 Install the raw water pump and secure with three bolts 1 to the front cover 11 Torque bolts to specification Refer to section A 003 See Figure 979 All information subject to change without notice Copyright DETROIT DIESEL CORPORATI...

Page 1634: ...s to specification Refer to section A 003 See Figure 980 1 Bolt 9 Spacer 2 Half Clamp 10 Washer 3 Raw Water Pump Elbow 11 Cover 4 Raw Water Pump Intake Elbow 12 Restrictor 5 O ring 13 Raw Water Supply Tube 6 Gasket 14 Raw Water Supply Connector 7 Sealing Ring 15 Raw Water Supply Elbow 8 Plug 16 Elbow Figure 980 Installing New O ring All information subject to change without notice C 1488 Copyright...

Page 1635: ...ow 3 and secure with clamps and four bolts 1 Torque bolts to specification Refer to section A 003 See Figure 980 9 Fill the coolant system and verify repair of raw water pump All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1489 ...

Page 1636: ...ration Reference 1 2 3 Connect electric cables 1 2 3 Connect raw water lines 1 2 3 Cut in raw water supply Refer to Operator s Guide 1 2 3 Fill raw water pump Refer to Operator s Guide 1 2 3 Enable engine power Refer to Operator s Guide Table 138 After Installation Operations for Marine Water Pump All information subject to change without notice C 1490 Copyright DETROIT DIESEL CORPORATION ...

Page 1637: ...emoval 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 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1491 ...

Page 1638: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1492 Copyright DETROIT DIESEL CORPORATION ...

Page 1639: ...W NOTE Refer to section before beginning any work in the coolant chambers See Figure 981 for a general view of the cooling system thermostat and distribution housings All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1493 ...

Page 1640: ...ribution Housing 5 Thermostat Element low temperature Circuit 14 Cover 6 O ring 15 Blanking Flange 7 Sealing Cone 16 Gasket 8 Nut 17 Elbow 9 Screw 18 Thermostat High temperature Circuit 19 Thermostat Housing Cover Low temperature Figure 981 General View of Cooling System Thermostat and Distribution Housings All information subject to change without notice C 1494 Copyright DETROIT DIESEL CORPORATIO...

Page 1641: ...tion housing and thermostat Application Number Installation tool restrictor installation removal coolant distribution housing Guide journal for restrictor Guide journal for restrictor Guide journal for restrictor Guide journal for restrictor Table 139 Special Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1495 ...

Page 1642: ...Remove oil filter Refer to section C 183 05 05 1 2 3 Remove oil centrifuge Refer to section C 184 05 05 1 2 3 Remove engine oil heat exchanger Refer to section C 185 05 05 1 2 3 Disconnect electric wiring Refer to section C 501 05 M 1 2 3 Remove fan drive Refer to section C 221 05 05 1 2 3 Remove engine mounts KGS Refer to section C 231 05 05 1 2 3 Remove coolant lines Refer to section C 204 05 05...

Page 1643: ... the removal of the coolant pipework and thermostat 1 To remove high temperature thermostat housing remove hex bolts not shown See Figure 982 1 Thermostat Housing Figure 982 Removing High temperature Thermostat Housing 2 Remove thermostat housing 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1497 ...

Page 1644: ...ove restrictor four thermostats with sealing rings and O rings See Figure 983 Figure 983 Removing Restrictor Thermostats with Sealing Rings O rings All information subject to change without notice C 1498 Copyright DETROIT DIESEL CORPORATION ...

Page 1645: ... bolts 3 attaching thermostat housing 2 to water pump 1 of the low temperature circuit See Figure 984 1 Low Temperature Thermostat Housing 2 Bolt Figure 984 Removing Low temperature Thermostat Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1499 ...

Page 1646: ...thermostat housing 2 See Figure 985 1 Washer 3 Thermostat Housing 2 Bolt Figure 985 Removing Thermostat Housing 6 Remove thermostat 4 with sealing ring All information subject to change without notice C 1500 Copyright DETROIT DIESEL CORPORATION ...

Page 1647: ...rer s cautionary notes 7 To remove distribution housing attach housing 4 with a lifting device slightly tensioned to crane See Figure 986 1 Hex Bolts 3 Cover 2 Hex Bolts 4 Distribution Housing Figure 986 Removing Distribution Housing 8 Remove hex bolts 2 and cover 3 9 Remove hex bolts 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1501 ...

Page 1648: ...able lifting device and review all manufacturer s cautionary notes 10 Lift distribution housing from gear case See Figure 987 1 O ring 3 Coolant Distribution Housing 2 Hex Bolt 4 Gear Case Figure 987 Lifting Distribution Housing from Gear Case All information subject to change without notice C 1502 Copyright DETROIT DIESEL CORPORATION ...

Page 1649: ...SERIES 4000 12 16V SERVICE MANUAL 11 Remove O rings 12 Remove elbow Not shown Refer to section C 208 05 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1503 ...

Page 1650: ... housings are not cracked continue inspection 5 Visually inspect all mating and sealing surfaces for wear and damage a If mating or sealing surfaces are worn or damaged rub down with an emery cloth or an oilstone as necessary b If damage is beyond repair replace component c If mating or sealing surfaces are not worn or damaged continue inspection 6 Visually inspect support bores of thermostat hous...

Page 1651: ...e distribution housing show leaks repair or replace the housing as necessary b If lube oil passages or coolant passages in the distribution housing do not show leaks continue inspection Inspection of Thermostats Perform the following steps for inspection of thermostats 1 Measure distance from thermostat collar to main valve head See Figure 988 Figure 988 Inspection of Thermostats 2 Hang thermostat...

Page 1652: ...le handling HOT components wear protective gloves and clothing 1 Inspect thermostat housing for start of opening with heat supply uniform and water constantly circulated a If the thermostat housing does not open within specified tolerance limits inspect and repair mechanism or replace thermostat housing as necessary b If start of opening is within specified limits heat water further to 88 C 190 4 ...

Page 1653: ...lbow Not shown Refer to sectionC 208 05 01 on distribution housing See Figure 989 1 O ring Figure 989 Installing O rings on Distributor Housing 2 Bolt cap plugs onto distribution housing and tighten 3 Coat O rings 1 with petroleum jelly and install on back of distribution housing 4 Coat mating surface arrow between rear of distribution housing and cylinder block with gasket eliminator All informat...

Page 1654: ... 1 O rings 2 Blanking Plugs Figure 990 Inserting O rings into Grooves in Gear Case 6 Install blanking plugs 2 on gear case if previously removed 7 Coat mating surface of distribution housing on gear case arrow with gasket eliminator All information subject to change without notice C 1508 Copyright DETROIT DIESEL CORPORATION ...

Page 1655: ... suitable lifting device and review all manufacturer s cautionary notes 8 Install lifting eyes into distribution housing See Figure 991 1 O ring 3 Coolant Distribution Housing 2 Hex Bolt 4 Gear Case Figure 991 Placing Housing on Gear Case All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1509 ...

Page 1656: ...ng distribution housing ensure that O rings on back of housing are not damaged 11 Install hex bolts 1 2 on distribution housing 1 See Figure 992 1 Hex Bolt 3 Cover 2 Hex Bolt 4 Distribution Housing Figure 992 Installing Hex Bolts and Distribution Housing Cover 12 Install distribution housing cover 2 13 Tighten hex bolts 1 to specification Refer to section A 003 14 To install high temperature therm...

Page 1657: ...ces are not contaminated continue installation 15 Install thermostats in thermostat housing bores See Figure 993 Figure 993 Installing Thermostats into Thermostat Housing 16 Coat O rings with petroleum jelly and insert into annular grooves All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1511 ...

Page 1658: ...stat Housing Bore 18 Install thermostat housing on coolant distribution housing by means of guide pins 19 Remove guide pins 20 Install hex bolts to secure thermostat housing Refer to section C 208 05 01 21 Tighten hex bolts to specification Refer to section A 003 All information subject to change without notice C 1512 Copyright DETROIT DIESEL CORPORATION ...

Page 1659: ...d thermostat element dry in thermostat housing See Figure 995 1 Thermostat Housing 3 Thermostat 2 Sealing Ring 4 Mounting Bolt Figure 995 Installing Sealing Ring and Thermostat Element in Thermostat Housing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1513 ...

Page 1660: ...r coolant pump 1 See Figure 996 1 Low Temperature Thermostat Housing 2 Bolt Figure 996 Installing Thermostat Housing on Charge Air Coolant Pump 24 Tighten hex bolts to specification Refer to section A 003 All information subject to change without notice C 1514 Copyright DETROIT DIESEL CORPORATION ...

Page 1661: ...es Refer to section C 501 05 M 1 2 3 Install engine mounts KGS Refer to section C 231 05 11 1 2 3 Install fan drive Refer to section C 221 05 11 1 2 3 Fill oil system with engine oil Refer to Operators Guide 1 2 3 Fill engine coolant system Refer to Operators Guide 1 2 3 Release engine start Refer to Operators Guide 1 2 3 Vent fuel system Refer to Operators Guide 1 2 3 Check for leaks Refer to Ope...

Page 1662: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1516 Copyright DETROIT DIESEL CORPORATION ...

Page 1663: ...fore 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 C 208 05 11 M Installation of the Surge Tank C 1527 C 208 05 12 M After Installation Operations C 1532 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1517 ...

Page 1664: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1518 Copyright DETROIT DIESEL CORPORATION ...

Page 1665: ... Expansion Tank 2 Union 10 Bolt 3 Coolant Line 11 Washer 4 O ring 12 Shock Mount 5 Plug in Pipe 13 Support 6 Bolt 14 Short Support Bolt 7 Half Pipe Clamp 15 Long Support Bolt 8 Retainer Bracket Figure 997 General View of Surge Tank All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1519 ...

Page 1666: ...e Operations Reference 1 2 3 Disable engine power Refer to Operator s Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 142 Before Removal Operations for the Surge Tank All information subject to change without notice C 1520 Copyright DETROIT DIESEL CORPORATION ...

Page 1667: ...emove the surge tank 1 Disconnect the static fill line 2 See Figure 998 1 Coolant Heat Exchanger 3 Surge Tank 2 Static Fill Line Figure 998 Removing Static Fill Line 2 Disconnect the bleed line tube 3 See Figure 999 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1521 ...

Page 1668: ...et 2 Adaptor 8 Hex Nut 3 Bleed Line 9 Pipe 4 Bracket 10 Union 5 Half Clamp 11 Distributor 6 Bolt 12 Distributor Bracket Figure 999 Disconnecting the Bleed Line Tube All information subject to change without notice C 1522 Copyright DETROIT DIESEL CORPORATION ...

Page 1669: ...MANUAL 3 Disconnect the coolant level sensor 1 See Figure 1000 1 Coolant Level Sensor Figure 1000 Disconnecting the Coolant Level Sensor All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1523 ...

Page 1670: ... 1001 1 Sealing Ring 9 Expansion Tank 2 Union 10 Bolt 3 Coolant Line 11 Washer 4 O ring 12 Shock Mount 5 Plug in Pipe 13 Support 6 Bolt 14 Short Support Bolt 7 Half Pipe Clamp 15 Long Support Bolt 8 Retainer Bracket Figure 1001 Removing Surge Tank Mounting Hardware All information subject to change without notice C 1524 Copyright DETROIT DIESEL CORPORATION ...

Page 1671: ...ove surge tank 9 See Figure 1001 6 Remove the four bolts 15 and 14 securing the supports 13 to the coolant heat exchanger base plate See Figure 1001 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1525 ...

Page 1672: ...inspect the surge tank for damage a If damage is found repair as necessary b If damage is beyond repair replace the surge tank c If no damage is found reuse the surge tank Interior of the Surge Tank Perform the following steps to clean inspect and repair the interior of the surge tank 1 Rinse the interior of the surge tank with a solution of water and soap 2 Rinse the interior of the surge tank wi...

Page 1673: ...owing steps to install the surge tank 1 Install the supports 13 to the coolant heat exchanger base plate and secure with four bolts 15 Torque bolts to specification Refer to section A 003 See Figure 1002 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1527 ...

Page 1674: ... Bolt 14 Short Support Bolt 7 Half Pipe Clamp 15 Long Support Bolt 8 Retainer Bracket Figure 1002 Installing Supports 2 Install the supports 13 to the coolant heat exchanger base plate and secure with four bolts 15 Torque bolts to specification Refer to section A 003 All information subject to change without notice C 1528 Copyright DETROIT DIESEL CORPORATION ...

Page 1675: ...all the coolant level sensor 1 and connect the wiring harness See Figure 1003 1 Coolant Level Sensor Figure 1003 Installing the Coolant Level Sensor All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1529 ...

Page 1676: ... 1 Sealing Ring 7 Grommet 2 Adaptor 8 Hex Nut 3 Bleed Line 9 Pipe 4 Bracket 10 Union 5 Half Clamp 11 Distributor 6 Bolt 12 Distributor Bracket Figure 1004 Installing the Bleed Line Tube All information subject to change without notice C 1530 Copyright DETROIT DIESEL CORPORATION ...

Page 1677: ...c fill line See Figure 1005 1 Coolant Heat Exchanger 3 Surge Tank 2 Static Fill Line Figure 1005 Installing the Static Fill Line 6 Verify repair of the surge tank All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1531 ...

Page 1678: ... 3 Enable engine power Refer to Operator s Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 143 After Installation Operations for the Surge Tank All information subject to change without notice C 1532 Copyright DETROIT DIESEL CORPORATION ...

Page 1679: ...Alternator C 1547 C 213 05 11 Installation of Battery Charging Alternator C 1548 C 213 05 12 After Installation Operations C 1556 C 213 05 M ALTERNATOR C 1557 C 213 05 01 M General View C 1559 C 213 05 04 M Before Removal Operations C 1560 C 213 05 05 M Removal of the Alternator C 1561 C 213 05 06 M Disassembly of the Alternator C 1567 C 213 05 08 M Inspection and Repair C 1568 C 213 05 10 M Assem...

Page 1680: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1534 Copyright DETROIT DIESEL CORPORATION ...

Page 1681: ... Battery Charging Alternator C 1539 C 213 05 06 Disassembly of Battery Charging Alternator C 1545 C 213 05 08 Inspection and Repair C 1546 C 213 05 10 Assembly of Battery Charging Alternator C 1547 C 213 05 11 Installation of Battery Charging Alternator C 1548 C 213 05 12 After Installation Operations C 1556 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 15...

Page 1682: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1536 Copyright DETROIT DIESEL CORPORATION ...

Page 1683: ...tery charging alternator 1 V Belt 8 Link 2 Hex Bolt 9 Alternator 3 Bracket 10 Belt Pulley 4 Hex Nut 11 Alternator Mount Bracket 5 Stud 12 Hex Bolt 6 Washer 13 O ring 7 Bolt 14 Alternator Drive Figure 1006 General View of Battery Charging Alternator All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1537 ...

Page 1684: ...nce 1 2 3 Disable engine power Refer to Operators Guide 1 2 3 Mark and disconnect electric cables 1 2 3 Remove protective guard 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 144 Before Removal Operations All information subject to change without notice C 1538 Copyright DETROIT DIESEL CORPORATION...

Page 1685: ...removal ensure that the negative battery pole is disconnected 1 Loosen the clamping nut 4 See Figure 1007 1 V Belt 4 Clamping Nut 2 Alternator 5 Alternator Mount Bracket 3 Locknut Figure 1007 Removing V belt from Alternator 2 Tilt alternator in direction of engine and remove V belt 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1539 ...

Page 1686: ... bolt 1 from alternator mount bracket 2 See Figure 1008 1 Hex Bolt 3 Nut 2 Alternator Mount Bracket Figure 1008 Removing Nut and Hex Bolt from Alternator Mount Bracket 5 Carefully pull down alternator All information subject to change without notice C 1540 Copyright DETROIT DIESEL CORPORATION ...

Page 1687: ...ve alternator mount bracket 4 See Figure 1009 1 Bracket 3 Hex Bolt 2 Hex Bolt 4 Alternator Mount Bracket Figure 1009 Removing Alternator Mount Bracket 7 Loosen nut not shown from hex bolt 2 and remove bracket 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1541 ...

Page 1688: ...MANUAL 8 Loosen hex bolt 2 and remove link 1 from alternator See Figure 1010 1 Link 2 Hex Bolt Figure 1010 Removing Link from Alternator All information subject to change without notice C 1542 Copyright DETROIT DIESEL CORPORATION ...

Page 1689: ...en hex nut 1 while holding alternator shaft in position with Allen key See Figure 1011 1 Hex Nut 2 Belt Pulley Figure 1011 Removing Pulley from Alternator 10 Remove pulley 2 from shaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1543 ...

Page 1690: ...r drive loosen hex bolts 1 See Figure 1012 1 Hex Bolt 2 Alternator Drive Figure 1012 Removing Alternator Drive 12 Carefully remove alternator drive 2 from gear case All information subject to change without notice C 1544 Copyright DETROIT DIESEL CORPORATION ...

Page 1691: ...E MANUAL C 213 05 06 DISASSEMBLY OF BATTERY CHARGING ALTERNATOR For disassembly of battery charging alternator refer to OEM guidelines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1545 ...

Page 1692: ...nator do not show damage or wear continue inspection 4 Visually inspect all mating surfaces for wear or damage a If mating surfaces show damage or wear rub down with oilstone or emery cloth as necessary b If damage or wear is beyond repair replace component as necessary c If mating surfaces do not show damage or wear continue inspection 5 Visually inspect threads for damage or wear a If threads ar...

Page 1693: ...VICE MANUAL C 213 05 10 ASSEMBLY OF BATTERY CHARGING ALTERNATOR For assembly of battery charging alternator refer to OEM guidelines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1547 ...

Page 1694: ...tall alternator drive 2 carefully into gear case See Figure 1013 1 Hex Bolt 2 Alternator Drive Figure 1013 Installing Alternator Drive NOTE Ensure the drive gear engages the idler gear 2 Install the hex bolts 1 and tighten diagonally and evenly to specification Refer to sectionA 003 All information subject to change without notice C 1548 Copyright DETROIT DIESEL CORPORATION ...

Page 1695: ... 1 Hex Nut 2 Pulley Figure 1014 Installing Pulley on Alternator 4 Install the hex nut 1 and tighten to specification Refer to section A 003 NOTE When tightening nut hold alternator shaft in position with Allen key All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1549 ...

Page 1696: ...igure 1015 Installing Link on Alternator NOTE Install hex bolts and hand tighten so that link can be moved to align with alternator 6 When alternator has been installed tighten hex bolt to specification Refer to section A 003 All information subject to change without notice C 1550 Copyright DETROIT DIESEL CORPORATION ...

Page 1697: ...nator Mount Bracket Figure 1016 Installing Alternator Mount Bracket 8 Install hex bolts 3 and tighten to specification Refer to section A 003 9 Position stud and mounting bracket on bracket 1 10 Install hex bolt 2 and tighten to specification Refer to section A 003 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1551 ...

Page 1698: ...s Align alternator 2 with spacer on hinge of bracket 3 See Figure 1017 1 Hex Bolt 3 Alternator Mount Bracket 2 Alternator 4 Nut Figure 1017 Installing Alternator 12 Install hex bolt 1 through spacer and hinge 13 Install nut 4 on hex bolt and tighten to specification Refer to section A 003 All information subject to change without notice C 1552 Copyright DETROIT DIESEL CORPORATION ...

Page 1699: ...amping Nut on Stud and Screwing on to End of Thread 15 Install stud into link 3 and secure with hex bolt 6 hand tight on engine 16 Install locknut 2 on spring pin and screw on until it engages 17 Move the alternator 1 in direction of engine 18 Install V belt and pull alternator away from engine to pretension the V belt All information subject to change without notice Copyright DETROIT DIESEL CORPO...

Page 1700: ...ighten clamping nut 3 to tension V belt away from engine until value on V belt tension gage See Figure 1020 is within the specified range 22 Retighten locknut 2 to specification Refer to section A 003 See Figure 1020 23 Tighten hex bolts 1 to specification Refer to section A 003 24 Again check V belt tension NOTE If measured value does not correspond to specified value retension V belt All informa...

Page 1701: ...in center between belt pulleys 1020 Figure 1020 Checking V belt Tension 26 Read off measured value on display 27 Settings for new V belt 57 70 kg 125 155 lbs Settings for run in V belt 57 70 kg 125 155 lbs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1555 ...

Page 1702: ...es in accordance with markings Refer to section C 501 05 M 1 2 3 Mount protective guard Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 145 After Installation Operations All information subject to change without notice C 1...

Page 1703: ...moval of the Alternator C 1561 C 213 05 06 M Disassembly of the Alternator C 1567 C 213 05 08 M Inspection and Repair C 1568 C 213 05 10 M Assembly of the Alternator C 1569 C 213 05 11 M Installation of the Alternator C 1570 C 213 05 12 M After Installation Operations C 1573 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1557 ...

Page 1704: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1558 Copyright DETROIT DIESEL CORPORATION ...

Page 1705: ... 11 Oil Seal 3 Alternator Clamp 12 Shaft 4 Bolt 13 Snap Ring 5 Alternator to Gear Case Mounting Bracket 14 Groove Ball Bearing 6 Washer 15 Spacer Ring 7 Heat Shield 16 Gear 8 Flange 17 Cylinder Roller Bearing 9 Hex Nut 18 O ring Figure 1021 General View of Alternator All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1559 ...

Page 1706: ...ce Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 146 Before Removal Operations for the Alternator All information subject to change without notice C 1560 Copyright DETROIT DIESEL CORPORATION ...

Page 1707: ...he alternator 1 Disconnect the battery system from the engine 2 Tag the alternator electrical leads for assembly 3 Disconnect the electrical leads from the alternator 4 Remove the engine harness attached to the alternator All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1561 ...

Page 1708: ...t 10 Coupling 2 Alternator 11 Oil Seal 3 Alternator Clamp 12 Shaft 4 Bolt 13 Snap Ring 5 Alternator to Gear Case Mounting Bracket 14 Groove Ball Bearing 6 Washer 15 Spacer Ring 7 Heat Shield 16 Gear 8 Flange 17 Cylinder Roller Bearing 9 Hex Nut 18 O ring Figure 1022 Removing Alternator All information subject to change without notice C 1562 Copyright DETROIT DIESEL CORPORATION ...

Page 1709: ... and washers securing the alternator bracket to the alternator 2 See Figure 1023 1 Mounting Bolts 2 Alternator Figure 1023 Removing Alternator Bracket to Alternator All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1563 ...

Page 1710: ... See Figure 1024 1 Alternator Bracket 2 Mounting Bolts Figure 1024 Removing Alternator Bracket to Gear Case Cover 8 Remove four bolts 4 securing the alternator clamps 3 to the alternator mounting bracket 1 remove the clamps 3 See Figure 1025 All information subject to change without notice C 1564 Copyright DETROIT DIESEL CORPORATION ...

Page 1711: ...se Mounting Bracket 14 Groove Ball Bearing 6 Washer 15 Spacer Ring 7 Heat Shield 16 Gear 8 Flange 17 Cylinder Roller Bearing 9 Hex Nut 18 O ring Figure 1025 Removing Alternator from the Mounting Bracket 9 Remove the alternator 2 from the mounting bracket 5 See Figure 1025 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1565 ...

Page 1712: ... bolts 4 and spacers securing the alternator mounting bracket to the front cover See Figure 1025 11 Remove the alternator mounting bracket 1 See Figure 1025 All information subject to change without notice C 1566 Copyright DETROIT DIESEL CORPORATION ...

Page 1713: ... 12 16V SERVICE MANUAL C 213 05 06 M DISASSEMBLY OF THE ALTERNATOR Refer to OEM guidelines to disassemble the alternator All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1567 ...

Page 1714: ...ed or defective repair as necessary b If alternator is not damaged or defective reuse the component 3 Clean the carrier and fixtures and visually inspect for damage a If carrier and fixtures are damaged replace the component as necessary b If carrier and fixtures are not damaged continue inspection 4 Visually inspect the condition of the threads for damage a If threads are damaged repair as necess...

Page 1715: ...000 12 16V SERVICE MANUAL C 213 05 10 M ASSEMBLY OF THE ALTERNATOR Refer to OEM guidelines to assemble the alternator All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1569 ...

Page 1716: ...spacers to the front cover Torque the bolts to specification Refer to section A 003 See Figure 1026 1 Alternator Bracket 10 Coupling 2 Alternator 11 Oil Seal 3 Alternator Clamps 12 Shaft 4 Bolt 13 Snap Ring 5 Alternator to Gear Case Mounting Bracket 14 Groove Ball Bearing 6 Washer 15 Spacer Ring 7 Heat Shield 16 Gear All information subject to change without notice C 1570 Copyright DETROIT DIESEL ...

Page 1717: ...lamps Torque the bolts to specification Refer to section A 003 See Figure 1026 3 Install three bolts 2 to secure the alternator bracket 1 to the front cover Torque the bolts to specification Refer to section A 003 See Figure 1027 1 Alternator Bracket 2 Mounting Bolts Figure 1027 Installing Alternator Bracket to Gear Case Cover All information subject to change without notice Copyright DETROIT DIES...

Page 1718: ...nstalling Bracket to Alternator 5 Install three bolts and washers to secure the alternator screen to the alternator See Figure 1028 6 Attach the engine harness to the alternator 7 Connect the electrical leads to the alternator 8 Connect the electrical leads to the alternator 9 Connect the engine battery system 10 Verify repair of the alternator All information subject to change without notice C 15...

Page 1719: ...ance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 147 Before Installation Operations for the Alternator All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1573 ...

Page 1720: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1574 Copyright DETROIT DIESEL CORPORATION ...

Page 1721: ...tion Operations C 1600 C 222 ROCKFORD SERIES 270 FAN CLUTCH C 1601 C 222 05 01 Operation of Rockford Series 270 Fan Clutch and General Views C 1603 C 222 05 02 Special Tools for Rockford Series 270 Fan Clutch C 1618 C 222 05 05 Removal of Rockford Series 270 Fan Clutch C 1620 C 222 05 06 Disassembly of Rockford Series 270 Fan Clutch C 1621 C 222 05 08 Inspection of Rockford Series 270 Fan Clutch C...

Page 1722: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1576 Copyright DETROIT DIESEL CORPORATION ...

Page 1723: ...tions C 1581 C 221 05 05 Removal of Fan Drive C 1582 C 221 05 06 Disassembly of Fan Drive C 1589 C 221 05 08 Inspection and Repair C 1590 C 221 05 10 Assembly of Fan Drive C 1591 C 221 05 11 Installation of Fan Drive C 1592 C 221 05 12 After Installation Operations C 1600 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1577 ...

Page 1724: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1578 Copyright DETROIT DIESEL CORPORATION ...

Page 1725: ... fan drive 1 Vee belt 7 Fan Mounting Bracket 2 Adapter 8 Bolt 3 Fitting 9 Bolt 4 Bolt 10 Fan Control Solenoid 5 Washer 11 Fan Hub Assembly 6 Hex Bolt 12 Crankshaft Pulley Figure 1029 General View of Fan Drive All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1579 ...

Page 1726: ... fan drive Application Number Press in sleeve for bearing outer race in belt pulley Press in sleeve for cap plugs Removal soft brass drift for ball bearing belt tensioner Press in sleeve for ball bearing belt tensioner Table 148 Special Tools All information subject to change without notice C 1580 Copyright DETROIT DIESEL CORPORATION ...

Page 1727: ...e power Refer to Operators Guide 1 2 3 Remove protective guard Refer to Operators Guide 1 2 3 Remove fan Refer to section C 221 05 05 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 149 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION ...

Page 1728: ... bolts 1 of fan hub bracket 2 but do not fully remove See Figure 1030 1 Hex Bolt 2 Fan Hub Bracket Figure 1030 Removing Vee belt 2 Loosen the adjusting bolt 1 to release Vee belt pretensioner See Figure 1031 All information subject to change without notice C 1582 Copyright DETROIT DIESEL CORPORATION ...

Page 1729: ...S 4000 12 16V SERVICE MANUAL 1 Adjusting Bolt 2 Vee belt Figure 1031 Loosening Adjusting Bolt 3 Remove Vee belt 2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1583 ...

Page 1730: ... manufacturer s cautionary notes 4 Attach fan hub assembly 2 to crane with lifting device and slightly pretension lifting device See Figure 1032 1 Hex Bolt 2 Fan Hub Assembly Figure 1032 Removing Hex Bolts and Fan Hub Assembly 5 Remove hex bolts 1 and remove fan hub assembly 2 All information subject to change without notice C 1584 Copyright DETROIT DIESEL CORPORATION ...

Page 1731: ...NUAL 6 Remove adapter 1 from fan hub assembly See Figure 1033 1 Adapter 2 Fan Hub Assembly Figure 1033 Removing Adapter from Hub Assembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1585 ...

Page 1732: ... cautionary notes 7 To remove fan mounting bracket 2 attach fan mounting bracket to suitable lifting device slightly tensioned to crane See Figure 1034 1 Hex Bolt 2 Fan Mounting Bracket Figure 1034 Removing Fan Mounting Bracket 8 Remove all hex bolts 1 9 Remove fan mounting bracket with crane All information subject to change without notice C 1586 Copyright DETROIT DIESEL CORPORATION ...

Page 1733: ...High Pressure Line 3 Hex Bolt 2 Oil Cooler Housing 4 Solenoid Valve Figure 1035 Removing Fan Control Solenoid 11 Loosen hex bolts 3 securing fan control solenoid on oil cooler housing 2 See Figure 1035 12 Remove fan control solenoid 4 See Figure 1035 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1587 ...

Page 1734: ...6 Removing Crankshaft Pulley 14 Remove all other hex bolts To avoid personal injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 15 Attach crankshaft pulley 2 with suitable lifting device to crane and remove via guide pins All information subject to change without notice C 1588 Copyright DETROIT DIESE...

Page 1735: ...RVICE MANUAL C 221 05 06 DISASSEMBLY OF FAN DRIVE Refer to section C 222 05 05 for overhaul of the Rockford Series 270 fan clutch All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1589 ...

Page 1736: ...or cracks replace component b If bracket does not show damage wear or cracks continue inspection 6 Visually inspect hex bolts for damage or wear a If hex bolts show damage or wear replace as necessary b If hex bolts do not show wear or damage continue inspection 7 Visually inspect all mating surfaces for damage or wear a If mating surfaces show damage or wear rub down with emery cloth or oilstone ...

Page 1737: ... Check fan hub assembly in a specialist workshop or at Manufacturer s have repaired in necessary Refer to section C 222 05 05 for overhaul of the Rockford Series 270 fan clutch All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1591 ...

Page 1738: ...al injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 2 Attach crankshaft pulley 3 with suitable lifting device to crane install over the guide pins and push against vibration damper 2 3 Insert hex bolts 1 and tighten by hand 4 Remove guide pins and install two hex bolts in their place 5 Tighten all ...

Page 1739: ...eath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 7 Attach fan bracket 2 with a suitable lifting device and install on distribution housing 4 via guide pins See Figure 1038 8 Install hex bolts 1 and tighten by hand See Figure 1038 9 Remove guide pins and install hex bolts 1 in their place tightening by hand See Figure 1038 10 Tighten all hex bolts 1...

Page 1740: ...olt 2 Oil Cooler Housing 4 Fan Control Solenoid Figure 1039 Installing Fan Control Solenoid Valve 12 Install hex bolts 3 attaching fan control solenoid and tighten to specification Refer to section A 003 See Figure 1039 13 Install the high pressure line 1 onto fan control solenoid 4 See Figure 1039 All information subject to change without notice C 1594 Copyright DETROIT DIESEL CORPORATION ...

Page 1741: ...nd tighten See Figure 1040 1 Adapter 2 Fan Hub Assembly Figure 1040 Installing Adapter on Fan Hub Assembly 15 Install guide pins at two opposite securing locations on fan mount bracket All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1595 ...

Page 1742: ...fting device and review all manufacturer s cautionary notes 16 Attach fan hub assembly 2 with suitable lifting device to crane and push on fan mount bracket via guide pins See Figure 1041 1 Hex Bolt 2 Fan Hub Assembly Figure 1041 Installing Hex Bolts All information subject to change without notice C 1596 Copyright DETROIT DIESEL CORPORATION ...

Page 1743: ...and properly tightened the fan hub assembly could loosen and engine damage could result 18 Remove guide pins and install two hex bolts in their place tightening by hand NOTE Ensure all eight bolts are installed and have been tightened to specification refer to section A 003 19 Install Vee belt 2 See Figure 1042 1 Adjusting Bolt 2 Vee belt Figure 1042 Installing Vee belt 20 Install adjusting bolt 1...

Page 1744: ...manufacturer s operator procedures 21 Remove lifting device 22 To tension Vee belt 1 position Vee belt tension gage in center between Vee belt pulleys on Vee belt See Figure 1043 1 Vee belt Figure 1043 Tensioning Vee belt 23 Read pretension value on gage All information subject to change without notice C 1598 Copyright DETROIT DIESEL CORPORATION ...

Page 1745: ...ts 25 Tighten securing bolts 1 of fan coupling to specification Refer to section A 003 26 Recheck Vee belt tension with the tension tester 27 Settings for the new Vee belt 250 295 kg 550 650 lbs Settings for run in Vee belt 250 295 kg 550 650 lbs NOTE If measured value does not correspond to specified value retension Vee belt All information subject to change without notice Copyright DETROIT DIESE...

Page 1746: ...ll fan Refer to section C 221 05 11 1 2 3 Mount protective guard Refer to Operators Guide 1 2 3 Enable engine start Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 150 After Installation Operations All information subject to change without notice C 1600 Copyright DETROIT D...

Page 1747: ...C 1618 C 222 05 05 Removal of Rockford Series 270 Fan Clutch C 1620 C 222 05 06 Disassembly of Rockford Series 270 Fan Clutch C 1621 C 222 05 08 Inspection of Rockford Series 270 Fan Clutch Components C 1646 C 222 05 10 Assembly of Rockford Series 270 Fan Clutch C 1659 C 222 05 11 Installation of Rockford Series 270 Fan Clutch C 1694 All information subject to change without notice Copyright DETRO...

Page 1748: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1602 Copyright DETROIT DIESEL CORPORATION ...

Page 1749: ...h thermal sensor located to sense the engine coolant temperature or by the engine s electronic control system The fan clutch automatically adjusts the fan speed to maintain specified coolant temperature It is controlled by the thermal sensor and solenoid valve which cause the fan speed to be increased or decreased smoothly without shock loads Oil cooled plates permit clutch slippage which allows v...

Page 1750: ...Ring 10 Rear Bearing Retainer 2 Front Main Bearing 11 Rear Oil Seal 3 Front Oil Seal 12 Large Seal Ring 4 Front Bearing Retainer 13 Piston 5 O ring Seal 14 Small Seal Ring 6 Bolt 15 Spring Washer 7 Washer 16 External Snap Ring 8 Steel Clutch Plates 17 Shim 9 Pulley 18 Rear Main Bearing Figure 1046 Input Components The slotted cup section of the bearing retainer drives the externally tanged steel c...

Page 1751: ...lted to the fan mounting hub A fan spacer is sometimes used on the fan mounting hub to position the fan relative to the radiator See Figure 1047 1 Front Main Bearing 6 Clutch Hub 2 Fan Mounting Hub 7 External Snap Ring 3 End Cap 8 Rear Sleeve Bearing 4 Retainer Seal Assembly 9 Front Sleeve Bearing 5 Front Wear Sleeve 10 Facing Plates Figure 1047 Output Components All information subject to change ...

Page 1752: ...2 Hook Type Seal Rings 6 Rear Main Bearing 3 Shaft and Bracket Assembly 7 External Snap Ring 4 Rear Wear Sleeve Figure 1048 Stationary Components Operation Modes The fan clutch is normally controlled by a thermal sensor and solenoid valve Some engine or machine manufacturers have incorporated the controls for the fan clutch into their own engine or vehicle control systems Basic fan clutch operatio...

Page 1753: ...ed engagement of the fan clutch Engine lubrication oil enters the solenoid through the inlet NO or INLET port The pressure out COM or CLUTCH opening of the solenoid valve is connected by a line to the CONTROL PRESSURE port in the fan clutch bracket The solenoid valve controls the speed of the vehicle cooling fan by regulating the amount of oil pressure supplied to engage modulate and allow release...

Page 1754: ...l reservoir sump The lower pressure inside the pressure cavity reduces the clamping force of the clutch piston The spring washer pushes the piston away from the facing plates and the clutch is allowed to slip more reducing fan speed Should engine coolant temperature stabilize fan speed stabilizes but this will rarely occur other than in tightly controlled test cell environments When the lower limi...

Page 1755: ...h supplies cooled filtered oil A flow limiting orifice in the fan clutch OIL IN port of the shaft and bracket assembly regulates the amount of oil supplied through the clutch Engine oil travels through the oil supply line from the engine to the OIL IN port on the fan clutch bracket See Figure 1050 Figure 1050 Lubricating and Cooling Oil Flow All information subject to change without notice Copyrig...

Page 1756: ...olled by oil pressure supplied through the solenoid valve Engine oil flowing from the COM or CLUTCH port of the solenoid valve enters the fan clutch through the CONTROL PRESSURE port of the shaft and bracket assembly and travels through shaft to the control pressure cavity of the fan clutch which is formed by the piston and the pulley or pulley adapter Pressure reacting within the pressure cavity ...

Page 1757: ...ag The code number see Figure 1051 illustrates the following 3 Part Number 04050157 3 Serial Number 36 3 Build Date September 1999 Rockford fan clutch date codes are listed in Table 151 Coded Date Built Year Month 3 1993 99 1999 A January G July 4 1994 00 2000 B February H August 5 1995 01 2001 C March J September 6 1996 02 2002 D April K October 7 1997 03 2003 E May L November 8 1998 04 2004 F Ju...

Page 1758: ...UAL See Figure 1052 for a sectional view of the Rockford 270 Series fan clutch Figure 1052 Sectional View of Rockford Series 270 Fan Clutch All information subject to change without notice C 1612 Copyright DETROIT DIESEL CORPORATION ...

Page 1759: ...g 11 Rear Oil Seal 3 Oil Seal 12 Large Seal Ring 4 Front Bearing Retainer 13 Piston 5 O ring Seal 14 Small Seal Ring 6 Bolt 15 Spring Washer 7 Washer 16 External Snap Ring 8 Steel Clutch Plates 17 Shim 9 Pulley 18 Rear Main Bearing Figure 1053 Rockford Series 270 Fan Clutch Input Components All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1613 ...

Page 1760: ...ain Bearing 6 Clutch Hub 2 Fan Mounting Hub 7 External Snap Ring 3 End Cap 8 Rear Sleeve Bearing 4 Retainer Seal Assembly 9 Front Sleeve Bearing 5 Front Wear Sleeve 10 Facing Plates Figure 1054 Rockford Series 270 Fan Clutch Output Components All information subject to change without notice C 1614 Copyright DETROIT DIESEL CORPORATION ...

Page 1761: ... 1 Pitot Tubes 5 Retainer Seal Assembly 2 Hook type Seal Rings 6 Rear Main Bearing 3 Shaft and Bracket Assembly 7 Rear Main Bearing 4 Rear Wear Sleeve 8 External Snap Ring Figure 1055 Rockford Series 270 Fan Clutch Stationary Components All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1615 ...

Page 1762: ... 16V SERVICE MANUAL See Figure 1056 for the DDEC IV fan clutch control system Figure 1056 DDEC IV Fan Clutch Control System All information subject to change without notice C 1616 Copyright DETROIT DIESEL CORPORATION ...

Page 1763: ...kford Series 270 fan clutch lubricating and cooling oil flow control pressure oil flow Figure 1057 Rockford Series 270 Fan Clutch Lubricating and Cooling Oil Flow Control Pressure Oil Flow All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1617 ...

Page 1764: ...ove and install sleeve bearings Special Tool 1 see Figure 1058 Special Tool 2 Remove bearings and install retainer seal assemblies and wear sleeves Special Tool 2 see Figure 1058 Special Tool 3 Install bearings and oil seals Special Tool 3 see Figure 1058 Table 152 Special Tools NOTE All special tools are to be locally fabricated All information subject to change without notice C 1618 Copyright DE...

Page 1765: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1058 Special Tools by Designation All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1619 ...

Page 1766: ...RVICE MANUAL C 222 05 05 REMOVAL OF ROCKFORD SERIES 270 FAN CLUTCH Refer to section C 221 05 05 for fan clutch removal procedures All information subject to change without notice C 1620 Copyright DETROIT DIESEL CORPORATION ...

Page 1767: ...an mounting hub facing upwards 2 Remove bolts and lock washers 1 securing front bearing retainer 3 to the fan clutch See Figure 1059 1 Bolt and Washers 3 Front Bearing Retainer 2 Socket Figure 1059 Removal of Bolts and Washers To avoid injury from a falling component while using a lifting device never stand beneath a suspended load All information subject to change without notice Copyright DETROIT...

Page 1768: ...ing retainer from the belt pulley and place on a bench See Figure 1060 NOTE A screwdriver may be used at the split line to break the bearing retainer loose from the pulley 1 Front Bearing Retainer 2 Belt Pulley Figure 1060 Removal of Front Bearing Retainer All information subject to change without notice C 1622 Copyright DETROIT DIESEL CORPORATION ...

Page 1769: ... Remove O ring seal 1 from the front bearing retainer See Figure 1061 1 O ring Seal 2 Front Bearing Retainer Figure 1061 Removal of O ring Seal All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1623 ...

Page 1770: ...aring retainer subassembly on a bench with the clutch hub 1 facing upwards Remove external snap ring 2 from the clutch hub 1 See Figure 1062 1 Clutch Hub 3 Snap Ring Pliers 2 External Snap Ring Figure 1062 Removal of External Snap Ring 6 Remove clutch hub 1 from front bearing retainer See Figure 1062 All information subject to change without notice C 1624 Copyright DETROIT DIESEL CORPORATION ...

Page 1771: ...nt bearing retainer 2 See Figure 1063 NOTE Ensure that there is support beneath the bearing retainer prior to removal 1 Fan Mounting Hub 3 Hydraulic Press Ram 2 Front Bearing Retainer Figure 1063 Removal of Front Bearing Retainer Subassembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1625 ...

Page 1772: ... from front bearing retainer 3 using a punch or drift 2 See Figure 1064 1 Front Oil Seal 3 Front Bearing Retainer 2 Punch or Drift Figure 1064 Removal of Front Oil Seal All information subject to change without notice C 1626 Copyright DETROIT DIESEL CORPORATION ...

Page 1773: ... internal snap ring 1 from bearing 2 using screwdriver 3 See Figure 1065 1 Internal Snap Ring 3 Screwdriver 2 Bearing Figure 1065 Removal of Snap Ring All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1627 ...

Page 1774: ...bearing removal tool 2 2 See Figure 1066 1 Front Bearing Retainer 3 Hydraulic Press 2 Special Bearing Removal Tool 2 Figure 1066 Removal of Front Bearing NOTICE To prevent front mount hub surface damage during removal ensure to use care to not cut through the wear sleeve with the chisel blade All information subject to change without notice C 1628 Copyright DETROIT DIESEL CORPORATION ...

Page 1775: ...with three marks 120 degrees apart 1 Wear Sleeve 3 Chisel 2 Fan Mount Hub Figure 1067 Removal of Wear Sleeve NOTE Do not perform step 12 if the retainer seal assembly is not damaged worn or otherwise in need of replacement Removal of the assembly can be omitted All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1629 ...

Page 1776: ...t off the fan mount hub 2 Remove the front retainer seal assembly from the fan mount hub See Figure 1068 1 Front Bearing Retainer 3 Crows Foot Pry Bar 2 Fan Mount Hub Figure 1068 Removal of Fan Mount Hub All information subject to change without notice C 1630 Copyright DETROIT DIESEL CORPORATION ...

Page 1777: ...ess bed With a piece of round bar stock 1 5 2 5 in diameter x 7 in long placed on the end cap press the end cap out from fan mount hub 1 See Figure 1069 1 Fan Mount Hub 2 Round Bar Stock Figure 1069 Removal of End Cap All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1631 ...

Page 1778: ...ng downwards to remove it from fan mount hub 1 See Figure 1070 NOTE The second sleeve bearing will be pressed out concurrently with the first 1 Fan Mount Hub 2 Special Removal Tool 1 Figure 1070 Removal of Sleeve Bearing All information subject to change without notice C 1632 Copyright DETROIT DIESEL CORPORATION ...

Page 1779: ...nd steel clutch plates 2 from within pulley 3 See Figure 1071 1 Facing Plates 3 Pulley 2 Steel Clutch Plates Figure 1071 Removal of Facing Plates and Steel Clutch Plates All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1633 ...

Page 1780: ... ring 1 shim 2 and spring washer 3 from pulley 4 See Figure 1072 1 External Snap Ring Spirolock 3 Spring Washer 2 Shim 4 Pulley Figure 1072 Removal External Snap Ring All information subject to change without notice C 1634 Copyright DETROIT DIESEL CORPORATION ...

Page 1781: ...ulley shaft assembly over on the bench 180 degrees Lift pulley 1 to allow piston 2 to fall out See Figure 1073 1 Pulley 2 Piston Figure 1073 Removal of Piston All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1635 ...

Page 1782: ...ston 3 See Figure 1074 1 Large Seal Ring 3 Piston 2 Small Seal Ring Figure 1074 Removal of Piston Seal Rings NOTE Ensure that the pulley is properly supported on the bench prior to performing step 19 All information subject to change without notice C 1636 Copyright DETROIT DIESEL CORPORATION ...

Page 1783: ...moved However if bearing retainer 3 is not able to be removed from pulley 2 stand the unit on the bench resting on the nose of the shaft Rap pulley 2 with a soft but heavy mallet to break it loose from rear bearing retainer 3 1 Bolts 3 Rear Bearing Retainer 2 Pulley 4 Socket Figure 1075 Removal of Rear Bearing Retainer All information subject to change without notice Copyright DETROIT DIESEL CORPO...

Page 1784: ...m the shaft Rotate pitot tubes 1 until the sealant securing them to the pulley shaft 2 is broken loose Grip the pitot tubes with a pair of pliers and gently tap the pliers to remove the pitot tubes from the hole in the shaft See Figure 1076 1 Pitot Tubes 3 Pliers 2 Pulley Shaft Figure 1076 Removal of Pulley Shaft All information subject to change without notice C 1638 Copyright DETROIT DIESEL CORP...

Page 1785: ...e seal rings 1 from pulley shaft See Figure 1077 1 Seal Rings 3 Pitot Tubes 2 Rear Bearing Retainer Figure 1077 Removal of Seal Rings from Pulley Shaft All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1639 ...

Page 1786: ... 23 Remove internal snap ring 3 See Figure 1078 NOTE Ensure that the rear bearing retainer is properly supported prior to removal of the shaft step 24 The retainer should be supported as close as possible to the bearing bore but not too close as to damage the retainer seal assembly All information subject to change without notice C 1640 Copyright DETROIT DIESEL CORPORATION ...

Page 1787: ...ydraulic press 4 press shaft 2 out from bearing 1 See Figure 1079 1 Bearing 3 Rear Bearing Retainer 2 Shaft 4 Hydraulic Press Figure 1079 Removal of Bearing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1641 ...

Page 1788: ...Remove oil seal 1 from rear bearing retainer 3 See Figure 1080 1 Oil Seal 3 Rear Bearing Retainer 2 Punch or Drift Figure 1080 Removal of Oil Seal All information subject to change without notice C 1642 Copyright DETROIT DIESEL CORPORATION ...

Page 1789: ...1 Rear Bearing Retainer 3 Hydraulic Press 2 Special Bearing Removal Tool 2 Figure 1081 Removal of Rear Bearing To avoid injury wear protective clothing and eye protection NOTICE To prevent hub surface damage during removal do not cut through the wear sleeve with the chisel blade All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1643 ...

Page 1790: ...leeve 3 Shaft 2 Chisel Figure 1082 Removal of Wear Sleeve NOTE Do not remove retainer seal assembly step 28 if not damaged worn or otherwise in need of replacement 28 Using an hydraulic press or large chisel remove the rear retainer seal assembly 1 from the shaft See Figure 1083 All information subject to change without notice C 1644 Copyright DETROIT DIESEL CORPORATION ...

Page 1791: ...4000 12 16V SERVICE MANUAL 1 Rear Retainer Seal Assembly 2 Shaft Figure 1083 Removal of Rear Retainer Seal Assembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1645 ...

Page 1792: ... the Rockford fan clutch see Figure 1084 see Figure 1085 see Figure 1086 see Figure 1087 and see Figure 1088 1 End Cap 4 Front Wear Sleeve 2 Fan Mounting Hub 5 Sleeve Bearing 3 Front Retainer Seal Assembly 6 Sleeve Bearing Figure 1084 Inspection of Fan Clutch View 1 of 5 All information subject to change without notice C 1646 Copyright DETROIT DIESEL CORPORATION ...

Page 1793: ...ear Wear Sleeve notched 4 Rear Oil Seal 11 Rear Retainer Seal Assembly 5 O ring Seal 12 Shaft Bracket Assembly 6 Rear Bearing Retainer 13 Pitot Tubes 7 Lock Washers 14 Orifice Figure 1085 Inspection of Fan Clutch View 2 of 5 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1647 ...

Page 1794: ...nal Snap Ring Spirolock 5 Small Seal Ring 2 Shim 6 Large Seal Ring 3 Spring Washer 7 Pulley 4 Piston Figure 1086 Inspection of Fan Clutch View 3 of 5 All information subject to change without notice C 1648 Copyright DETROIT DIESEL CORPORATION ...

Page 1795: ... Steel Clutch Plates 3 Internal Snap Ring 9 Facing Plates 4 Bolts 10 Clutch Hub 5 Lock Washers 11 External Snap Ring 6 Front Bearing Retainer Figure 1087 Inspection of Fan Clutch View 4 of 5 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1649 ...

Page 1796: ...tion of Fan Clutch View 5 of 5 Inspection of Shaft and Bracket Assembly Perform the following inspections listed in Table 153 for the shaft and bracket assembly All information subject to change without notice C 1650 Copyright DETROIT DIESEL CORPORATION ...

Page 1797: ...n spinning and is not less than 3 7398 in 94 9909 mm diameter the shaft may be reused However the bearing must be installed using Loctite 242 or equivalent Table 153 Inspection Criteria for Shaft and Bracket Assembly Inspection of Shaft Bracket Assembly Orifice Perform the following inspection listed in Table 154 for the shaft and bracket assembly orifice Part Description Wear Limit Orifice 14 see...

Page 1798: ...ged Table 157 Inspection Criteria for Pulley Inspection of Rear Bearing Retainer Perform the following inspections listed in Table 158 for the rear bearing retainer Part Description Wear Limit Bore for rear bearing 3 see Figure 1085 For large bearing 6 6921 in 169 9793 mm and 5 7079 in 144 9807 mm diameter maximum Bore for rear oil seal 4 see Figure 1085 5 1265 in 130 213 mm diameter maximum Gener...

Page 1799: ...y Inspection of External Snap Ring Perform the following inspections listed in Table 161 for the external snap ring Part Description Wear Limit External snap ring 1 see Figure 1085 Reuse unless worn damaged or distorted External Snap Ring 11 see Figure 1087 Reuse unless worn damaged or distorted External Snap Ring Spirolock 1 see Figure 1086 Reuse unless worn damaged or distorted Table 161 Inspect...

Page 1800: ...Small seal ring 5 see Figure 1086 Replace Table 164 Inspection Criteria for Piston Seal Rings Inspection of Clutch Hub Perform the following inspections listed in Table 165 for the clutch hub Part Description Wear Limit Clutch hub 10 see Figure 1087 3 Replace if inside diameter teeth are severely worn 3 Replace if wear notches made by facing plates have straight sides 3 If the wear marks have smoo...

Page 1801: ...ection Criteria for Facing Plates Inspection of Steel Clutch Plates Perform the following inspections listed in Table 167 for the steel clutch plates Part Description Wear Limit Steel clutch plates 8 see Figure 1087 3 Must pass between two plate surfaces 11X11 in spaced 0 130 in 3 302 mm apart set at a 45 degree angle 3 Replace if wear on drive surfaces of the external tangs exceeds 0 005 in 0 127...

Page 1802: ...41 in 94 9985 mm shaft may be reused but the bearing must be reinstalled using Loctite 609 or equivalent End cap bore 3 378 in 85 8012 mm diameter and free of nicks General 3 Snap ring grooves must have straight sides and square edges 3 Bearing bore must not have nicks or scratches which extend above the bore surface 3 Spline must not be excessively worn 3 Bore holes must not be worn or damaged se...

Page 1803: ...m depth of the wear mark should not exceed 0 020 in 0 508 mm but if the notches have smooth entry and exit sides the notch will not resist movement of the steel plate Table 170 Inspection Criteria for Front Bearing Retainer Inspection of Sleeve Bearing Perform the following inspections listed in Table 171 for sleeve bearings Part Description Wear Limit Sleeve bearing 5 see Figure 1084 Replace if n...

Page 1804: ...n Criteria for Pitot Tubes Inspection of O ring Seal Perform the following inspections listed in Table 175 for the O ring seal Part Description Wear Limit O ring seal 5 see Figure 1085 Replace O ring seal 7 see Figure 1087 Replace Table 175 Inspection Criteria for O ring Seal Inspection of Spring Washer Perform the following inspection listed in Table 176 for the spring washer Part Description Wea...

Page 1805: ...sealants Follow manufacturer s recommendations regarding minimum cure time to prevent oil from washing the sealant from the sealing surfaces NOTICE Visually check to ensure the retainer seal assembly is installed straight and not bent or damaged in any way which will cause interference between it and the bearing retainer after assembly All information subject to change without notice Copyright DET...

Page 1806: ...the inside diameter of the front wear sleeve 2 and the wear sleeve diameter of the shaft with Loctite 242 or equivalent Press the front wear sleeve onto the shaft flush with the shoulder using special tool 2 See Figure 1090 NOTE The front wear sleeve 2 is not interchangeable with the rear wear sleeve NOTE Early fan mounting hubs were manufactured with a small lube hole under the wear sleeve The ne...

Page 1807: ...ES 4000 12 16V SERVICE MANUAL 1 Special Tool 2 2 Front Wear Sleeve Figure 1090 Installation of Front Wear Sleeve All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1661 ...

Page 1808: ... See Figure 1091 1 Rear Sleeve Bearing 3 Chamfer 2 Fan Mounting Hub Figure 1091 Installation of Rear Sleeve Bearing 4 Place the front retainer seal assembly with the splined shaft facing down Using special tool 1 see Figure 1058 press front sleeve bearing 1 into fan mounting hub 2 until All information subject to change without notice C 1662 Copyright DETROIT DIESEL CORPORATION ...

Page 1809: ... is 0 25 0 28 in 6 35 7 112 mm below the shoulder See Figure 1092 1 Front Sleeve Bearing 3 Special Tool 1 2 Fan Mounting Hub Figure 1092 Installation of Front Sleeve Bearing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1663 ...

Page 1810: ...3 Installation of End Cap To avoid injury from freezing or suffocation when using liquid nitrogen wear a face shield and protective clothing and work in a well ventilated area 6 Freeze end cap 1 in a freezer or dry ice for 15 30 minutes See Figure 1093 NOTE Liquid nitrogen may be used to freeze the end cap All information subject to change without notice C 1664 Copyright DETROIT DIESEL CORPORATION...

Page 1811: ...sure the retainer seal assembly is installed straight and not bent or damaged in any way which will cause interference between it and the bearing retainer after assembly 8 Using special tool 2 press rear retainer seal assembly 1 onto shaft 3 0 40 in 10 16 mm below the shoulder See Figure 1094 1 Rear Retainer Seal Assembly 3 Shaft 2 Special Tool 2 Figure 1094 Installation of Rear Retainer Seal Asse...

Page 1812: ...ole in the shaft or damage will result 10 Locate rear wear sleeve 2 so the notch of the sleeve is aligned with the small lube hole in shoulder shaft 3 Using special tool 3 4 press rear wear sleeve onto the fan mounting hub flush with the shoulder See Figure 1095 NOTICE When pressing the rear bearing into the rear bearing retainer press only the outer race of the bearing and stop pressing when it r...

Page 1813: ...ar bearing 1 into rear bearing retainer 2 See Figure 1096 1 Rear Bearing 3 Bearing Press Block 2 Rear Bearing Retainer 4 Hydraulic Press Figure 1096 Installation of Rear Bearing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1667 ...

Page 1814: ...ternal snap ring 1 into rear bearing retainer 2 See Figure 1097 1 Internal Snap Ring 2 Rear Bearing Retainer Figure 1097 Installation of Internal Snap Ring All information subject to change without notice C 1668 Copyright DETROIT DIESEL CORPORATION ...

Page 1815: ...raulic Press 2 Bearing Press Block Figure 1098 Installation of Rear Oil Seal NOTICE Spin the bearing retainer to ensure there is no sound or other indication of contact between the retainer seal assembly and the bearing retainer If interference is detected remove the bearing retainer and eliminate the point of interference 14 Place shaft subassembly on the press bed Coat the bore of the bearing an...

Page 1816: ...1 onto the shaft until it stops at the bottom of the shoulder See Figure 1099 1 Bearing 3 Special Tool 3 2 Rear Bearing Retainer Figure 1099 Installation of Rear Bearing Retainer Subassembly All information subject to change without notice C 1670 Copyright DETROIT DIESEL CORPORATION ...

Page 1817: ...lation of External Snap Ring NOTICE Ensure the pitot tube holes in the shaft are clean and free of burrs and staking material so that the pitot tubes will fit into the holes and seat completely to the bottom Improperly seated pitot tubes will damage the fan clutch assembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1671 ...

Page 1818: ...ithin the pulley locating shoulder of the rear bearing retainer 2 NOTE Rotate the tube so the open bent end faces in a counterclockwise direction and is exactly parallel to the surface of the rear bearing retainer A large Phillips head screwdriver inserted in the end of the tube can be conveniently used as an alignment gage 18 Repeat step 17 for the second pitot tube Using a punch 3 stake each pit...

Page 1819: ...Tubes 2 Rear Bearing Retainer Figure 1102 Installation of Seal Rings NOTICE Press only on the outer race of the bearing and press it to the bottom of the bore An improperly seated bearing will cause fan clutch damage All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1673 ...

Page 1820: ...42 Using hydraulic press 3 press front bearing into front bearing retainer 1 See Figure 1103 1 Front Bearing Retainer 3 Hydraulic Press 2 Bearing Press Block Figure 1103 Installation of Front Bearing All information subject to change without notice C 1674 Copyright DETROIT DIESEL CORPORATION ...

Page 1821: ...g 1 to secure bearing 2 in front bearing retainer 3 See Figure 1104 1 Internal Snap Ring 3 Front Bearing Retainer 2 Bearing Figure 1104 Installation of Internal Snap Ring All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1675 ...

Page 1822: ...gure 1105 Installation of Oil Seal 23 Coat the outside diameter of front oil seal 1 with Loctite 242 or equivalent Using bearing press block 2 install oil seal 1 in front bearing retainer 3 flush with the front face See Figure 1105 24 Place the fan mounting assembly on the press bed All information subject to change without notice C 1676 Copyright DETROIT DIESEL CORPORATION ...

Page 1823: ...06 27 Using special tool 3 1 press bearing 2 down into front bearing retainer 3 until it stops at the bottom of the shoulder See Figure 1106 28 Rotate front bearing retainer 3 to ensure that there is no sound or other indication of contact between the retainer seal assembly and front bearing retainer 3 See Figure 1106 NOTE If interference is detected remove the bearing retainer and eliminate the s...

Page 1824: ... 1 onto fan mounting hub 2 See Figure 1107 NOTE The splines should be open and facing upwards 1 Clutch Hub 2 Fan Mounting Hub Figure 1107 Installation of Clutch Hub All information subject to change without notice C 1678 Copyright DETROIT DIESEL CORPORATION ...

Page 1825: ...3 install external snap ring 2 to secure clutch hub 1 in place See Figure 1108 1 Clutch Hub 3 Snap Ring Pliers 2 External Snap Ring Figure 1108 Installation of Snap Ring All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1679 ...

Page 1826: ...Vee shape all the way around the diameter Install small seal ring 2 into the groove See Figure 1109 1 Large Ring 3 Piston 2 Small Seal Ring Figure 1109 Installation of Small Seal Ring NOTE Note the shape of the groove It will properly accept the small seal ring 2 in only one way See Figure 1109 All information subject to change without notice C 1680 Copyright DETROIT DIESEL CORPORATION ...

Page 1827: ...0 Installation of Large Seal Ring NOTE Note the shape of the groove It will properly accept the seal ring in only one way 33 Lubricate the internal and external surfaces that the small seal rings 2 and large seal rings 1 will be in contact with See Figure 1110 NOTE Use an oil soluble lubricant NOTICE Do not push the piston into place during installation Seal ring damage could occur damaging the pu...

Page 1828: ...ulley Figure 1111 Installation of Piston 35 Without pressing down on piston 1 rotate the piston slowly clockwise then counter clockwise until the piston falls into place within the pulley 2 See Figure 1111 All information subject to change without notice C 1682 Copyright DETROIT DIESEL CORPORATION ...

Page 1829: ... tangs and the retainer will rest against belt pulley 2 See Figure 1112 1 Front Bearing Retainer 2 Belt Pulley Figure 1112 Installation of Fan Clutch Assembly 37 Rotate front bearing retainer 1 until the bolt holes align in the front bearing retainer 1 and belt pulley 2 See Figure 1112 38 Remove front bearing retainer 1 from belt pulley 2 See Figure 1112 All information subject to change without n...

Page 1830: ...of Shim Spring Washer and External Snap Ring 40 Install shim 2 onto spring washer 3 See Figure 1113 41 Install external snap ring 1 into groove See Figure 1113 NOTE The shim must be centered on the spring washer to prevent it from interfering with the movement of the piston All information subject to change without notice C 1684 Copyright DETROIT DIESEL CORPORATION ...

Page 1831: ... Dip the facing plates in engine oil to get them wet 43 Install one steel clutch plate 1 in place in the bearing retainer Then place one face plate on top of a steel clutch plate 1 See Figure 1114 NOTE Alternately stack the remaining plates until a total of seven plates have been placed on the stack and the top plate is a facing plate All information subject to change without notice Copyright DETR...

Page 1832: ...leum jelly or an oil soluble grease place the front O ring seal 1 into the pulley groove See Figure 1115 1 O ring 2 Pulley Figure 1115 Installation of O ring All information subject to change without notice C 1686 Copyright DETROIT DIESEL CORPORATION ...

Page 1833: ...guide bolt in one of the bolt holes of the pulley 1 Turn pulley 1 over on the bench and lift with a hoist Carefully lower pulley 1 until it rests on the front bearing retainer 2 See Figure 1116 1 Pulley 2 Front Bearing Retainer Figure 1116 Installation of Pulley All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1687 ...

Page 1834: ...hten three bolts to secure front bearing retainer 2 to the pulley 1 See Figure 1117 1 Pulley 3 Socket 2 Front Bearing Retainer Figure 1117 Installation of Bolts All information subject to change without notice C 1688 Copyright DETROIT DIESEL CORPORATION ...

Page 1835: ...e 1118 1 O ring Seal 2 Pulley Figure 1118 Installation of O ring Seal NOTICE When installing the shaft subassembly into the pulley ensure to not nick the sleeve bearings with the shaft Bearing damage could result in fan clutch failure All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1689 ...

Page 1836: ...er the shaft subassembly into the pulley bore and onto the pulley until the retainer rests on the pulley See Figure 1119 1 Shaft Subassembly 2 Pulley Figure 1119 Installation of Shaft Subassembly All information subject to change without notice C 1690 Copyright DETROIT DIESEL CORPORATION ...

Page 1837: ...subassembly 2 to the pulley Torque bolts to 26 32 lb ft 115 142 N m See Figure 1120 1 Bolts and Lock Washers 3 Torque Wrench 2 Shaft Subassembly Figure 1120 Installation of Bolts and Lock Washers All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1691 ...

Page 1838: ...50 Install orifice fitting 1 into the oil in port of the bracket See Figure 1121 1 Orifice Fitting Figure 1121 Installation of Orifice Fitting All information subject to change without notice C 1692 Copyright DETROIT DIESEL CORPORATION ...

Page 1839: ...emaining bolts and lock washers 1 Torque bolts to 26 32 ft lbs 115 142 N m See Figure 1122 1 Bolts and Lock Washers 2 Torque Wrench Figure 1122 Installation of Remaining Bolts and Lock Washers All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1693 ...

Page 1840: ...ON OF ROCKFORD SERIES 270 FAN CLUTCH Perform the following step to install the fan clutch assembly 1 Refer to section C 221 05 11 to install the fan clutch assembly All information subject to change without notice C 1694 Copyright DETROIT DIESEL CORPORATION ...

Page 1841: ... 10 Assembly for Trunnion Mount C 1706 C 231 05 11 Installation of Trunnion Mount C 1711 C 231 05 12 After Installation Operations C 1713 C 231 05 M ENGINE MOUNTS C 1715 C 231 05 01 M General View C 1717 C 231 05 04 M Before Removal Operations C 1718 C 231 05 05 M Removal of the Marine Engine Mounts C 1719 C 231 05 08 M Inspection and Repair C 1721 C 231 05 11 M Installation of the Marine Engine M...

Page 1842: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1696 Copyright DETROIT DIESEL CORPORATION ...

Page 1843: ...01 C 231 05 05 Removal of Trunnion Mount C 1702 C 231 05 06 Disassembly of the Trunnion Mount C 1704 C 231 05 08 Inspection and Repair C 1705 C 231 05 10 Assembly for Trunnion Mount C 1706 C 231 05 11 Installation of Trunnion Mount C 1711 C 231 05 12 After Installation Operations C 1713 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1697 ...

Page 1844: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1698 Copyright DETROIT DIESEL CORPORATION ...

Page 1845: ...UAL C 231 05 01 GENERAL VIEW See Figure 1123 1 Hex Bolt 4 Isolator 2 Washer 5 Trunnion 3 Carrier Figure 1123 General View of Trunnion Mount All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1699 ...

Page 1846: ...unnion mount Application Number Press in sleeve for bearing outer race in belt pulley Press in sleeve for cap plugs Removal soft brass drift for ball bearing belt tensioner Press in sleeve for ball bearing belt tensioner Table 178 Special Tools All information subject to change without notice C 1700 Copyright DETROIT DIESEL CORPORATION ...

Page 1847: ...ors Guide 1 2 3 Remove protective guard Refer to Operators Guide 1 2 3 Remove fan wheel Refer to section C 221 05 05 1 2 3 Remove V belt Refer to OEM Guidelines 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 179 Before Removal Operations All information subject to change without notice Copyright ...

Page 1848: ...unt remove two opposite hex bolts 1 from trunnion mount See Figure 1124 1 Hex Bolt Figure 1124 Removing Hex Bolts 2 Install guide pins in place of hex bolts and remove remaining hex bolts See Figure 1125 All information subject to change without notice C 1702 Copyright DETROIT DIESEL CORPORATION ...

Page 1849: ...er stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 3 Loosen the trunnion mount from bracket and attach to crane with a lifting device under slight pretension 4 Remove trunnion mount completely from engine All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1703 ...

Page 1850: ...1 Use soft iron drift to remove carrier 1 from trunnion mount 3 See Figure 1126 1 Carrier 3 Trunnion Mount 2 Isolator Figure 1126 Removing Carrier and Isolator 2 Remove isolator halves 2 from carrier bore in trunnion mount 3 cutting them if necessary All information subject to change without notice C 1704 Copyright DETROIT DIESEL CORPORATION ...

Page 1851: ...bracket b If bracket is not damaged worn or cracked continue inspection 4 Visually inspect all mating surfaces and fits a If mating surfaces and fits are damaged or worn rub down with oilstone or emery cloth as necessary b If mating surfaces and fits are beyond repair replace components c If mating surfaces and fits are not damaged or worn continue inspection 5 Visually inspect condition of thread...

Page 1852: ...nt with petroleum jelly See Figure 1127 1 Carrier Bore Figure 1127 Coating Carrier Bore 2 Install one isolator half 1 into carrier bore of trunnion mount 2 and press in until it contacts isolator shoulder See Figure 1128 All information subject to change without notice C 1706 Copyright DETROIT DIESEL CORPORATION ...

Page 1853: ...SERVICE MANUAL 1 Isolator Half 2 Trunion Mount Figure 1128 Installing First Isolator Half 3 Rotate trunnion mount by 180 degrees All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1707 ...

Page 1854: ...ately 20 mm above mating surface of trunnion mount 1 See Figure 1129 1 Trunion Mount 2 Isolator Figure 1129 Installing Second Rubber Bushing 5 Coat inner surface of isolator half 2 with petroleum jelly 6 Carefully insert carrier 1 into isolator 2 See Figure 1130 All information subject to change without notice C 1708 Copyright DETROIT DIESEL CORPORATION ...

Page 1855: ...rrier NOTE When aligning carrier to trunnion mount the TOP mark on surface of carrier must face upward 7 Use press 1 to push carrier 2 into trunnion mount 3 until in contact with shoulder See Figure 1131 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1709 ...

Page 1856: ...IES 4000 12 16V SERVICE MANUAL 1 Press 3 Trunion Mount 2 Carrier Figure 1131 Pushing Carrier into Trunnion Mount All information subject to change without notice C 1710 Copyright DETROIT DIESEL CORPORATION ...

Page 1857: ...nal injury while using a lifting device never stand beneath a suspended load Use a suitable lifting device and review all manufacturer s cautionary notes 2 Attach trunnion mount with lifting device to crane and push toward bracket via guide pins See Figure 1132 3 Install hex bolts and tighten by hand See Figure 1132 All information subject to change without notice Copyright DETROIT DIESEL CORPORAT...

Page 1858: ...bolts in their place See Figure 1132 5 Tighten all hex bolts 1 diagonally and evenly to specification Refer to section A 003 See Figure 1133 1 Hex Bolt Figure 1133 Tightening Hex Bolts All information subject to change without notice C 1712 Copyright DETROIT DIESEL CORPORATION ...

Page 1859: ...OEM Guidelines 1 2 3 Install fan wheel Refer to section C 221 05 11 1 2 3 Mount protective guard Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 180 After Installation Operations All information subject to change without n...

Page 1860: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1714 Copyright DETROIT DIESEL CORPORATION ...

Page 1861: ...emoval Operations C 1718 C 231 05 05 M Removal of the Marine Engine Mounts C 1719 C 231 05 08 M Inspection and Repair C 1721 C 231 05 11 M Installation of the Marine Engine Mounts C 1722 C 231 05 12 M After Installation Operations C 1724 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1715 ...

Page 1862: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1716 Copyright DETROIT DIESEL CORPORATION ...

Page 1863: ...for a general view of the marine engine mounts 1 Washer 5 O ring 2 Bolt 6 Engine Carrier 3 Rubber Mount 7 Hex Nut 4 Dowel Pin 8 Base Plate Figure 1134 General View Marine Engine Mounts All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1717 ...

Page 1864: ...3 Disable engine power Refer to Operators Guide 1 2 3 Remove protective guard 1 2 3 Remove fan wheel 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 181 Before Removal Operations for the Marine Engine Mounts All information subject to change without notice C 1718 Copyright DETROIT DIESEL CORPORATI...

Page 1865: ...m the following steps to remove the engine mounts See Figure 1135 1 Washer 5 O ring 2 Bolt 6 Engine Carrier 3 Rubber Mount 7 Hex Nut 4 Dowel Pin 8 Base Plate Figure 1135 Removing Marine Engine Mounts All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1719 ...

Page 1866: ... suitable lifting device 2 Rest the engine on a sturdy support device 3 Remove bolts 2 and washers 1 securing rubber mount 3 to the base plate 8 See Figure 1135 4 Remove four bolts 2 and washers 1 securing the engine support bracket to the cylinder block See Figure 1135 5 Remove the engine support bracket and O ring 5 See Figure 1135 All information subject to change without notice C 1720 Copyrigh...

Page 1867: ...replace the components b If engine mounts are not cracked continue inspection NOTE Bearing inner race and bearing outer race are considered a single unit and must be replaced in pairs 5 Visually inspect all mating surfaces and fits for damage or wear a If mating surfaces or fits are damaged or worn rub down with oilstone or emery cloth as necessary b If damage is beyond repair replace component as...

Page 1868: ...id personal injury when handling and lifting a heavy object use a suitable lifting device to lift heavy objects and follow the manufacturer s operator procedures 1 Lift the engine with a suitable lifting device 2 Rest the engine on a sturdy support device if necessary All information subject to change without notice C 1722 Copyright DETROIT DIESEL CORPORATION ...

Page 1869: ... Base Plate Figure 1136 Installing Marine Engine Mounts 4 Install four bolts 2 and washers 1 to secure the engine support bracket to the cylinder block Torque bolts to 385 N m 284 lb ft See Figure 1136 5 Install bolts 2 and washers 1 to secure rubber mount 3 to the base plate 8 See Figure 1136 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1723 ...

Page 1870: ... 2 3 Install fan wheel 1 2 3 Mount protective guard 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 182 After Installation Operations for the Marine Engine Mounts All information subject to change without notice C 1724 Copyright DETROIT DIESEL COR...

Page 1871: ...55 05 12 After Installation Operations C 1740 C 259 05 AUXILIARY PTO ASSEMBLY C 1741 C 259 05 01 General View C 1743 C 259 05 02 Special Tools C 1744 C 259 05 04 Before Removal Operations C 1745 C 259 05 05 Removal of the Auxiliary PTO Assembly C 1746 C 259 05 06 Disassembly of the Auxiliary PTO Assembly C 1747 C 259 05 08 Cleaning Inspection and Repair C 1748 C 259 05 10 Assembly of the Auxiliary...

Page 1872: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1726 Copyright DETROIT DIESEL CORPORATION ...

Page 1873: ...5 05 Removal of Flex Coupling C 1731 C 255 05 06 Disassembly of Flex Coupling C 1732 C 255 05 08 Inspection and Repair C 1735 C 255 05 10 Assembly of Flex Coupling C 1737 C 255 05 11 Installation of Flex Coupling C 1739 C 255 05 12 After Installation Operations C 1740 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1727 ...

Page 1874: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1728 Copyright DETROIT DIESEL CORPORATION ...

Page 1875: ... VIEW See Figure 1137 for a general view of the flex coupling 1 Hex Head Bolt 3 Adapter 2 Flex Coupling 4 Ring Gear Figure 1137 General View of the Flex Coupling All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1729 ...

Page 1876: ...eference 1 2 3 Disable engine power Refer to Operators Guide 1 2 3 Separate engine from gearbox or alternator 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 183 Before Removal Operations All information subject to change without notice C 1730 Copyright DETROIT DIESEL CORPORATION ...

Page 1877: ...SERIES 4000 12 16V SERVICE MANUAL C 255 05 05 REMOVAL OF FLEX COUPLING Refer to section All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1731 ...

Page 1878: ... Figure 1138 Notice Remove flex coupling only if absolutely necessary Hex bolts are staked in place and may damage adapter when removed 1 Hex Bolts 2 Flex Coupling Figure 1138 Removing Flex Coupling 2 Remove flex coupling 2 NOTE Remove ring gear only if it is to be replaced because of damage All information subject to change without notice C 1732 Copyright DETROIT DIESEL CORPORATION ...

Page 1879: ...ind ring gear 2 at four to six points evenly distributed around ring gear as deeply as possible See Figure 1139 1 Adapter 2 Ring Gear Figure 1139 Removing Ring Gear NOTE Take care not to damage adapter when grinding The minimum distance of grinding disc to adapter A 1 mm All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1733 ...

Page 1880: ...ow the manufacturer s operator procedures 4 Hit ring gear hard with a hammer to loosen from adapter NOTE If ring gear cannot be loosened by hitting with a hammer heat uniformly maximum 170 C around entire circumference for a brief period to expand All information subject to change without notice C 1734 Copyright DETROIT DIESEL CORPORATION ...

Page 1881: ...e limit value replace as necessary b If flex coupling is not scored or pitted greater than maximum permissible continue inspection 5 Visually inspect seating surface of ring gear on adapter for wear scoring and pitting a If seating surface of ring gear is worn scored or pitted smooth with emery cloth or oilstone b If damage is beyond repair replace component c If seating surface of ring gear is no...

Page 1882: ...late safety goggles a If ring gear is worn or tooth flanks are chipped regrind as necessary b If ring gear wear or tooth flank chips are beyond repair replace component c If ring gear is not worn and tooth flanks are not chipped continue inspection All information subject to change without notice C 1736 Copyright DETROIT DIESEL CORPORATION ...

Page 1883: ... See Figure 1140 1 Adapter 2 Ring Gear Figure 1140 Installing Ring Gear To avoid personal injury while handling HOT components wear protective gloves and clothing 2 Heat ring gear uniformly to maximum 200 C and install on adapter NOTE The ring gear must contact adapter with no gaps around the entire circumference All information subject to change without notice Copyright DETROIT DIESEL CORPORATION...

Page 1884: ... A fan side must face toward fan wheel 1 Adapter 3 Ring Gear 2 Hex Head Bolt Figure 1141 Installing Flex Coupling 4 Install hex bolts 2 and tighten diagonally and evenly to specification Refer to section A 003 5 Stake hex bolts at projecting thread against adapter 1 All information subject to change without notice C 1738 Copyright DETROIT DIESEL CORPORATION ...

Page 1885: ...SERIES 4000 12 16V SERVICE MANUAL C 255 05 11 INSTALLATION OF FLEX COUPLING Refer to section C 032 05 11 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1739 ...

Page 1886: ... 2 3 Connect engine with gearbox alternator Refer to section C 213 05 11 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 184 After Installation Operations All information subject to change without notice C 1740 Copyright DETROIT DIESEL CORPORATION...

Page 1887: ... of the Auxiliary PTO Assembly C 1746 C 259 05 06 Disassembly of the Auxiliary PTO Assembly C 1747 C 259 05 08 Cleaning Inspection and Repair C 1748 C 259 05 10 Assembly of the Auxiliary PTO Assembly C 1749 C 259 05 11 Installation of the Auxiliary PTO Assembly C 1750 C 259 05 12 After Installation Operations C 1751 All information subject to change without notice Copyright DETROIT DIESEL CORPORAT...

Page 1888: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1742 Copyright DETROIT DIESEL CORPORATION ...

Page 1889: ... See Figure 1142 for a general view of the auxiliary PTO assembly 1 Hex Head Bolt 3 O ring 2 Auxiliary PTO Assembly Figure 1142 General View of Auxiliary PTO Assembly All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1743 ...

Page 1890: ...ary PTO assembly Application Number Press in sleeve for bearing outer race in belt pulley Press in sleeve for cap plugs Removal brass drift for ball bearing belt tensioner Press in sleeve for ball bearing belt tensioner Table 185 Special Tools All information subject to change without notice C 1744 Copyright DETROIT DIESEL CORPORATION ...

Page 1891: ... 1 2 3 Disable engine power Refer to Operators Guide 1 2 3 Remove protective guard 1 2 3 Remove V belt Refer to OEM Guidelines 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 186 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1745 ...

Page 1892: ...TO ASSEMBLY 1 To remove auxiliary PTO assembly remove hex bolts 1 See Figure 1143 1 Hex Bolt Figure 1143 Removing Hex Bolts 2 Carefully remove auxiliary PTO assembly from gear case All information subject to change without notice C 1746 Copyright DETROIT DIESEL CORPORATION ...

Page 1893: ...ERIES 4000 12 16V SERVICE MANUAL C 259 05 06 DISASSEMBLY OF THE AUXILIARY PTO ASSEMBLY Refer to OEM guidelines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1747 ...

Page 1894: ...xiliary PTO assembly does show ease of movement continue inspection 4 Visually inspect auxiliary PTO assembly for wear and cracks a If auxiliary PTO assembly does show wear or cracks replace component b If auxiliary PTO assembly does not show wear or cracks continue inspection 5 Visually inspect mating surfaces for damage or wear a If mating surfaces show damage or wear rub with emery cloth or oil...

Page 1895: ...SERIES 4000 12 16V SERVICE MANUAL C 259 05 10 ASSEMBLY OF THE AUXILIARY PTO ASSEMBLY Refer to OEM guidelines All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1749 ...

Page 1896: ...sembly in gear case See Figure 1144 1 Hex Bolt Figure 1144 Installing Auxiliary PTO Assembly in Gear Case 2 Inspect gear lash on the drive 3 Insert hex bolts 1 and tighten diagonally and evenly to specification Refer to section A 003 All information subject to change without notice C 1750 Copyright DETROIT DIESEL CORPORATION ...

Page 1897: ...and V belt tension Refer to OEM Guidelines 1 2 3 Mount protective guard Refer to Operators Guide 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 187 After Installation Operations All information subject to change without notice Copyright DETROIT D...

Page 1898: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1752 Copyright DETROIT DIESEL CORPORATION ...

Page 1899: ...ors and Wiring Harnesses C 1778 C 502 05 12 M After Installation Operations C 1780 C 503 05 CONSTRUCTION AND INDUSTRIAL ENGINE INJECTOR HARNESSES OPTIONAL ROUTING C 1781 C 503 05 01 General View of B Side Fuel Injector Wiring Harness C 1783 C 503 05 05 Removal of B Side Fuel Injector Wiring Harness C 1785 C 503 05 08 Inspection and Repair of B Side Fuel Injector Wiring Harness C 1788 C 503 05 11 I...

Page 1900: ... C 503 05 11 Operation and Verification C 1847 C 503 05 ENGINE TUNE UP C 1849 C 503 05 11 Engine Tune Up C 1851 C 503 05 PREVENTIVE MAINTENANCE C 1855 C 503 05 11 Preventive Maintenance C 1857 C 503 05 GENERAL TOOLS SHOP EQUIPMENT C 1859 C 503 05 11 General Tools Shop Equipment C 1861 C 503 05 Kent Moore TOOL GRAPHICS C 1863 C 503 05 11 Kent Moore Tool Graphics C 1865 All information subject to ch...

Page 1901: ...nic Control Unit C 1759 C 501 05 06 M Disassembly of the Electronic Control Unit C 1761 C 501 05 08 M Inspection and Repair C 1762 C 501 05 10 M Assembly of the Electronic Control Unit C 1763 C 501 05 11 M Installation of the Electronic Control Unit C 1764 C 501 05 12 M After Installation Operations C 1765 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1755...

Page 1902: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1756 Copyright DETROIT DIESEL CORPORATION ...

Page 1903: ...145for a general view of the electronic control unit 1 Bolt 4 Damper Element 2 Electronic Control Unit 5 Spacer 3 Mounting Bracket Figure 1145 General View of Electronic Control Unit All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1757 ...

Page 1904: ...ntenance Operation Reference 1 2 3 Disable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 188 Before Removal Operations All information subject to change without notice C 1758 Copyright DETROIT DIESEL CORPORATION ...

Page 1905: ... for reassembly 2 Disconnect the wiring harnesses from the ECU 3 Remove the four bolts 1 and spacers 5 securing the ECU to the heat exchanger See Figure 1146 1 Bolt 4 Damper Element 2 Electronic Control Unit 5 Spacer 3 Mounting Bracket Figure 1146 Removing the ECU All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1759 ...

Page 1906: ...ECU 2 from the heat exchanger See Figure 1146 5 Remove bolts 1 securing the ECU to the mounting brackets 3 and remove the mounting brackets See Figure 1146 All information subject to change without notice C 1760 Copyright DETROIT DIESEL CORPORATION ...

Page 1907: ...ISASSEMBLY OF THE ELECTRONIC CONTROL UNIT The ECU is a non serviceable component Contact Detroit Diesel Technical Service for further disassembly information All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1761 ...

Page 1908: ...1 05 08 M INSPECTION AND REPAIR The ECU is a non serviceable component Contact Detroit Diesel Technical Service for further inspection information All information subject to change without notice C 1762 Copyright DETROIT DIESEL CORPORATION ...

Page 1909: ...M ASSEMBLY OF THE ELECTRONIC CONTROL UNIT The ECU is a non serviceable component Contact Detroit Diesel Technical Service for further assembly information All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1763 ...

Page 1910: ...ting brackets 4 with bolts 1 See Figure 1147 1 Bolt 4 Damper Element 2 Electronic Control Unit 5 Spacer 3 Mounting Bracket Figure 1147 Installing the ECU 2 Secure the ECU to the heat exchanger with four bolts 1 See Figure 1147 3 Connect the wiring harnesses to the ECU 4 Verify repair of the ECU All information subject to change without notice C 1764 Copyright DETROIT DIESEL CORPORATION ...

Page 1911: ...aintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 189 After Installation Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1765 ...

Page 1912: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1766 Copyright DETROIT DIESEL CORPORATION ...

Page 1913: ...al Operations C 1773 C 502 05 05 M Removal of Engine Sensors and Wiring Harnesses C 1774 C 502 05 08 M Inspection and Repair C 1777 C 502 05 11 M Installation of Engine Sensors and Wiring Harnesses C 1778 C 502 05 12 M After Installation Operations C 1780 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1767 ...

Page 1914: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1768 Copyright DETROIT DIESEL CORPORATION ...

Page 1915: ... Figure 1149 for the 12V marine engine sensor harness S8 see Figure 1150for the 12V marine engine injector harness SB2 and see Figure 1151 for the 16V marine engine injector harness SB3 Figure 1148 8 12 16V Marine Engine Sensor Harness S6 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1769 ...

Page 1916: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1149 12V Marine Engine Sensor Harness S8 All information subject to change without notice C 1770 Copyright DETROIT DIESEL CORPORATION ...

Page 1917: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1150 12V Marine Engine Injector Harness SB2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1771 ...

Page 1918: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1151 16V Marine Engine Injector Harness SB3 All information subject to change without notice C 1772 Copyright DETROIT DIESEL CORPORATION ...

Page 1919: ...sensors Level of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide 1 The engine is to be completely disassembled 2 The engine is to be removed but not completely disassembled 3 The engine is to remain installed Table 190 Before Removal Operations All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1773 ...

Page 1920: ...erform the following steps to remove the engine sensors and engine sensor wiring harness NOTE Tag engine wiring harness connectors and MDEC engine control unit harnesses for identification prior to removal All information subject to change without notice C 1774 Copyright DETROIT DIESEL CORPORATION ...

Page 1921: ...10 Communication Connector Plug X6 5 Engine Connector Plug LOP X1 11 Mounting Bracket 6 Cable Harness Connector Plug X3 12 Mounting Plate Figure 1152 Removal of MDEC Engine Control Unit Harnesses 2 Disconnect engine sensor harnesses from the sensor units See Figure 1148for the 8 12 16V marine engine sensor harness S6 see Figure 1149 for the 12V marine engine All information subject to change witho...

Page 1922: ...50for the 12V marine engine injector harness SB2 and see Figure 1151 for the 16V marine engine injector harness SB3 for sensor locations 3 Remove engine sensors if necessary All information subject to change without notice C 1776 Copyright DETROIT DIESEL CORPORATION ...

Page 1923: ... no damage is detected 2 Visually check connectors for bent and missing pins a Repair connectors if damage is detected as necessary b Replace wiring harness if connectors are unrepairable c Reuse wiring harness if no damage is detected 3 Visually check each sensor connector for bent or missing pins a Repair sensors which have bent pins as necessary b Replace sensors which are unrepairable c Reuse ...

Page 1924: ...e engine sensors and wiring harnesses 1 Install engine sensors if necessary 2 Connect engine sensor harnesses to the appropriate engine sensors See Figure 1148for the 8 12 16V marine engine sensor harness S6 see Figure 1149 for the 12V marine engine All information subject to change without notice C 1778 Copyright DETROIT DIESEL CORPORATION ...

Page 1925: ...ine control unit See Figure 1153 1 Cover 7 Sensor Plug X2 2 Cover Screws 8 Power Supply Plug X5 3 Housing 9 Cable Harness Plug X4 4 Seals 10 Communication Connector Plug X6 5 Engine Connector Plug LOP X1 11 Mounting Bracket 6 Cable Harness Connector Plug X3 12 Mounting Plate Figure 1153 Installation of MDEC Engine Control Unit Harnesses All information subject to change without notice Copyright DE...

Page 1926: ... After Installation Operations for the engine sensor harnesses and engine sensors Level of Maintenance Operation Reference 1 2 3 Enable engine power Refer to Operators Guide Table 191 After Installation Operations All information subject to change without notice C 1780 Copyright DETROIT DIESEL CORPORATION ...

Page 1927: ...f B Side Fuel Injector Wiring Harness C 1783 C 503 05 05 Removal of B Side Fuel Injector Wiring Harness C 1785 C 503 05 08 Inspection and Repair of B Side Fuel Injector Wiring Harness C 1788 C 503 05 11 Installation of B Side Fuel Injector Wiring Harness C 1789 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1781 ...

Page 1928: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1782 Copyright DETROIT DIESEL CORPORATION ...

Page 1929: ...1066 for a general view of the 12V construction and industrial fuel injector harness 1 Wire Terminal Connectors 3 ECM Connectors 2 Fuel Injector Harness Figure 1066 Construction and Industrial 12V Fuel Injector Harness All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1783 ...

Page 1930: ...6V construction and industrial fuel injector harness 1 Wire Terminal Connectors 3 ECM Connectors 2 Fuel Injector Harness Figure 1067 Construction and Industrial 16V Fuel Injector Harness All information subject to change without notice C 1784 Copyright DETROIT DIESEL CORPORATION ...

Page 1931: ...remove the air intake manifold 3 Refer to section C 056 05 11C 056 05 05 and remove the rocker covers 4 Remove the nylon ties securing the fuel injector wiring harness to the jumper line 5 Remove the fuel injector metal grommet from the cylinder head 6 Remove the screws securing the wiring harness leads to the injector solenoids and remove the leads All information subject to change without notice...

Page 1932: ...m behind the high pressure fuel rail See Figure 1068 view E Figure 1068 Removal of Fuel Injector Wiring Harness 8 Remove the clip securing the fuel injector harness to the back of the water pump See Figure 1068 view D All information subject to change without notice C 1786 Copyright DETROIT DIESEL CORPORATION ...

Page 1933: ...ecuring the clip Remove the clip and wiring harness See Figure 1068 view B 12 Remove the third oil pan bolt from the front of the engine and remove the clip See Figure 1068 view A 13 Remove the fuel injector harness from behind the fuel filters 14 Disconnect the fuel injector harness connectors from the ECM 15 Remove the fuel injector harness from the engine All information subject to change witho...

Page 1934: ...ing harness if no damage is detected 2 Visually check wiring harness connectors for bent and missing pins a Repair connectors if damage is detected b Replace wiring harness if connectors are unrepairable c Reuse wiring harness if no damage is detected 3 Visually check each wiring harness connector for bent or missing pins a Repair sensor connectors that have bent pins b Replace sensor connectors t...

Page 1935: ...all of the valve covers on the B side of the engine 3 Remove the intake manifolds from each cylinder on the B side of the engine 4 Disconnect the old wiring harness from all of the injectors and remove the grommet nuts where the wiring harness enters the cylinder head 5 Disconnect the B side injector wiring harness from the ECMs as follows a 16V engine P N 0005300934 remove the black connector fro...

Page 1936: ...ew wiring harness into clip P N 08923507 and bolt the clip in place between the spacer and bolt See Figure 1069 view A Figure 1069 Removal of B Side Fuel Injector Harness 10 Tighten the bolt to 60 66 N m 44 49 lb ft All information subject to change without notice C 1790 Copyright DETROIT DIESEL CORPORATION ...

Page 1937: ...Thread the injector metal grommet into the head and fasten the injector wiring harness leads to the injector Tighten the injector terminal to 1 4 2 0 N m 1 1 5 lb ft 21 Secure the wiring harness to the back of the high pressure fuel rail with nylon ties in between each fuel jumper line 22 Refer to section C 056 05 08C 056 05 08 of the service manual and perform rocker cover related inspection and ...

Page 1938: ... will catch on the wiring harness and that no sharp edges are rubbing against it 27 Connect the power supply 28 Start the engine and check for proper operation All information subject to change without notice C 1792 Copyright DETROIT DIESEL CORPORATION ...

Page 1939: ...SERIES 4000 12 16V SERVICE MANUAL ENGINE TOOLS All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1793 ...

Page 1940: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1794 Copyright DETROIT DIESEL CORPORATION ...

Page 1941: ...Barring Tool Starting Mounting Pad V71 92 149 J 21850 BLK Core Plug Inst Water B P Block V71 92 J 21996 01 BLK Plug Remover Water B P Block V71 92 J 39693 Block And Head Pressure Test Kit 50 50G J 23019 Block Air Box Core Plug Rem Inst V71 92 149 J 29571 Block Air Box Plug Tool 71 V71 J 24542 Block Align Tool 149 J 24543 Block Align Tool 149 J 22486 Block Alignment Tool 149 J 21799 Block Alignment...

Page 1942: ...9 8 2L J 36224 Dowel Installer Set J 41171 Eng Lift Hook Use W 3 PT Spreader 149 J 36237 Engine Barring Tool 50 60 92 J 36130 812 Engine Lifting Bracket 40 50 50G 53 55 60 71 V71 92 8 2L J 39289 A Engine Stand Adaptor Plate 40 J 41576 Engine Stand Adapter Plate 55 J 36107 Exhaust Manifold Guide Studs 50 60 50G J 26816 A Exhaust Manifest Nut Wrench 149 PT 7276 Gasket Eliminator Loctite 50 50G 60 J ...

Page 1943: ...09 Overhaul Stand Less Adapters 30G 40 50 50G 53 V53 55 60 71 V71 92 8 2L J 9398 04 Overhaul Stand Less Adapters V71 92 J 29013 A Overhaul Stand Adapters 8 2L J 33850 Overhaul Stand Adapters 53 V53 71 V71 92 J 35635 A Overhaul Stand Adapters 60 J 39652 Overhaul Stand Adapters 50 50G J 8650 Overhaul Stand Adapters V71 92 J 6387 Parts Dolly 40 50 50G 53 V53 55 60 71 V71 92 PT 2050 D Porta Matic Basi...

Page 1944: ...ixture 50 60 J 28511 C Cylinder Head Locating Pins 149 J 28454 Cylinder Head Pressure Test Fixture 71 V71 92 J 41567 Cylinder Head Pressure Test Kit 55 J 24252 Cylinder Head Puller 55 J 36224 Dowel Installer Set 50 50G 60 J 21545 Fuel Line Nut Wrench 9 16 149 J 39108 Fuel Line Nut Wrench 11 16 149 J 38189 Head Bolt Counterbore Cutter 50 60 J 1928 02 Head Bolt Wrench 15 16 X1 2 Drive 71 V71 J 41169...

Page 1945: ...city Gage 53 V53 71 V71 92 149 J 26541 213 Valve Seat Cutter 1 50 X 15 60 Deg 55 71 V71 J 26541 628 Valve Seat Cutter 1 50 X 31 Deg 71 V71 J 26541 292 Valve Seat Cutter 1 50 X 15 60 Deg 55 149 J 26541 649 Valve Seat Cutter 1 75 X 31 Degree 149 J 26541 343 Valve Seat Cutter Pilot 0 344 71 V71 J 26541 344 Valve Seat Cutter Pilot 0 345 71 V71 J 26541 345 Valve Seat Cutter Pilot 0 346 71 V71 J 26541 3...

Page 1946: ...t Install Exhaust 40 J 22711 A Valve Seat Insert Installer 149 J 24357 Valve Seat Insert Installer 92 J 39535 Valve Seat Insert Installer 40 J 33190 Valve Seat Insert Installer Intake 50 60 J 41585 Valve Seat Insert Installer Intake 55 J 23479 35 Valve Seat Insert Puller Assembly 50 53 V53 60 71 V71 92 149 J 23479 37 Valve Seat Insert Puller Body 149 PT 6390 45 Valve Seat Insert Puller Collet 40 J...

Page 1947: ...alve Seat Remover Collet 4 Valve 71 V71 PT 6399 9 Valve Seat Remover Collet Intake 50 60 J 23479 49 Valve St Insert Rem Non Ceramic HD 149 PT 6399 6 Valve Seat Remover Collet 2 Valve 71 EXH 50 60 71 V71 J 36582 Valve Stem Seal Installer 8 2L J 39109 Valve Stem Seal Installer 50 60 J 41571 Valve Stem Seal Installer 55 J 41282 Valve Stem Seal Installer Narrow 149 J 35373 Valve Stem Seal Installer 4 ...

Page 1948: ... 53 V53 71 V71 92 8 2L J 23038 Lapping Compound Liquid 53 V53 71 V71 92 149 8 2L J 35369 Old Num 26298 Master Injector Kit 53 V53 71 V71 92 J 29898 Master Injector 8 2L 8 2L J 22693 01 Valve Spring Compress CYL HD Remove 149 J 7455 A Valve Spring Compressor 53 V53 71 V71 92 8 2L J 8062 Valve Spring Compressor CYL HD OFF 53 V53 71 V71 92 8 2L J 22738 02 Valve Spring Tester 50 50G 53 V53 55 60 71 V7...

Page 1949: ...ster 149 J 35993 Crankshaft Oil Seal Remover 50 50G 60 92 8 2L J 41599 Front Crankshaft Seal REM INST 55 J 7454 Front Seal Expander STD 6V 53 53 V53 J 29008 B Front Seal Installer STD Seal 8 2L J 9783 Front Seal Installer STD Seal 53 V5371 V71 92 J 22153 Front Seal Installer STD 8V 53 V53 J 29007 A Front Seal Remover 8 2L J 22524 Front Seal Sleeve Installer 6V 53 53 V53 J 22518 Front Seal Bearing ...

Page 1950: ...ersize Seal 8 2L J 8682 Seal Expander O S EX 6 8 12V71 V71 92 J 24171 A Seal Remover 50 53 V53 60 71 V71 92 149 8 2L J 39184 Seal Wear Sleeve Installer 40 J 39266 Wear Sleeve Installer 40 J 41593 Wear Sleeve Installer FRT RR Crank 55 J 37075 A Wear Sleeve Remover 50 50G 60 V71 92 8 2L J 35651 Gear Case To Block Alignment Tool 50 50G 60 J 5356 Puller Remover Rubber Bushed 71 V71 92 J 29025 A Pulley...

Page 1951: ...ressor 53 V53 J 22405 02 Piston Ring Expander Pliers 149 J 8128 Piston Ring Expander Pliers 53 V53 71 V71 92 8 2L J 29511 Piston Ring Groove Gage Set 30G 40 J 24421 Piston Seal Ring Compressor 149 J 5438 01 Piston To Liner Feeler Gage Set 53 V53 71 V71 92 149 J 23453 Seal Ring Compressor Croshd Piston 53 V53 71 V71 92 149 8 2L J 35945 Connecting Rod Installation Guides 50 60 J 8995 Connecting Rod ...

Page 1952: ...71 92 J 7593 03 Cam Bal Shaft Bushg Rem Install 53 V53 J 29141 A Cam Bushing Remover Installer 8 2L J 28462 Cam Coupling Torque Wrench Adapter 149 J 24094 Cam Cup Plug Installer 53 V53 71 V71 J 34033 Cam Installation Pilot 8 2L J 39537 Cam Shaft Bushing R I 30G 40 J 41580 Camshaft Pilot 55 J 7932 Gear Cam Pulley Remover Adapter V71 92 J 9790 Upper Front Cover Seal Installer 53 V53 J 35949 Cam Gear...

Page 1953: ...048 Main Bearing Guide Studs 2000 J 8386 01 Master Ring Cylinder Block Bore 71 V71 J 8385 01 Master Ring Liner ID 53 V53 PT 7145 A Right Angle Drill 50 60 J 38359 Threaded Insert 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 PT 2000 400 X Long Finish Line 50 60 J 42955 Cylinder Head Alignment Bar 4000 J 41962 Cylinder Head Bolt Bottom Tap 30G J 42954 Cylinder Head Guide Studs 4000 J 41823 Cylin...

Page 1954: ...J 43030 Gearcase Reaming Fixture 50 60 J 42511 Crankshaft Pulley Gear Remover Cento J 42999 Flywheel Vib damper Guide Studs 4000 J 42953 Flywheel Guide Studs 4000 J 42734 Flywheel Housing Alignment Tool 4000 J 41733 Piston Crown ID Gage 92 J 42256 Piston Ring Compressor 2000 J 42727 Piston Ring Compressor 4000 J 43011 Series 2000 Piston Ring Pliers 2000 J 43012 Series 4000 Piston Ring Pliers 4000 ...

Page 1955: ...de Studs 55 J 34691 A Flywheel Housing Guide Studs 55 J 41746 Cup Plug Installer 55 J 22410 226 Injector Seat 92 J 43394 Alignment Tool 2000 Table 192 Engine Tools All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1809 ...

Page 1956: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1810 Copyright DETROIT DIESEL CORPORATION ...

Page 1957: ...SERIES 4000 12 16V SERVICE MANUAL FUEL SYSTEM ELECTRONIC All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1811 ...

Page 1958: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1812 Copyright DETROIT DIESEL CORPORATION ...

Page 1959: ...vice Set DDA Gear G Torot Type 92 J 39300 Calibrator 92 J 28611 A Injector Tube Swagging Tool 92 J 38500 H Pro Link DDR for DDEC III and IV 92 J 34930 A Crank Position Timing Tool 92 J 35888 60A DDEC Repair Kit 50 60 149 J 35888 A DDEC Repair Kit 50 60 71 92 149 J 38500 152 Diagnostic Reader CBL ADPT AMP 50 60 71 92 J 38500 60A Diagnostic Reader CBL ADPT Deutsch 60 71 92 J 38596 A ECM Test Harness...

Page 1960: ...pter 55 J 34760 147A Injector Pop Fixture ADP Electronic 50 60 92 J 24517 B Injector Tube Reconditioning Set 149 J 6355 Fuel Pressure Gauge 0 100 PSI 149 J 8151 Fuel Pressure Gauge 100PSI 53 V53 71 V71 92 149 8 2L J 34607 A Fuel Pump Repair Kit 149 J 38767 A Fuel Pump Repair Kit 50 60 J 4242 Fuel Pump Wrench 53 V53 71 V71 92 149 8 2L J 41518 GFI Diagnostic Cable 50G J 33854 Needle Bearing Installe...

Page 1961: ...2 J 38500 1500 Multi Protocol Cartridge V1 70 1 72 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 J 38500 1DD Pro Link Diagnostic Reader 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 J 38500 155 Prolink Adapter DDEC Marine 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 J 42980 Series 40E ECM Terminal Crimpers 40E J 38500 2100 Series 40E PCMCIA Navistar 40 40E J 42731 Fuel Railing Engine Fix...

Page 1962: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1816 Copyright DETROIT DIESEL CORPORATION ...

Page 1963: ...SERIES 4000 12 16V SERVICE MANUAL FUEL SYSTEM MECHANICAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1817 ...

Page 1964: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1818 Copyright DETROIT DIESEL CORPORATION ...

Page 1965: ...1967 01 Gov Weight Shaft Ret Ring Installer 71 V71 92 149 J 36840 Gov Weight Wedge Static Gap Setting 53 V53 71 V71 92 149 J 35516 Governor Housing Repair Kit V71 92 PT 7150 A Governor Housing Repair Kit V71 92 J 35618 Linkage Gage Electronic 8 2L J 23176 Weight Housing Plug Rem Replacer 149 J 8984 Weight Spacer 6V 53 V53 J 4685 Drive Ring Remover V71 149 J 34998 Master Injector 149 149 J 29097 No...

Page 1966: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1820 Copyright DETROIT DIESEL CORPORATION ...

Page 1967: ...SERIES 4000 12 16V SERVICE MANUAL LUBRICATION SYSTEM All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1821 ...

Page 1968: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1822 Copyright DETROIT DIESEL CORPORATION ...

Page 1969: ...380 Gear Instal 5 500 16V 71 12V 16V92 V71 92 J 9381 Gear Installer V71 92 J 9382 Gear Installer 8 060 16V V71 92 J 39769 Idler Shaft Wrench 50 50G J 41975 Oil Cooler Test Plate 30G J 43097 Oil Cooling Plate 40E J 29325 4 Oil Pressure Gauge 0 160 PSI 50 50G 53 V53 55 60 71 V71 92 149 8 2L J 39816 Oil Pump Gear Holder 50 50G J 29925 Filter Cutter Fuel and Lube 40 50 50G 53 V53 55 60 71 V71 92 149 8...

Page 1970: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1824 Copyright DETROIT DIESEL CORPORATION ...

Page 1971: ...SERIES 4000 12 16V SERVICE MANUAL COOLING SYSTEM All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1825 ...

Page 1972: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1826 Copyright DETROIT DIESEL CORPORATION ...

Page 1973: ...L J 29190 B Impeller Remover Installer 8 2L J 35517 1 Seal Installer Unitized 60 8 2L J 22143 Water Pump Impeller Remover V71 J 35988 B Water Pump Service Set 50 50G 60 J 24460 01 Cooling System Pressure Tester 40 50 50G 53 V53 55 60 71 V71 92 149 8 2L J 29003 A Radiator Pressure Tester ADPT 53 V53 60 71 V71 92 149 8 2L Table 196 Cooling System All information subject to change without notice Copy...

Page 1974: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1828 Copyright DETROIT DIESEL CORPORATION ...

Page 1975: ...SERIES 4000 12 16V SERVICE MANUAL FUEL LUBRICATING OIL COOLANT All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1829 ...

Page 1976: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1830 Copyright DETROIT DIESEL CORPORATION ...

Page 1977: ...t Fluid Tester 40 50 50G 53 53V 55 60 71 V71 92 149 8 2L J 26568 Eng Coolant Batt Fluid Tester 40 50 50G 53 53V 55 60 71 V71 92 149 8 2L J 29545 Fluorescent Coolant Dye 24 1OZ 30G 40 40E 50 50G 53 53V 55 60 71 V71 92 149 8 2 J 28428 E High Intensity Black Light Kit 30G 40 40E 50 50G 53 53V 55 60 71 V71 92 149 8 2 J 39258 A Engine Pre Luber 30G 40 40E 50 50G 53 53V 55 60 71 V71 92 149 8 2 J 28431 B...

Page 1978: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1832 Copyright DETROIT DIESEL CORPORATION ...

Page 1979: ...SERIES 4000 12 16V SERVICE MANUAL AIR INTAKE SYSTEM All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1833 ...

Page 1980: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1834 Copyright DETROIT DIESEL CORPORATION ...

Page 1981: ... Instal V71 92 J 38707 A Double Lip Seal OS Wear SL Instal 149 J 33001 Drive Shaft Alignment Tool V71 92 J 21843 01 Drive Alignment Set V71 J 1471 Drive Cam Installer 71 V71 J 5209 Drive Cam Installer 53 V53 J 23641 Drive Gear Hub Socket 149 J 1698 02 Rotor Clearance Feeler Gage Set 53 V53 71 V71 92 149 J 4254 Rotor SHFT REM INST Set 3 4 6 71 71 J 22706 C Service Tool Set 149 J 8147 Service Tool S...

Page 1982: ... MANUAL J 29091 Sled Gage Base 53 V53 71 V71 92 149 J 28507 Snap Ring Pliers Internal 53 V53 71 V71 92 149 Table 198 Air Intake System All information subject to change without notice C 1836 Copyright DETROIT DIESEL CORPORATION ...

Page 1983: ...SERIES 4000 12 16V SERVICE MANUAL ELECTRICAL EQUIPMENT All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1837 ...

Page 1984: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1838 Copyright DETROIT DIESEL CORPORATION ...

Page 1985: ...ctrical system Tool Number Tool Description Application J 41723 Alternator Pulley Holder 50 50G 60 92 J 21008 A Test Light Self Powered 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 Table 199 Electrical Equipment All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1839 ...

Page 1986: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1840 Copyright DETROIT DIESEL CORPORATION ...

Page 1987: ...SERIES 4000 12 16V SERVICE MANUAL SPECIAL EQUIPMENT All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1841 ...

Page 1988: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1842 Copyright DETROIT DIESEL CORPORATION ...

Page 1989: ...ve Service Set 50 50G 60 J 29547 A Freon Leak Detect 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 8 2L 20 J 6714 D Hysrostarter Accumulator Charge Kit 53 V53 71 V71 J 25447 B Inlet Valve Stop Remover 50 50G 60 J 36311 Hub Installer 53 V53 71 V71 92 149 J 36309 Hub Remover 53 V53 71 V71 92 149 Table 200 Special Equipment All information subject to change without notice Copyright DETROIT DIESEL CORPORAT...

Page 1990: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1844 Copyright DETROIT DIESEL CORPORATION ...

Page 1991: ...SERIES 4000 12 16V SERVICE MANUAL OPERATION AND VERIFICATION All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1845 ...

Page 1992: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1846 Copyright DETROIT DIESEL CORPORATION ...

Page 1993: ... Application J 7334 E Comp Gauge Pack 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 J 41960 Compression Gauge Adapter 30G J 38450 5 Printer Paper 5 Roll Pack 50 60 71 92 149 J 38480 Printer Portable 110V Recharger 50 60 71 92 149 Table 201 Operation And Verification All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1847 ...

Page 1994: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1848 Copyright DETROIT DIESEL CORPORATION ...

Page 1995: ...SERIES 4000 12 16V SERVICE MANUAL ENGINE TUNE UP All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1849 ...

Page 1996: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1850 Copyright DETROIT DIESEL CORPORATION ...

Page 1997: ...2 149 8 2L J 8397 Dry Air Cleaner Gage 53 V53 60 71 V71 92 149 8 2L J 22195 Elec Gov Link Setting V71 J 29534 B Engine Diagnosis Kit 8 2L J 29139 Flywheel Timing Pin Adapter 8 2L J 28598 B Governor Adjusting Tool VHSLS V71 92 J 23185 Governor Gap GA Limiting Speed Gov 53 V53 71 V71 92 149 J 5407 Governor Gap Gage 170 71 J 23478 Governor Gap Gage 200 V71 J 29646 A Governor Gap Gage 216 8 2L J 34184...

Page 1998: ...g Tool 2000 J 9708 20 Feeler GA 20 Exhaust VLV Lash 50 60 J 9708 C Feeler GA Set 53 V53 71 V71 92 149 8 2L J 9708 21 Feeler Gage 800 Intake VLV Lach 50 60 J 5956 Fuel System Primer 50 53 V53 60 71 V71 92 149 8 2L J 29523 Injector Control Rack pin 8 2L J 26645 Injector Control Rack Gage 160 149 J 35586 Injector Rack Gage 200 53 V563 J 29825 Injector Rack Gage 220 149 J 26646 Injector Rack Gage 290 ...

Page 1999: ...njector Timing Gage 1 490 V53 71 V71 92 J 9595 Injector Timing Gage 1 496 V53 71 V71 92 J 25454 Injector Timing Gage 1 500 V53 71 V71 92 J 8909 Injector Timing Gage 1 508 V53 71 V71 J 34192 Injector Timing Gage 1 515 92 J 25502 Injector Timing Gage 1 520 V71 92 J 36869 Injector Timing Gage 2 170 149 J 22412 A Injector Timing Gage 2 175 149 J 29116 A Injector Timing Gage 2 185 149 J 24283 A Injecto...

Page 2000: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1854 Copyright DETROIT DIESEL CORPORATION ...

Page 2001: ...SERIES 4000 12 16V SERVICE MANUAL PREVENTIVE MAINTENANCE All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1855 ...

Page 2002: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1856 Copyright DETROIT DIESEL CORPORATION ...

Page 2003: ...ion Gauge Adapter 53 V53 71 V71 92 J 42868 DDC Diagnostic PC Cart 30G 40 50 50G 53 V53 55 60 71 V71 92 14 J 39257 Engine Field Test Kit 40 J 42948 Engine Harness Repair Kit 40E PT 7144 A Infrared Thermometer 30G 40 50 50G 53 V53 55 60 71 V71 92 14 J 35825 Phasar Tach 30G 40 40E50 50G 53 V53 55 60 71 V71 92 J 35603 Terminal Crimping Tool 30G 40 40E 50 50G 53 V53 55 60 71 V71 9 J 42949 Terminal Rele...

Page 2004: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1858 Copyright DETROIT DIESEL CORPORATION ...

Page 2005: ...SERIES 4000 12 16V SERVICE MANUAL GENERAL TOOLS SHOP EQUIPMENT All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1859 ...

Page 2006: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1860 Copyright DETROIT DIESEL CORPORATION ...

Page 2007: ... 11 4 21 8 TE 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 J 26900 33 Gauge Set 5 16 6 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 J 26900 14 Holy Gauge Set 125 500 30G 40 40E 50 50G 53 V53 55 60 71 V71 92 149 8 2 J 7872 Magnetic base Dial Indicator 40 50 50G 53 V53 55 60 71 V71 J 26900 1 Micrometer Inch MM 0 1 40 50 50G 53 V53 55 60 71 V71 92 149 8 2L J 26900 2 Micrometer Inch MM 1 2 40 ...

Page 2008: ...0 71 V71 92 149 8 2L 2000 4000 Ce J 35810 Great Crate II Rack System 40 50 50G 53 V53 55 60 71 V71 92 149 8 2L 2000 4000 Ce J 35805 Great Crate II Storage Box 40 50 50G 53 V53 55 60 71 V71 92 149 8 2L 2000 4000 Ce J 36130 806 Load Rotor 4000 LB 40 50 50G 53 V53 55 60 71 V71 92 149 8 2L 2000 4000 Ce PT 7272 old number J 26558 242 Lock N Seal 40 50 50G 53 V53 55 60 71 V71 92 149 8 2L 2000 4000 Ce PT...

Page 2009: ...SERIES 4000 12 16V SERVICE MANUAL Kent Moore TOOL GRAPHICS All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1863 ...

Page 2010: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice C 1864 Copyright DETROIT DIESEL CORPORATION ...

Page 2011: ...ion contains all of the tools supported in the Kent Moore tool manual Figure 1070 Aftercooler Adaptor Plug Rem Inst J 25275 Figure 1071 Barring Tool Starter Mounting Pad J 22582 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1865 ...

Page 2012: ... SERVICE MANUAL Figure 1072 BLK Core Plug Inst Water B P Block J 21850 Figure 1073 BLK Plug Remover Water B P Block J 21996 01 All information subject to change without notice C 1866 Copyright DETROIT DIESEL CORPORATION ...

Page 2013: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1074 Block And Head Test Pressure Kit J 39693 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1867 ...

Page 2014: ... 12 16V SERVICE MANUAL Figure 1075 Block Air Box Core Plug Rem Inst J 23019 Figure 1076 Block AIr Box Plug Tool J 29571 All information subject to change without notice C 1868 Copyright DETROIT DIESEL CORPORATION ...

Page 2015: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1077 Block Align Tool J 24542 Figure 1078 Block Align Tool J 24543 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1869 ...

Page 2016: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1079 Block Alignment Tool J 22486 All information subject to change without notice C 1870 Copyright DETROIT DIESEL CORPORATION ...

Page 2017: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1080 Block Alignment Tool J 21799 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1871 ...

Page 2018: ...2 16V SERVICE MANUAL Figure 1081 Block Assembly Wrench Set 16V J 25451 B Figure 1082 Block Assembly Wrench Set 16V J 28651 All information subject to change without notice C 1872 Copyright DETROIT DIESEL CORPORATION ...

Page 2019: ...0 12 16V SERVICE MANUAL Figure 1083 Block Head Bolt Hole Depth Gage J 26244 Figure 1084 Block Lifting Eye Bolts J 35595 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1873 ...

Page 2020: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1085 Block Pressure Test Kit J 24051 B All information subject to change without notice C 1874 Copyright DETROIT DIESEL CORPORATION ...

Page 2021: ...4000 12 16V SERVICE MANUAL Figure 1086 Block Torque Adapter J 24533 Figure 1087 Counterbore Cutter Plate PT 2200 30 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1875 ...

Page 2022: ...0 12 16V SERVICE MANUAL Figure 1088 Counterbore Cutter Plate PT 2200 31 Figure 1089 Counterbore Cutter Pate PT 2200 37 All information subject to change without notice C 1876 Copyright DETROIT DIESEL CORPORATION ...

Page 2023: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1090 Counterbore Tool PT 2250 B Figure 1091 Cup Plug Installer J 33420 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1877 ...

Page 2024: ...12 16V SERVICE MANUAL Figure 1092 Cup Plug Installer requires J 7079 2 J 41746 Figure 1093 Cup Plug Installer Set J 35653 All information subject to change without notice C 1878 Copyright DETROIT DIESEL CORPORATION ...

Page 2025: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1094 Cyl Head Block Pressure Kit J 36223 D All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1879 ...

Page 2026: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1095 Cylinder Block Pressure Kit J 41566 All information subject to change without notice C 1880 Copyright DETROIT DIESEL CORPORATION ...

Page 2027: ...IES 4000 12 16V SERVICE MANUAL Figure 1096 Cylinder Bore Set J 34698 Figure 1097 Cylinder Bore Plug Set J 34699 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1881 ...

Page 2028: ...4000 12 16V SERVICE MANUAL Figure 1098 Cylinder Bore Ridge Reamer J 24270 Figure 1099 Cylinder Head Bolt Tap J 25384 All information subject to change without notice C 1882 Copyright DETROIT DIESEL CORPORATION ...

Page 2029: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1100 Cylinder Head Bolt Tap PT 2950 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1883 ...

Page 2030: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1101 Cylinder Home Glaze Breaker J 5902 01 All information subject to change without notice C 1884 Copyright DETROIT DIESEL CORPORATION ...

Page 2031: ...4000 12 16V SERVICE MANUAL Figure 1102 Cylinder Hone Stones J 5902 18 Figure 1103 Cylinder Liner Depth Gage J 24898 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1885 ...

Page 2032: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1104 Cylinder Liner Lifter J 36398 Figure 1105 Deck Checker PT 5075 B All information subject to change without notice C 1886 Copyright DETROIT DIESEL CORPORATION ...

Page 2033: ...00 12 16V SERVICE MANUAL Figure 1106 Deck Checker Conversion PT 5071 Figure 1107 Dial Bore Gage 3 3 32 8 Dia J 5347 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1887 ...

Page 2034: ...00 12 16V SERVICE MANUAL Figure 1108 Dowel Installer Set J 36224 Figure 1109 Eng Lift Hook Use W 3 PT Spreader J 41171 All information subject to change without notice C 1888 Copyright DETROIT DIESEL CORPORATION ...

Page 2035: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1110 Engine Barring Tool J 36237 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1889 ...

Page 2036: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1111 Engine Lifting Bracket J 36130 812 All information subject to change without notice C 1890 Copyright DETROIT DIESEL CORPORATION ...

Page 2037: ...0 12 16V SERVICE MANUAL Figure 1112 Engine Stand Adaptor Plate J 39298 A Figure 1113 Engine Stand Adapter Plate J 41576 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1891 ...

Page 2038: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1114 Exhaust Manifold Guide Studs J 36107 All information subject to change without notice C 1892 Copyright DETROIT DIESEL CORPORATION ...

Page 2039: ...0 12 16V SERVICE MANUAL Figure 1115 Exhaust Manifest Nut Wrench J 26816 A Figure 1116 Gasket Eliminator Loctite PT 7276 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1893 ...

Page 2040: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1117 Inter Block Seal Installer J 38894 All information subject to change without notice C 1894 Copyright DETROIT DIESEL CORPORATION ...

Page 2041: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1118 Jib Crane 4000 LB Max Lifting Cap J 33050 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1895 ...

Page 2042: ...ES 4000 12 16V SERVICE MANUAL Figure 1119 Lifting Eye Bolts J 41564 Figure 1120 Line Boring Complete Kit J 41060 All information subject to change without notice C 1896 Copyright DETROIT DIESEL CORPORATION ...

Page 2043: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1121 Line Boring Main BRG Adapter Kit J 41061 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1897 ...

Page 2044: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1122 Liner Hold Clamps Down J 21793 B All information subject to change without notice C 1898 Copyright DETROIT DIESEL CORPORATION ...

Page 2045: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1123 Liner Hold Down Clamps J 24565 02 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1899 ...

Page 2046: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1124 Liner Installer J 22461 A All information subject to change without notice C 1900 Copyright DETROIT DIESEL CORPORATION ...

Page 2047: ...ES 4000 12 16V SERVICE MANUAL Figure 1125 Liner Installer J 41441 Figure 1126 Liner Installer Hold Down J 35597 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1901 ...

Page 2048: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1127 Liner Puller J 41543 All information subject to change without notice C 1902 Copyright DETROIT DIESEL CORPORATION ...

Page 2049: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1128 Liner Remover Screw Type J 21716 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1903 ...

Page 2050: ...00 12 16V SERVICE MANUAL Figure 1129 Liner Remover Screw Type J 22431 A Figure 1130 Liner Remover Screw Type J 24563 A All information subject to change without notice C 1904 Copyright DETROIT DIESEL CORPORATION ...

Page 2051: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1131 Liner Remover Screw Type J 35791 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1905 ...

Page 2052: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1132 Liner Remover Screw Type J 1918 02 All information subject to change without notice C 1906 Copyright DETROIT DIESEL CORPORATION ...

Page 2053: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1133 Liner Remover Screw Type J 22490 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1907 ...

Page 2054: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1134 Liner Removal Universal Screw Type PT 6410 B All information subject to change without notice C 1908 Copyright DETROIT DIESEL CORPORATION ...

Page 2055: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1135 Liner Seat Resurfacer Kit J 41749 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1909 ...

Page 2056: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1136 Main Sad Bushing PT 8530 1 Figure 1137 Main Sad Bushing PT 8531 1 All information subject to change without notice C 1910 Copyright DETROIT DIESEL CORPORATION ...

Page 2057: ... 12 16V SERVICE MANUAL Figure 1138 Master Ring Cylinder Block Bore J 8386 01 Figure 1139 Master Ring Liner I D J 8385 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1911 ...

Page 2058: ...ES 4000 12 16V SERVICE MANUAL Figure 1140 Master Ring Liner I D J 22613 Figure 1141 Master Ring Liner I D J 24564 All information subject to change without notice C 1912 Copyright DETROIT DIESEL CORPORATION ...

Page 2059: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1142 Oil Cooler Guide Studs J 35786 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1913 ...

Page 2060: ...12 16V SERVICE MANUAL Figure 1143 Oil Gallery Spacer Installer J 38895 Figure 1144 Oil Nozzle Calibration Device J 41542 All information subject to change without notice C 1914 Copyright DETROIT DIESEL CORPORATION ...

Page 2061: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1145 Overhaul Stand Less Adapters J 29109 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1915 ...

Page 2062: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1146 Overhaul Stand Less Adapters J 9398 04 All information subject to change without notice C 1916 Copyright DETROIT DIESEL CORPORATION ...

Page 2063: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1147 Engine Overhaul Stand 12V and 16V J 9389 04 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1917 ...

Page 2064: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1148 Overhaul Stand AdaptersJ 29013 A All information subject to change without notice C 1918 Copyright DETROIT DIESEL CORPORATION ...

Page 2065: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1149 Overhaul Stand Adapters J 33850 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1919 ...

Page 2066: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1150 Overhaul Stand Adapters J 35635 A All information subject to change without notice C 1920 Copyright DETROIT DIESEL CORPORATION ...

Page 2067: ...S 4000 12 16V SERVICE MANUAL Figure 1151 Overhaul Stand Adapters J 39652 Figure 1152 Overhaul Stand AdaptersJ 8650 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1921 ...

Page 2068: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1153 Parts Dolly J 6387 All information subject to change without notice C 1922 Copyright DETROIT DIESEL CORPORATION ...

Page 2069: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1154 Porta Matic Basic PT 2050 D All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1923 ...

Page 2070: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1155 Setting Master 3 8 Dial Bore J 23059 01 All information subject to change without notice C 1924 Copyright DETROIT DIESEL CORPORATION ...

Page 2071: ...IES 4000 12 16V SERVICE MANUAL Figure 1156 Setting Master Adapter 2 8 J 23059 4 Figure 1157 Sled Gage J 22273 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1925 ...

Page 2072: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1158 Surface Conditioning Set J 36571 All information subject to change without notice C 1926 Copyright DETROIT DIESEL CORPORATION ...

Page 2073: ...000 12 16V SERVICE MANUAL Figure 1159 T D C Timing Set J 29011 A Figure 1160 Thread Repair CYL HD Bolt Holes J 38359 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1927 ...

Page 2074: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1161 Thread Repair Main BRG HD Bolt Hole J 29513 All information subject to change without notice C 1928 Copyright DETROIT DIESEL CORPORATION ...

Page 2075: ...12 16V SERVICE MANUAL Figure 1162 Thread Rework Kit 15mm PT 2860 A Figure 1163 Top Liner Cooler Modification Kit J 39852 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1929 ...

Page 2076: ...16V SERVICE MANUAL Figure 1164 Torquing Device Main Bearing Bolts J 35371 Figure 1165 Water Hole Sleeve Installer J 24233 01 All information subject to change without notice C 1930 Copyright DETROIT DIESEL CORPORATION ...

Page 2077: ...0 12 16V SERVICE MANUAL Figure 1166 Water Jacket Spacer Installer J 38893 Figure 1167 Water Port Plug Installer J 24597 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1931 ...

Page 2078: ...0 12 16V SERVICE MANUAL Figure 1168 1 1 2 X45 Degree Cutter J 26541 620 Figure 1169 1 3 4 X30 Degree Cutter J 26541 647 All information subject to change without notice C 1932 Copyright DETROIT DIESEL CORPORATION ...

Page 2079: ...S 4000 12 16V SERVICE MANUAL Figure 1170 Cam Follower Service Fixture J 33421 A Figure 1171 Ceramic Cutter J 39639 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1933 ...

Page 2080: ...000 12 16V SERVICE MANUAL Figure 1172 Car Plug Install Rocker Arm Shaft J36326 Figure 1173 Cup Plug Installer J 41746 All information subject to change without notice C 1934 Copyright DETROIT DIESEL CORPORATION ...

Page 2081: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1174 Cylinder Head Guide Studs J 24748 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1935 ...

Page 2082: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1175 Cylinder Head Guide Studs J 35784 All information subject to change without notice C 1936 Copyright DETROIT DIESEL CORPORATION ...

Page 2083: ...0 12 16V SERVICE MANUAL Figure 1176 Cylinder Head Guide Studs J 9665 Figure 1177 Cylinder Head Holding Fixture J 41558 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1937 ...

Page 2084: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1178 Cylinder Head Holding Plates J 3087 01 All information subject to change without notice C 1938 Copyright DETROIT DIESEL CORPORATION ...

Page 2085: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1179 Cylinder Head Lifting Fixture J 22062 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1939 ...

Page 2086: ...2 16V SERVICE MANUAL Figure 1180 Cylinder Head Lifting Fixture J 35641 A Figure 1181 Cylinder Head Locating Pins J 28511 C All information subject to change without notice C 1940 Copyright DETROIT DIESEL CORPORATION ...

Page 2087: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1182 Cylinder Head Pressure Test Fixture J 28454 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1941 ...

Page 2088: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1183 Cylinder Head Pressure Test Fixture J 41567 All information subject to change without notice C 1942 Copyright DETROIT DIESEL CORPORATION ...

Page 2089: ...IES 4000 12 16V SERVICE MANUAL Figure 1184 Cylinder Head Puller J 24252 Figure 1185 Dowel Installer Set J 36224 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1943 ...

Page 2090: ...00 12 16V SERVICE MANUAL Figure 1186 Fuel Line Nut Wrench 9 16 J 21545 Figure 1187 Fuel Line Nut Wrench 11 16 J 39108 All information subject to change without notice C 1944 Copyright DETROIT DIESEL CORPORATION ...

Page 2091: ...16V SERVICE MANUAL Figure 1188 Head Bolt Counterbore Cutter J 38189 Figure 1189 Head Bolt Wrench 15 16 X1 2 Drive J 1928 02 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1945 ...

Page 2092: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1190 Head Modification Kit Bolt Hole SL J 41169 All information subject to change without notice C 1946 Copyright DETROIT DIESEL CORPORATION ...

Page 2093: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1191 Holding Fixture J 23741 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1947 ...

Page 2094: ... 4000 12 16V SERVICE MANUAL Figure 1192 Injector Puller 39272 Figure 1193 Injector Tube Reconditioning Kit J 29124 All information subject to change without notice C 1948 Copyright DETROIT DIESEL CORPORATION ...

Page 2095: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1194 Injector Tube Reconditioning Set J 22342 D All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1949 ...

Page 2096: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1195 Injector Tube Reconditioning Set J 22515 B All information subject to change without notice C 1950 Copyright DETROIT DIESEL CORPORATION ...

Page 2097: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1196 Injector Tube Reconditioning Set J 24517 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1951 ...

Page 2098: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1197 Injector Tube Reconditioning Set J 33880 All information subject to change without notice C 1952 Copyright DETROIT DIESEL CORPORATION ...

Page 2099: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1198 Injector Vice J 22396 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1953 ...

Page 2100: ...S 4000 12 16V SERVICE MANUAL Figure 1199 Lifting Eye Bolts J 41564 Figure 1200 Nozzle Fixture Clamp Plate J 39264 All information subject to change without notice C 1954 Copyright DETROIT DIESEL CORPORATION ...

Page 2101: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1201 Nozzle Holding Fixture J 39263 Figure 1202 Nozzle Puller J 41165 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1955 ...

Page 2102: ...S 4000 12 16V SERVICE MANUAL Figure 1203 Nozzle Sleeve Installer J 39261 Figure 1204 Nozzle Sleeve Remover J 39262 All information subject to change without notice C 1956 Copyright DETROIT DIESEL CORPORATION ...

Page 2103: ...16V SERVICE MANUAL Figure 1205 Overhaul Stand Adaptor Cyl Head J 35636 A Figure 1206 Pipe Plug Remover SQ Drive Plug J 34650 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1957 ...

Page 2104: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1207 Push Rod Remover Set J 3092 01 All information subject to change without notice C 1958 Copyright DETROIT DIESEL CORPORATION ...

Page 2105: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1208 Rocker Arm Shaft Lifter J 35996 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1959 ...

Page 2106: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1209 Rocker Arm Shaft Lifter J 39647 A All information subject to change without notice C 1960 Copyright DETROIT DIESEL CORPORATION ...

Page 2107: ...ES 4000 12 16V SERVICE MANUAL Figure 1210 Rocker Arm Shaft Stud Socket J 36003 A Figure 1211 Sled Gage J 22273 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1961 ...

Page 2108: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1212 Spark Plug Adaptor Remover J 41488 All information subject to change without notice C 1962 Copyright DETROIT DIESEL CORPORATION ...

Page 2109: ...2 16V SERVICE MANUAL Figure 1213 Valve Button Retainer Expander J 36347 Figure 1214 Valve Button Retainer Expander J 39196 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1963 ...

Page 2110: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1215 Valve Guide Reamer J 39260 Figure 1216 Valve Guide Remover J 269 All information subject to change without notice C 1964 Copyright DETROIT DIESEL CORPORATION ...

Page 2111: ... 4000 12 16V SERVICE MANUAL Figure 1217 Valve Guide Remover J 41164 Figure 1218 Valve Seal Installer Set J 39880 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1965 ...

Page 2112: ...V SERVICE MANUAL Figure 1219 Valve Seat Concentricity Gage J 8165 2 Figure 1220 Valve Seat Cutter 1 50 X 15 60 DegJ 26541 213 All information subject to change without notice C 1966 Copyright DETROIT DIESEL CORPORATION ...

Page 2113: ... SERVICE MANUAL Figure 1221 Valve Seat Cutter 1 50 X 31DegJ 26541 628 Figure 1222 Valve Seat Cutter 1 75 X 15 60Deg J 26541 292 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1967 ...

Page 2114: ...SERVICE MANUAL Figure 1223 Valve Seat Cutter 1 75 X 31 Degree J 26541 649 Figure 1224 Valve Seat Cutter Pilot 0 344 J 26541 343 All information subject to change without notice C 1968 Copyright DETROIT DIESEL CORPORATION ...

Page 2115: ...6V SERVICE MANUAL Figure 1225 Valve Seat Cutter Pilot 0 345 J 26541 344 Figure 1226 Valve Seat Cutter Pilot 0 346 J 26541 345 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1969 ...

Page 2116: ...6V SERVICE MANUAL Figure 1227 Valve Seat Cutter Pilot 0 347 J 26541 346 Figure 1228 Valve Seat Cutter Pilot 0 375 J 26541 375 All information subject to change without notice C 1970 Copyright DETROIT DIESEL CORPORATION ...

Page 2117: ...6V SERVICE MANUAL Figure 1229 Valve Seat Cutter Pilot 0 376 J 26541 376 Figure 1230 Valve Seat Cutter Pilot 0 377 J 26541 377 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1971 ...

Page 2118: ...6V SERVICE MANUAL Figure 1231 Valve Seat Cutter Pilot 0 378 J 26541 378 Figure 1232 Valve Seat Cutter Pilot 9 mm J 26541 354 All information subject to change without notice C 1972 Copyright DETROIT DIESEL CORPORATION ...

Page 2119: ...12 16V SERVICE MANUAL Figure 1233 Valve Seat Cutting Set J 26541 Figure 1234 Valve Seat Cutting Set Power Unit J 26541 3 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1973 ...

Page 2120: ...RVICE MANUAL Figure 1235 Valve Seat Grind Adapt Kit 2 Valv 53 J 7924 02 Figure 1236 Valve Seat Grind Adapt Kit 4 Valv 71 J 6390 02 All information subject to change without notice C 1974 Copyright DETROIT DIESEL CORPORATION ...

Page 2121: ...ERVICE MANUAL Figure 1237 Valve Seat Grind Adapt Kit 2 Valv 71 J 8165 8 Figure 1238 Valve Seat Grind ADPT Kit 4 Valv 53 J 7792 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1975 ...

Page 2122: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1239 Valve Seat Grinder Adapter Kit 149 J 4627 02 All information subject to change without notice C 1976 Copyright DETROIT DIESEL CORPORATION ...

Page 2123: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1240 Valve Seat Grinder Adapter Kit 60 J 36805 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1977 ...

Page 2124: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1241 Valve Seat Grinder Adapter Kit 92 J 24566 All information subject to change without notice C 1978 Copyright DETROIT DIESEL CORPORATION ...

Page 2125: ...12 16V SERVICE MANUAL Figure 1242 Valve Seat Grind Adapter Kit 8 2L J 29645 Figure 1243 Valve Seat Grinder Pilot J 8165 3 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1979 ...

Page 2126: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1244 Valve Seat Grinder Less Stone Pilot J 7040 A All information subject to change without notice C 1980 Copyright DETROIT DIESEL CORPORATION ...

Page 2127: ...V SERVICE MANUAL Figure 1245 Valve Seat Grinding Wheel 21 Degree J 41535 Figure 1246 Valve Seat Insert Install 2 Valve J 1736 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1981 ...

Page 2128: ...16V SERVICE MANUAL Figure 1247 Valve Seat Insert Install 2 Valve J 6976 Figure 1248 Valve Seat Insert Install 4 Valve J 6568 All information subject to change without notice C 1982 Copyright DETROIT DIESEL CORPORATION ...

Page 2129: ...6V SERVICE MANUAL Figure 1249 Valve Seat Insert Install 4 Valve J 7790 Figure 1250 Valve Seat Insert Install Exhaust J 34983 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1983 ...

Page 2130: ... 16V SERVICE MANUAL Figure 1251 Valve Seat Insert Install Exhaust J 39536 Figure 1252 Valve Seat Insert Installer J 22711 A All information subject to change without notice C 1984 Copyright DETROIT DIESEL CORPORATION ...

Page 2131: ...0 12 16V SERVICE MANUAL Figure 1253 Valve Seat Insert Installer J 24357 Figure 1254 Valve Seat Insert Installer J 39535 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1985 ...

Page 2132: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1255 Valve Seat Insert Installer Intake J 33190 All information subject to change without notice C 1986 Copyright DETROIT DIESEL CORPORATION ...

Page 2133: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1256 Valve Seat Insert Installer Intake J 41585 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1987 ...

Page 2134: ...V SERVICE MANUAL Figure 1257 Valve Seat Insert Puller Assembly J 23479 35 Figure 1258 Valve Seat Insert Puller Body J 23479 37 All information subject to change without notice C 1988 Copyright DETROIT DIESEL CORPORATION ...

Page 2135: ...RVICE MANUAL Figure 1259 Valve Seat Insert Puller Collet PT 6390 45 Figure 1260 Valve Seat Insert Puller Collet 4 Valv J 23479 28 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1989 ...

Page 2136: ...CE MANUAL Figure 1261 Valve Seat Insert Puller Collet 4 Valv J 23479 30 Figure 1262 Valve Seat Insert Puller Collet 2 Valv J 23479 27 All information subject to change without notice C 1990 Copyright DETROIT DIESEL CORPORATION ...

Page 2137: ...ICE MANUAL Figure 1263 Valve Seat Insert Puller Collet Intake J 23479 100A Figure 1264 Valve Seat Insert Remove Ceramic HD J 22512 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1991 ...

Page 2138: ...12 16V SERVICE MANUAL Figure 1265 Valve Seat Insert Remover J 23479 271 Figure 1266 Valve Seat Insert Remover J 23479 492 All information subject to change without notice C 1992 Copyright DETROIT DIESEL CORPORATION ...

Page 2139: ...000 12 16V SERVICE MANUAL Figure 1267 Valve Seat Insert Remover J 41583 Figure 1268 Valve Seat Insert Remover PT 6300 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1993 ...

Page 2140: ...ERVICE MANUAL Figure 1269 Valve Seat Insert Remover 2 Valv71 J 23479 29 Figure 1270 Valve Seat Insert Remover 2 Valv J 23479 253 All information subject to change without notice C 1994 Copyright DETROIT DIESEL CORPORATION ...

Page 2141: ...SERVICE MANUAL Figure 1271 Valve Seat Insert Remover 4 Valv J 23479 471 Figure 1272 Valve Seat Insert Remover 4 Valv J 23479 453 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1995 ...

Page 2142: ...ERVICE MANUAL Figure 1273 Valve Seat Insert Remover Intake J 23479 460 A Figure 1274 Valve Seat Insert Remover Collet J 23479 33 All information subject to change without notice C 1996 Copyright DETROIT DIESEL CORPORATION ...

Page 2143: ...6V SERVICE MANUAL Figure 1275 Valve Seat Insert Remover Collet J 23479 38 Figure 1276 Valve Seat Insert Remover Set J 23479 E All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1997 ...

Page 2144: ... 12 16V SERVICE MANUAL Figure 1277 Valve Seat Installer Exhaust J 41578 Figure 1278 Valve Seat Installer Exhaust J 41822 All information subject to change without notice C 1998 Copyright DETROIT DIESEL CORPORATION ...

Page 2145: ...0 12 16V SERVICE MANUAL Figure 1279 Valve Seat Puller Basic Kit PT 6391 Figure 1280 Valve Seat Remover Collet PT 6399 7 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 1999 ...

Page 2146: ...ERVICE MANUAL Figure 1281 Valve Seat Remover Collet 2 Valv 53 PT 6399 3 Figure 1282 Valve Seat Remover Collet 2 Valv 53 PT 6399 4 All information subject to change without notice C 2000 Copyright DETROIT DIESEL CORPORATION ...

Page 2147: ...16V SERVICE MANUAL Figure 1283 Valve Seat Remover Collet 4 Valv 71 PT 6399 5 Figure 1284 Valve Seat Remover Collet PT 6399 9 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2001 ...

Page 2148: ...VICE MANUAL Figure 1285 Valve St Insert Rem Non Ceramic HD J 23479 49 Figure 1286 Valve Seat Remover Collet 2Valv 71 EXH PT 6399 6 All information subject to change without notice C 2002 Copyright DETROIT DIESEL CORPORATION ...

Page 2149: ...000 12 16V SERVICE MANUAL Figure 1287 Valve Stem Seal Installer J 36582 Figure 1288 Valve Stem Seal Installer J 39109 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2003 ...

Page 2150: ...12 16V SERVICE MANUAL Figure 1289 Valve Stem Seal Installer J 41571 Figure 1290 Valve Stem Seal Installer Narrow J 41282 All information subject to change without notice C 2004 Copyright DETROIT DIESEL CORPORATION ...

Page 2151: ... 12 16V SERVICE MANUAL Figure 1291 Valve Stem Seal Installer 4Valv J 35373 Figure 1292 Water Nozzle Installer J 24857 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2005 ...

Page 2152: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1293 Body Reamer N S Injections J 21089 All information subject to change without notice C 2006 Copyright DETROIT DIESEL CORPORATION ...

Page 2153: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1294 INJ Tip CONC Gage Rack Free Tester J 29584 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2007 ...

Page 2154: ... 16V SERVICE MANUAL Figure 1295 Injector Calibrator Adaptor Marine J 22410 696 Figure 1296 Injector Holding Fixture J 29136 All information subject to change without notice C 2008 Copyright DETROIT DIESEL CORPORATION ...

Page 2155: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1297 Injector Nut Carbon Remover Set J 29575 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2009 ...

Page 2156: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1298 Injector Nut Carbon Remover Set 149 J 22096 02 All information subject to change without notice C 2010 Copyright DETROIT DIESEL CORPORATION ...

Page 2157: ...00 12 16V SERVICE MANUAL Figure 1299 Injector Nut Seal Ring Installer J 29197 Figure 1300 Injector Nut Socket J 22799 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2011 ...

Page 2158: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1301 Injector Pop N Fixture J 24760 B All information subject to change without notice C 2012 Copyright DETROIT DIESEL CORPORATION ...

Page 2159: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1302 Injector Pop Fixt Mechanical Only J 34760 150A Old Num 23010 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2013 ...

Page 2160: ...V SERVICE MANUAL Figure 1303 Injector Pop Fixt Adapter Marine J 23010 265 Figure 1304 Injector Pop Fixt Adpt 53 71 J 34760 145 All information subject to change without notice C 2014 Copyright DETROIT DIESEL CORPORATION ...

Page 2161: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1305 Injector Pop Fixture Adapter 149 J 34760 144 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2015 ...

Page 2162: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1306 Injector Pop Fixture Adapter 8 2L J 34760 146 All information subject to change without notice C 2016 Copyright DETROIT DIESEL CORPORATION ...

Page 2163: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1307 Injector Pop Fixture Power Supply J 34760 300 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2017 ...

Page 2164: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1308 Injector Service Set N Injector J 23435 C All information subject to change without notice C 2018 Copyright DETROIT DIESEL CORPORATION ...

Page 2165: ...ERVICE MANUAL Figure 1309 Injector Spray Tip Carbon Remover J 22800 01 Figure 1310 Injector Spray Tip Needle Lift Gage J 9462 02 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2019 ...

Page 2166: ... 16V SERVICE MANUAL Figure 1311 Injector Spray Tip Wire 009 J 22885 Figure 1312 Injector Tag Remover Installer Set J 24767 All information subject to change without notice C 2020 Copyright DETROIT DIESEL CORPORATION ...

Page 2167: ...2 16V SERVICE MANUAL Figure 1313 Injector Tip Concentricity Gage J 23905 Figure 1314 Injector Tip Polishing Sticks J 22964 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2021 ...

Page 2168: ...ES 4000 12 16V SERVICE MANUAL Figure 1315 Lapping Block Set J 22090 A Figure 1316 Lapping Compound Liquid J 23038 All information subject to change without notice C 2022 Copyright DETROIT DIESEL CORPORATION ...

Page 2169: ...0 12 16V SERVICE MANUAL Figure 1317 Master Injector Kit J 35369 Old Num 26298 Figure 1318 Master Injector 8 2L J 29898 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2023 ...

Page 2170: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1319 Valve Spring Compress CYL HD Remove J 22693 01 All information subject to change without notice C 2024 Copyright DETROIT DIESEL CORPORATION ...

Page 2171: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1320 Valve Spring Compressor J 7455 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2025 ...

Page 2172: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1321 Valve Spring Compressor CYL HD OFF J 8062 All information subject to change without notice C 2026 Copyright DETROIT DIESEL CORPORATION ...

Page 2173: ...12 16V SERVICE MANUAL Figure 1322 Valve Spring Tester J 22738 02 Figure 1323 Valve Spring Tester ON Cylinder HD J 25076 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2027 ...

Page 2174: ...6V SERVICE MANUAL Figure 1324 Valve Bridge Guide Broken Remover J 7453 Figure 1325 Valve Bridge Guide Instal PRSD GDE J 7482 All information subject to change without notice C 2028 Copyright DETROIT DIESEL CORPORATION ...

Page 2175: ... 16V SERVICE MANUAL Figure 1326 Valve Bridge Guide Install Threaded J 6846 Figure 1327 Valve Bridge Guide Installer J 22487 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2029 ...

Page 2176: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1328 Valve Bridge Guide Remover Press J 7091 01 All information subject to change without notice C 2030 Copyright DETROIT DIESEL CORPORATION ...

Page 2177: ...0 12 16V SERVICE MANUAL Figure 1329 Valve Bridge Holding Fixture J 21772 Figure 1330 Valve Guide Cleaning Brush J 5437 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2031 ...

Page 2178: ...12 16V SERVICE MANUAL Figure 1331 Valve Guide Cleaning Brush J 5585 Figure 1332 Valve Guide Cleaning Brush 4 Valv J 7793 All information subject to change without notice C 2032 Copyright DETROIT DIESEL CORPORATION ...

Page 2179: ...00 12 16V SERVICE MANUAL Figure 1333 Valve Guide Installer J 33191 A Figure 1334 Valve Guide Installer 2 Valve J 7560 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2033 ...

Page 2180: ...12 16V SERVICE MANUAL Figure 1335 Valve Guide Installer 2 Valve J 9530 Figure 1336 Valve Guide Installer 4 Valve J 21520 All information subject to change without notice C 2034 Copyright DETROIT DIESEL CORPORATION ...

Page 2181: ...16V SERVICE MANUAL Figure 1337 Valve Guide Installer 4 Valve J 24519 Figure 1338 Valve Guide Installer Large Stem J 22082 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2035 ...

Page 2182: ...IES 4000 12 16V SERVICE MANUAL Figure 1339 Valve Guide Remover J 23458 Figure 1340 Valve Guide Remover J 34696 B All information subject to change without notice C 2036 Copyright DETROIT DIESEL CORPORATION ...

Page 2183: ...4000 12 16V SERVICE MANUAL Figure 1341 Valve Guide Remover J 6569 A Figure 1342 Valve Guide Remover 2 Valve J 267 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2037 ...

Page 2184: ...12 16V SERVICE MANUAL Figure 1343 Valve Guide Remover 4 Valve J 7775 A Figure 1344 Valve Guide Remover Installer J 28612 All information subject to change without notice C 2038 Copyright DETROIT DIESEL CORPORATION ...

Page 2185: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1345 Valve Stem Seal Installer 4 Val 53 J 29579 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2039 ...

Page 2186: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1346 Crankshaft Gear Remover Installer J 35642 All information subject to change without notice C 2040 Copyright DETROIT DIESEL CORPORATION ...

Page 2187: ...0 12 16V SERVICE MANUAL Figure 1347 Crankshaft Main Bearing Remover J 36187 A Figure 1348 Crankshaft Protector J 35994 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2041 ...

Page 2188: ... SERVICE MANUAL Figure 1349 Crankshaft Torque Wrench Adapter J 22898 A Figure 1350 Crankshaft Torque Wrench Adapter Set J 22897 All information subject to change without notice C 2042 Copyright DETROIT DIESEL CORPORATION ...

Page 2189: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1351 Front Crankshaft Cup Plug Tester J 34728 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2043 ...

Page 2190: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1352 Crankshaft Oil Seal Remover J 35993 All information subject to change without notice C 2044 Copyright DETROIT DIESEL CORPORATION ...

Page 2191: ...12 16V SERVICE MANUAL Figure 1353 Front Crankshaft Seal REM INST J 41599 Figure 1354 Front Seal Expander STD 6V 53 J 7454 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2045 ...

Page 2192: ...2 16V SERVICE MANUAL Figure 1355 Front Seal Installer STD Seal J 29008 B Figure 1356 Front Seal Installer STD Seal J 9783 All information subject to change without notice C 2046 Copyright DETROIT DIESEL CORPORATION ...

Page 2193: ...000 12 16V SERVICE MANUAL Figure 1357 Front Seal Installer STD 8V 53 J 22153 Figure 1358 Front Seal Remover J 29007 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2047 ...

Page 2194: ...6V SERVICE MANUAL Figure 1359 Front Seal Sleeve Installer 6V 53 J 22524 Figure 1360 Front Seal Bearing Installer STD J 22518 All information subject to change without notice C 2048 Copyright DETROIT DIESEL CORPORATION ...

Page 2195: ...0 12 16V SERVICE MANUAL Figure 1361 Front Rear Seal Expander J 22425 B Figure 1362 Front Rear Seal Installer J 4194 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2049 ...

Page 2196: ...16V SERVICE MANUAL Figure 1363 Front Rear Seal Installer J 9727 A Figure 1364 Front Rear Seal Wear Sleeve Install J 35686 A All information subject to change without notice C 2050 Copyright DETROIT DIESEL CORPORATION ...

Page 2197: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1365 FRT RR Seal Expander Oversize J 4195 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2051 ...

Page 2198: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1366 Rear Crank Wear Sleeve Remover J 41592 All information subject to change without notice C 2052 Copyright DETROIT DIESEL CORPORATION ...

Page 2199: ...000 12 16V SERVICE MANUAL Figure 1367 Rear Seal Expander J 4239 Figure 1368 Rear Seal Expander Oversize Seal J 22766 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2053 ...

Page 2200: ... 16V SERVICE MANUAL Figure 1369 Rear Seal Expander Standard Seal J 22605 Figure 1370 Rear Seal Expander STD Seal J 29009 A All information subject to change without notice C 2054 Copyright DETROIT DIESEL CORPORATION ...

Page 2201: ... 12 16V SERVICE MANUAL Figure 1371 Rear Seal Expander Adapter J 23341 Figure 1372 Rear Seal Expander Guide Studs J 25002 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2055 ...

Page 2202: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1373 Rear Seal Expander STD Seal 536V 53 J 9769 All information subject to change without notice C 2056 Copyright DETROIT DIESEL CORPORATION ...

Page 2203: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1374 Rear Seal Insert STD SL Cup PLG REM J 22604 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2057 ...

Page 2204: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1375 Rear Seal Instal Except 6 8 12V71 J 21112 B All information subject to change without notice C 2058 Copyright DETROIT DIESEL CORPORATION ...

Page 2205: ...0 12 16V SERVICE MANUAL Figure 1376 Rear Seal Install STD Seal 53 6V 53 J 9479 Figure 1377 Rear Seal Installer J 41596 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2059 ...

Page 2206: ... 16V SERVICE MANUAL Figure 1378 Rear Seal Installer STD Seal J 29010 B Figure 1379 Rear Seal Installer Guide Studs J 9727 2 All information subject to change without notice C 2060 Copyright DETROIT DIESEL CORPORATION ...

Page 2207: ...6V SERVICE MANUAL Figure 1380 Rear Seal Installer Guide Studs J 9727 5 Figure 1381 Rear Seal Installer Remover Set J 3154 04 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2061 ...

Page 2208: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1382 Rear Seal Sleeve Installer J 21983 All information subject to change without notice C 2062 Copyright DETROIT DIESEL CORPORATION ...

Page 2209: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1383 Rear Seal Sleeve Installer J 22676 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2063 ...

Page 2210: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1384 Rear Seal Sleeve Installer J 33426 All information subject to change without notice C 2064 Copyright DETROIT DIESEL CORPORATION ...

Page 2211: ...12 16V SERVICE MANUAL Figure 1385 Rear Seal Sleeve Installer 6V53 J 21277 Figure 1386 Rear Seal Sleeve Installer J 41163 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2065 ...

Page 2212: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1387 Seal Expander Oversize Seal J 33873 All information subject to change without notice C 2066 Copyright DETROIT DIESEL CORPORATION ...

Page 2213: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1388 Seal Expander O S EX 6 8 12V71 J 8682 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2067 ...

Page 2214: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1389 Seal Remover J 24171 A All information subject to change without notice C 2068 Copyright DETROIT DIESEL CORPORATION ...

Page 2215: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1390 Seal Wear Sleeve Installer J 39184 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2069 ...

Page 2216: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1391 Wear Sleeve Installer J 39266 All information subject to change without notice C 2070 Copyright DETROIT DIESEL CORPORATION ...

Page 2217: ... 12 16V SERVICE MANUAL Figure 1392 Wear Sleeve Installer FRT RR Crank J 41593 Figure 1393 Wear Sleeve Remover J 37075 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2071 ...

Page 2218: ...2 16V SERVICE MANUAL Figure 1394 Gear Case To Block Alignment Tool J 35651 Figure 1395 Puller Remover Rubber Bushed J 5356 All information subject to change without notice C 2072 Copyright DETROIT DIESEL CORPORATION ...

Page 2219: ...0 12 16V SERVICE MANUAL Figure 1396 Pulley Gear Remover Installer Set J 29025 A Figure 1397 Pulley Installer Set J 7773 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2073 ...

Page 2220: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1398 Eye Bolts 2 Pcs J 25026 2 All information subject to change without notice C 2074 Copyright DETROIT DIESEL CORPORATION ...

Page 2221: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1399 Flywheel Guide Studs J 36235 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2075 ...

Page 2222: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1400 Flywheel Lifting Fixture J 25026 A All information subject to change without notice C 2076 Copyright DETROIT DIESEL CORPORATION ...

Page 2223: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1401 Flywheel Lifting Tool J 6361 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2077 ...

Page 2224: ... 4000 12 16V SERVICE MANUAL Figure 1402 Flywheel Lock J 36375 A Figure 1403 Flywheel Runout Gauge Adapter J 9737 11 All information subject to change without notice C 2078 Copyright DETROIT DIESEL CORPORATION ...

Page 2225: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1404 Flywheel Housing Alignment Stud Set J 1927 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2079 ...

Page 2226: ... 16V SERVICE MANUAL Figure 1405 Flywheel Housing Alignment Stud ST J 7540 Figure 1406 Flywheel Housing Guide Studs J 34691 All information subject to change without notice C 2080 Copyright DETROIT DIESEL CORPORATION ...

Page 2227: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1407 Flywheel Housing Runout Gauge Set J 9737 D All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2081 ...

Page 2228: ... 4000 12 16V SERVICE MANUAL Figure 1408 Flywheel Runout Gauge Adapter J 9737 11 Figure 1409 Feeler Gauge Set J 3172 All information subject to change without notice C 2082 Copyright DETROIT DIESEL CORPORATION ...

Page 2229: ... 4000 12 16V SERVICE MANUAL Figure 1410 Pin Retainer Installer J 38088 Figure 1411 Piston Crown I D Gage J 25397 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2083 ...

Page 2230: ... 12 16V SERVICE MANUAL Figure 1412 Piston Crown I D Gage J 41971 Figure 1413 Piston Crown I D Gage 3 5MM Fire J 38609 A All information subject to change without notice C 2084 Copyright DETROIT DIESEL CORPORATION ...

Page 2231: ...2 16V SERVICE MANUAL Figure 1414 Piston Groove Gage Compression J 38689 A Figure 1415 Piston Groove Gage Fire Ring J 24599 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2085 ...

Page 2232: ... 12 16V SERVICE MANUAL Figure 1416 Piston Groove Gage Fire Ring J 35884 A Figure 1417 Piston Pin Alignment Tool J 38390 All information subject to change without notice C 2086 Copyright DETROIT DIESEL CORPORATION ...

Page 2233: ... 4000 12 16V SERVICE MANUAL Figure 1418 Piston Ring Compressor J 22387 Figure 1419 Piston Ring Compressor J 24227 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2087 ...

Page 2234: ...4000 12 16V SERVICE MANUAL Figure 1420 Piston Ring Compressor J 29614 A Figure 1421 Piston Ring Compressor J 3272 03 All information subject to change without notice C 2088 Copyright DETROIT DIESEL CORPORATION ...

Page 2235: ...4000 12 16V SERVICE MANUAL Figure 1422 Piston Ring Compressor J 35598 A Figure 1423 Piston Ring Compressor J 6883 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2089 ...

Page 2236: ... 12 16V SERVICE MANUAL Figure 1424 Piston Ring Expander Pliers J 22405 02 Figure 1425 Piston Ring Expander Pliers J 8128 All information subject to change without notice C 2090 Copyright DETROIT DIESEL CORPORATION ...

Page 2237: ...0 12 16V SERVICE MANUAL Figure 1426 Piston Ring Groove Gage Set J 29511 Figure 1427 Piston Seal Ring Compressor J 24421 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2091 ...

Page 2238: ...V SERVICE MANUAL Figure 1428 Piston To Liner Feeler Gage Set J 5438 01 Figure 1429 Seal Ring Compressor Croshd Piston J 23453 All information subject to change without notice C 2092 Copyright DETROIT DIESEL CORPORATION ...

Page 2239: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1430 Connecting Rod Installation Guides J 35945 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2093 ...

Page 2240: ...16V SERVICE MANUAL Figure 1431 Connecting Rod Nozzle Remover J 8995 Figure 1432 Pin Retainer Instal 71 TRK TY PST J 24107 01 All information subject to change without notice C 2094 Copyright DETROIT DIESEL CORPORATION ...

Page 2241: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1433 Piston Rod Bushing REM INST SET J 1513 02 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2095 ...

Page 2242: ... 12 16V SERVICE MANUAL Figure 1434 Piston Rod Bushing REM INST SET J 7587 Figure 1435 Piston Pin Alignment Tool J 24285 All information subject to change without notice C 2096 Copyright DETROIT DIESEL CORPORATION ...

Page 2243: ... 12 16V SERVICE MANUAL Figure 1436 Piston Pin Alignment Tool J 35619 Figure 1437 Piston Pin Bushing Reamer Kit J 3071 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2097 ...

Page 2244: ... 16V SERVICE MANUAL Figure 1438 Piston Pin Bushing Reamer Kit J 4970 02 Figure 1439 Piston Pin Retainer Installer J 23762 A All information subject to change without notice C 2098 Copyright DETROIT DIESEL CORPORATION ...

Page 2245: ...2 16V SERVICE MANUAL Figure 1440 Piston Pin Retainer Installer J 24274 B Figure 1441 Piston Pin Retainer Installer J 35572 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2099 ...

Page 2246: ...V SERVICE MANUAL Figure 1442 Piston Pin Retainer Leak Detector J 23987 B Figure 1443 Piston Pin Retainer Leak Test Cup J 24629 All information subject to change without notice C 2100 Copyright DETROIT DIESEL CORPORATION ...

Page 2247: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1444 Piston Ring Compressor J 41328 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2101 ...

Page 2248: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1445 Piston Conn Rod Holding Fixture J 36211 All information subject to change without notice C 2102 Copyright DETROIT DIESEL CORPORATION ...

Page 2249: ... 4000 12 16V SERVICE MANUAL Figure 1446 Rod Holder J 7632 Figure 1447 Connecting Rod Bushing Reaming Set J 29588 53 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2103 ...

Page 2250: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1448 Flywheel Lock Timing J 41786 All information subject to change without notice C 2104 Copyright DETROIT DIESEL CORPORATION ...

Page 2251: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1449 Generator Gear Dial Indicator J 29893 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2105 ...

Page 2252: ... 12 16V SERVICE MANUAL Figure 1450 Lower Idler Gear Socket J 41167 Figure 1451 Puller Adapter Pressed Tach DRVS J 24730 All information subject to change without notice C 2106 Copyright DETROIT DIESEL CORPORATION ...

Page 2253: ... 16V SERVICE MANUAL Figure 1452 Tach Drive Alignment Tool Set J 23068 Figure 1453 Balance Shaft Assembly Support J 39814 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2107 ...

Page 2254: ...16V SERVICE MANUAL Figure 1454 Balance Shaft Bushing Inst Remvr J 39819 Figure 1455 Balance Shaft Installation Pilot J 39817 All information subject to change without notice C 2108 Copyright DETROIT DIESEL CORPORATION ...

Page 2255: ...VICE MANUAL Figure 1456 Balance WT Cam Coupling Torque Wrench Adapter J 9791 Figure 1457 Cam Bal Shaft Bushg Rem Install J 7593 03 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2109 ...

Page 2256: ...6V SERVICE MANUAL Figure 1458 Cam Bushing Remover Installer J 29141 A Figure 1459 Cam Coupling Torque Wrench Adapter J 28462 All information subject to change without notice C 2110 Copyright DETROIT DIESEL CORPORATION ...

Page 2257: ...S 4000 12 16V SERVICE MANUAL Figure 1460 Cam Cup Plug Installer J 24094 Figure 1461 Cam Installation Pilot J 34033 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2111 ...

Page 2258: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1462 Cam Shaft Bushing R I J 39537 All information subject to change without notice C 2112 Copyright DETROIT DIESEL CORPORATION ...

Page 2259: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1463 Camshaft Pilot J 41580 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2113 ...

Page 2260: ... 16V SERVICE MANUAL Figure 1464 Gear Cam Pulley Remover Adapter J 7932 Figure 1465 Upper Front Cover Seal Installer J 9790 All information subject to change without notice C 2114 Copyright DETROIT DIESEL CORPORATION ...

Page 2261: ...ES 4000 12 16V SERVICE MANUAL Figure 1466 Cam Gear Assembly Fixture J 35949 Figure 1467 Cam Gear Installer J 1903 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2115 ...

Page 2262: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1468 Cam Gear Pilot J 35906 All information subject to change without notice C 2116 Copyright DETROIT DIESEL CORPORATION ...

Page 2263: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1469 Cam Gear Puller J 1902 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2117 ...

Page 2264: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1470 Cam Gear Retaining Tool J 35652 All information subject to change without notice C 2118 Copyright DETROIT DIESEL CORPORATION ...

Page 2265: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1471 Cam Idler Gear Nut Socket Set J 29744 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2119 ...

Page 2266: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1472 Poly Vee Pulley Hub Nut Finger Set J 22556 6 All information subject to change without notice C 2120 Copyright DETROIT DIESEL CORPORATION ...

Page 2267: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1473 RR Cam Gear Puller Adapt In Chassis J 6202 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2121 ...

Page 2268: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1474 Bull Cam Idler Gear Guide Studs J 35785 All information subject to change without notice C 2122 Copyright DETROIT DIESEL CORPORATION ...

Page 2269: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1475 Cam Idler Gear Lash Adapter J 35596 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2123 ...

Page 2270: ...0 12 16V SERVICE MANUAL Figure 1476 Cam Idler Gear Nut Spanner Wrench J 22556 Figure 1477 Timing Gear Installer J 7557 All information subject to change without notice C 2124 Copyright DETROIT DIESEL CORPORATION ...

Page 2271: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1478 Accessory Drive J 38662 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2125 ...

Page 2272: ...16V SERVICE MANUAL Figure 1479 Accessory Drive Seal Alignment Tool J 21166 Figure 1480 Accessory Drive Service Set J 36024 C All information subject to change without notice C 2126 Copyright DETROIT DIESEL CORPORATION ...

Page 2273: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1481 DDEC Repair Kit J 35888 60A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2127 ...

Page 2274: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1482 DDEC Repair Kit J 35888 A All information subject to change without notice C 2128 Copyright DETROIT DIESEL CORPORATION ...

Page 2275: ...SERVICE MANUAL Figure 1483 Diagnostic Reader CBL ADPT AMP J 38500 152 Figure 1484 Diagnostic Reader CBL ADPT Deutsch J 38500 60A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2129 ...

Page 2276: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1485 ECM Test Harness J 38596 A All information subject to change without notice C 2130 Copyright DETROIT DIESEL CORPORATION ...

Page 2277: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1486 Jumper Wire Set J 35751 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2131 ...

Page 2278: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1487 Prom Remover Tool J 35889 A All information subject to change without notice C 2132 Copyright DETROIT DIESEL CORPORATION ...

Page 2279: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1488 Push Terminal Release Tool J 36400 5 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2133 ...

Page 2280: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1489 Terminal Crimper Deutsch J 34182 All information subject to change without notice C 2134 Copyright DETROIT DIESEL CORPORATION ...

Page 2281: ... 12 16V SERVICE MANUAL Figure 1490 Terminal Crimper Group III J 35688 Figure 1491 Terminal Crimper Metri Pack J 38125 6 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2135 ...

Page 2282: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1492 Terminal Crimper Group 1 Metri PK J 35123 All information subject to change without notice C 2136 Copyright DETROIT DIESEL CORPORATION ...

Page 2283: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1493 Terminal Crimper Metri Pack 280 J 39848 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2137 ...

Page 2284: ...000 12 16V SERVICE MANUAL Figure 1494 Terminal Remover Deutsch J 34513 Figure 1495 Terminal Remover Deutsch J 38582 3 All information subject to change without notice C 2138 Copyright DETROIT DIESEL CORPORATION ...

Page 2285: ... 16V SERVICE MANUAL Figure 1496 Terminal Remover Micro Pack 280 J 33095 Figure 1497 Terminal Remover Metri Pack J 39125 12A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2139 ...

Page 2286: ... 12 16V SERVICE MANUAL Figure 1498 Terminal REMV GRP 1 1Metri Pack 150 J 35689 A Figure 1499 TRS Alignment Tool J 39815 All information subject to change without notice C 2140 Copyright DETROIT DIESEL CORPORATION ...

Page 2287: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1500 V I M Adapter Kit J 41005 149 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2141 ...

Page 2288: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1501 Volt Ohm Meter Kit J 34520 A All information subject to change without notice C 2142 Copyright DETROIT DIESEL CORPORATION ...

Page 2289: ...ICE MANUAL Figure 1502 DDEC II DDEC III Cartridge Version 5 0 J 38500 750 Figure 1503 Diagnostic Reader CBL ADPT Packard T J 34812 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2143 ...

Page 2290: ...IES 4000 12 16V SERVICE MANUAL Figure 1504 TRS Alignment Tool J 39298 2 Figure 1505 Fuel Line Wrench Set J 26617 All information subject to change without notice C 2144 Copyright DETROIT DIESEL CORPORATION ...

Page 2291: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1506 Electronic Unit Injector Tester J 37050 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2145 ...

Page 2292: ...0 12 16V SERVICE MANUAL Figure 1507 Fuel Line Nut Wrench Internal J 41424 Figure 1508 Fuel Nozzle Test Adapter J 41568 All information subject to change without notice C 2146 Copyright DETROIT DIESEL CORPORATION ...

Page 2293: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1509 Injector Pop Fixture ADP Electronic J 34760 147A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2147 ...

Page 2294: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1510 Injector Tube Reconditioning Set J 24517 B All information subject to change without notice C 2148 Copyright DETROIT DIESEL CORPORATION ...

Page 2295: ...0 12 16V SERVICE MANUAL Figure 1511 Fuel Pressure Gauge 0 100 PSI J 6355 Figure 1512 Fuel Pressure Gauge 100PSI J 8151 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2149 ...

Page 2296: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1513 Fuel Pump Repair Kit J 34607 A All information subject to change without notice C 2150 Copyright DETROIT DIESEL CORPORATION ...

Page 2297: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1514 Fuel Pump Repair Kit J 38767 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2151 ...

Page 2298: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1515 Fuel Pump Wrench J 4242 Figure 1516 GFI Diagnostic Cable J 41518 All information subject to change without notice C 2152 Copyright DETROIT DIESEL CORPORATION ...

Page 2299: ...16V SERVICE MANUAL Figure 1517 Needle Bearing Instlr Barnes Pump J 33854 Figure 1518 Needle Bearing Remvr Barnes Cup J 33853 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2153 ...

Page 2300: ...0 12 16V SERVICE MANUAL Figure 1519 Seal Installer Barnes Cup J 34158 Figure 1520 Body Nut Thread Recon System J 22690 All information subject to change without notice C 2154 Copyright DETROIT DIESEL CORPORATION ...

Page 2301: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1521 Injector Service Set J 1241 07 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2155 ...

Page 2302: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1522 Injector Fuel Hole Brush J 8152 All information subject to change without notice C 2156 Copyright DETROIT DIESEL CORPORATION ...

Page 2303: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1523 Injector Spray Tip P B Flow Gauge J 25600 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2157 ...

Page 2304: ...00 12 16V SERVICE MANUAL Figure 1524 Injector Tip Assembly Tester J 22640 A Figure 1525 Fuel Line Nut Wrench J 8932 B All information subject to change without notice C 2158 Copyright DETROIT DIESEL CORPORATION ...

Page 2305: ...S 4000 12 16V SERVICE MANUAL Figure 1526 Fuel Line Wrench Set J 26617 A Figure 1527 Torque Wrench Adapter J 41787 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2159 ...

Page 2306: ... 12 16V SERVICE MANUAL Figure 1528 Contrl Link BRG Remov Install J 8985 Figure 1529 Cover Spring Housing Remover J 21068 All information subject to change without notice C 2160 Copyright DETROIT DIESEL CORPORATION ...

Page 2307: ...ERVICE MANUAL Figure 1530 Gov Weight Shaft Ret Ring Installer J 21967 01 Figure 1531 Gov Weight Wedge Static Gap Setting J 36840 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2161 ...

Page 2308: ... 12 16V SERVICE MANUAL Figure 1532 Governor Housing Repair Kit J 35516 Figure 1533 Governor Housing Repair Kit PT 7150 A All information subject to change without notice C 2162 Copyright DETROIT DIESEL CORPORATION ...

Page 2309: ... 12 16V SERVICE MANUAL Figure 1534 Linkage Gage Electronic J 35618 Figure 1535 Weight Housing Plug Rem Replacer J 23176 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2163 ...

Page 2310: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1536 Weight Spacer 6V 53 J 8984 Figure 1537 Drive Ring Remover J 4685 All information subject to change without notice C 2164 Copyright DETROIT DIESEL CORPORATION ...

Page 2311: ...00 12 16V SERVICE MANUAL Figure 1538 Bushing Remover Installer Set J 29140 Figure 1539 Drive Gear Installer J 8968 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2165 ...

Page 2312: ... 16V SERVICE MANUAL Figure 1540 Drive Gear Sip TST TRQ WR ADPT J 23126 Figure 1541 Drive Shaft Dear INST 6 01 6 8V J 22398 All information subject to change without notice C 2166 Copyright DETROIT DIESEL CORPORATION ...

Page 2313: ... 4000 12 16V SERVICE MANUAL Figure 1542 Gear Instal 5 500 16V 71 12V 16V92 J 9380 Figure 1543 Gear Installer J 9381 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2167 ...

Page 2314: ...ES 4000 12 16V SERVICE MANUAL Figure 1544 Gear Installer 8 060 16V J 9382 Figure 1545 Idler Shaft Wrench J 39769 All information subject to change without notice C 2168 Copyright DETROIT DIESEL CORPORATION ...

Page 2315: ...RIES 4000 12 16V SERVICE MANUAL Figure 1546 Oil Cooler Test Plate J 41975 Figure 1547 Oil Cooling Plate J 43075 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2169 ...

Page 2316: ...000 12 16V SERVICE MANUAL Figure 1548 Oil Pressure Gauge 0 160 PSI J 29325 4 Figure 1549 Oil Pump Gear Holder J 39816 All information subject to change without notice C 2170 Copyright DETROIT DIESEL CORPORATION ...

Page 2317: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1550 Filter Cutter Fuel and Lube J 29925 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2171 ...

Page 2318: ...2 16V SERVICE MANUAL Figure 1551 Lube Oil Filter Spin on Wrench J 29917 Figure 1552 Lube Oil Filter Spin on Wrench J 24783 All information subject to change without notice C 2172 Copyright DETROIT DIESEL CORPORATION ...

Page 2319: ... 16V SERVICE MANUAL Figure 1553 Oil Filter Cooler Base Tool J 42513 Figure 1554 Oil Filter Wrench AC Large Filters J 22775 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2173 ...

Page 2320: ...00 12 16V SERVICE MANUAL Figure 1555 Fluorescent Oil Additives 1OZ J 28431 6 Figure 1556 Oil Pan Removal Tool J 41423 All information subject to change without notice C 2174 Copyright DETROIT DIESEL CORPORATION ...

Page 2321: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1557 Coolant Flow Checker Air Injection J 39944 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2175 ...

Page 2322: ...0 12 16V SERVICE MANUAL Figure 1558 Impeller Remover Installer J 29190 B Figure 1559 Seal Installer Unitized J 35517 1 All information subject to change without notice C 2176 Copyright DETROIT DIESEL CORPORATION ...

Page 2323: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1560 Water Pump Impeller Remover J 22143 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2177 ...

Page 2324: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1561 Water Pump Service Set J 35988 B All information subject to change without notice C 2178 Copyright DETROIT DIESEL CORPORATION ...

Page 2325: ...16V SERVICE MANUAL Figure 1562 Cooling System Pressure Tester J 24460 01 Figure 1563 Radiator Pressure Tester ADPT J 29003 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2179 ...

Page 2326: ...2 16V SERVICE MANUAL Figure 1564 Diesel Fuel Hydrometer J 34352 Figure 1565 Diesel Fuel Quality TSTR Hydrometer J 38641 A All information subject to change without notice C 2180 Copyright DETROIT DIESEL CORPORATION ...

Page 2327: ...12 16V SERVICE MANUAL Figure 1566 Eng Coolant Batt Fluid Tester J 23688 Figure 1567 Eng Coolant Batt Fluid Tester J 26568 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2181 ...

Page 2328: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1568 Fluorescent Coolant Dye 24 1OZ J 29545 All information subject to change without notice C 2182 Copyright DETROIT DIESEL CORPORATION ...

Page 2329: ...4000 12 16V SERVICE MANUAL Figure 1569 High Intensity Black Light Kit J 28428 E Figure 1570 Engine Pre Luber J 39258 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2183 ...

Page 2330: ...S 4000 12 16V SERVICE MANUAL Figure 1571 Fluorescent Oil Dye 24 1OZ J 28431 B Figure 1572 Support Fixture J 29086 All information subject to change without notice C 2184 Copyright DETROIT DIESEL CORPORATION ...

Page 2331: ...IES 4000 12 16V SERVICE MANUAL Figure 1573 Thrust Spacer Plug Sleeve INSTJ 29090 Figure 1574 Tool Box J 29149 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2185 ...

Page 2332: ...4000 12 16V SERVICE MANUAL Figure 1575 Turbo Inlet Compress Shield J 26554 A Figure 1576 Turbo Shaft Check J 29089 A All information subject to change without notice C 2186 Copyright DETROIT DIESEL CORPORATION ...

Page 2333: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1577 Turbo Shaft Checker J 39164 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2187 ...

Page 2334: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1578 Turbocharger Inlet Cap J 41813 All information subject to change without notice C 2188 Copyright DETROIT DIESEL CORPORATION ...

Page 2335: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1579 Turbocharger Tool Kit J 29149 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2189 ...

Page 2336: ...000 12 16V SERVICE MANUAL Figure 1580 By Pass Valve Service Kit J 37466 Figure 1581 Charged Air Cooler Tester J 41473 All information subject to change without notice C 2190 Copyright DETROIT DIESEL CORPORATION ...

Page 2337: ...6V SERVICE MANUAL Figure 1582 Double Lip Seal OS Wear Instal J 35787 A Figure 1583 Double Lip Seal OS Wear SL InstalJ 38707 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2191 ...

Page 2338: ...4000 12 16V SERVICE MANUAL Figure 1584 Drive Shaft Alignment Tool J 33001 Figure 1585 Drive Alignment Set J 21843 01 All information subject to change without notice C 2192 Copyright DETROIT DIESEL CORPORATION ...

Page 2339: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1586 Drive Cam Installer J 1471 Figure 1587 Drive Cam Installer J 5209 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2193 ...

Page 2340: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1588 Drive Gear Hub Socket J 23641 All information subject to change without notice C 2194 Copyright DETROIT DIESEL CORPORATION ...

Page 2341: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1589 Rotor Clearance Feeler Gage Set J 1698 02 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2195 ...

Page 2342: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1590 Rotor SHFT REM INST Set 3 4 6 71 J 4254 All information subject to change without notice C 2196 Copyright DETROIT DIESEL CORPORATION ...

Page 2343: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1591 Service Tool Set J 22706 C All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2197 ...

Page 2344: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1592 Service Tool Set 2 71 J 8147 All information subject to change without notice C 2198 Copyright DETROIT DIESEL CORPORATION ...

Page 2345: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1593 Service Tool Set 8V 53 J 21672 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2199 ...

Page 2346: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1594 Service Tool Set EXCEPT 8V 53 J 23679 A All information subject to change without notice C 2200 Copyright DETROIT DIESEL CORPORATION ...

Page 2347: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1595 Service Tool Set Except 2 71 J 6270 G All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2201 ...

Page 2348: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1596 Compressor Impeller Nut Wrench J 21223 02 All information subject to change without notice C 2202 Copyright DETROIT DIESEL CORPORATION ...

Page 2349: ...IES 4000 12 16V SERVICE MANUAL Figure 1597 Compressor Impeller Remover J 9496 Figure 1598 Drill Fixture J 29087 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2203 ...

Page 2350: ...IES 4000 12 16V SERVICE MANUAL Figure 1599 Groove Pin Installer J 29088 Figure 1600 Seal Ring Installer J 29104 All information subject to change without notice C 2204 Copyright DETROIT DIESEL CORPORATION ...

Page 2351: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1601 Seal Ring Installer J 29105 Figure 1602 Sled Gage Base J 29091 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2205 ...

Page 2352: ...000 12 16V SERVICE MANUAL Figure 1603 Snap Ring Pliers Internal J 28507 Figure 1604 Alternator Pulley Holder J 41732 All information subject to change without notice C 2206 Copyright DETROIT DIESEL CORPORATION ...

Page 2353: ... 12 16V SERVICE MANUAL Figure 1605 Test Light Self Powered J 21008 A Figure 1606 Compressor Drive Service Set J 36310 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2207 ...

Page 2354: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1607 Freon Leak Detect J 29547 A All information subject to change without notice C 2208 Copyright DETROIT DIESEL CORPORATION ...

Page 2355: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1608 Hysrostarter Accumulator Charge Kit J 6714 D All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2209 ...

Page 2356: ...IES 4000 12 16V SERVICE MANUAL Figure 1609 Inlet Valve Stop Remover J 25447 B Figure 1610 Hub Installer J 36311 All information subject to change without notice C 2210 Copyright DETROIT DIESEL CORPORATION ...

Page 2357: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1611 Hub Remover J 36309 Figure 1612 Comp Gauge Pack J 7334 E All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2211 ...

Page 2358: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1613 Compression Gauge Adapter J 41960 All information subject to change without notice C 2212 Copyright DETROIT DIESEL CORPORATION ...

Page 2359: ...12 16V SERVICE MANUAL Figure 1614 Printer Paper 5 Roll Pack J 38450 5 Figure 1615 Printer Portable 110V Recharger J 39480 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2213 ...

Page 2360: ...00 12 16V SERVICE MANUAL Figure 1616 Compression Gauge Adapter J 22503 C Figure 1617 Compression Gauge Adapter J 41541 All information subject to change without notice C 2214 Copyright DETROIT DIESEL CORPORATION ...

Page 2361: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1618 Compression Pres GA Hose Assy J 6692 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2215 ...

Page 2362: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1619 Current Clamp 0 600 AMPS J 35590 All information subject to change without notice C 2216 Copyright DETROIT DIESEL CORPORATION ...

Page 2363: ... 16V SERVICE MANUAL Figure 1620 Cylinder Compression Test ADPT Set J 38767 A Figure 1621 Cylinder Leak Down Tester J 29006 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2217 ...

Page 2364: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1622 Diagnosis Test Kit J 22506 All information subject to change without notice C 2218 Copyright DETROIT DIESEL CORPORATION ...

Page 2365: ...ES 4000 12 16V SERVICE MANUAL Figure 1623 Diagnostic Test Kit J 9531 C Figure 1624 Diagnostic Test Kit J 34680 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2219 ...

Page 2366: ...00 12 16V SERVICE MANUAL Figure 1625 Digital Photo Tach J 28838 B Figure 1626 Digital Pyrometer 30 to 1800 D F J 39422 All information subject to change without notice C 2220 Copyright DETROIT DIESEL CORPORATION ...

Page 2367: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1627 Dry Air Cleaner Gage J 8397 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2221 ...

Page 2368: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1628 Elec Gov Link Setting J 22195 All information subject to change without notice C 2222 Copyright DETROIT DIESEL CORPORATION ...

Page 2369: ...000 12 16V SERVICE MANUAL Figure 1629 Engine Diagnosis Kit J 29534 B Figure 1630 Flywheel Timing Pin Adapter J 29139 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2223 ...

Page 2370: ...6V SERVICE MANUAL Figure 1631 Governor Adjusting Tool VHSLS J 28598 B Figure 1632 Governor Gap GA Limiting Speed Gov J 23185 All information subject to change without notice C 2224 Copyright DETROIT DIESEL CORPORATION ...

Page 2371: ...ES 4000 12 16V SERVICE MANUAL Figure 1633 Governor Gap Gage 170 J 5407 Figure 1634 Governor Gap Gage 200 J 23478 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2225 ...

Page 2372: ...00 12 16V SERVICE MANUAL Figure 1635 Governor Gap Gage 216 J 29646 A Figure 1636 Governor Link Dial Indicator J 34184 All information subject to change without notice C 2226 Copyright DETROIT DIESEL CORPORATION ...

Page 2373: ...0 12 16V SERVICE MANUAL Figure 1637 Governor Nut Wrench J 1652 01 Figure 1638 Governor Retainer Nut SPNR Wrench J 5895 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2227 ...

Page 2374: ... 12 16V SERVICE MANUAL Figure 1639 Governor Setting Kit J 5345 E Figure 1640 Governor Speed Spring Wrench PSG J 4873 01 All information subject to change without notice C 2228 Copyright DETROIT DIESEL CORPORATION ...

Page 2375: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1641 Hydraulic Governor Linkage GA J 23475 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2229 ...

Page 2376: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1642 Hydraulic Governor Linkage Gauge J 21304 All information subject to change without notice C 2230 Copyright DETROIT DIESEL CORPORATION ...

Page 2377: ...00 12 16V SERVICE MANUAL Figure 1643 Injection Pump Plunger Pin J 41162 Figure 1644 Injection Pump Timing Pin J 41161 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2231 ...

Page 2378: ...4000 12 16V SERVICE MANUAL Figure 1645 Injector Flooding Bar J 29522 Figure 1646 Injector Timing Gage 2 710 J 7186 A All information subject to change without notice C 2232 Copyright DETROIT DIESEL CORPORATION ...

Page 2379: ...16V SERVICE MANUAL Figure 1647 Lever Positioning Pin 16V71 92 J 21779 Figure 1648 Limiting Speed Mech Linkage Gov GAJ 21780 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2233 ...

Page 2380: ...RIES 4000 12 16V SERVICE MANUAL Figure 1649 Monometer 12 0 12 J 7333 6 Figure 1650 Manometer 18 0 18 J 8639 01 All information subject to change without notice C 2234 Copyright DETROIT DIESEL CORPORATION ...

Page 2381: ...ES 4000 12 16V SERVICE MANUAL Figure 1651 Manometer 2 1 2 0 2 1 2 J 9531 23 Figure 1652 Manometer 24 0 24 J 29021 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2235 ...

Page 2382: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1653 Marine Engine Diagnostic Kit J 38477 A All information subject to change without notice C 2236 Copyright DETROIT DIESEL CORPORATION ...

Page 2383: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1654 Push Rod Adjusting Wrench Set J 21100 E All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2237 ...

Page 2384: ...ICE MANUAL Figure 1655 Spanner Nut Socket Hi Speed Spring J 5345 12 old number J 5345 5 Figure 1656 Thermometer 0 300deg F J 9531 17 All information subject to change without notice C 2238 Copyright DETROIT DIESEL CORPORATION ...

Page 2385: ... 4000 12 16V SERVICE MANUAL Figure 1657 Throttle Delay Pin GA 690GO 072NG J 25558 Figure 1658 Tune Up Kit J 34651 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2239 ...

Page 2386: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1659 Tune Up Kit J 24790 D All information subject to change without notice C 2240 Copyright DETROIT DIESEL CORPORATION ...

Page 2387: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1660 Crankshaft Position Timing Tool J 43028 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2241 ...

Page 2388: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1661 Feeler GA 20 Exhaust VLV Lash J 9708 20 All information subject to change without notice C 2242 Copyright DETROIT DIESEL CORPORATION ...

Page 2389: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1662 Feeler GA Set J 9708 C All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2243 ...

Page 2390: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1663 Feeler Gage 800 Intake VLV Lach J 9708 21 All information subject to change without notice C 2244 Copyright DETROIT DIESEL CORPORATION ...

Page 2391: ...ES 4000 12 16V SERVICE MANUAL Figure 1664 Fuel System Primer J 5956 Figure 1665 Injector Control Rack pin J 29523 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2245 ...

Page 2392: ...00 12 16V SERVICE MANUAL Figure 1666 Injector Control Rack Gage 160 J 26645 Figure 1667 Injector Rack Gage 200 J 35586 All information subject to change without notice C 2246 Copyright DETROIT DIESEL CORPORATION ...

Page 2393: ...S 4000 12 16V SERVICE MANUAL Figure 1668 Injector Rack Gage 220 J 29285 Figure 1669 Injector Rack Gage 290 J 26646 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2247 ...

Page 2394: ...S 4000 12 16V SERVICE MANUAL Figure 1670 Injector Rack Gage 345 J 24889 Figure 1671 Injector Rack Gage 365 J 28779 All information subject to change without notice C 2248 Copyright DETROIT DIESEL CORPORATION ...

Page 2395: ...S 4000 12 16V SERVICE MANUAL Figure 1672 Injector Rack Gage 385 J 24882 Figure 1673 Injector Rack Gage 430 J 35735 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2249 ...

Page 2396: ...S 4000 12 16V SERVICE MANUAL Figure 1674 Injector Rack Gage 454 J 23190 Figure 1675 Injector Rack Gage 465 J 33156 All information subject to change without notice C 2250 Copyright DETROIT DIESEL CORPORATION ...

Page 2397: ...S 4000 12 16V SERVICE MANUAL Figure 1676 Injector Rack Gage 480 J 34080 Figure 1677 Injector Rack Gage 490 J 33157 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2251 ...

Page 2398: ...S 4000 12 16V SERVICE MANUAL Figure 1678 Injector Rack Gage 504 J 29062 Figure 1679 Injector Rack Gage 520 J 24872 All information subject to change without notice C 2252 Copyright DETROIT DIESEL CORPORATION ...

Page 2399: ...S 4000 12 16V SERVICE MANUAL Figure 1680 Injector Rack Gage 550 J 34609 Figure 1681 Injector Rack Gage 570 J 25559 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2253 ...

Page 2400: ...4000 12 16V SERVICE MANUAL Figure 1682 Injector Rack Gage 586 686 J 26927 Figure 1683 Injector Rack Gage 594 J 29063 All information subject to change without notice C 2254 Copyright DETROIT DIESEL CORPORATION ...

Page 2401: ...S 4000 12 16V SERVICE MANUAL Figure 1684 Injector Rack Gage 610 J 34079 Figure 1685 Injector Rack Gage 636 J 25560 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2255 ...

Page 2402: ...0 12 16V SERVICE MANUAL Figure 1686 Injector Rack Gage 660 J 29064 Figure 1687 Injector Timing Dial Indicator J 29014 C All information subject to change without notice C 2256 Copyright DETROIT DIESEL CORPORATION ...

Page 2403: ...00 12 16V SERVICE MANUAL Figure 1688 Injector Timing Gage 1 458 J 34610 Figure 1689 Injector Timing Gage 1 460 J 1853 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2257 ...

Page 2404: ...00 12 16V SERVICE MANUAL Figure 1690 Injector Timing Gage 1 464 J 34081 Figure 1691 Injector Timing Gage 1 466 J 26888 All information subject to change without notice C 2258 Copyright DETROIT DIESEL CORPORATION ...

Page 2405: ...00 12 16V SERVICE MANUAL Figure 1692 Injector Timing Gage 1 470 J 24236 Figure 1693 Injector Timing Gage 1 475 J 34921 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2259 ...

Page 2406: ...00 12 16V SERVICE MANUAL Figure 1694 Injector Timing Gage 1 480 J 29065 Figure 1695 Injector Timing Gage 1 484 J 1242 All information subject to change without notice C 2260 Copyright DETROIT DIESEL CORPORATION ...

Page 2407: ...00 12 16V SERVICE MANUAL Figure 1696 Injector Timing Gage 1 490 J 29066 Figure 1697 Injector Timing Gage 1 496 J 9595 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2261 ...

Page 2408: ...000 12 16V SERVICE MANUAL Figure 1698 Injector Timing Gage 1 500 J25454 Figure 1699 Injector Timing Gage 1 508 J 8909 All information subject to change without notice C 2262 Copyright DETROIT DIESEL CORPORATION ...

Page 2409: ...00 12 16V SERVICE MANUAL Figure 1700 Injector Timing Gage 1 515 J 34192 Figure 1701 Injector Timing Gage 1 520 J 25502 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2263 ...

Page 2410: ...0 12 16V SERVICE MANUAL Figure 1702 Injector Timing Gage 2 170 J 36869 Figure 1703 Injector Timing Gage 2 175 J 22412 A All information subject to change without notice C 2264 Copyright DETROIT DIESEL CORPORATION ...

Page 2411: ... 12 16V SERVICE MANUAL Figure 1704 Injector Timing Gage 2 185 J 29116 A Figure 1705 Injector Timing Gage 2 205 J 24283 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2265 ...

Page 2412: ...0 12 16V SERVICE MANUAL Figure 1706 Injector Timing Gage 2 590 J 39762 Figure 1707 Injector Timing Gage 64 1MM J 38349 All information subject to change without notice C 2266 Copyright DETROIT DIESEL CORPORATION ...

Page 2413: ...12 16V SERVICE MANUAL Figure 1708 Injector Timing Gage 78 2 MM J 35637 A Figure 1709 Injector Timing Gage 78 8 MM J 39697 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2267 ...

Page 2414: ... 4000 12 16V SERVICE MANUAL Figure 1710 Throttle Delay Gage 404 J 9509 C Figure 1711 Injector Rack Gage 395 J 28479 All information subject to change without notice C 2268 Copyright DETROIT DIESEL CORPORATION ...

Page 2415: ...12 16V SERVICE MANUAL Figure 1712 0 30 Vacuum Gauge W Protective Boot J 9531 55 Figure 1713 Belt Tension Gauge J 33889 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2269 ...

Page 2416: ...12 16V SERVICE MANUAL Figure 1714 Cylinder Compression Gauge Adapter J 7915 E Figure 1715 DDC Diagnostic PC Cart J 42868 All information subject to change without notice C 2270 Copyright DETROIT DIESEL CORPORATION ...

Page 2417: ... 4000 12 16V SERVICE MANUAL Figure 1716 Engine Field Test Kit J 39257 Figure 1717 Engine Harness Repair Kit J 42948 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2271 ...

Page 2418: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1718 Infrared Thermometer PT 7144 A Figure 1719 Phasar Tach J 35825 All information subject to change without notice C 2272 Copyright DETROIT DIESEL CORPORATION ...

Page 2419: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1720 Terminal Crimping Tool J 35603 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2273 ...

Page 2420: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1721 Terminal Release Tool Kit J 42949 All information subject to change without notice C 2274 Copyright DETROIT DIESEL CORPORATION ...

Page 2421: ...ES 4000 12 16V SERVICE MANUAL Figure 1722 Belt tension Gauge J 25386 B Figure 1723 Belt tension Gauge BT 3372 DD All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2275 ...

Page 2422: ...IES 4000 12 16V SERVICE MANUAL Figure 1724 Belt tension Gauge BT 3373 F Figure 1725 Belt Tension Gauge J 41251 B All information subject to change without notice C 2276 Copyright DETROIT DIESEL CORPORATION ...

Page 2423: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1726 Belt Tension Gauge 275 475 LBS J 39966 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2277 ...

Page 2424: ...RVICE MANUAL Figure 1727 Belt Tension Gauge 30 180LBS BT 3373 F Old No J 23600 B Figure 1728 Caliper 0 150 MM Dial Type J 26900 7 All information subject to change without notice C 2278 Copyright DETROIT DIESEL CORPORATION ...

Page 2425: ... 12 16V SERVICE MANUAL Figure 1729 Caliper 0 6 MM Dial Type J 26900 6 Figure 1730 Caliper 0 6 MM Vernier Type J 26900 5 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2279 ...

Page 2426: ...S 4000 12 16V SERVICE MANUAL Figure 1731 Dial Indicator Roller ADPT J 23672 Figure 1732 Dial Indicator Set J 8001 All information subject to change without notice C 2280 Copyright DETROIT DIESEL CORPORATION ...

Page 2427: ...IES 4000 12 16V SERVICE MANUAL Figure 1733 Gauge 11 4 21 8 TE J 26900 23 Figure 1734 Gauge Set 5 16 6 J 26900 33 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2281 ...

Page 2428: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1735 Holy Gauge Set 125 500 J 26900 14 All information subject to change without notice C 2282 Copyright DETROIT DIESEL CORPORATION ...

Page 2429: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1736 Magnetic Base Dial Indicator J 7872 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2283 ...

Page 2430: ...4000 12 16V SERVICE MANUAL Figure 1737 Micrometer Inch MM 0 1 J 26900 1 Figure 1738 Micrometer Inch MM 1 2 J 26900 2 All information subject to change without notice C 2284 Copyright DETROIT DIESEL CORPORATION ...

Page 2431: ...4000 12 16V SERVICE MANUAL Figure 1739 Micrometer Inch MM 2 3 J 26900 3 Figure 1740 Micrometer Inch MM 3 4 J 26900 4 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2285 ...

Page 2432: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1741 Micrometer Inch MM 4 5 J 26900 30 All information subject to change without notice C 2286 Copyright DETROIT DIESEL CORPORATION ...

Page 2433: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1742 Micrometer Inch MM 5 6 J 26900 32 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2287 ...

Page 2434: ... 4000 12 16V SERVICE MANUAL Figure 1743 Micrometer Ball Attachment J 4757 Figure 1744 Outside Micrm 3 4 J 26900 37 All information subject to change without notice C 2288 Copyright DETROIT DIESEL CORPORATION ...

Page 2435: ...S 4000 12 16V SERVICE MANUAL Figure 1745 Outside Micrm 5 6 J 26900 39 Figure 1746 Spring Tester 0 125 LBS J 29296 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2289 ...

Page 2436: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1747 Tele GA 75 1 25 J 26900 16 All information subject to change without notice C 2290 Copyright DETROIT DIESEL CORPORATION ...

Page 2437: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1748 Harmonic Balancer Hub Puller J 24420 C All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2291 ...

Page 2438: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1749 Hydraulic Ram Pump 17 1 2 Ton J 35951 175 All information subject to change without notice C 2292 Copyright DETROIT DIESEL CORPORATION ...

Page 2439: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1750 Hydraulic Shop Press 17 1 2 Ton J 35951 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2293 ...

Page 2440: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1751 Slide Hammer Puller Set J 5901 01 All information subject to change without notice C 2294 Copyright DETROIT DIESEL CORPORATION ...

Page 2441: ...4000 12 16V SERVICE MANUAL Figure 1752 Three Jaw Puller J 25031 A Figure 1753 Universal Driver Handle 3 4 10 J 8092 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2295 ...

Page 2442: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1754 Universal Puller Range 13 Dia J 8190 All information subject to change without notice C 2296 Copyright DETROIT DIESEL CORPORATION ...

Page 2443: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1755 Torque Angle Meter J 37990 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2297 ...

Page 2444: ... 4000 12 16V SERVICE MANUAL Figure 1756 Torque Bit Socket Set J 25359 C Figure 1757 Torque Multipier 1000LB J 23410 All information subject to change without notice C 2298 Copyright DETROIT DIESEL CORPORATION ...

Page 2445: ...ICE MANUAL Figure 1758 Torque Wrench 100 600 FT LBS J 23775 01 Figure 1759 Adjustable Torque Wrench 3 8 in Drive 10 250 lbs J 24405 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2299 ...

Page 2446: ...00 12 16V SERVICE MANUAL Figure 1760 Torque Wrench 15 100 lbs J 24406 Figure 1761 Torque Wrench 30 250 FT LBS J 24407 All information subject to change without notice C 2300 Copyright DETROIT DIESEL CORPORATION ...

Page 2447: ... 12 16V SERVICE MANUAL Figure 1762 Torque Wrench 1 2 0 150 FT LBS J 1313 B Figure 1763 Great Crate I Rack System J 34755 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2301 ...

Page 2448: ...00 12 16V SERVICE MANUAL Figure 1764 Great Crate I Storage Box J 34100 Figure 1765 Great Crate II Rack System J 35810 All information subject to change without notice C 2302 Copyright DETROIT DIESEL CORPORATION ...

Page 2449: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1766 Great Crate II Storage Box J 35805 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2303 ...

Page 2450: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1767 Load Rotor 4000 LB J 36130 806 All information subject to change without notice C 2304 Copyright DETROIT DIESEL CORPORATION ...

Page 2451: ...ES 4000 12 16V SERVICE MANUAL Figure 1768 Lock N Seal PT 7272 old number J 26558 242 Figure 1769 Loctite PT 7260 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2305 ...

Page 2452: ...00 12 16V SERVICE MANUAL Figure 1770 Oil Filter Wrench J 29927 Figure 1771 Pipe Sealant PT 7271 old number J 26558 92 All information subject to change without notice C 2306 Copyright DETROIT DIESEL CORPORATION ...

Page 2453: ...12 16V SERVICE MANUAL Figure 1772 Slide Hammer pair W Adapters J 6125 B Figure 1773 Slide Hammer With Adapters J 6471 02 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2307 ...

Page 2454: ...12 16V SERVICE MANUAL Figure 1774 Snap Ring Pliers Vacuum Grip J 5586 A Figure 1775 Storage Case Variety Set Of 3 J 35550 All information subject to change without notice C 2308 Copyright DETROIT DIESEL CORPORATION ...

Page 2455: ...RIES 4000 12 16V SERVICE MANUAL Figure 1776 Thread Repair Kit J 26520 Figure 1777 Tube Flaring Set 45 J 8051 01 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2309 ...

Page 2456: ... 4000 12 16V SERVICE MANUAL Figure 1778 Abrasive Pads 20 J 2901 Figure 1779 Block Align Tool 020 OS 12 16V J 24542 All information subject to change without notice C 2310 Copyright DETROIT DIESEL CORPORATION ...

Page 2457: ... 16V SERVICE MANUAL Figure 1780 Block Align Tool 040 OS 12 16V J 24543 Figure 1781 Counterbore Cutter Tool Conv Kit J 41065 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2311 ...

Page 2458: ...4000 12 16V SERVICE MANUAL Figure 1782 Cylinder Sleeve Holding Adapters J 43095 Figure 1783 Depth Collar PT 2200 83 All information subject to change without notice C 2312 Copyright DETROIT DIESEL CORPORATION ...

Page 2459: ...ERIES 4000 12 16V SERVICE MANUAL Figure 1784 Depth Set Collar PT 2200 138 Figure 1785 Dial Depth Gauge PT 5025 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2313 ...

Page 2460: ...RIES 4000 12 16V SERVICE MANUAL Figure 1786 Engine Barring Tool J 41594 Figure 1787 Engine Barring Tool J 41997 All information subject to change without notice C 2314 Copyright DETROIT DIESEL CORPORATION ...

Page 2461: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1788 Extension Arm Kit PT 5020 5SP Figure 1789 Flex Hone J 41972 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2315 ...

Page 2462: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1790 ICP Adapter Plug Kit J 43104 Figure 1791 Liner Puller J 42779 All information subject to change without notice C 2316 Copyright DETROIT DIESEL CORPORATION ...

Page 2463: ...RIES 4000 12 16V SERVICE MANUAL Figure 1792 Liner Remover J 22490 Figure 1793 Main Bearing Guide Studs J 43048 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2317 ...

Page 2464: ... 12 16V SERVICE MANUAL Figure 1794 Master Ring Cylinder Block Bore J 8386 01 Figure 1795 Master Ring Liner ID J 8385 01 All information subject to change without notice C 2318 Copyright DETROIT DIESEL CORPORATION ...

Page 2465: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1796 Right Angle Drill PT 7145 A Figure 1797 Threaded Insert J 38359 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2319 ...

Page 2466: ...000 12 16V SERVICE MANUAL Figure 1798 X Long Finish Line PT 2000 400 Figure 1799 Cylinder Head Alignment Bar J 42955 All information subject to change without notice C 2320 Copyright DETROIT DIESEL CORPORATION ...

Page 2467: ...0 12 16V SERVICE MANUAL Figure 1800 Cylinder Head Bolt Bottom Tap J 41962 Figure 1801 Cylinder Head Guide Studs J 42954 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2321 ...

Page 2468: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1802 Cylinder Head Lifter Bracket J 41823 All information subject to change without notice C 2322 Copyright DETROIT DIESEL CORPORATION ...

Page 2469: ...16V SERVICE MANUAL Figure 1803 Cylinder Head Lifting Fixture J 42730 Figure 1804 Cylinder Head Magnet Intake Shield J 43099 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2323 ...

Page 2470: ... 12 16V SERVICE MANUAL Figure 1805 Cylinder Headbolt Wrench M12 J 42514 Figure 1806 Cylinder Headbolt Wrench M14 J 42637 All information subject to change without notice C 2324 Copyright DETROIT DIESEL CORPORATION ...

Page 2471: ...IES 4000 12 16V SERVICE MANUAL Figure 1807 Fuel Line Nut Wrench 11 16 J 39108 Figure 1808 Guide Stud Set J 43096 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2325 ...

Page 2472: ...2 16V SERVICE MANUAL Figure 1809 Infrared Thermometer 0 1600 Deg F PT 7149 Figure 1810 Valve Seat Insert Installer J 24357 All information subject to change without notice C 2326 Copyright DETROIT DIESEL CORPORATION ...

Page 2473: ...S 4000 12 16V SERVICE MANUAL Figure 1811 Bridge Guide Installer J 41574 Figure 1812 Bridge Holding Fixture J 41569 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2327 ...

Page 2474: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1813 Crankshaft Cup Plug Installer J 41960 All information subject to change without notice C 2328 Copyright DETROIT DIESEL CORPORATION ...

Page 2475: ...12 16V SERVICE MANUAL Figure 1814 Crankshaft Remover Protector J 42778 Figure 1815 Front Crankshaft Hub Installer J 42196 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2329 ...

Page 2476: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1816 Rear Crankshaft Flange Installer J 42733 All information subject to change without notice C 2330 Copyright DETROIT DIESEL CORPORATION ...

Page 2477: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1817 Crank Wear Sleeve Remover J 41968 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2331 ...

Page 2478: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1818 Front Crankshaft Hub Seal Installer J 42736 All information subject to change without notice C 2332 Copyright DETROIT DIESEL CORPORATION ...

Page 2479: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1819 Front Seal Installer J 41966 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2333 ...

Page 2480: ...4000 12 16V SERVICE MANUAL Figure 1820 Front Seal Installer J 42261 Figure 1821 Front Wear Sleeve Installer J 42257 All information subject to change without notice C 2334 Copyright DETROIT DIESEL CORPORATION ...

Page 2481: ...2 16V SERVICE MANUAL Figure 1822 Rear Crankshaft Seal Installer J 42259 Figure 1823 Rear Crankshaft Seal Installer J 42735 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2335 ...

Page 2482: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1824 Rear Seal Installer J 41974 All information subject to change without notice C 2336 Copyright DETROIT DIESEL CORPORATION ...

Page 2483: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1825 Seal Remover J 41963 Figure 1826 Wear Ring Installer J 39284 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2337 ...

Page 2484: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1827 Wear Sleeve Remover Front J 41598 All information subject to change without notice C 2338 Copyright DETROIT DIESEL CORPORATION ...

Page 2485: ...00 12 16V SERVICE MANUAL Figure 1828 Gear Case Bushing Kit 40 J 43030 40 Figure 1829 Gearcase Reaming Fixture J 43030 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2339 ...

Page 2486: ... 16V SERVICE MANUAL Figure 1830 Crankshaft Pulley Gear Remover J 42511 Figure 1831 Flywheel Vib damper Guide Studs J 42999 All information subject to change without notice C 2340 Copyright DETROIT DIESEL CORPORATION ...

Page 2487: ...00 12 16V SERVICE MANUAL Figure 1832 Flywheel Guide Studs J 42953 Figure 1833 Flywheel Housing Alignment Tool J 42734 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2341 ...

Page 2488: ...ES 4000 12 16V SERVICE MANUAL Figure 1834 Piston Crown ID Gage J 41733 Figure 1835 Piston Ring Compressor J 42256 All information subject to change without notice C 2342 Copyright DETROIT DIESEL CORPORATION ...

Page 2489: ...00 12 16V SERVICE MANUAL Figure 1836 Piston Ring Compressor J 42727 Figure 1837 Series 2000 Piston Ring Pliers J 43011 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2343 ...

Page 2490: ...0 12 16V SERVICE MANUAL Figure 1838 Series 4000 Piston Ring Pliers J 43012 Figure 1839 Piston Rod Lifting Tool J 42781 All information subject to change without notice C 2344 Copyright DETROIT DIESEL CORPORATION ...

Page 2491: ...12 16V SERVICE MANUAL Figure 1840 Piston Pin Retainer Installer J 24274 B Figure 1841 Rod Bearing Adjusting Tool J 42726 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2345 ...

Page 2492: ... 12 16V SERVICE MANUAL Figure 1842 Connecting Rod Guide Caps J 41969 Figure 1843 Cam Follower remover Installer J 42258 All information subject to change without notice C 2346 Copyright DETROIT DIESEL CORPORATION ...

Page 2493: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1844 Camshaft Pilot J 42264 Figure 1845 Fuel Injector Puller J 42732 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2347 ...

Page 2494: ...4000 12 16V SERVICE MANUAL Figure 1846 Fuel Injector Remover Tool J 42946 Figure 1847 ICP Breakout T Harness J 43101 All information subject to change without notice C 2348 Copyright DETROIT DIESEL CORPORATION ...

Page 2495: ... 4000 12 16V SERVICE MANUAL Figure 1848 Injector Remover Replacer J 42512 Figure 1849 Injector Test Harness J 43098 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2349 ...

Page 2496: ...12 16V SERVICE MANUAL Figure 1850 Fuel Injector Sleeve Installer J 42947 Figure 1851 Fuel Injector Sleeve Remover J 42945 All information subject to change without notice C 2350 Copyright DETROIT DIESEL CORPORATION ...

Page 2497: ...000 12 16V SERVICE MANUAL Figure 1852 Fuel Pump Drive Bearing Inst Remv J 41795 Figure 1853 CEC Breakout Box J 43102 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2351 ...

Page 2498: ...000 12 16V SERVICE MANUAL Figure 1854 DDC DDEC III IV PC Card J 38500 2300 Figure 1855 DDEC Diagnostic Kit J 35887 1 All information subject to change without notice C 2352 Copyright DETROIT DIESEL CORPORATION ...

Page 2499: ...0 12 16V SERVICE MANUAL Figure 1856 DDEC Marine Prolink Kit Vers 1 3 J 39110 A Figure 1857 DDEC Sensor Tester J 37164 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2353 ...

Page 2500: ...SERVICE MANUAL Figure 1858 Fluke 87 Digital Multimeter Kit J 39200 Figure 1859 Multi Protocol Cartridge V1 70 1 72 J 38500 1500 All information subject to change without notice C 2354 Copyright DETROIT DIESEL CORPORATION ...

Page 2501: ... 16V SERVICE MANUAL Figure 1860 Pro Link Diagnostic Reader J 38500 1DD Figure 1861 Prolink Adapter DDEC Marine J 38500 155 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2355 ...

Page 2502: ...16V SERVICE MANUAL Figure 1862 Series 40E ECM Terminal Crimpers J 42980 Figure 1863 Series 40E PCMCIA Navistar J 38500 2100 All information subject to change without notice C 2356 Copyright DETROIT DIESEL CORPORATION ...

Page 2503: ... 4000 12 16V SERVICE MANUAL Figure 1864 Fuel Railing Engine Fixture J 42731 Figure 1865 Master Injector 149 J 34998 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2357 ...

Page 2504: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1866 Nozzle Adapt Kit J 29097 Figure 1867 Nozzle Tester J 29075 All information subject to change without notice C 2358 Copyright DETROIT DIESEL CORPORATION ...

Page 2505: ...0 12 16V SERVICE MANUAL Figure 1868 Ultrasonic Nozzle Cleaner J 29653 Figure 1869 Fuel Line Nut Wrench External J 41994 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2359 ...

Page 2506: ...RIES 4000 12 16V SERVICE MANUAL Figure 1870 Nozzle Puller AdapterJ 41570 Figure 1871 Nozzle Tube SocketJ 41575 All information subject to change without notice C 2360 Copyright DETROIT DIESEL CORPORATION ...

Page 2507: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1872 Valve Guide InstallerJ 43100 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2361 ...

Page 2508: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1873 Valve Spring CompressorJ 41587 All information subject to change without notice C 2362 Copyright DETROIT DIESEL CORPORATION ...

Page 2509: ...ES 4000 12 16V SERVICE MANUAL Figure 1874 Valve Spring CompressorJ 41824 Figure 1875 Torque Wrench AdapterJ 41787 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2363 ...

Page 2510: ...4000 12 16V SERVICE MANUAL Figure 1876 Flywheel Guide StudsJ 41595 Figure 1877 Flywheel Housing Guide StudsJ 34691 A All information subject to change without notice C 2364 Copyright DETROIT DIESEL CORPORATION ...

Page 2511: ...ES 4000 12 16V SERVICE MANUAL Figure 1878 EEC Variable Speed Cont Gov J 36325 Figure 1879 Terminal CrimperJ 38706 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2365 ...

Page 2512: ...0 12 16V SERVICE MANUAL Figure 1880 Cup Plug Installer J 41746 Figure 1881 Cylinder Compression Test Adaptor SetJ 38768 All information subject to change without notice C 2366 Copyright DETROIT DIESEL CORPORATION ...

Page 2513: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1882 Dial Bore Gage 3 3 32 8 Dia J 5437 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2367 ...

Page 2514: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1883 Injector Seat J 22410 226 All information subject to change without notice C 2368 Copyright DETROIT DIESEL CORPORATION ...

Page 2515: ... SERVICE MANUAL Figure 1884 Series 60 14L Piston Ring Compressor J 43397 Figure 1885 Series 60 14L Cylinder Kit Puller J 43396 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2369 ...

Page 2516: ...6V SERVICE MANUAL Figure 1886 Series 60 14L Rod Bolt Protector J 34317 Figure 1887 Series 60 14L Oil Nozzle Protector J 43661 All information subject to change without notice C 2370 Copyright DETROIT DIESEL CORPORATION ...

Page 2517: ...VICE MANUAL Figure 1888 Series 60 14L Air Compressor Wrench J 35948 Figure 1889 Series 60 14L Turbocharger Support Fixture J 29086 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2371 ...

Page 2518: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1890 Series 60 14L Snap Ring Pliers J 28507 All information subject to change without notice C 2372 Copyright DETROIT DIESEL CORPORATION ...

Page 2519: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1891 Series 60 14L Magnetic Base J 7872 2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2373 ...

Page 2520: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1892 Series 60 14L Extension Rod J 7872 3 All information subject to change without notice C 2374 Copyright DETROIT DIESEL CORPORATION ...

Page 2521: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1893 Series 60 14L Extension Rod J 7872 1 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2375 ...

Page 2522: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1894 Series 60 14L Dial Indicator J 8001 3 All information subject to change without notice C 2376 Copyright DETROIT DIESEL CORPORATION ...

Page 2523: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1895 Injector Test Oil J 26400 5B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2377 ...

Page 2524: ...4000 12 16V SERVICE MANUAL Figure 1896 Injector Nut Socket J 4983 01 Figure 1897 Injector Spray Tip Driver J 1291 02 All information subject to change without notice C 2378 Copyright DETROIT DIESEL CORPORATION ...

Page 2525: ...0 12 16V SERVICE MANUAL Figure 1898 Spray Tip Carbon Remover J 24838 Figure 1899 Injector Wire Sharpening Stone J 8170 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2379 ...

Page 2526: ...4000 12 16V SERVICE MANUAL Figure 1900 Injector Spray Hole Cleaner J 8169 03 Figure 1901 Spray Hole Wire J 21460 01 All information subject to change without notice C 2380 Copyright DETROIT DIESEL CORPORATION ...

Page 2527: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1902 Wire Brush Brass J 7944 Figure 1903 Rack Hole Brush J 8150 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2381 ...

Page 2528: ...0 12 16V SERVICE MANUAL Figure 1904 Injector Nut Carbon Remover Set J 9418 Figure 1905 Spring Tester 0 125 lbs J 29196 All information subject to change without notice C 2382 Copyright DETROIT DIESEL CORPORATION ...

Page 2529: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1906 Injector Tube Reconditioning Set J 22525 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2383 ...

Page 2530: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1907 Service Set DDA Gear G Rotor Type J 1508 E All information subject to change without notice C 2384 Copyright DETROIT DIESEL CORPORATION ...

Page 2531: ...IES 4000 12 16V SERVICE MANUAL Figure 1908 Injector Pop Fixture J 34760 B Includes J 34760 147A and J 34760 150A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2385 ...

Page 2532: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1909 Calibrator J 39300 All information subject to change without notice C 2386 Copyright DETROIT DIESEL CORPORATION ...

Page 2533: ...S 4000 12 16V SERVICE MANUAL Figure 1910 Slide Hammer J 23907 1 Figure 1911 Clutch Pilot Bearing Remover J 23907 2 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2387 ...

Page 2534: ...4000 12 16V SERVICE MANUAL Figure 1912 Dial Indicator Adaptor J 21224 Figure 1913 Water Pump Seal Installer J 38858 All information subject to change without notice C 2388 Copyright DETROIT DIESEL CORPORATION ...

Page 2535: ...ES 4000 12 16V SERVICE MANUAL Figure 1914 Pliers Tru Arc J 4646 Figure 1915 Handle and Striker Assembly J 2619 5 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2389 ...

Page 2536: ...ES 4000 12 16V SERVICE MANUAL Figure 1916 Tension Scale J 8129 Figure 1917 Line Boring Complete Kit main J 29005 All information subject to change without notice C 2390 Copyright DETROIT DIESEL CORPORATION ...

Page 2537: ...S 4000 12 16V SERVICE MANUAL Figure 1918 Injector Tube Swagging Tool J 28611 A Figure 1919 Driver Handle J 3154 1A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2391 ...

Page 2538: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1920 Pro Link for DDEC III and IV J 38500 H All information subject to change without notice C 2392 Copyright DETROIT DIESEL CORPORATION ...

Page 2539: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1921 Crankshaft Position Timing Tool J 34930 A All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2393 ...

Page 2540: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1922 Water Pump Drive Gear Installer J 25257 All information subject to change without notice C 2394 Copyright DETROIT DIESEL CORPORATION ...

Page 2541: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1923 Water Pump Seal Remover J 22150 B All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2395 ...

Page 2542: ... 4000 12 16V SERVICE MANUAL Figure 1924 Water Pump Seal Remover J 8501 Figure 1925 Thermostat Seal Installer J 8550 All information subject to change without notice C 2396 Copyright DETROIT DIESEL CORPORATION ...

Page 2543: ...IES 4000 12 16V SERVICE MANUAL Figure 1926 Driver Handle J 7079 2 Figure 1927 Impeller Slip Test Adaptor J 33765 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2397 ...

Page 2544: ...000 12 16V SERVICE MANUAL Figure 1928 Belt Tension Gage Poly Vee Belts J 23586 Figure 1929 Digital Tachometer J 26791 All information subject to change without notice C 2398 Copyright DETROIT DIESEL CORPORATION ...

Page 2545: ...SERIES 4000 12 16V SERVICE MANUAL Figure 1930 Injector Calibrator and Injector Seat J 22410 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION C 2399 ...

Page 2546: ...IES 4000 12 16V SERVICE MANUAL Figure 1931 Injector Timing Gage 1 540 J 44191 Figure 1932 Alignment Tool J 43394 All information subject to change without notice C 2400 Copyright DETROIT DIESEL CORPORATION ...

Page 2547: ...D TOLERANCE AND WEAR LIMITS Section Page D 000 GENERAL INFORMATION D 3 D 010 CYLINDER LINER D 7 D 020 ASSEMBLY SPECIFICATIONS D 81 ...

Page 2548: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice D 2 Copyright DETROIT DIESEL CORPORATION ...

Page 2549: ...SERIES 4000 12 16V SERVICE MANUAL D 000 GENERAL INFORMATION Section Page General Information D 5 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 3 ...

Page 2550: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice D 4 Copyright DETROIT DIESEL CORPORATION ...

Page 2551: ...e Difference between bore and shaft diameters when bore diameter is smaller than shaft diameter Table 1 Explanation of Terms Dimensions Terms for Reconditioning and Operational Limits Explanation Wear Limit The limit dimensions specified do not represent the absolute maximum values permissible for satisfactory engine operation They indicate that the next basic overhaul can be reached safely If a l...

Page 2552: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice D 6 Copyright DETROIT DIESEL CORPORATION ...

Page 2553: ...shaft Gear D 36 Coaxial Tolerance of Crankshaft Main Bearing Journals D 37 Crankshaft Dynamic Balancing D 38 Connecting Rod Bearing D 40 Connecting Rod Locating Pin D 42 Connecting Rod Bearing Bore D 43 Connecting Rod Shells D 44 Connecting Rod Bores Parallelism D 45 Piston Bearing D 46 Piston Rings D 48 Piston Clearance in Cylinder Liner Without Scraper Ring D 50 Piston Clearance in Cylinder Line...

Page 2554: ...ust Rocker Arm Bearing D 70 Engine Coolant Pump for H P Temperature System D 72 Engine Coolant Pump for H P Temperature System D 74 Engine Coolant Pump for Low Pressure Temperature System D 76 Engine Coolant Pump for Low Pressure Temperature System D 78 All information subject to change without notice D 8 Copyright DETROIT DIESEL CORPORATION ...

Page 2555: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 9 ...

Page 2556: ...aper Ring See Figure 1067 for a general view and listed in Table 3 are the tolerance and wear limits for the cylinder liner without scraper ring Figure 1067 Cylinder Liner All information subject to change without notice D 10 Copyright DETROIT DIESEL CORPORATION ...

Page 2557: ...6 2 Cylinder liner lower fit 2 190 0s6 0 079 0 050 0 050 0 125 3 Bushing bore installed 165 0H7 0 0 040 4 Marking for stage Reconditioning Instructions Re 1 and 2 In event of cavitation at upper and or lower fit of cylinder block bore introduce next repair stage and install cylinder liner of corresponding stage Re 4 Marking with numeral punches 6mm 0 236 in high For Stage 1 0 5 For Stage 2 1 0 Tab...

Page 2558: ... See Figure 1068 for a general view and listed in Table 4 are the tolerance specifications for the cylinder liner with scraper ring Figure 1068 Cylinder Liner with Scraper Ring All information subject to change without notice D 12 Copyright DETROIT DIESEL CORPORATION ...

Page 2559: ... 0 0 050 3 Scraper ring OD 170 0g7 0 054 0 014 0 014 0 104 4 Scraper ring bore 164 0H8 0 0 063 5 Bushing bore installed 165 0H7 0 0 040 6 Marking for stage Reconditioning Instructions Re 1 and 2 In event of cavitation at upper and or lower fit of cylinder block bore introduce next repair stage and install cylinder liner of corresponding stage Re 3 and 4 Check scraper ring OD and ID when fitted Re ...

Page 2560: ... See Figure 1069 for a view of the main bearing cap and listed in Table 5 are the tolerance specifications for the main bearing cap Figure 1069 Main Bearing Cap All information subject to change without notice D 14 Copyright DETROIT DIESEL CORPORATION ...

Page 2561: ...088 0 022 0 184 Bearing cap gap 298 0H7 0 0 052 2 Bearing cap width 298 0p6 0 056 0 088 0 004 0 088 3 Bolt length 348 0 0 500 0 500 NOTE Re Install bearing cap as specified and torque screws as per tightening specification refer to section A 003 A 003 Table 5 Main Bearing Cap Tolerance Specifications All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 15 ...

Page 2562: ...ores 3 Determine diameters a b1 and b2 each in 2 measuring planes and from the results determine the mean values of a b1 and b2 Check roundness of bores 3 Possible deviations from roundness result from the mean values of a b1 and b2 in accordance with the equation 0 5 b1 b2 a Vertical ovality a value greater than 0 5 b1 b2 is not permissible Figure 1070 Main Bearing Bore All information subject to...

Page 2563: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 17 ...

Page 2564: ...r a view of the coaxial tolerance points for the cylinder block bores and crankshaft bearings and listed in Table 6 are the maximum coaxial deviations Figure 1071 Coaxial Tolerance of Cylinder Block Bores for Crankshaft Bearings All information subject to change without notice D 18 Copyright DETROIT DIESEL CORPORATION ...

Page 2565: ... from main bearing 1 to 7 Diameter 0 080 c applicable for all bearings 0 500 d applicable for all bearings 0 100 e applicable for all bearings not concave O 0 010 _ 0 010 f applicable for all bearings 0 015 Table 6 Maximum Permissible Coaxial Deviation All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 19 ...

Page 2566: ...7 are the maximum permissible coaxial deviations Figure 1072 Coaxial Tolerance Points of Cylinder Block Bores for Camshaft Bearings Maximum Permissible Coaxial Deviation New Condition a with adjacent left and right bearings Diameter 0 040 b from camshaft bearing 1 to 7 Diameter 0 080 Table 7 Maximum Permissible Coaxial Deviation All information subject to change without notice D 20 Copyright DETRO...

Page 2567: ...o Designation Tol Size Lower Upper Min Max Min Max Equipment carrier bore 81 0H7 0 0 035 1 Axle OD 81 0 h7 0 035 0 0 0 070 Gear bore 80 0H7 0 0 030 2 Bushing bore 80 0s6 0 059 0 078 0 029 0 078 Bushing bore Installed 75 0H8 0 0 046 Removed 75 0E6 0 060 0 079 3 Axle OD 75 0e7 0 090 0 060 0 060 0 136 Table 8 Tolerance Specifications for the Free End Idler Gear All information subject to change witho...

Page 2568: ...angement See Figure 1074 for a free end main bearing arrangement view and listed in Table 9 are the tolerance specifications Figure 1074 Free End Main Bearing Arrangement All information subject to change without notice D 22 Copyright DETROIT DIESEL CORPORATION ...

Page 2569: ...rrier bore 193 000H6 0 0 029 1 Bearing OD removed 193 204 0 0 029 0 175 0 233 Bearing bushing bore bearing fitted 180 121 0 0 069 2 Drive flange OD not press fitted 179 800 h7 0 040 0 0 321 0 430 Table 9 Main Bearing Tolerance Specifications All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 23 ...

Page 2570: ...nner star bore 198 00 H7 0 0 046 1 Drive flange OD not press fitted 198 00j6 0 013 0 016 0 059 0 016 Seal carrier bore 230 00H8 0 0 072 2 Shaft seal OD 230 47 0 120 0 120 0 518 0 590 3 Running surface OD 198 80h8 0 115 0 4 Radial lip oil seal fitted flush Reconditioning Instructions Re 3 Running surface worn metal spray running surface and grind using feed in method Table 10 Free End Crankshaft Se...

Page 2571: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 25 ...

Page 2572: ...ent See Figure 1076 for the main bearing alignment and listed in Table 11 are the main bearing alignment tolerance specifications Figure 1076 Main Bearing Alignment All information subject to change without notice D 26 Copyright DETROIT DIESEL CORPORATION ...

Page 2573: ...Alignment bearing diameter installed 1 3 158 620 0 0 054 0 0 160 000h6 0 1 159 500h6 0 2 159 000h6 0 3 158 500h6 0 025 0 1 0 160 000h6 1 1 159 500h6 1 2 159 000h6 2 Main bearing journal 1 3 158 500h6 0 025 0 0 120 0 199 0 0 171 200 0 1 171 200 0 2 171 200 0 3 171 200 0 0 500 1 0 171 700 1 1 171 700 1 2 171 700 3 Spreading dimension alignment bearing Upper Half Lower Half 1 3 171 700 0 0 500 Table ...

Page 2574: ...See Figure 1077 for a view of the main bearing tolerance points and listed in Table 12 are the tolerance values for the main bearing Figure 1077 Main Bearing All information subject to change without notice D 28 Copyright DETROIT DIESEL CORPORATION ...

Page 2575: ...59 120 Alignment bearing diameter Installed 1 3 158 620 0 0 054 0 0 160 000h6 0 1 159 500h6 0 2 159 000h6 0 3 158 500h6 0 025 0 1 0 160 000h6 1 1 159 500h6 1 2 159 000h6 2 Main bearing journal 1 3 158 500h6 0 025 0 0 120 0 199 0 0 171 400 0 1 171 400 0 2 171 400 0 3 171 400 0 1 000 1 0 171 900 1 1 171 900 1 2 171 900 3 Spreading dimension alignment bearing Upper half Lower half 1 3 171 900 0 1 000...

Page 2576: ...s and listed in Table 13 are the crankshaft axial clearances Figure 1078 Crankshaft Axial Clearance Points Clearance No Designation Min Max 1 Crankshaft axial play 0 200 0 600 2 PTO flange fitted flush Table 13 Crankshaft Axial Clearance All information subject to change without notice D 30 Copyright DETROIT DIESEL CORPORATION ...

Page 2577: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 31 ...

Page 2578: ...re 1079 for a view of the driving end crankshaft seal tolerance points and listed in Table 14 are the driving end crankshaft seal tolerances Figure 1079 Driving End Crankshaft Seal All information subject to change without notice D 32 Copyright DETROIT DIESEL CORPORATION ...

Page 2579: ...7 440 0 265 0 314 Flywheel housing bore 240 000 240 046 3 Radial lip shaft seal OD 240 350 240 590 0 301 0 590 4 Running surface OD 209 585 209 700 5 Radial lip shaft seal press fitted flush Reconditioning Instructions Re 4 Running surface worn Metal spray running surface and grind using feed in method Table 14 Driving End Crankshaft Seal Tolerances All information subject to change without notice...

Page 2580: ...suring planes 1 and 2 and in each case calculate mean values of a b1 and b2 3 Check roundness of bores a Possible deviations from roundness result from the mean values of a b1 and b2 in accordance with the equation 0 5 b1 b2 a 4 Replace bearing shells a If deviation from roundness 0 040 b If b1 and b2 are 0 040 c With vertical ovality a 0 5 b1 b2 is not permissible Figure 1080 Crankshaft Bearing S...

Page 2581: ...alues Figure 1081 Counterweight Fixture Deviation No Designation Tol Size Lower Upper Wear Limit 1 Bolt length removed 130 0 0 40 0 Max length 132 0 Reconditioning Instructions Re 1 If the wear limit has been exceeded replace counterweight bolt Table 15 Counterweight Fixture Tolerance Values All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 35 ...

Page 2582: ...e 16 are the free end crankshaft gear tolerance values Figure 1082 Free End Crankshaft Gear Deviation No Designation Tol Size Lower Upper 1 Gear press fitted crankshaft end to gear face 145 50 0 30 0 30 Table 16 Free End Crankshaft Gear Tolerances All information subject to change without notice D 36 Copyright DETROIT DIESEL CORPORATION ...

Page 2583: ... bearing journals coaxial tolerances Figure 1083 Coaxial Tolerance of Crankshaft Main Bearing Journals Maximum Permissible Coaxial Deviation New Condition From main bearing journal 1 to main bearing journal 7 0 100 From main bearing journal to main bearing journal 0 050 Table 17 Crankshaft Main Bearing Journals Coaxial Tolerances All information subject to change without notice Copyright DETROIT D...

Page 2584: ...or each balancing plane during initial balancing 160 gcm Permissible residual imbalance for each balancing plane for comparable balancing in other clamping or balancing machinery 480 gcm Reconditioning Instructions It will only be necessary to rebalance the crankshaft if the counterweights have been replaced If a crankshaft has been reworked to the next repair stage rebalancing will not be necessa...

Page 2585: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 39 ...

Page 2586: ... Figure 1085 for a view of the connecting rod bearing tolerance points and listed in Table 19 are the connecting rod bearing tolerances Figure 1085 Connecting Rod Bearing All information subject to change without notice D 40 Copyright DETROIT DIESEL CORPORATION ...

Page 2587: ... 3 116 482 0 0 048 0 0 117 000h6 0 1 116 800h6 0 2 116 600h6 2 0 3 116 400h6 0 022 0 0 082 0 158 Crankpin length 97 500 0 100 0 100 3 Connecting rod width 48 600 0 100 0 0 200 0 600 0 0 126 400 0 1 126 400 0 2 126 400 4 Spreading dimension connecting rod bearing shell Upper half Lower half 0 3 126 400 0 0 100 Table 19 Connecting Rod Bearing Tolerances All information subject to change without noti...

Page 2588: ... Figure 1086 Connecting Rod Locating Pin Deviation Interference No Designation Stage Tol Size Lower Upper Min Max 0 7 0H7 1 7 3H7 Locating pin bore 2 7 6H7 0 0 015 0 7 0r6 1 7 3r6 1 Locating pin OD 2 7 6r6 0 019 0 028 0 004 0 028 Also permitted for new engines Table 20 Connecting Rod Locating Pin Tolerances All information subject to change without notice D 42 Copyright DETROIT DIESEL CORPORATION ...

Page 2589: ... Tol Size Lower Upper Wear Limit 1 Bolt length removed 103 00 0 40 0 20 104 50 NOTE For connecting rod connecting rod cap reassembly without bearing shells and bolts must be torqued to 10 20 N m 7 38 14 75 lb ft and not to specified torque Connecting rod bearing measure bearing bore in a b and c Minimum dimension must be in direction a Table 21 Connecting Rod Bearing Bore Tolerances All informatio...

Page 2590: ...viation No Designation Tol Size Lower Upper Wear Limit 1 Bolt length removed 103 00 0 40 0 20 104 50 NOTE Torque connecting rod bearing connecting rod connecting rod cap refer to section A 003 A 003 Connecting rod bearing measure bearing bore in a b and c Minimum dimension must be in direction a Table 22 Connecting Rod Bearing Shells Tolerances All information subject to change without notice D 44...

Page 2591: ...th bushing but without bearing shells 354 000 0 100 0 100 1 Connecting rod length without bushing and without bearing shells 354 000 0 100 0 100 2 Parallelism of axes non parallelism 0 070 measured at distance of 100 mm 3 94 in Non parallelism maximum 0 100 Parallelism of axes twist 0 250 measured at distance of 100 mm 3 94 in Twist maximum 0 350 3 Connecting rod weight 9 530 kg 0 060 kg 0 060 kg ...

Page 2592: ...ring See Figure 1090 for a view of the piston bearing tolerance points and listed in Table 24 are the piston bearing tolerances Figure 1090 Piston Bearing All information subject to change without notice D 46 Copyright DETROIT DIESEL CORPORATION ...

Page 2593: ... in stalled min 17000 N Bushing ID finish machined 68 00 0 008 0 018 2 Piston pin OD 68 00 0 005 0 0 008 0 023 Bushing ID finish machined 68 00 0 008 0 018 3 Piston pin OD 68 00 0 005 0 0 008 0 023 4 MTU part number and stage stamped on Reconditioning Instructions Re 1 Bushing loose at 17000 N test load replace bushing introduce next repair stage if necessary Table 24 Piston Bearing Tolerances All...

Page 2594: ...section ring 4 000 0 350 0 0 170 0 540 Groove width 4 000 0 080 0 100 2 Taper face compression ring 4 000 0 350 0 0 080 0 450 Groove width 5 000 0 080 0 100 3 Oil control ring 5 000 0 350 0 0 080 0 450 4 Ring end clearance rectangular section ring taper face compression ring oil control ring 0 400 1 000 0 450 0 700 1 300 0 800 NOTE Re 4 Measure ring end clearance in ring gage 165 0H4 Table 25 Pist...

Page 2595: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 49 ...

Page 2596: ...ston clearance in cylinder liner without a scraper ring Listed in Table 26 are the tolerance values for the piston clearance in the cylinder liner without a scraper ring Figure 1092 Piston Clearance in Cylinder Liner Without Scraper Ring All information subject to change without notice D 50 Copyright DETROIT DIESEL CORPORATION ...

Page 2597: ...er bore 165 000H7 0 0 040 5 Piston crown diameter 164 380 0 025 0 025 0 595 0 685 6 Piston crown crowned falling oval 7 Piston skirt crowned falling oval Reconditioning Instructions Re 1 to 5 Measure piston crown and piston skirt diameters at right angles to piston pin axis Table 26 Piston Clearance in Cylinder Liner Without Scraper Ring Tolerances Piston Clearance in Cylinder Liner With Scraper R...

Page 2598: ...own diameter 164 580 0 020 0 020 0 400 0 840 Scraper ring bore 164 000H8 0 0 063 4 Piston crown diameter 163 400 0 025 0 025 0 575 0 688 Scraper ring bore 164 000H8 0 0 063 5 Piston crown diameter 163 255 0 025 0 025 0 715 0 833 6 Piston skirt crowned falling oval Reconditioning Instructions Re 1 to 5 Measure piston crown and piston skirt diameters at right angles to piston pin axis Table 27 Pisto...

Page 2599: ... 0 021 1 Valve guide ODO 19 000k6 0 028 0 041 0 007 0 041 Valve guide bore installed 11 000H7 0 0 018 2 Valve stem diameter 10 935 0 010 0 010 0 055 0 093 3 Valve clearance Exhaust 0 400 4 Valve clearance Inlet 0 500 NOTE Re 2 Finish machine valve guide bore after pressing into cylinder head It must be possible to insert the go end plug gage by pushing gently onto the valve guide length No go plug...

Page 2600: ...Designation Tol Size Lower Upper 1 Inlet Gage mandrel diameter 87 13 0 0 2 Inlet Reference dimension plug gage 4 80 0 10 0 10 3 Inlet Cylinder head bore depth 13 80 0 0 10 4 Exhaust Gage mandrel diameter 73 20 0 0 5 Exhaust Reference dimension plug gage 4 80 0 10 0 10 6 Exhaust Cylinder head bore depth 13 80 0 0 10 Table 29 Tolerances for Inlet and Exhaust Valve Seats All information subject to ch...

Page 2601: ...et Valve Deviation No Designation Tol Size Lower Upper 1 Valve head OD 57 00 0 20 0 20 Reference dimension Valve seat diameter 54 00 2 Valve seat width 4 05 0 20 0 10 Reference dimension Valve seat diameter 44 00 3 Valve seat width 6 59 0 20 0 Table 30 Inlet Valve Tolerances All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 55 ...

Page 2602: ...haust Valve Deviation No Designation Tol Size Lower Upper 1 Valve head OD 56 00 0 20 0 20 Reference dimension Valve seat diameter 54 00 2 Valve seat width 4 18 0 20 0 10 Reference dimension Valve seat diameter 44 00 3 Valve seat width 7 02 0 20 0 Table 31 Exhaust Valve Tolerances All information subject to change without notice D 56 Copyright DETROIT DIESEL CORPORATION ...

Page 2603: ...prings See Figure 1098 for a view of the outer valve springs Listed in Table 32 are the tolerances for the outer valve springs Figure 1098 Outer Valve Springs All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 57 ...

Page 2604: ...ng length 47 70 1073 00 N 5 Coil diameter 34 40 6 Wire diameter 5 30 e1 Permissible deviation of surface line from vertical with unloaded spring max 2 5 mm e2 Spring support permissible deviation from parallelism less than 0 6 mm Table 32 Outer Valve Springs Tolerances Inner Valve Springs See Figure 1099 for a view of the inner valve springs Listed in Table 33 are the tolerances for the inner valv...

Page 2605: ... length 46 75 466 00 N 19 N 19 N 4 Spring length loaded 42 50 4 1 Spring power at spring length 42 50 529 00 N 5 Coil diameter 23 00 6 Wire diameter 3 60 e1 Permissible deviation of surface line from vertical with unloaded spring max 2 3 mm e2 Spring support permissible deviation from parallelism less than 0 4 mm Table 33 Inner Valve Springs Tolerances All information subject to change without not...

Page 2606: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice D 60 Copyright DETROIT DIESEL CORPORATION ...

Page 2607: ...der head mating face protective sleeve and valve bridge Listed in Table 34 are the tolerances for cylinder head mating face protective sleeve and valve bridge Figure 1100 Cylinder Head Mating Face Protective Sleeve Valve Bridge All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 61 ...

Page 2608: ...leeve OD 44 10 0 100 0 0 200 0 300 Cylinder head thread M24x1 5 4 Protective sleeve thread M24x1 5 Cylinder head bore 14 00 N7 0 023 0 005 5 Sliding pin diameter 14 00 m6 0 007 0 018 0 012 0 041 Valve bridge bore 14 00 D7 0 050 0 068 6 Sliding pin diameter 14 00 m6 0 007 0 018 0 032 0 061 Table 34 Cylinder Head Mating Face Protective Sleeve Valve Bridge Tolerances All information subject to change...

Page 2609: ...in Table 35 are the tolerances for the cylinder head screw fixture Figure 1101 Cylinder Head Screw Fixture Deviation No Designation Tol Size Lower Upper 1 Bolt removed 283 00 0 30 0 30 Table 35 Cylinder Head Screw Fixture Tolerances All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 63 ...

Page 2610: ...re 1102 Coaxial Tolerances of Camshaft Bearings Maximum permissible deviation from coaxial tolerance New condition of bearing 1 to bearing 7 0 050 See Figure 1102 a of bearing to bearing 0 025 See Figure 1102 b all cams 0 010 See Figure 1102 _ 0 010 See Figure 1102 Table 36 Coaxial Tolerances of Camshaft Bearings All information subject to change without notice D 64 Copyright DETROIT DIESEL CORPOR...

Page 2611: ...t Bearing See Figure 1103 for a view of the camshaft bearing Listed in Table 37 are the tolerances for the camshaft bearing Figure 1103 Camshaft Bearing All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 65 ...

Page 2612: ...1 Bushing OD removed 0 0 1 0 97 080 97 580 0 0 050 0 058 0 130 Bushing bore installed removed 92 012 93 900 0 0 200 0 052 0 200 2 Camshaft OD 92 000e7 0 107 0 072 0 084 0 171 a With adjacent left and right bearings b From camshaft bearing 1 to 7 Table 37 Camshaft Bearing Tolerances All information subject to change without notice D 66 Copyright DETROIT DIESEL CORPORATION ...

Page 2613: ...ft axial clearance Figure 1104 Camshaft Axial Clearance Deviation Clearance No Designation Tol Size Lower Upper Min Max Gear bore 32 00H7 0 0 025 1 Camshaft OD 32 00h7 0 025 0 0 0 050 2 Axial play Camshaft 0 100 0 178 Table 38 Camshaft Axial Clearance Tolerances All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 67 ...

Page 2614: ... Clearance Interference No Designation Tol Size Lower Upper Min Max Min Max Rocker arm bore 50 00H7 0 0 025 1 Bushing OD 50 00s6 0 043 0 059 0 018 0 059 Bushing bore 45 00E6 0 050 0 066 2 Rocker shaft OD 45 00f6 0 041 0 025 0 075 0 107 Bearing pedestal bore 45 00U7 0 086 0 061 3 Rocker shaft OD 45 00f6 0 041 0 025 0 020 0 061 Table 39 Inlet and Exhaust Rocker Arm Bearing Tolerances All information...

Page 2615: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 69 ...

Page 2616: ...igure 1106 for the inlet and exhaust rocker arm bearing Listed in Table 40 are the tolerances for the inlet and exhaust rocker arm bearing Figure 1106 Inlet and Exhaust Rocker Arm Bearing All information subject to change without notice D 70 Copyright DETROIT DIESEL CORPORATION ...

Page 2617: ...emoved 32 00G7 0 009 0 034 2 Shaft OD 32 00 f6 0 041 0 025 0 025 0 091 Roller bore 21 00E7 0 040 0 061 3 Bushing OD 21 00h7 0 021 0 0 40 0 082 Bushing bore 14 00E7 0 032 0 061 4 Pin OD 14 00h5 0 008 0 0 032 0 053 Rocker arm bore 14 00P6 0 026 0 015 5 Pin OD 14 00h5 0 008 0 0 007 0 026 Table 40 Inlet and Exhaust Rocker Arm Bearing Tolerances All information subject to change without notice Copyrigh...

Page 2618: ...ngine coolant pump for high pressure temperature system Listed in Table 41 are the tolerances for the engine coolant pump for high pressure temperature system Figure 1107 Engine Coolant Pump for H P Temperature System All information subject to change without notice D 72 Copyright DETROIT DIESEL CORPORATION ...

Page 2619: ...0 3 Shaft OD 40 00k5 0 002 0 013 0 002 0 025 Spacer sleeve bore 40 00N7 0 033 0 008 4 Shaft OD 40 00k5 0 002 0 013 0 010 0 045 Housing bore 80 00K7 0 021 0 009 5 Bearing OD 80 00 0 015 0 0 024 0 024 Bearing bore 40 00 0 012 0 6 Shaft OD 40 00k5 0 002 0 013 0 002 0 025 Gear bore 39 00H7 0 0 025 7 Shaft OD 30 00s6 0 043 0 059 0 018 0 059 Table 41 Engine Coolant Pump for H P Temperature System Tolera...

Page 2620: ...gine coolant pump for high pressure temperature system Listed in Table 42 are the tolerances for the engine coolant pump for high pressure temperature system Figure 1108 Engine Coolant Pump for H P Temperature System All information subject to change without notice D 74 Copyright DETROIT DIESEL CORPORATION ...

Page 2621: ... carrier bore 78 10H7 0 0 030 3 Rotary seal OD 78 20 0 003 0 0 067 0 100 Impeller bore 30 00H5 0 0 009 4 Shaft OD 30 00t5 0 041 0 050 0 032 0 050 Reconditioning Instructions Re 2 Running surface worn Metal spray pump shaft and grind using feed in method Table 42 Engine Coolant Pump for H P Temperature System Tolerances All information subject to change without notice Copyright DETROIT DIESEL CORPO...

Page 2622: ...engine coolant pump for low pressure temperature system Listed in Table 43 are the tolerances for the engine coolant pump for low pressure temperature system Figure 1109 Engine Coolant Pump for Low Pressure Temperature System All information subject to change without notice D 76 Copyright DETROIT DIESEL CORPORATION ...

Page 2623: ...haft OD 40 00k6 0 002 0 013 0 002 0 025 Spacer sleeve bore 40 00N7 0 033 0 008 4 Shaft OD 40 00k5 0 002 0 013 0 010 0 045 Housing bore 80 00K7 0 021 0 009 5 Bearing OD 80 00 0 015 0 0 024 0 024 Bearing bore 40 00 0 012 0 6 Shaft OD 40 00k5 0 002 0 013 0 002 0 025 Gear bore 39 00H7 0 0 025 7 Shaft OD 30 00s6 0 043 0 059 0 018 0 059 Table 43 Engine Coolant Pump for Low Pressure Temperature System To...

Page 2624: ...engine coolant pump for low pressure temperature system Listed in Table 44 are the tolerances for the engine coolant pump for low pressure temperature system Figure 1110 Engine Coolant Pump for Low Pressure Temperature System All information subject to change without notice D 78 Copyright DETROIT DIESEL CORPORATION ...

Page 2625: ...rier bore 78 10H7 0 0 030 3 Rotary seal OD 78 20 0 003 0 0 067 0 100 Impeller bore 30 00H5 0 0 009 4 Shaft OD 30 00t5 0 041 0 050 0 032 0 050 Reconditioning Instructions Re 2 Running surface worn Metal spray pump shaft and grind using feed in method Table 44 Engine Coolant Pump for Low Pressure Temperature System Tolerances All information subject to change without notice Copyright DETROIT DIESEL ...

Page 2626: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice D 80 Copyright DETROIT DIESEL CORPORATION ...

Page 2627: ...SERIES 4000 12 16V SERVICE MANUAL D 020 ASSEMBLY SPECIFICATIONS Section Page Assembly Specifications D 83 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION D 81 ...

Page 2628: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice D 82 Copyright DETROIT DIESEL CORPORATION ...

Page 2629: ... mount 7 gear 0 056 0 247 Idler to mount 8 gear 0 136 0 266 End Play Crankshaft pre check 0 250 0 500 Crankshaft 0 250 0 570 Camshaft 0 080 0 178 Timing Camshaft timing see note 1 8 43 8 73 Hub Press Depth Front 11 3 15 5 Rear C I 13 7 17 0 Rear Marine 16 7 20 0 Cylinder Block to Filler Strip Plane Variance Flywheel housing mating surface rear plane 0 10 0 10 Oil pan mating surface bottom plane 0 ...

Page 2630: ... TDC Verify intake valve lash on all cylinders reset as necessary Use Go No Go feeler gage 0 007 0 009 in Verify exhaust valve lash on all cylinders reset as necessary Use Go No Go feeler gage 0 019 0 021 in Table 45 Engine Assembly Specifications All information subject to change without notice D 84 Copyright DETROIT DIESEL CORPORATION ...

Page 2631: ...E TROUBLESHOOTING Section Page E 010 MECHANICAL TROUBLESHOOTING E 3 E 020 TESTING E 45 ...

Page 2632: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice E 2 Copyright DETROIT DIESEL CORPORATION ...

Page 2633: ...perature Too High E 26 E 012 05 N Charge Air Pressure Too Low E 27 E 012 05 O Charge Air Cooler Coolant Discharge at Weep Hole E 27 E 012 05 P Exhaust Gases Black E 28 E 012 05 Q Exhaust Gases Blue E 29 E 012 05 R Exhaust Gases White E 30 E 012 05 S Starter Power Supply Faulty E 31 E 012 05 T Engine Oil Consumption Abnormally High E 32 E 012 05 U Engine Oil Level Abnormally High E 33 E 012 05 V En...

Page 2634: ...Charge Air Coolant Pressure Too Low E 41 E 012 05 AI Charge Air Coolant Loss E 42 E 012 05 AJ Charge Air Coolant Level Rising E 42 E 012 05 AK Charge Air Coolant Pump Leaking E 43 E 012 05 AL Fan Drive Faulty E 43 All information subject to change without notice E 4 Copyright DETROIT DIESEL CORPORATION ...

Page 2635: ...RVICE MANUAL E 011 FAN CLUTCH Section Page E 011 01 General Mechanical Troubleshooting Information E 7 E 011 02 Fault Conditions E 8 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION E 5 ...

Page 2636: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice E 6 Copyright DETROIT DIESEL CORPORATION ...

Page 2637: ...lic clutch fan remove loose items of clothing and jewelry tie back or contain long hair that could be caught in any moving part causing injury A hydraulic fan may start without warning Before investigating a complaint it will be necessary to fully understand the operation of the fan clutch and the fan clutch controls Refer to section C 222 05 01C 222 05 01 for information on the description and op...

Page 2638: ...d with a hydraulic clutch fan remove loose items of clothing and jewelry tie back or contain long hair that could be caught in any moving part causing injury A hydraulic fan may start without warning Disconnect the solenoid wires at the harness connector to lock up the fan clutch Check fan lockup with a strobotac Match mark the fan and fan clutch pulley The two marks should rotate at exactly the s...

Page 2639: ...utch fan 3 Never work in close proximity to the fan 3 Never try to keep the fan from rotating by holding the fan 3 Never tie down the fan with straps chains or other restraints 3 Never shut off the oil supply to the fan clutch To avoid injury when working near or on an operating engine equipped with a hydraulic clutch fan remove loose items of clothing and jewelry tie back or contain long hair tha...

Page 2640: ...ing near or on an operating engine equipped with a hydraulic clutch fan remove loose items of clothing and jewelry tie back or contain long hair that could be caught in any moving part causing injury A hydraulic fan may start without warning Check fan release with a strobotac Match mark the fan and fan clutch pulley Start the engine The two marks should not rotate at exactly the same speed If they...

Page 2641: ...ded in mounting the fan to the fan mounting hub If washers are used they too should be hardened Bolts holding the fan on the fan mounting hub must fully engage the threads but must not extend too far through the fan mounting hub to contact the front of the bearing retainer or other components 5 A manual override switch may be preventing the fan clutch from releasing Although not recommended by Roc...

Page 2642: ...quence of operation Noisy Operation Perform the following corrective actions to resolve noisy operation 1 Noise originating elsewhere but telegraphing to appear as though the fan or the fan clutch is noisy On some engines a severe noise originates in the air conditioner compressor and telegraphs through belts to be heard in the fan clutch Go to step 2 for further checking If no noise is present fa...

Page 2643: ...Check to ensure bearings in the fan clutch have not been damaged Go to step 2 for a further probable cause 2 The main bearings in the fan clutch may have failed Check for forward rearward axial movement of the fan If movement exists repair the fan clutch Determine cause of oil starvation or bearing overload Go to step 3 for a further probable cause 3 Fan belt is slipping Properly tension a loose b...

Page 2644: ... to step 2 for a further probable cause 2 Orifice may have been left out of the fan clutch Some fan clutches operate without an orifice or have the orifice designed into internal passageways of the fan clutch Refer to a parts manual to determine if a separate orifice plug is used Install the correct orifice if the fan clutch does not have the correct one When the proper orifice fitting is installe...

Page 2645: ... Gases Black E 28 E 012 05 Q Exhaust Gases Blue E 29 E 012 05 R Exhaust Gases White E 30 E 012 05 S Starter Power Supply Faulty E 31 E 012 05 T Engine Oil Consumption Abnormally High E 32 E 012 05 U Engine Oil Level Abnormally High E 33 E 012 05 V Engine Oil Temperature Too High E 33 E 012 05 W Engine Oil Pressure Too High E 34 E 012 05 X Engine Oil Pressure Too Low E 34 E 012 05 Y Engine Coolant ...

Page 2646: ...MANUAL E 012 05 AJ Charge Air Coolant Level Rising E 42 E 012 05 AK Charge Air Coolant Pump Leaking E 43 E 012 05 AL Fan Drive Faulty E 43 All information subject to change without notice E 16 Copyright DETROIT DIESEL CORPORATION ...

Page 2647: ...rosion inhibitor oil kerosene or diesel fuel into the combustion chambers via the opening inlet valves Before restarting the repaired engine fill with new oil and coolant in compliance with the current specification in the publication Oil Fuel and Filter Requirements DDC MTU Series 2000 MTU DDC Series 4000 7SE273 It is essential to change the engine oil after 50 operating hours as the oil may be c...

Page 2648: ...Causes Check Remedial Action Battery Battery charge state Cable connections Charge battery replace if necessary Connect replace if necessary Starter Starter engine wiring Connect replace if necessary Start repeat relay Replace Starter Replace Ring gear Replace Vehicle Monitoring DDEC Vehicle monitoring start release Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troub...

Page 2649: ...ir filter Replace Refer to G121 051 01Operator Guide Charge Air Cooler Clean replace if necessary Compression pressure too low Refer to E 012 05 G Refer to E 012 05 G Engine does not reach firing speed Battery Charge replace if necessary Starter engine wiring Connect replace Starter Replace Electronics wiring loose or faulty Voltage supply Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and...

Page 2650: ...ck Remedial Action Engine coolant preheat temperature too low Refer to section E 012 05 AE Refer to section E 012 05 AE Fuel system is aerated Whether engine fires steadily after short period Run for 5 minutes to de aerate fuel Fuel injection equipment faulty Injector wiring fault recorder fault display Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Gu...

Page 2651: ...Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 H P fuel pump generating insufficient pressure Refer to section E 012 05 H Refer to section E 012 05 H If visual checks are OK refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Engine receiving insufficient fuel Refer to section E 012 05 K Refer to section E 012 05 K Ch...

Page 2652: ...r to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 H P fuel pump suction valve sluggish H P fuel pump with data recorder Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Check suction valve for ease of movement Repair replace if necessary DDEC Engine governor Replace sensor Refer to DDEC III...

Page 2653: ...able 7 perform the check and take the suggested remedial action If the problem persists go to the next probable cause perform the check etc until troubleshooting is complete Probable Causes Check Remedial Action Fuel sensor faulty Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Replace sensor H P fuel pump of fuel quantity regulator pressur...

Page 2654: ...E497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Replace sensor H P fuel pump quantity pres sure regulator actuating solenoid Harsh engine running noise at idling connector and wiring Suction valve Repair replace if necessary Table 8 Fuel Pressure Too High E 012 05 J HIGH PRESSURE FUEL PUMP LEAKING Start with the first probable cause for high pressure fuel pump leaking at the weep hole list...

Page 2655: ... filter Refer to G083 051 03Operator Guide Fuel delivery pump faulty Fuel delivery pump and drive Repair replace if necessary Table 10 Fuel Pressure Too Low E 012 05 L TURBOCHARGER ABNORMAL RUNNING NOISES Start with the first probable cause for exhaust turbocharger abnormal running noises listed in Table 11 perform the check and take the suggested remedial action If the problem persists go to the ...

Page 2656: ...ntration too high Engine coolant Charge air coolant Rectify concentration as per specifications Incorrect corrosion inhibitor deposits in CAC charge air cooler Charge air coolant Coolant inhibitor Clean coolant system Treat engine coolant Oil Fuel and Filter Requirements DDC MTU Series 2000 MTU DDC Series 4000 7SE273 Replace CAC charge air cooler if necessary Temperature transmitter on engine A or...

Page 2657: ...r on engine A or B side faulty Pressure transmitter with dialogue unit fault recorder or fault display via flashing light Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Table 13 Charge Air Pressure Too Low E 012 05 O CHARGE AIR COOLER COOLANT DISCHARGE AT WEEP HOLE Start with the first probable cause for the charge air cooler coolant disch...

Page 2658: ...12 05 N Refer to section E 012 05 N Fuel injection equipment faulty Refer to section E 012 05 D Refer to section E 012 05 D Too high resistance in exhaust system Exhaust back pressure Exhaust system Clean exhaust silencer Engine overload power take off too high Auxiliary PTO power power consumption too high dialogue unit data recorder speed sensitive fuel limiter actual specified torque Refer to D...

Page 2659: ...ete Probable Causes Check Remedial Action Too much oil in combustion chambers Engine oil level Correct oil level Refer to G180 000 01 Operator Guide Exhaust turbocharger Repair Cylinder block ventilation Replace Valve stem seals Replace Piston rings Replace Valve guides Replace Cylinder liners Replace Compression pressure too low Refer to section E 012 05 G Refer to section E 012 05 G Table 16 Exh...

Page 2660: ...obable Causes Check Remedial Action Engine coolant preheat temperature too low Refer to section E 012 05 AE Refer to section E 012 05 AE Drain fuel prefilter Engine cold Engine coolant temperature Refer to section E 012 05 Z Exhaust turbocharger Repair Coolant in combustion chambers Charge air cooler Replace Cylinder head gaskets Replace Cylinder heads cracked Replace Cylinder liners Replace Table...

Page 2661: ...n replace if necessary Generator alternator Repair or replace Battery Replace Charge Indicator Lamp does not display charge with engine running Connection cable to indicator lamp Fuses Charge indicator lamp Battery Generator voltage regulator Secure Replace Replace Replace Replace Generator alternator Tighten cable fixtures Replace Connection cable on starter Secure DDEC Engine monitoring system R...

Page 2662: ...ace Engine oil system leaking externally External subassemblies Seal pipework External pipework Check connections tighten if necessary Engine oil drains Seal Shaft seals Replace Oil pan Seal pipework Cylinder block Repair Engine oil system leaking internally Coolant quality Oil line connection to engine oil heat exchanger Replace sealing rings Exhaust turbocharger leaking Exhaust turbocharger Repl...

Page 2663: ...ribution housing Replace Table 20 Engine Oil Level Abnormally High E 012 05 V ENGINE OIL TEMPERATURE TOO HIGH Start with the first probable cause of engine oil temperature too high listed in Table 21 perform the check and take the suggested remedial action If the problem persists go to the next probable cause perform the check etc until troubleshooting is complete Probable Causes Check Remedial Ac...

Page 2664: ...probable cause perform the check etc until troubleshooting is complete Probable Causes Check Remedial Action Engine oil filter dirty Engine oil filter Replace filter Engine oil level too low Engine oil level Replenish Engine oil pressure sensor faulty Pressure transmitter with dialogue unit fault recorder or fault display via flashing light Replace Refer to DDEC III IV Single ECM Troubleshooting 6...

Page 2665: ...DEC Indicator lamp Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Fan drive faulty Refer to section E 012 05 AL Refer to section E 012 05 AL Engine coolant thermostat faulty Engine coolant thermostat Replace Engine coolant pressure too low Refer to section E 012 05 AA Refer to section E 012 05 AA Engine coolant temperature transmitter not ...

Page 2666: ...e Causes Check Remedial Action Engine coolant thermostat faulty Engine coolant thermostat Replace Engine coolant temperature transmitter not working Fan drive faulty always on Temperature transmitter and wiring with dialogue unit fault recorder or fault display via flashing light Repair replace if necessary Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshootin...

Page 2667: ...Check connections tighten if necessary Coolant drain points Seal Cylinder block Check for leaks replace if necessary Engine coolant heat exchanger Repair Engine coolant level too low Engine coolant level Add engine coolant Engine coolant pump faulty Engine coolant pump Replace Engine coolant system leaking internally Oil quality Change engine oil Cylinder heads Replace Cylinder liner gaskets Repla...

Page 2668: ... recorder or fault display via flashing light Repair replace if necessary Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Table 27 Engine Coolant Loss E 012 05 AC ENGINE COOLANT LEVEL RISING Start with the first probable cause engine coolant level rising listed in Table 28 perform the check and take the suggested remedial action If the prob...

Page 2669: ...ng Replace slip ring replace engine coolant pump if necessary Table 29 Engine Coolant Pump Leaking at Weep Hole E 012 05 AE PREHEAT TEMPERATURE TOO LOW Start with the first probable cause for preheat temperature too low listed in Table 30 perform the check and take the suggested remedial action If the problem persists go to the next probable cause perform the check etc until troubleshooting is com...

Page 2670: ... air coolant temperature transmitter faulty Temperature transmitter and wiring dialogue unit fault recorder or fault display via flashing light Repair replace if necessary Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Table 31 Charge Air Coolant Temperature Too High E 012 05 AG CHARGE AIR COOLANT TEMPERATURE TOO LOW Start with the first p...

Page 2671: ...bassemblies Check connections tighten if necessary Charge air coolant drain points Seal Charge air cooler Check for leaks replace if necessary Charge air coolant heat exchanger Repair Charge air coolant level too low Charge air coolant level Add charge air coolant Charge air coolant pump faulty Charge air coolant pump Replace Charge air coolant system leaking internally Oil quality Refer to sectio...

Page 2672: ...l quality Refer to section E 012 05 O Refer to section E 012 05 O Display fault Charge air coolant level transmitter Transmitter wiring dialogue unit fault recorder or fault display via flashing light Repair replace if necessary Refer to DDEC III IV Single ECM Troubleshooting 6SE497 and or DDEC Multi ECM Troubleshooting Guide 6SE496 Table 34 Charge Air Coolant Loss E 012 05 AJ CHARGE AIR COOLANT L...

Page 2673: ...e coolant pump if necessary Table 36 Charge Air Coolant Pump Leaking at Weep Hole E 012 05 AL FAN DRIVE FAULTY Start with the first probable cause for a faulty fan drive listed in Table 37 perform the check and take the suggested remedial action If the problem persists go to the next probable cause perform the check etc until troubleshooting is complete Probable Causes Check Remedial Action Vee be...

Page 2674: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice E 44 Copyright DETROIT DIESEL CORPORATION ...

Page 2675: ...12 16V SERVICE MANUAL E 020 TESTING Section Page E 021 SOLENOID VALVE TESTING E 47 E 021 01 Testing the Solenoid Valve E 49 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION E 45 ...

Page 2676: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice E 46 Copyright DETROIT DIESEL CORPORATION ...

Page 2677: ...IES 4000 12 16V SERVICE MANUAL E 021 SOLENOID VALVE TESTING Section Page E 021 01 Testing the Solenoid Valve E 49 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION E 47 ...

Page 2678: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice E 48 Copyright DETROIT DIESEL CORPORATION ...

Page 2679: ...applied to the solenoid 1 Attach an accurate pressure gage and drain line to the solenoid Pressure from the solenoid must be measured 2 Unless this test is being conducted on the engine attach line from external pressure source to the solenoid NO or INLET port Heat the coolant gradually All information subject to change without notice Copyright DETROIT DIESEL CORPORATION E 49 ...

Page 2680: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice E 50 Copyright DETROIT DIESEL CORPORATION ...

Page 2681: ...F PREVENTIVE MAINTENANCE Section Page F 010 Rockford Fan Clutch F 3 ...

Page 2682: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice F 2 Copyright DETROIT DIESEL CORPORATION ...

Page 2683: ...VICE MANUAL F 010 ROCKFORD FAN CLUTCH Section Page F 010 05 Rockford Fan Clutch F 5 F 010 05 08 Maintenance of Rockford Fan Clutch F 7 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION F 3 ...

Page 2684: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice F 4 Copyright DETROIT DIESEL CORPORATION ...

Page 2685: ...4000 12 16V SERVICE MANUAL F 010 05 ROCKFORD FAN CLUTCH Section Page F 010 05 08 Maintenance of Rockford Fan Clutch F 7 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION F 5 ...

Page 2686: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice F 6 Copyright DETROIT DIESEL CORPORATION ...

Page 2687: ... long hair that could be caught in any moving part causing injury A hydraulic fan may start without warning The fan drive system requires a minimum of maintenance A few simple checks made periodically will ensure correct operation and a long life Fan Hub Assembly to Mounting Bracket Bolts Check bolt torque after first week of operation and every 500 hours thereafter Fan To Fan Mounting Hub Bolts C...

Page 2688: ...essary to provide an external supply of oil pressure at 40 psi minimum 100 psi maximum The oil supply should be compatible with the oil being used in the engine 2 Clutch Plate Drive Slot Wear With the engine off and the clutch locked by means of the external oil supply rotate the fan with a light force clockwise counterclockwise Movement at a point 30 in from the center of the fan blade should not...

Page 2689: ...rge Air Cooler After Installation Operations C 1025 Air Intake System From Turbocharger to Charge Air Cooler Before Removal Operation C 1016 Air Intake System From Turbocharger to Charge Air Cooler Cleaning Inspection and Repair C 1020 Air Intake System From Turbocharger to Charge Air Cooler General View C 1015 Air Intake System From Turbocharger to Charge Air Cooler Installation C 1022 Air Intake...

Page 2690: ...Assembly Disassembly C 1747 Auxiliary PTO Assembly General View C 1743 Auxiliary PTO Assembly Installation C 1750 Auxiliary PTO Assembly Removal C 1746 Auxiliary PTO Assembly Special Tools C 1744 C Camshaft C 517 Camshaft After Installation Operations C 550 Camshaft Before Removal Operations C 521 Camshaft General View C 519 Camshaft Inspection and Repair C 530 Camshaft Installation C 533 Camshaft...

Page 2691: ...C 929 Charge Air Cooler Before Removal Operations C 920 Charge Air Cooler Disassembly C 923 Charge Air Cooler General View C 919 Charge Air Cooler Inspection and Repair C 924 Charge Air Cooler Installation C 930 Charge Air Cooler Removal C 921 Charge Air Cooler Cooling System Pipework C 1465 Charge Air Cooler Cooling System Pipework After Installation Operations C 1472 Charge Air Cooler Cooling Sy...

Page 2692: ...er Installation Operations C 1515 Coolant Pipework With Thermostat Before Removal Operations C 1496 Coolant Pipework With Thermostat General View C 1493 Coolant Pipework With Thermostat Inspection and Repair C 1504 Coolant Pipework With Thermostat Installation C 1507 Coolant Pipework With Thermostat Removal C 1497 Coolant Pipework With Thermostat Special Tools C 1495 Cooling System C 1281 Cooling ...

Page 2693: ...er Block Special Tools C 11 Cylinder Block Ventilation C 161 Cylinder Block Ventilation After Installation Operations C 187 Cylinder Block Ventilation Assembly C 178 Cylinder Block Ventilation Before Removal Operations C 166 Cylinder Block Ventilation Disassembly C 169 Cylinder Block Ventilation General View C 163 Cylinder Block Ventilation Inspection and Repair C 176 Cylinder Block Ventilation In...

Page 2694: ...ectronic Control Unit After Installation Operations C 1765 Electronic Control Unit Assembly C 1763 Electronic Control Unit Before Removal Operations C 1758 Electronic Control Unit Disassembly C 1761 Electronic Control Unit General View C 1757 Electronic Control Unit Inspection and Repair C 1762 Electronic Control Unit Installation C 1764 Electronic Control Unit Removal C 1759 Engine Coolant System...

Page 2695: ...erations C 1773 Engine Sensor Harnesses General View C 1769 Engine Sensor Harnesses Inspection and Repair C 1777 Engine Sensor Harnesses Installation C 1778 Engine Sensor Harnesses Removal C 1774 Exhaust Manifold C 1041 Exhaust Manifold After Installation Operations C 1060 Exhaust Manifold Before Removal Operations C 1045 Exhaust Manifold General View C 1043 Exhaust Manifold Inspection and Repair ...

Page 2696: ...Inspection and Repair C 152 Flywheel Housing Installation C 157 Flywheel Housing Removal C 147 Flywheel Housing Special Tools C 145 Fuel Filter C 791 Fuel Filter After Installation Operations C 810 Fuel Filter Assembly C 805 Fuel Filter Before Removal Operations C 795 Fuel Filter Disassembly C 800 Fuel Filter General View C 793 Fuel Filter Inspection and Repair C 802 Fuel Filter Installation C 807...

Page 2697: ...moval C 783 Fuel Return Rails and Lines C 821 Fuel Return Rails and Lines After Installation Operations C 839 Fuel Return Rails and Lines Assembly C 834 Fuel Return Rails and Lines Before Removal Operations C 825 Fuel Return Rails and Lines Disassembly C 832 Fuel Return Rails and Lines General View C 823 Fuel Return Rails and Lines Inspection and Repair C 833 Fuel Return Rails and Lines Installati...

Page 2698: ...Water Pump With Attachments Inspection and Repair C 1307 High temperature Water Pump With Attachments Installation C 1334 High temperature Water Pump With Attachments Removal C 1298 High temperature Water Pump With Attachments Special Tools C 1296 High pressure Fuel Pump C 663 High pressure Fuel Pump After Installation Operations C 685 High pressure Fuel Pump Before Removal Operations C 668 High p...

Page 2699: ...Installation Operations C 140 Lifting Attachments for Engine and Running Gear Before Removal Operations C 135 Lifting Attachments for Engine and Running Gear General View C 133 Lifting Attachments for Engine and Running Gear Inspection and Repair C 137 Lifting Attachments for Engine and Running Gear Installation C 139 Lifting Attachments for Engine and Running Gear Removal C 136 Lube Oil Pump With...

Page 2700: ...Housing After Installation Operations C 1000 Marine Left Intake Housing Assembly C 994 Marine Left Intake Housing Before Removal Operations C 986 Marine Left Intake Housing Disassembly C 992 Marine Left Intake Housing General View C 985 Marine Left Intake Housing Inspection and Repair C 993 Marine Left Intake Housing Installation C 996 Marine Left Intake Housing Removal C 987 Marine Raw Water Pump...

Page 2701: ... and Repair C 897 Marine Turbocharger Actuator Installation C 898 Marine Turbocharger Actuator Removal C 893 O Oil Cooling C 1179 Oil Cooling After Installation Operations C 1207 Oil Cooling Before Removal Operations C 1182 Oil Cooling General View C 1181 Oil Cooling Inspection and Repair C 1191 Oil Cooling Installation C 1197 Oil Cooling Removal C 1183 Oil Heat Exchanger C 1153 Oil Heat Exchanger...

Page 2702: ...tallation Operations C 1244 Oil Supply Lines for Exhaust Turbocharger Before Removal Operations C 1238 Oil Supply Lines for Exhaust Turbocharger General View C 1237 Oil Supply Lines for Exhaust Turbocharger Inspection and Repair C 1241 Oil Supply Lines for Exhaust Turbocharger Installation C 1243 Oil Supply Lines for Exhaust Turbocharger Removal C 1239 Oil System for Piston Cooling C 1209 Oil Syst...

Page 2703: ...upling Disassembly C 1732 Resilient Coupling General View C 1729 Resilient Coupling Inspection and Repair C 1735 Resilient Coupling Installation C 1739 Resilient Coupling Removal C 1731 S Starter C 1063 Starter After Installation Operations C 1077 Starter Assembly C 1073 Starter Before Removal Operations C 1067 Starter Disassembly C 1070 Starter General View C 1065 Starter Inspection and Repair C ...

Page 2704: ...uator Control Solenoid Valve Marine After Installation Operations Marine C 913 Turbocharger Actuator Control Solenoid Valve Marine Before Removal Operations Marine C 906 Turbocharger Actuator Control Solenoid Valve Marine General View Marine C 905 Turbocharger Actuator Control Solenoid Valve Marine Inspection and Repair Marine C 909 Turbocharger Actuator Control Solenoid Valve Marine Installation ...

Page 2705: ...cial Tools C 605 Vent Lines C 1355 Vent Lines After Installation Operations C 1363 Vent Lines Before Removal Operations C 1359 Vent Lines General View C 1357 Vent Lines Inspection and Repair C 1361 Vent Lines Installation C 1362 Vent Lines Removal C 1360 All information subject to change without notice Copyright DETROIT DIESEL CORPORATION Index 17 ...

Page 2706: ...SERIES 4000 12 16V SERVICE MANUAL All information subject to change without notice Index 18 Copyright DETROIT DIESEL CORPORATION ...

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