Detroit Diesel 4000 Series Service Manual
  1. Manuals
  2. Brands
  3. Detroit Diesel Manuals
  4. Engine
  5. 4000 Series
  6. Service manual
Detroit Diesel 4000 Series Service Manual

Detroit Diesel 4000 Series Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 4000 Series and is the answer not in the manual?

Questions and answers

Related Manuals for Detroit Diesel 4000 Series

Summary of Contents for Detroit Diesel 4000 Series

  • Page 3 Abstract This manual provides instruction for construction and industrial and marine applications of Detroit Diesel Series 4000 Engines. Specifically, a basic overview of each major component and system along with recommendations for removal, cleaning, inspection, criteria for replacement, repair and installation and mechanical...
  • Page 4 Revision Notification Modification to this manual are announced in the form of Service Information Bulletins. The bulletins include attachment pages and are posted on the World Wide Web (www.detroitdiesel.com/svc/sibinex.htm). Revisions to this manual will be sent marked with a revision bar (see Example 2). Sections containing revisions will have a third line in the page footer (compare Examples 1 and 2).
  • Page 5 To avoid injury while operating an engine, ensure the work area is properly ventilated. Engine exhaust is toxic. Please note this caution and remember: Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system.

  • Page 7: Table Of Contents

    C 013.05.11 Installation of Cylinder Liner ....C -101 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 8 C -185 C 018.05.12 M After-Installation Operations ....C -187 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 9 Special Tools ........C -349 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 10 C -554 C 052.05.04 Before-Removal Operations ....C -555 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 11 C -678 C 073.05.12 After-Installation Operations ....C -685 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 12 Removal of Fuel Filter ......C -796 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 13 C -871 C 101.05.08 M Inspection and Repair (Marine) ....C -872 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 14 Inspection and Repair ......C -965 All information subject to change without notice. viii Copyright © DETROIT DIESEL CORPORATION...
  • Page 15 C 141.05.05 Removal of Exhaust System ....C -1033 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 16 Special Tools ........C -1114 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 17 C -1237 C 187.05.04 Before-Removal Operations ....C -1238 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 18 C -1334 C 202.05.12 After-Installation Operations ....C -1336 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 19 C -1441 C 206.05.12 After-Installation Operations ....C -1445 All information subject to change without notice. xiii Copyright © DETROIT DIESEL CORPORATION...
  • Page 20 Removal of the Surge Tank ..... C -1521 C 208.05.08 M Cleaning, Inspection and Repair ....C -1526 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 21 Components ........C -1646 C 222.05.10 Assembly of Rockford Series 270 Fan Clutch ..C -1659 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 22 C -1750 C 259.05.12 After-Installation Operations ....C -1751 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 23 Air Intake System ......C -1835 All information subject to change without notice. xvii Copyright © DETROIT DIESEL CORPORATION...
  • Page 24 Hole ......... . . E -27 All information subject to change without notice. xviii Copyright © DETROIT DIESEL CORPORATION...
  • Page 25 ..........F-13 All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 26 E000.000.07Engine does not reach full-load speed ......All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 27 G000.000.27Attachments — Securing Bolt Tightness Check ....G000.000.29Attachments — Hose and Hose Connections Check ... All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 28 G140.000.03Exhaust System — Security Check ......All information subject to change without notice. xxii Copyright © DETROIT DIESEL CORPORATION...
  • Page 29 G256.051.01Universal Shaft Lubrication ........G256.051.03Universal Shaft Bearing Clearance Check ..... All information subject to change without notice. xxiii Copyright © DETROIT DIESEL CORPORATION...
  • Page 30 Correct Use ........T-25 All information subject to change without notice. xxiv Copyright © DETROIT DIESEL CORPORATION...
  • Page 31 G000.000.01 Disabling Engine Start ........All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 32 G120.000.05 Air System — Intake Depression Check ..... . All information subject to change without notice. xxvi Copyright © DETROIT DIESEL CORPORATION...
  • Page 33 G210.000.01 Wiring — Security and Condition Check ..... . All information subject to change without notice. xxvii Copyright © DETROIT DIESEL CORPORATION...
  • Page 34 012 Remove seals from engine air system ....... . . All information subject to change without notice. xxviii Copyright © DETROIT DIESEL CORPORATION...
  • Page 35 013 Remove seals from engine exhaust system ......All information subject to change without notice. xxix Copyright © DETROIT DIESEL CORPORATION...
  • Page 36 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. Copyright © DETROIT DIESEL CORPORATION...
  • Page 37 A – GENERAL INFORMATION Section Page A 001 IMPORTANT INFORMATION ........A -3 A 002 GENERAL ENGINE INFORMATION .
  • Page 38 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -2 Copyright © DETROIT DIESEL CORPORATION...

  • Page 39: A 001 Important Information

    SERIES 4000 12/16V SERVICE MANUAL A 001 – IMPORTANT INFORMATION Section Page All information subject to change without notice. A -3 Copyright © DETROIT DIESEL CORPORATION...
  • Page 40 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -4 Copyright © DETROIT DIESEL CORPORATION...
  • Page 41 An alphabetical subject index in Section A provides direct access to the individual groups. The Group Summary at the start of Section C lists the individual main function groups. All information subject to change without notice. A -5 Copyright © DETROIT DIESEL CORPORATION...
  • Page 42 The surfaces of parts that slide against each other must be lubricated with engine oil when installed, unless otherwise specified. O-rings and surfaces moving against them during installation (bores and shafts) must be coated with petroleum jelly, unless otherwise specified. All information subject to change without notice. A -6 Copyright © DETROIT DIESEL CORPORATION...
  • Page 43 Do not use an open flame to heat bearing inner races. The temperature should be between 80 and 100 C (176 - 212 F). It must never exceed 120 C (248 All information subject to change without notice. A -7 Copyright © DETROIT DIESEL CORPORATION...
  • Page 44 Proceed in a similar manner with torsionally protected threaded connections. These instructions apply also to testing torque. All information subject to change without notice. A -8 Copyright © DETROIT DIESEL CORPORATION...
  • Page 45 Always mark each fastener upon completion of the torquing process to ensure torque is applied to all and none of the fasteners were missed. All information subject to change without notice. A -9 Copyright © DETROIT DIESEL CORPORATION...
  • Page 46 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -10 Copyright © DETROIT DIESEL CORPORATION...

  • Page 47: A 002 General Engine Information

    SERIES 4000 12/16V SERVICE MANUAL A 002 – GENERAL ENGINE INFORMATION Section Page All information subject to change without notice. A -11 Copyright © DETROIT DIESEL CORPORATION...
  • Page 48 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -12 Copyright © DETROIT DIESEL CORPORATION...
  • Page 49 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. A -13 Copyright © DETROIT DIESEL CORPORATION...
  • Page 50 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 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. A -15 Copyright © DETROIT DIESEL CORPORATION...
  • Page 52 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 Figure 4 Option Label All information subject to change without notice. A -17 Copyright © DETROIT DIESEL CORPORATION...
  • Page 54 Certain component parts used on a given model or in a particular engine type may be superseded or replaced at the discretion of Detroit Diesel. In most cases when this occurs, only the newer part is available for service. Parts catalogs and microfiche are revised periodically to reflect any changes.
  • Page 55 16V: A1 – A7 – B4 – B6 – A4 – B8 – A2 – A8 – B3 – B5 – A3 – A5 –B2 – A6 – B1 – B7 All information subject to change without notice. A -19 Copyright © DETROIT DIESEL CORPORATION...
  • Page 56 Listed in Table 3 are the valve clearances with engine cold, 20 C (68 Component Description Dimension Inlet 0.20 mm (0.008 in.) Exhaust 0.50 mm (0.02 in.) Table 3 Valve Clearance All information subject to change without notice. A -20 Copyright © DETROIT DIESEL CORPORATION...
  • Page 57 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 (0.07874 in.) Table 4 Camshaft and Valve Lift All information subject to change without notice. A -21 Copyright © DETROIT DIESEL CORPORATION...
  • Page 58 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -22 Copyright © DETROIT DIESEL CORPORATION...

  • Page 59: A 003 Torque Specifications

    SERIES 4000 12/16V SERVICE MANUAL A 003 – TORQUE SPECIFICATIONS Section Page All information subject to change without notice. A -23 Copyright © DETROIT DIESEL CORPORATION...
  • Page 60 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -24 Copyright © DETROIT DIESEL CORPORATION...
  • Page 61 Bolt, Class 10.9 Standard 160-176 Bolt, Class 10.9 Standard 250-275 Flywheel/Flex Plate Bolt, Class 10.9 (Reference F and H)* 60 Degrees Bolt, Class 10.9 Standard 350-385 All information subject to change without notice. A -25 Copyright © DETROIT DIESEL CORPORATION...
  • Page 62 Standard 95-105 Steel/Cast Iron Plug, Copper Washer in M33 X 2.0 Standard 120-132 Steel/Cast Iron Plug, Copper Washer in M36 X 1.5 Standard 130-143 Steel/Cast Iron All information subject to change without notice. A -26 Copyright © DETROIT DIESEL CORPORATION...
  • Page 63 M30 X 1.5 Standard 90-99 Aluminum Plug, Copper Washer in M30 X 2.0 Standard 85-94 Aluminum Plug, Copper Washer in M33 x 2.0 Standard 110-121 Aluminum All information subject to change without notice. A -27 Copyright © DETROIT DIESEL CORPORATION...
  • Page 64 (-12 Hose) Fitting, Steel 37 Degree, 9/16 - 18 Standard 24-28 Flared (-6 Hose) Fitting, Steel 37 Degree, 3/4 - 16 Standard 52-58 Flared (-8 Hose) All information subject to change without notice. A -28 Copyright © DETROIT DIESEL CORPORATION...
  • Page 65 12.4-14.7 Vee-Band Clamp* (F) Turbo Turbine Clamp — 17-19 Vee-Band Clamp* (F) Nut to Isolator Nut - Hex Jam 1 - 14 603 - 617 Washer All information subject to change without notice. A -29 Copyright © DETROIT DIESEL CORPORATION...
  • Page 66 ** Main bearing cap stud stretching detailed in assembly referenced in 6A1 Group. Category A — Load within design capability. Process verification controlled by correct tooling. Verification — to minimum torque value. All information subject to change without notice. A -30 Copyright © DETROIT DIESEL CORPORATION...
  • Page 67 NOTE: Torque specification does not apply to hot engines. Re-check of torque at room temperature to be not less than 90 percent of minimum assembly values. All information subject to change without notice. A -31 Copyright © DETROIT DIESEL CORPORATION...
  • Page 68 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -32 Copyright © DETROIT DIESEL CORPORATION...

  • Page 69: A 004 Safety Precautions

    SERIES 4000 12/16V SERVICE MANUAL A 004 – SAFETY PRECAUTIONS Section Page All information subject to change without notice. A -33 Copyright © DETROIT DIESEL CORPORATION...
  • Page 70 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -34 Copyright © DETROIT DIESEL CORPORATION...
  • Page 71 SERIES 4000 12/16V SERVICE MANUAL Safety Precautions The following safety precautions must be observed when working on a Detroit Diesel engine: The exhaust products of an internal combustion engine are toxic. They may cause injury or death if inhaled. All...
  • Page 72 5. Do not drop, drag, roll, or strike a cylinder forcefully. 6. Always close valves completely when finished welding or cutting. All information subject to change without notice. A -36 Copyright © DETROIT DIESEL CORPORATION...
  • Page 73 Using defective electrical equipment can cause severe injury. Improper use of electrical equipment can result in electrical shock, fire, or explosion under certain conditions which may cause severe injury. All information subject to change without notice. A -37 Copyright © DETROIT DIESEL CORPORATION...
  • Page 74 ) air pressure. Transport Lift the engine only with the lifting eyes provided. Use only the transport and lifting equipment approved by Detroit Diesel Technical Service. The engine must be transported only in an installation position. Fuel Lines Remove fuel lines as an assembly. Do not remove fuel lines individually. Avoid mixing fuel injection lines.
  • Page 75 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 notice. A -39 Copyright © DETROIT DIESEL CORPORATION...
  • Page 76 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 notice. A -40 Copyright © DETROIT DIESEL CORPORATION...
  • Page 77 Use protective gloves, goggles or face shield, and apron whenever using caustic chemicals. Exercise care when using oxalic acid to clean engine cooling passages. All information subject to change without notice. A -41 Copyright © DETROIT DIESEL CORPORATION...
  • Page 78 Injection of excessive ether may result in an uncontrolled internal engine explosion that could cause engine damage. Follow the manufacturer’s instructions on proper product use. All information subject to change without notice. A -42 Copyright © DETROIT DIESEL CORPORATION...
  • Page 79 This is extremely corrosive and, if touched by bare skin, may cause severe burns, sometimes with symptoms delayed for several hours. All information subject to change without notice. A -43 Copyright © DETROIT DIESEL CORPORATION...
  • Page 80 SERIES 4000 12/16V SERVICE MANUAL Cleaning Use only fluids and lubricants that have been tested and approved by Detroit Diesel Technical Service. Before removing any engine subassemblies (but after removing electrical equipment), thoroughly clean the engine exterior. NOTICE: Engine sensors, and other electronic components, may be damaged if subjected to the high temperatures of a solvent tank.
  • Page 81 Service parts are available throughout the world. A complete list of distributors and dealers is provided in the Detroit Diesel Corporation Worldwide Distributor/Dealer Directory, 6SE280. This publication is available from all authorized Detroit Diesel distributors. When parts are ordered, the distributor or dealer must be provided with the engine identification and model number.
  • Page 82 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. A -47 Copyright © DETROIT DIESEL CORPORATION...
  • Page 84 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -48 Copyright © DETROIT DIESEL CORPORATION...

  • Page 85: General Description Of Series 4000 Operation

    8V, 12V, or 16V configurations, ranging from 850 to 2700 hp (634–2013 kW). The Series 4000 is the result of a strategic partnership between MTU Motoren-und Turbinen-Union (MTU) and Detroit Diesel Corporation (DDC) to design, produce and distribute an engine for applications requiring 850–2700 hp (634–2013 kW).
  • Page 86 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 information subject to change without notice. A -50 Copyright © DETROIT DIESEL CORPORATION...

  • Page 87: A 006 Data Sheets

    SERIES 4000 12/16V SERVICE MANUAL A 006 – DATA SHEETS Section Page All information subject to change without notice. A -51 Copyright © DETROIT DIESEL CORPORATION...
  • Page 88 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -52 Copyright © DETROIT DIESEL CORPORATION...

  • Page 89: Data Sheets

    See Figure 14 for crankshaft data sheet. See Figure 15 and see Figure 16 for the W6 component list and dyno test data. All information subject to change without notice. A -53 Copyright © DETROIT DIESEL CORPORATION...
  • 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. A -55 Copyright © DETROIT DIESEL CORPORATION...
  • 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. A -57 Copyright © DETROIT DIESEL CORPORATION...
  • 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. A -59 Copyright © DETROIT DIESEL CORPORATION...
  • 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. A -61 Copyright © DETROIT DIESEL CORPORATION...
  • 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. A -63 Copyright © DETROIT DIESEL CORPORATION...
  • Page 100 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -64 Copyright © DETROIT DIESEL CORPORATION...

  • Page 101: A 007 Conversion Tables

    SERIES 4000 12/16V SERVICE MANUAL A 007 – CONVERSION TABLES Section Page All information subject to change without notice. A -65 Copyright © DETROIT DIESEL CORPORATION...
  • Page 102 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -66 Copyright © DETROIT DIESEL CORPORATION...
  • Page 103 To get equivalent number of: Foot/second (ft/sec 0.3048 Meter/second (m/s Inch/second (in./sec 0.0254 Meter/second (m/s Multiply Torque To get equivalent number of: Pound-inch (lb·in.) 0.11298 Newton-meters (N·m) All information subject to change without notice. A -67 Copyright © DETROIT DIESEL CORPORATION...
  • Page 104 To get equivalent number of: Miles/hour (mile/hr) 1.6093 Kilometers/hour (km/hr) Table 8 English-to-metric Conversion Table Decimal and Fraction Equivalents Listed in Table 9 are the decimal and fraction equivalents: All information subject to change without notice. A -68 Copyright © DETROIT DIESEL CORPORATION...
  • Page 105 29/64 0.453125 11.50937 61/64 0.953125 24.20937 15/32 0.46875 11.90625 31/32 0.96875 24.60625 31/64 0.484375 12.30312 63/64 0.984375 25.00312 0.500 12.70000 1.00 25.40000 Table 9 Conversion Chart All information subject to change without notice. A -69 Copyright © DETROIT DIESEL CORPORATION...
  • Page 106 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -70 Copyright © DETROIT DIESEL CORPORATION...

  • Page 107: A 008 Repairing Threaded Bores

    SERIES 4000 12/16V SERVICE MANUAL A 008 – REPAIRING THREADED BORES Section Page All information subject to change without notice. A -71 Copyright © DETROIT DIESEL CORPORATION...
  • Page 108 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -72 Copyright © DETROIT DIESEL CORPORATION...
  • Page 109 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 to change without notice. A -73 Copyright © DETROIT DIESEL CORPORATION...
  • Page 110 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 DIESEL CORPORATION...
  • Page 111 6. Insert 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. A -75 Copyright © DETROIT DIESEL CORPORATION...
  • Page 112 SERIES 4000 12/16V SERVICE 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 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. A -77 Copyright © DETROIT DIESEL CORPORATION...
  • Page 114 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. A -78 Copyright © DETROIT DIESEL CORPORATION...

  • Page 115: Boperation Schedules

    B – OPERATION SCHEDULES Section Page B 001 CHECKING ENGINE CONDITION BEFORE A MAJOR OVERHAUL ........... . . B -3 B 002 W5 MAINTENANCE OPERATIONS .
  • Page 116 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -2 Copyright © DETROIT DIESEL CORPORATION...

  • Page 117: B 001 Checking Engine Condition Before A Major Overhaul

    Checking Engine Condition Before a Major Overhaul ......B -5 All information subject to change without notice. B -3 Copyright © DETROIT DIESEL CORPORATION...
  • Page 118 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -4 Copyright © DETROIT DIESEL CORPORATION...
  • Page 119 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. B -5 Copyright © DETROIT DIESEL CORPORATION...
  • Page 120 Flush cooling system Flush charge air cooling system Shut down engine Operators Guide Check compression pressure Operators Guide Table 1 Checking Engine Condition before a Major Overhaul All information subject to change without notice. B -6 Copyright © DETROIT DIESEL CORPORATION...

  • Page 121: B 002 W5 Maintenance Operations

    W5 Maintenance Operations ..........B -9 All information subject to change without notice. B -7 Copyright © DETROIT DIESEL CORPORATION...
  • Page 122 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -8 Copyright © DETROIT DIESEL CORPORATION...
  • Page 123 Fan: check tension and condition of drive belt Operators Guide Air conditioner compressor: check tension and condition of drive belt Operators Guide Refer to section C Replace high-pressure sensor 073.05.05C 073.05.05 All information subject to change without notice. B -9 Copyright © DETROIT DIESEL CORPORATION...
  • Page 124 Operators Guide Check intake air system for leaks Operators Guide Compressor unit: check operating pressure; check hoses, lines, and connections Operators Guide Shut down engine Operators Guide All information subject to change without notice. B -10 Copyright © DETROIT DIESEL CORPORATION...
  • Page 125 SERIES 4000 12/16V SERVICE MANUAL Operations 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. B -11 Copyright © DETROIT DIESEL CORPORATION...
  • Page 126 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -12 Copyright © DETROIT DIESEL CORPORATION...

  • Page 127: B 003 W6 Maintenance Operations

    SERIES 4000 12/16V SERVICE MANUAL B 003 – W6 MAINTENANCE OPERATIONS Section Page All information subject to change without notice. B -13 Copyright © DETROIT DIESEL CORPORATION...
  • Page 128 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -14 Copyright © DETROIT DIESEL CORPORATION...
  • Page 129 The W6 Engine Overhaul requirements do not include recommended product improvement updates, that should be considered at time of overhaul. For more information on recommended product improvements updates, contact your regional representative or Detroit Diesel Technical Service Department. Refer to Section D for tolerances and wear limits. NOTE: Air compressors, alternators, and starters are not part of the engine rebuild.
  • Page 130 Rockford fan hub assembly ® Replace with reliabilt assembly Dyno test See Dyno test data on the Series 4000 component list; refer to section A 006 All information subject to change without notice. B -16 Copyright © DETROIT DIESEL CORPORATION...

  • Page 131: B 004 Engine Removal

    Engine Removal ............B -19 All information subject to change without notice. B -17 Copyright © DETROIT DIESEL CORPORATION...
  • Page 132 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -18 Copyright © DETROIT DIESEL CORPORATION...
  • Page 133 Table 3 Operations for Engine Removal Engine Weight (Dry weight) 12V is approximately 6070 kg (13, 920 lbs). 16V is approximately 7173 kg (15,814 lbs). All information subject to change without notice. B -19 Copyright © DETROIT DIESEL CORPORATION...
  • Page 134 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -20 Copyright © DETROIT DIESEL CORPORATION...

  • Page 135: B 005 Engine Run-In

    Inspection Report ............B -26 All information subject to change without notice. B -21 Copyright © DETROIT DIESEL CORPORATION...
  • Page 136 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -22 Copyright © DETROIT DIESEL CORPORATION...

  • Page 137: Engine Run-In

    Check operation of emergency shutdown system Preheat engine coolant Operators Guide Start engine Operators Guide Shut down engine after approximately one minute no-load operation and carry out following operations: All information subject to change without notice. B -23 Copyright © DETROIT DIESEL CORPORATION...
  • Page 138 Drain engine oil and coolant Operators Guide Adopt suitable protective measures if engine is scheduled for marine transport Remove air intake, exhaust, engine coolant and fuel lines All information subject to change without notice. B -24 Copyright © DETROIT DIESEL CORPORATION...
  • Page 139 Table 6 Dyno Test Specifications Haul Truck Load Bank Test Load bank on the load reference curve at 1200, 1500, 1800 and 1900 rpm @15 minutes each. All information subject to change without notice. B -25 Copyright © DETROIT DIESEL CORPORATION...
  • Page 140 Consumption: Hourly (B) (kg/h) and Specific (b) g/(kWh) Rack setting (R-deg.) (mm): Lube oil pressure Before filter (bar): Before engine (bar): In supercharger or before turbocharger (bar): Measuring block/last bearing (bar): All information subject to change without notice. B -26 Copyright © DETROIT DIESEL CORPORATION...
  • Page 141 Py (kW, n): n = (rpm): Electric starter motor: Remarks: No evident faults or deficiencies occurred during the acceptance test. Signed for DDC: Signed for the purchaser: All information subject to change without notice. B -27 Copyright © DETROIT DIESEL CORPORATION...
  • Page 142 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -28 Copyright © DETROIT DIESEL CORPORATION...

  • Page 143: B 006 Engine Installation And Operation

    Engine Installation and Operation ......... . B -31 All information subject to change without notice. B -29 Copyright © DETROIT DIESEL CORPORATION...
  • Page 144 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -30 Copyright © DETROIT DIESEL CORPORATION...
  • Page 145 Operators Guide (Note: An engine preservation run was carried out after the test-stand run.) Table 7 Engine Installation and Operation All information subject to change without notice. B -31 Copyright © DETROIT DIESEL CORPORATION...
  • Page 146 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. B -32 Copyright © DETROIT DIESEL CORPORATION...
  • Page 147 C – MAINTENANCE Section Page C 010 CYLINDER BLOCK ..........C -3 C 020 GEAR CASE .
  • Page 148 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -2 Copyright © DETROIT DIESEL CORPORATION...

  • Page 149: Cylinder Block

    Special Tools ..........C -145 All information subject to change without notice. C -3 Copyright © DETROIT DIESEL CORPORATION...
  • Page 150 After-Installation Operations ....... C -187 All information subject to change without notice. C -4 Copyright © DETROIT DIESEL CORPORATION...
  • Page 151 After-Installation Operations ........C -86 All information subject to change without notice. C -5 Copyright © DETROIT DIESEL CORPORATION...
  • Page 152 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -6 Copyright © DETROIT DIESEL CORPORATION...

  • Page 153: General View

    SERIES 4000 12/16V SERVICE MANUAL 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. C -7 Copyright © DETROIT DIESEL CORPORATION...
  • Page 154 15. O-ring 7. 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 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. C -9 Copyright © DETROIT DIESEL CORPORATION...
  • Page 156 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: Special Tools

    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. C -11 Copyright © DETROIT DIESEL CORPORATION...

  • Page 158: Before-Removal Operations

    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: Removal Of Cylinder Block And Main Bearings

    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. C -13 Copyright © DETROIT DIESEL CORPORATION...
  • Page 160 13. Oil-level Dipstick 6. Blanking Plug 14. Dipstick Tube 15. O-ring 7. 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 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. C -15 Copyright © DETROIT DIESEL CORPORATION...
  • Page 162 #9 (16V) or #7 (12V) main bearing journal (front of engine). See Figure 6. 1. Oil Pump 2. #9 Main Bearing Journal Figure 6 Removing Oil Pump (16V Shown) All information subject to change without notice. C -16 Copyright © DETROIT DIESEL CORPORATION...
  • Page 163 5. Remove the filler spacer (1) at 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. C -17 Copyright © DETROIT DIESEL CORPORATION...
  • Page 164 6. The other 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 #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. C -19 Copyright © DETROIT DIESEL CORPORATION...

  • Page 166: Disassembly Of Cylinder Block And Main

    The A side is on the right when the cylinder block is viewed from the bottom. See Figure 10. 1. Identification Number Figure 10 Identifying Marking on Cylinder Block Bearing Cap All information subject to change without notice. C -20 Copyright © DETROIT DIESEL CORPORATION...
  • Page 167 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. C -21 Copyright © DETROIT DIESEL CORPORATION...
  • Page 168 (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 SERIES 4000 12/16V SERVICE MANUAL 5. Turn 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. C -23 Copyright © DETROIT DIESEL CORPORATION...
  • Page 170 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 8. Position both dial gage styluses in the 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 All information subject to change without notice. C -25 Copyright © DETROIT DIESEL CORPORATION...
  • Page 172 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 notice. C -26 Copyright © DETROIT DIESEL CORPORATION...
  • Page 173 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. C -27 Copyright © DETROIT DIESEL CORPORATION...
  • Page 174 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 without notice. C -28 Copyright © DETROIT DIESEL CORPORATION...
  • Page 175 See Figure 19. 1. Camshaft 2. Camshaft Bushing Figure 19 Removing Camshaft Bushing NOTE: Remove core plug only if necessary (for example in event of leakages). All information subject to change without notice. C -29 Copyright © DETROIT DIESEL CORPORATION...
  • Page 176 25. Using a brass 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 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 subject to change without notice. C -31 Copyright © DETROIT DIESEL CORPORATION...
  • Page 178 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 Remove the slide hammer, main bearing stud nuts, main bearing cap, and lower main bearing shell. NOTE: Care should be taken not to allow the main bearing cap to drop and become damaged. All information subject to change without notice. C -33 Copyright © DETROIT DIESEL CORPORATION...

  • Page 180: Inspection And Repair

    [a] If mating surfaces are beyond repair, replace component as necessary. [b] If mating surfaces, sealing surfaces or bores are not damaged, worn or pitted, continue inspection. All information subject to change without notice. C -34 Copyright © DETROIT DIESEL CORPORATION...
  • Page 181 [a] If damage is beyond repair, replace as necessary. [b] If threads are not damaged, continue inspection. 5. Replace gasket. NOTE: Ensure access cover with oil filler neck is perfectly clean. All information subject to change without notice. C -35 Copyright © DETROIT DIESEL CORPORATION...
  • Page 182 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 without notice. C -36 Copyright © DETROIT DIESEL CORPORATION...
  • Page 183 [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 notice. C -37 Copyright © DETROIT DIESEL CORPORATION...
  • Page 184 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 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 inspection. All information subject to change without notice. C -39 Copyright © DETROIT DIESEL CORPORATION...
  • Page 186 [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 [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. C -41 Copyright © DETROIT DIESEL CORPORATION...
  • Page 188 [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 [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. C -43 Copyright © DETROIT DIESEL CORPORATION...
  • Page 190 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 (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. C -45 Copyright © DETROIT DIESEL CORPORATION...
  • Page 192 [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 inspection. All information subject to change without notice. C -46 Copyright © DETROIT DIESEL CORPORATION...
  • Page 193 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. C -47 Copyright © DETROIT DIESEL CORPORATION...
  • Page 194 (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 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. C -49 Copyright © DETROIT DIESEL CORPORATION...
  • Page 196 See information on installing bearing cap and refer to section C 011.05.06 . For an example of data sheet, refer to section A 006A 006 . All information subject to change without notice. C -50 Copyright © DETROIT DIESEL CORPORATION...
  • Page 197 Perform the following 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. C -51 Copyright © DETROIT DIESEL CORPORATION...
  • Page 198 (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 [b] Marking location is at the top edge of the cylinder block side surface below the roof surface, beside the affected cylinder. For an example of data sheet, refer to section A 006A006 . All information subject to change without notice. C -53 Copyright © DETROIT DIESEL CORPORATION...

  • Page 200: Assembly Of Crankshaft And Main Bearings

    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 drift. All information subject to change without notice. C -54 Copyright © DETROIT DIESEL CORPORATION...
  • Page 201 (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. C -55 Copyright © DETROIT DIESEL CORPORATION...
  • Page 202 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 (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 change without notice. C -57 Copyright © DETROIT DIESEL CORPORATION...
  • Page 204 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 © DETROIT DIESEL CORPORATION...
  • Page 205 (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. C -59 Copyright © DETROIT DIESEL CORPORATION...
  • Page 206 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 [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. All information subject to change without notice. C -61 Copyright © DETROIT DIESEL CORPORATION...
  • Page 208 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 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. C -63 Copyright © DETROIT DIESEL CORPORATION...
  • Page 210 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 (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. C -65 Copyright © DETROIT DIESEL CORPORATION...
  • Page 212 SERIES 4000 12/16V SERVICE MANUAL 29. Install 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 30. Connect high-pressure hose of 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. C -67 Copyright © DETROIT DIESEL CORPORATION...
  • Page 214 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 34. Operate hydraulic 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. C -69 Copyright © DETROIT DIESEL CORPORATION...
  • Page 216 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 information subject to change without notice. C -70 Copyright © DETROIT DIESEL CORPORATION...
  • Page 217 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. C -71 Copyright © DETROIT DIESEL CORPORATION...
  • Page 218 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 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. C -73 Copyright © DETROIT DIESEL CORPORATION...
  • Page 220 280 N·m. See Figure 60. 1. Hydraulic Hand Pump 3. Hydraulic Pretensioner 2. J 43196 Dial Indicator Bridge Figure 60 Stretching Main Bearing Studs All information subject to change without notice. C -74 Copyright © DETROIT DIESEL CORPORATION...
  • Page 221 Stretching Main Bearing Studs 7. Using a dial indicator, measure the oil pump gear backlash. Oil pump gear lash should be 0.127 – 0.346 mm (0.005 – 0.0136 in.) All information subject to change without notice. C -75 Copyright © DETROIT DIESEL CORPORATION...

  • Page 222: Installation Of Cylinder Block And Main Bearings

    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 subject to change without notice. C -76 Copyright © DETROIT DIESEL CORPORATION...
  • Page 223 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 without notice. C -77 Copyright © DETROIT DIESEL CORPORATION...
  • Page 224 All information subject to change without notice. C -78 Copyright © DETROIT DIESEL CORPORATION...
  • Page 225 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. C -79 Copyright © DETROIT DIESEL CORPORATION...
  • Page 226 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 © DETROIT DIESEL CORPORATION...
  • Page 227 With a liquid marking pen, mark each bearing as to its location and properly protect for storage. See Figure 66. 1. Flexible Bearing Pushing Tool Figure 66 Removing Upper Main Bearing Shell All information subject to change without notice. C -81 Copyright © DETROIT DIESEL CORPORATION...
  • Page 228 See Figure 67. 1. Upper Main Bearing 2. Bearing Alignment Tool Figure 67 Installing Lower Main Shell All information subject to change without notice. C -82 Copyright © DETROIT DIESEL CORPORATION...
  • Page 229 (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. C -83 Copyright © DETROIT DIESEL CORPORATION...
  • Page 230 (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 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. C -85 Copyright © DETROIT DIESEL CORPORATION...

  • Page 232: After-Installation Operations

    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: Cylinder Liner

    After-Installation Operations ........C -106 All information subject to change without notice. C -87 Copyright © DETROIT DIESEL CORPORATION...
  • Page 234 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -88 Copyright © DETROIT DIESEL CORPORATION...

  • Page 235: General View

    C 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. C -89 Copyright © DETROIT DIESEL CORPORATION...
  • Page 236 See Figure 72 for a 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 See Figure 73 for a cutaway view 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. C -91 Copyright © DETROIT DIESEL CORPORATION...

  • Page 238: Special Tools

    Listed in Table 4 are the 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: Before-Removal Operations

    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 5 Before-Removal Operations All information subject to change without notice. C -93 Copyright © DETROIT DIESEL CORPORATION...

  • Page 240: Removal Of Cylinder Liner

    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 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. C -95 Copyright © DETROIT DIESEL CORPORATION...

  • Page 242: Inspection And Repair

    [a] If carbon scraper ring appears to jam, measure the bore in the cylinder liner. Replace carbon scraper ring if necessary. [b] If carbon scraper ring does not jam, continue inspection. All information subject to change without notice. C -96 Copyright © DETROIT DIESEL CORPORATION...
  • Page 243 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 information subject to change without notice. C -97 Copyright © DETROIT DIESEL CORPORATION...
  • Page 244 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 SERIES 4000 12/16V SERVICE 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. C -99 Copyright © DETROIT DIESEL CORPORATION...
  • Page 246 2. 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: Installation Of Cylinder Liner

    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. C -101 Copyright © DETROIT DIESEL CORPORATION...
  • 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 SERIES 4000 12/16V SERVICE MANUAL 4. 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. C -103 Copyright © DETROIT DIESEL CORPORATION...
  • Page 250 5. Press cylinder liner (1) with 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 9. If cylinder liner measures out-of-round, remove liner and measure I.D. and O.D. 10. If cylinder liner is confirmed to be out-of-round, replace liner as necessary. All information subject to change without notice. C -105 Copyright © DETROIT DIESEL CORPORATION...
  • Page 252 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 6 After-Installation Operations All information subject to change without notice. C -106 Copyright © DETROIT DIESEL CORPORATION...
  • Page 253 After-Installation Operations ........C -130 All information subject to change without notice. C -107 Copyright © DETROIT DIESEL CORPORATION...
  • Page 254 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -108 Copyright © DETROIT DIESEL CORPORATION...
  • Page 255 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. C -109 Copyright © DETROIT DIESEL CORPORATION...
  • Page 256 See Figure 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 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 information subject to change without notice. C -111 Copyright © DETROIT DIESEL CORPORATION...
  • Page 258 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 Listed in 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. C -113 Copyright © DETROIT DIESEL CORPORATION...
  • Page 260 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 8 Before-Removal Operations All information subject to change without notice. C -114 Copyright © DETROIT DIESEL CORPORATION...
  • Page 261 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. C -115 Copyright © DETROIT DIESEL CORPORATION...
  • Page 262 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 spacer. All information subject to change without notice. C -116 Copyright © DETROIT DIESEL CORPORATION...
  • Page 263 Remove front end of the oil pan to the floor. rRemove the oil pan from under the engine. All information subject to change without notice. C -117 Copyright © DETROIT DIESEL CORPORATION...
  • Page 264 [a] If suction basket, spacer block and mating mount flange in oil pan show surface irregularities, repair to ensure proper sealing. [b] If damage is beyond repair, replace component. All information subject to change without notice. C -118 Copyright © DETROIT DIESEL CORPORATION...
  • Page 265 [c] If suction basket, 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. C -119 Copyright © DETROIT DIESEL CORPORATION...
  • Page 266 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 subject to change without notice. C -120 Copyright © DETROIT DIESEL CORPORATION...
  • Page 267 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. C -121 Copyright © DETROIT DIESEL CORPORATION...
  • Page 268 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 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 change without notice. C -123 Copyright © DETROIT DIESEL CORPORATION...
  • Page 270 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 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. C -125 Copyright © DETROIT DIESEL CORPORATION...
  • Page 272 [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 CORPORATION...
  • Page 273 NOTE: Do not allow the “A” and “B” bank strip seal corners to be pinched between the gear case and oil pan during assembly. All information subject to change without notice. C -127 Copyright © DETROIT DIESEL CORPORATION...
  • Page 274 11. Torque the remaining four M10 X 60 bolts on each side to 60 N·m. 12. Torque all the remaining bolts (M10 X 90 bolt with long spacers) to 30 N·m in any sequence. All information subject to change without notice. C -128 Copyright © DETROIT DIESEL CORPORATION...
  • Page 275 17. Remove lockout from truck and start engine; let run at idle for five minutes while checking for oil leaks. Recheck oil level and top off to correct level. 18. Release truck. All information subject to change without notice. C -129 Copyright © DETROIT DIESEL CORPORATION...
  • Page 276 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 9 After-Installation Operations All information subject to change without notice. C -130 Copyright © DETROIT DIESEL CORPORATION...
  • Page 277 After-Installation Operations ........C -140 All information subject to change without notice. C -131 Copyright © DETROIT DIESEL CORPORATION...
  • Page 278 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -132 Copyright © DETROIT DIESEL CORPORATION...

  • Page 279: General View

    GENERAL 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. C -133 Copyright © DETROIT DIESEL CORPORATION...
  • Page 280 SERIES 4000 12/16V SERVICE MANUAL 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: Before-Removal Operations

    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. C -135 Copyright © DETROIT DIESEL CORPORATION...

  • Page 282: Removal Of Engine Lifting Attachments

    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: Inspection And Repair

    1. Visually inspect thread and bolt head mating surface to ensure that they are in perfect condition. [a] If thread or bolt head mating surface is not in perfect condition, replace component as necessary. All information subject to change without notice. C -137 Copyright © DETROIT DIESEL CORPORATION...
  • Page 284 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: Installation Of Engine Lifting Attachments

    “cylinder head tightening diagram” applies entirely; refer to section A 003. For installation of cylinder head, refer to section C 041.05.11. All information subject to change without notice. C -139 Copyright © DETROIT DIESEL CORPORATION...

  • Page 286: After-Installation Operations

    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 After-Installation Operations ........C -160 All information subject to change without notice. C -141 Copyright © DETROIT DIESEL CORPORATION...
  • Page 288 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -142 Copyright © DETROIT DIESEL CORPORATION...

  • Page 289: 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. C -143 Copyright © DETROIT DIESEL CORPORATION...
  • Page 290 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: Special Tools

    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. C -145 Copyright © DETROIT DIESEL CORPORATION...

  • Page 292: Before-Removal Operations

    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: Removal Of Flywheel Housing

    , 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. C -147 Copyright © DETROIT DIESEL CORPORATION...
  • Page 294 All information subject to change without notice. C -148 Copyright © DETROIT DIESEL CORPORATION...
  • Page 295 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. C -149 Copyright © DETROIT DIESEL CORPORATION...

  • Page 296: Disassembly Of Flywheel Housing

    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 SERIES 4000 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. C -151 Copyright © DETROIT DIESEL CORPORATION...

  • Page 298: Inspection And Repair

    [c] If threads are not damaged or worn, continue inspection. Measure Crankshaft Bore in Flywheel Housing Perform the following steps to measure crankshaft bore in flywheel housing. All information subject to change without notice. C -152 Copyright © DETROIT DIESEL CORPORATION...
  • Page 299 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. C -153 Copyright © DETROIT DIESEL CORPORATION...

  • Page 300: Assembly Of Flywheel Housing

    1. Mount 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 Applying 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. C -155 Copyright © DETROIT DIESEL CORPORATION...
  • Page 302 5. Smooth gasket eliminator (1) on the 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: Installation Of Flywheel Housing

    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. C -157 Copyright © DETROIT DIESEL CORPORATION...
  • Page 304 Refer to section A 003. 7. Remove flywheel housing alignment tool J 42734 from flywheel housing and screw the hex bolts in the bores as they become visible. All information subject to change without notice. C -158 Copyright © DETROIT DIESEL CORPORATION...
  • Page 305 (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 subject to change without notice. C -159 Copyright © DETROIT DIESEL CORPORATION...

  • Page 306: After-Installation Operations

    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 After-Installation Operations ........C -187 All information subject to change without notice. C -161 Copyright © DETROIT DIESEL CORPORATION...
  • Page 308 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -162 Copyright © DETROIT DIESEL CORPORATION...
  • Page 309 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. C -163 Copyright © DETROIT DIESEL CORPORATION...
  • Page 310 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 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. C -165 Copyright © DETROIT DIESEL CORPORATION...
  • Page 312 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 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. C -167 Copyright © DETROIT DIESEL CORPORATION...
  • Page 314 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 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. C -169 Copyright © DETROIT DIESEL CORPORATION...
  • 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 3. 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. C -171 Copyright © DETROIT DIESEL CORPORATION...
  • Page 318 4. Remove four bolts (1), washers and nuts securing 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 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. C -173 Copyright © DETROIT DIESEL CORPORATION...
  • Page 320 6. Remove six bolts (1) and washers securing the cylinder 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 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. C -175 Copyright © DETROIT DIESEL CORPORATION...
  • Page 322 6. Visually inspect pipes and housing for leaks in water bath, using compressed air. [a] If bubbles are detected, indicating leaks, replace components as necessary. [b] If no leaks are detected, continue inspection. All information subject to change without notice. C -176 Copyright © DETROIT DIESEL CORPORATION...
  • Page 323 [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. C -177 Copyright © DETROIT DIESEL CORPORATION...
  • Page 324 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 325 3. Replace six bolts (1) and washers securing 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. C -179 Copyright © DETROIT DIESEL CORPORATION...
  • Page 326 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 5. Replace four bolts (1), washers and nuts securing 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. C -181 Copyright © DETROIT DIESEL CORPORATION...
  • Page 328 6. Replace vent tubing (1) that 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 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. C -183 Copyright © DETROIT DIESEL CORPORATION...
  • Page 330 SERIES 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 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 change without notice. C -185 Copyright © DETROIT DIESEL CORPORATION...
  • Page 332 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 = 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. C -187 Copyright © DETROIT DIESEL CORPORATION...
  • Page 334 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -188 Copyright © DETROIT DIESEL CORPORATION...
  • Page 335 After-Installation Operations ....... C -228 All information subject to change without notice. C -189 Copyright © DETROIT DIESEL CORPORATION...
  • Page 336 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -190 Copyright © DETROIT DIESEL CORPORATION...
  • Page 337 After-Installation Operations ........C -210 All information subject to change without notice. C -191 Copyright © DETROIT DIESEL CORPORATION...
  • Page 338 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -192 Copyright © DETROIT DIESEL CORPORATION...
  • Page 339 18. Stud 7. Pressure Regulator 19. Threaded Bushing 8. O-ring 20. Oil Pump 21. Hex Nut 9. Intermediate Gear Axle 10. Crankshaft Outboard Bearing 22. Cover All information subject to change without notice. C -193 Copyright © DETROIT DIESEL CORPORATION...
  • Page 340 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 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. C -195 Copyright © DETROIT DIESEL CORPORATION...
  • Page 342 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 18 Before-Removal Operations All information subject to change without notice. C -196 Copyright © DETROIT DIESEL CORPORATION...
  • Page 343 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. C -197 Copyright © DETROIT DIESEL CORPORATION...
  • Page 344 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 345 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. C -199 Copyright © DETROIT DIESEL CORPORATION...
  • Page 346 6. Check threads and shaft of hex bolts and studs for damage. [a] If threads or shaft of hex bolts are damaged, replace bolts. [b] If threads or shaft of hex bolts are not damaged, continue inspection. All information subject to change without notice. C -200 Copyright © DETROIT DIESEL CORPORATION...
  • Page 347 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. C -201 Copyright © DETROIT DIESEL CORPORATION...
  • Page 348 [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, continue inspection. All information subject to change without notice. C -202 Copyright © DETROIT DIESEL CORPORATION...
  • Page 349 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 notice. C -203 Copyright © DETROIT DIESEL CORPORATION...
  • Page 350 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 351 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. C -205 Copyright © DETROIT DIESEL CORPORATION...
  • Page 352 11. Place guide 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 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. C -207 Copyright © DETROIT DIESEL CORPORATION...
  • Page 354 20. Install nuts and washers and tighten. 21. Torque securing bolts and nuts to specification. Refer to section A 003. NOTE: Ensure that final strength of surface sealant is correct. All information subject to change without notice. C -208 Copyright © DETROIT DIESEL CORPORATION...
  • Page 355 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. C -209 Copyright © DETROIT DIESEL CORPORATION...
  • Page 356 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 19 After-Installation Operations All information subject to change without notice. C -210 Copyright © DETROIT DIESEL CORPORATION...
  • Page 357 After-Installation Operations ........C -228 All information subject to change without notice. C -211 Copyright © DETROIT DIESEL CORPORATION...
  • Page 358 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -212 Copyright © DETROIT DIESEL CORPORATION...
  • Page 359 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. C -213 Copyright © DETROIT DIESEL CORPORATION...
  • Page 360 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 20 Before-Removal Operations All information subject to change without notice. C -214 Copyright © DETROIT DIESEL CORPORATION...
  • Page 361 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. C -215 Copyright © DETROIT DIESEL CORPORATION...
  • Page 362 SERIES 4000 12/16V SERVICE MANUAL 4. 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 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. C -217 Copyright © DETROIT DIESEL CORPORATION...
  • Page 364 6. Check bolts for damage and check condition of threads. [a] Replace bolts if damaged. [b] If bolts are not damaged, continue with inspection. All information subject to change without notice. C -218 Copyright © DETROIT DIESEL CORPORATION...
  • Page 365 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. C -219 Copyright © DETROIT DIESEL CORPORATION...
  • Page 366 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 [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. C -221 Copyright © DETROIT DIESEL CORPORATION...
  • Page 368 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 nitrogen. All information subject to change without notice. C -222 Copyright © DETROIT DIESEL CORPORATION...
  • Page 369 To avoid injury while handling ’HOT’ components, wear protective gloves and clothing. 4. Heat idler gear to 80 C (176 5. Insert cooled bushing flush into idler gear. All information subject to change without notice. C -223 Copyright © DETROIT DIESEL CORPORATION...
  • Page 370 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 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. C -225 Copyright © DETROIT DIESEL CORPORATION...
  • Page 372 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 DIESEL CORPORATION...
  • Page 373 [a] If values are exceeded, replace idler gears. Refer to section C 025.05.05. [b] If values are not exceeded, proceed with after-installation operations. Refer to sectionC 025.05.12. All information subject to change without notice. C -227 Copyright © DETROIT DIESEL CORPORATION...
  • Page 374 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 21 After-Installation Operations All information subject to change without notice. C -228 Copyright © DETROIT DIESEL CORPORATION...
  • Page 375 C 037.05.06 Disassembly of Piston with Connecting Rod ....C -384 All information subject to change without notice. C -229 Copyright © DETROIT DIESEL CORPORATION...
  • Page 376 After-Installation Operations ....... C -453 All information subject to change without notice. C -230 Copyright © DETROIT DIESEL CORPORATION...
  • Page 377 After-Installation Operations ........C -319 All information subject to change without notice. C -231 Copyright © DETROIT DIESEL CORPORATION...
  • Page 378 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -232 Copyright © DETROIT DIESEL CORPORATION...
  • Page 379 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. C -233 Copyright © DETROIT DIESEL CORPORATION...
  • Page 380 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 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. C -235 Copyright © DETROIT DIESEL CORPORATION...
  • Page 382 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 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. C -237 Copyright © DETROIT DIESEL CORPORATION...
  • Page 384 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 (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. C -239 Copyright © DETROIT DIESEL CORPORATION...
  • Page 386 6. Install hydraulic bolt 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 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. C -241 Copyright © DETROIT DIESEL CORPORATION...
  • Page 388 10. Position the two dial gage styluses (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 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. C -243 Copyright © DETROIT DIESEL CORPORATION...
  • Page 390 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 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 information subject to change without notice. C -245 Copyright © DETROIT DIESEL CORPORATION...
  • Page 392 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 SERIES 4000 12/16V SERVICE MANUAL 24. 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. C -247 Copyright © DETROIT DIESEL CORPORATION...
  • Page 394 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 SERIES 4000 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. C -249 Copyright © DETROIT DIESEL CORPORATION...
  • Page 396 4. Expand crankshaft gear with suitable wedge and remove. 5. Smooth seating surface with emery cloth and remove minor scoring. 6. Clean crankshaft, refer to section C 031.05.08. All information subject to change without notice. C -250 Copyright © DETROIT DIESEL CORPORATION...
  • Page 397 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. C -251 Copyright © DETROIT DIESEL CORPORATION...
  • Page 398 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 9. Visually inspect oil passage to running surface transitions for burrs. [a] If burrs are found, polish oil passage. [b] If no burrs are found, continue inspection. All information subject to change without notice. C -253 Copyright © DETROIT DIESEL CORPORATION...
  • Page 400 Perform the following steps to check crankshaft for cracks: 1. Visually inspect counterweight mating surfaces (2) for wear. [a] If counterweight mating surfaces are worn, machine-grind. All information subject to change without notice. C -254 Copyright © DETROIT DIESEL CORPORATION...
  • Page 401 2.5 A/cm to 4 A/cm. NOTE: A component is considered sufficiently demagnetized when a paper clip suspended on a thread is no longer attracted by the component. All information subject to change without notice. C -255 Copyright © DETROIT DIESEL CORPORATION...
  • Page 402 9. Grind to specified repair stage only after bearing journals have been hardened. Cracks Caused by Grinding Review the following comments on cracks caused by grinding: All information subject to change without notice. C -256 Copyright © DETROIT DIESEL CORPORATION...
  • Page 403 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. C -257 Copyright © DETROIT DIESEL CORPORATION...
  • Page 404 [a] If minor scoring or damage is found, polish with emery cloth. [b] If no scoring or damage is found, continue inspection. Measuring Crankshaft Journal Perform the following steps to measure the crankshaft journal: All information subject to change without notice. C -258 Copyright © DETROIT DIESEL CORPORATION...
  • Page 405 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 without notice. C -259 Copyright © DETROIT DIESEL CORPORATION...
  • Page 406 [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 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. C -261 Copyright © DETROIT DIESEL CORPORATION...
  • Page 408 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 -262 Copyright © DETROIT DIESEL CORPORATION...
  • Page 409 To prevent damage to bearing shells and ensure adequate lubrication, perform oil bores check with great care. Check concentricity and axial runout. Check hardness. Check for cracks. All information subject to change without notice. C -263 Copyright © DETROIT DIESEL CORPORATION...
  • Page 410 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 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 7 All information subject to change without notice. C -265 Copyright © DETROIT DIESEL CORPORATION...
  • Page 412 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 information subject to change without notice. C -266 Copyright © DETROIT DIESEL CORPORATION...
  • Page 413 [a] If cracks are detected on counterweight, replace counterweight. [b] If cracks are not detected, continue inspection. 2. Check crankshaft mating surface (2) for wear. [a] If crankshaft mating surface is worn, machine-grind. All information subject to change without notice. C -267 Copyright © DETROIT DIESEL CORPORATION...
  • Page 414 [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 CORPORATION...
  • Page 415 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 notice. C -269 Copyright © DETROIT DIESEL CORPORATION...
  • Page 416 6. The sputtered 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 negatively affecting bearing function. All information subject to change without notice. C -270 Copyright © DETROIT DIESEL CORPORATION...
  • Page 417 The groove geometry corresponds to new condition. The wear layer is fully retained within the grooves. Dark spots are primarily embedded particles of oil carbon. See Figure 196 and see Figure 197. All information subject to change without notice. C -271 Copyright © DETROIT DIESEL CORPORATION...
  • 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 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. C -273 Copyright © DETROIT DIESEL CORPORATION...
  • Page 420 SERIES 4000 12/16V 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 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. C -275 Copyright © DETROIT DIESEL CORPORATION...
  • 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 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. C -277 Copyright © DETROIT DIESEL CORPORATION...
  • Page 424 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 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. C -279 Copyright © DETROIT DIESEL CORPORATION...
  • Page 426 For intermediate 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 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. C -281 Copyright © DETROIT DIESEL CORPORATION...
  • Page 428 For wear layer fatigue 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 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. C -283 Copyright © DETROIT DIESEL CORPORATION...
  • Page 430 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 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. C -285 Copyright © DETROIT DIESEL CORPORATION...
  • Page 432 3. Remove material to balance crankshaft only from counterweights by drilling radially with twist drill. 4. After balancing, recheck numbers on counterweights and renumber if necessary. All information subject to change without notice. C -286 Copyright © DETROIT DIESEL CORPORATION...
  • Page 433 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. C -287 Copyright © DETROIT DIESEL CORPORATION...
  • Page 434 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 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: Ensure that all components are perfectly clean. All information subject to change without notice. C -289 Copyright © DETROIT DIESEL CORPORATION...
  • Page 436 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 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. C -291 Copyright © DETROIT DIESEL CORPORATION...
  • Page 438 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 notice. C -292 Copyright © DETROIT DIESEL CORPORATION...
  • Page 439 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. C -293 Copyright © DETROIT DIESEL CORPORATION...
  • Page 440 [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 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. C -295 Copyright © DETROIT DIESEL CORPORATION...
  • Page 442 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 14. Using a mallet, 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. C -297 Copyright © DETROIT DIESEL CORPORATION...
  • Page 444 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 (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. C -299 Copyright © DETROIT DIESEL CORPORATION...
  • Page 446 17. Install hydraulic 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 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. C -301 Copyright © DETROIT DIESEL CORPORATION...
  • Page 448 21. Position the two dial gage styluses centrally 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 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. C -303 Copyright © DETROIT DIESEL CORPORATION...
  • Page 450 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 -304 Copyright © DETROIT DIESEL CORPORATION...
  • Page 451 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. C -305 Copyright © DETROIT DIESEL CORPORATION...
  • Page 452 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 -306 Copyright © DETROIT DIESEL CORPORATION...
  • Page 453 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. C -307 Copyright © DETROIT DIESEL CORPORATION...
  • Page 454 3. 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 See Figure 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. C -309 Copyright © DETROIT DIESEL CORPORATION...
  • Page 456 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 CORPORATION...
  • Page 457 15. When the components have cooled, lubricate crankshaft gear with engine oil. 16. Coat O-ring with petroleum jelly and fit in groove on crankshaft. See Figure 237. All information subject to change without notice. C -311 Copyright © DETROIT DIESEL CORPORATION...
  • Page 458 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 4. To protect crankshaft, 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. C -313 Copyright © DETROIT DIESEL CORPORATION...
  • Page 460 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 10. Insert the lower main bearing shells with bearing installation tool. NOTE: The numbers of the main bearing cap locations must align and face toward the flywheel end direction. All information subject to change without notice. C -315 Copyright © DETROIT DIESEL CORPORATION...
  • Page 462 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 463 ) 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 without notice. C -317 Copyright © DETROIT DIESEL CORPORATION...
  • Page 464 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 change without notice. C -318 Copyright © DETROIT DIESEL CORPORATION...
  • Page 465 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. C -319 Copyright © DETROIT DIESEL CORPORATION...
  • Page 466 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -320 Copyright © DETROIT DIESEL CORPORATION...
  • Page 467 After-Installation Operations ........C -343 All information subject to change without notice. C -321 Copyright © DETROIT DIESEL CORPORATION...
  • Page 468 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -322 Copyright © DETROIT DIESEL CORPORATION...
  • Page 469 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. C -323 Copyright © DETROIT DIESEL CORPORATION...
  • Page 470 Listed in Table 27 are the special tools 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 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. C -325 Copyright © DETROIT DIESEL CORPORATION...
  • Page 472 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 3. Screw in two guide pins in 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. C -327 Copyright © DETROIT DIESEL CORPORATION...
  • Page 474 9. Install the adapter hub onto the crankshaft ensuring that the arrow is aligned with the dowel hole on the crankshaft 10. Remove the plug from the drive flange expansion port. All information subject to change without notice. C -328 Copyright © DETROIT DIESEL CORPORATION...
  • Page 475 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 tighten at this time. All information subject to change without notice. C -329 Copyright © DETROIT DIESEL CORPORATION...
  • Page 476 Do not exceed maximum pressure. 20. Remove nut, washers and pressure sleeve. 21. Remove the high-pressure line. 22. Remove the drive flange 23. Remove the adapter hub. All information subject to change without notice. C -330 Copyright © DETROIT DIESEL CORPORATION...
  • Page 477 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. C -331 Copyright © DETROIT DIESEL CORPORATION...
  • Page 478 9. Inspect thread in drive hub for condition and ease of movement. [a] If threads of drive hub are not in perfect condition or do not show ease of movement, rechase threads as necessary. All information subject to change without notice. C -332 Copyright © DETROIT DIESEL CORPORATION...
  • Page 479 [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. C -333 Copyright © DETROIT DIESEL CORPORATION...
  • Page 480 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 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. C -335 Copyright © DETROIT DIESEL CORPORATION...
  • Page 482 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 8. Connect high-pressure line. 9. Connect high-pressure line of hand pump to hydraulic press. 10. Fully tighten nut, and pump hand pump until pressure starts to rise. All information subject to change without notice. C -337 Copyright © DETROIT DIESEL CORPORATION...
  • Page 484 Figure 253 Operating Hydraulic Hand Pumps 19. Operate hand pump (2) for hydraulic press and, by applying minimum pressure, seat press against drive hub. See Figure 253. All information subject to change without notice. C -338 Copyright © DETROIT DIESEL CORPORATION...
  • Page 485 29. Allow specified retention time to elapse; remove nut, hydraulic press, pressure sleeve and draw spindle. NOTE: The press-on connection must not be subjected to operational load for at least 8 hours. All information subject to change without notice. C -339 Copyright © DETROIT DIESEL CORPORATION...
  • Page 486 30. To install flex coupling, screw in two guide 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 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. C -341 Copyright © DETROIT DIESEL CORPORATION...
  • Page 488 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 489 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. C -343 Copyright © DETROIT DIESEL CORPORATION...
  • Page 490 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -344 Copyright © DETROIT DIESEL CORPORATION...

  • Page 491: Crankshaft Vibration Damper

    After-Installation Operations ........C -370 All information subject to change without notice. C -345 Copyright © DETROIT DIESEL CORPORATION...
  • Page 492 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -346 Copyright © DETROIT DIESEL CORPORATION...

  • Page 493: General View

    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. C -347 Copyright © DETROIT DIESEL CORPORATION...
  • Page 494 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: Special Tools

    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. C -349 Copyright © DETROIT DIESEL CORPORATION...

  • Page 496: Before-Removal Operations

    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: C 035.05.05 Removal Of The Vibration Damper

    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. C -351 Copyright © DETROIT DIESEL CORPORATION...
  • Page 498 7. Attach a suitable lifting device and crane to the vibration damper (3) and remove from guide studs. See Figure 260. 8. Remove guide studs (1). See Figure 260. All information subject to change without notice. C -352 Copyright © DETROIT DIESEL CORPORATION...
  • Page 499 9. To remove front drive flange removal procedure, install crankshaft adapter to the crankshaft. All information subject to change without notice. C -353 Copyright © DETROIT DIESEL CORPORATION...
  • Page 500 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 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. C -355 Copyright © DETROIT DIESEL CORPORATION...
  • Page 502 Operating Hydraulic Press and Hand Pump for Removal 20. Maintain this pressure for approximately 5 minutes. NOTE: Maximum expansion pressure (p ) is stamped on drive hub. All information subject to change without notice. C -356 Copyright © DETROIT DIESEL CORPORATION...
  • Page 503 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. C -357 Copyright © DETROIT DIESEL CORPORATION...

  • Page 504: C 035.05.06 Disassembly Of The Vibration Damper

    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: C 035.05.08 Inspection And Repair

    [a] If hex bolts are damaged or their threads do not show ease of movement, replace bolts as necessary. [b] If hex bolts are not damaged, continue inspection. 8. Replace O-rings. All information subject to change without notice. C -359 Copyright © DETROIT DIESEL CORPORATION...

  • Page 506: Assembly Of 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 degrease contact areas of dished washers (6). See Figure 265. All information subject to change without notice. C -360 Copyright © DETROIT DIESEL CORPORATION...
  • Page 507 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 Figure 266. Figure 266 Checking Torque Dimensions All information subject to change without notice. C -361 Copyright © DETROIT DIESEL CORPORATION...
  • Page 508 SERIES 4000 12/16V 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 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. C -363 Copyright © DETROIT DIESEL CORPORATION...

  • Page 510: C 035.05.11 Installation Of The Vibration Damper

    Do not touch or get lubricant on the Crankshaft Teflon seal lip or on the damper hub sealing surface when it is installed. Ensure that the lip and sealing surface are clean and dry. All information subject to change without notice. C -364 Copyright © DETROIT DIESEL CORPORATION...
  • Page 511 Push until enough oil is released to allow drive flange to seat. All information subject to change without notice. C -365 Copyright © DETROIT DIESEL CORPORATION...
  • Page 512 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 16. Open bleed screw at pump to release oil pressure. 17. Disconnect the pump line at the drive flange. 18. Wait one hour before removing the drive-on nut. All information subject to change without notice. C -367 Copyright © DETROIT DIESEL CORPORATION...
  • Page 514 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 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. C -369 Copyright © DETROIT DIESEL CORPORATION...

  • Page 516: After-Installation Operations

    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 DIESEL CORPORATION...
  • Page 517 After-Installation Operations ........C -453 All information subject to change without notice. C -371 Copyright © DETROIT DIESEL CORPORATION...
  • Page 518 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -372 Copyright © DETROIT DIESEL CORPORATION...

  • Page 519: General View

    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. C -373 Copyright © DETROIT DIESEL CORPORATION...
  • Page 520 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: Special Tools

    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 subject to change without notice. C -375 Copyright © DETROIT DIESEL CORPORATION...

  • Page 522: Before-Removal Operations

    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 34 Before-Removal Operations All information subject to change without notice. C -376 Copyright © DETROIT DIESEL CORPORATION...

  • Page 523: Removal Of Piston With Connecting Rod

    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 -377 Copyright © DETROIT DIESEL CORPORATION...
  • Page 524 Removing Piston with Connecting Rod (Mounted on Engine Stand) Perform the following steps to remove piston with connecting rod in turnover stand. All information subject to change without notice. C -378 Copyright © DETROIT DIESEL CORPORATION...
  • Page 525 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. C -379 Copyright © DETROIT DIESEL CORPORATION...
  • Page 526 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 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 bearing shell from connecting rod and protect from damage. All information subject to change without notice. C -381 Copyright © DETROIT DIESEL CORPORATION...
  • Page 528 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 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. C -383 Copyright © DETROIT DIESEL CORPORATION...

  • Page 530: Disassembly Of Piston With Connecting Rod

    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 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. C -385 Copyright © DETROIT DIESEL CORPORATION...
  • Page 532 7. Remove piston rings 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 9. Use socket to unscrew 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. C -387 Copyright © DETROIT DIESEL CORPORATION...

  • Page 534: C 037.05.08 Inspection And Repair

    Perform the following steps to inspect and repair piston skirt and top land. 1. Check piston skirt surface condition for wear, pitting and scoring. [a] If worn, pitted or scored, replace the piston. All information subject to change without notice. C -388 Copyright © DETROIT DIESEL CORPORATION...
  • Page 535 4. Inspect piston for scoring or scuffing on top land (piston crown). [a] Remove scoring or scuffing on top land (piston crown) of piston if localized and does not extend as far as first ring groove. All information subject to change without notice. C -389 Copyright © DETROIT DIESEL CORPORATION...
  • Page 536 [a] If piston skirt shows localized scuffing, replace piston. [b] If piston skirt does not show localized scuffing, continue inspection. Checking Piston Crown Perform the following steps to inspect and repair the piston crown. All information subject to change without notice. C -390 Copyright © DETROIT DIESEL CORPORATION...
  • Page 537 8. Inspect sealing surface of piston crown and piston skirt for fretting. [a] If minor fretting is found, smooth sealing surface with oilstone. [b] If excessively fretted, replace piston. [c] If not fretted, continue inspection. All information subject to change without notice. C -391 Copyright © DETROIT DIESEL CORPORATION...
  • Page 538 Perform the following steps to inspect and repair the piston crown bolts. 1. Measure shaft length of bolt with depth gage. [a] If bolt is not proper length, replace bolt. All information subject to change without notice. C -392 Copyright © DETROIT DIESEL CORPORATION...
  • Page 539 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. C -393 Copyright © DETROIT DIESEL CORPORATION...
  • Page 540 [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 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 change without notice. C -395 Copyright © DETROIT DIESEL CORPORATION...
  • Page 542 [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 Perform the following steps to inspect and repair the piston rings. 1. Replace piston rings during W6 overhaul. 2. Clean combustion residue from piston rings and inspect for damage. [a] If damaged, replace piston rings. All information subject to change without notice. C -397 Copyright © DETROIT DIESEL CORPORATION...
  • Page 544 [a] If oil slits of oil control ring are clogged with carbon, remove carbon deposits. [b] If oil slits of control ring are not clogged with carbon, continue inspection. All information subject to change without notice. C -398 Copyright © DETROIT DIESEL CORPORATION...
  • Page 545 [a] If connecting rod, connecting rod cap or connecting rod bolts are cracked, replace cracked components. All information subject to change without notice. C -399 Copyright © DETROIT DIESEL CORPORATION...
  • Page 546 8. Check connecting rod main bore for wear or damage. [a] If connecting rod main bore is worn or damaged, smooth with emery cloth. [b] If main bore is not worn or damaged, continue inspection. All information subject to change without notice. C -400 Copyright © DETROIT DIESEL CORPORATION...
  • Page 547 [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 notice. C -401 Copyright © DETROIT DIESEL CORPORATION...
  • Page 548 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 without notice. C -402 Copyright © DETROIT DIESEL CORPORATION...
  • Page 549 9. Lightly secure test brass drift with securing screw. NOTE: Insert test brass drifts so that tension pins of narrow section of test brass drifts are aligned in the same direction. All information subject to change without notice. C -403 Copyright © DETROIT DIESEL CORPORATION...
  • Page 550 6. Move test brass drift in small connecting rod eye (2) through dial gage styluses (1) at highest point of test brass drift axle. 7. Determine and record deviations on dial gages. All information subject to change without notice. C -404 Copyright © DETROIT DIESEL CORPORATION...
  • Page 551 +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 check axial twist. All information subject to change without notice. C -405 Copyright © DETROIT DIESEL CORPORATION...
  • Page 552 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 1. To determine connecting rod bore axial twist, calculate value measured at 100 mm (3.9370 in.) intervals. [a] If limit value is exceeded, replace connecting rod. All information subject to change without notice. C -407 Copyright © DETROIT DIESEL CORPORATION...
  • Page 554 Perform the following steps to check and assess connecting rod bearing shells (sputtered bearing-lower half). 1. Check rod bearing shells for wear. [a] If worn, replace rod bearing shells. All information subject to change without notice. C -408 Copyright © DETROIT DIESEL CORPORATION...
  • Page 555 (groove mostly new) should be used for comparison. 7. The condition of the sputtered bearings is assessed in five groups: Continued use All information subject to change without notice. C -409 Copyright © DETROIT DIESEL CORPORATION...
  • Page 556 2. Running-in Layer (from 1µm — 3µm) 4. Protective Steel Shell Corresponds to Approximately 88% of Bearing Thickness Figure 302 Checking and Assessing Connecting Rod Bearing Shells All information subject to change without notice. C -410 Copyright © DETROIT DIESEL CORPORATION...
  • Page 557 Measuring Connecting Rod Cap Bolt 3. For maximum permissible shaft length, refer to section C 037.05.01. Storing Connecting Rod Perform the following steps to store connecting rod. All information subject to change without notice. C -411 Copyright © DETROIT DIESEL CORPORATION...
  • Page 558 See Figure 304. Figure 304 Cleaning Bearing Shell Mating Surfaces NOTE: New connecting rod bearing shells (1) must be installed as part of every W6 overhaul. All information subject to change without notice. C -412 Copyright © DETROIT DIESEL CORPORATION...
  • Page 559 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. C -413 Copyright © DETROIT DIESEL CORPORATION...
  • Page 560 12. Install connecting rod cap bolts until bolt heads make contact, and use socket wrench to tighten firmly. 13. Connecting rod and connecting rod cap serrations on short and long connecting rod arms must be closed. All information subject to change without notice. C -414 Copyright © DETROIT DIESEL CORPORATION...
  • Page 561 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. C -415 Copyright © DETROIT DIESEL CORPORATION...
  • Page 562 SERIES 4000 12/16V SERVICE MANUAL 1. Bore 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 [a] If worn or scored, machine bore to repair size or replace connecting rod. [b] If not worn or scored, continue procedure. 2. Before measuring, smooth big end bore (2) with emery cloth. All information subject to change without notice. C -417 Copyright © DETROIT DIESEL CORPORATION...
  • Page 564 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 change without notice. C -418 Copyright © DETROIT DIESEL CORPORATION...
  • Page 565 SERIES 4000 12/16V SERVICE MANUAL Figure 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. C -419 Copyright © DETROIT DIESEL CORPORATION...
  • Page 566 [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 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. C -421 Copyright © DETROIT DIESEL CORPORATION...

  • Page 568: C 037.05.10 Assembly Of Piston With Connecting Rod

    ASSEMBLY OF PISTON WITH 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 4. Stamp connecting rod bushing repair stage diameter on surface (B) of connecting rod bushing with 2 mm (.7874 in.) numeral punch and on surface (C) of connecting rod with 4 mm (.1574 in.) numeral punch. See Figure 314. All information subject to change without notice. C -423 Copyright © DETROIT DIESEL CORPORATION...
  • Page 570 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 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. C -425 Copyright © DETROIT DIESEL CORPORATION...
  • Page 572 [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 change without notice. C -426 Copyright © DETROIT DIESEL CORPORATION...
  • Page 573 1. Chrome 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. C -427 Copyright © DETROIT DIESEL CORPORATION...
  • Page 574 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 subject to change without notice. C -428 Copyright © DETROIT DIESEL CORPORATION...
  • Page 575 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. C -429 Copyright © DETROIT DIESEL CORPORATION...
  • Page 576 SERIES 4000 12/16V SERVICE 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: C 037.05.11 Installation Of Piston With Connecting Rod

    3. Clean crankpin and running surface of cylinder liner and spray with engine oil. Cylinder Liner without Carbon Scraper Ring Perform the following steps to install cylinder liner without carbon scraper ring. All information subject to change without notice. C -431 Copyright © DETROIT DIESEL CORPORATION...
  • Page 578 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 CORPORATION...
  • Page 579 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. C -433 Copyright © DETROIT DIESEL CORPORATION...
  • Page 580 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 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. C -435 Copyright © DETROIT DIESEL CORPORATION...
  • Page 582 (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 12. By hand, push bearing installation device (with 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. C -437 Copyright © DETROIT DIESEL CORPORATION...
  • Page 584 14. Position bearing shell half (1) 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 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. C -439 Copyright © DETROIT DIESEL CORPORATION...
  • Page 586 21. If the oil spray nozzle is damaged, remove spray nozzle and replace. NOTE: In order to guide the connecting rod and avoid damage to the oil spray nozzle, piston installation must be carried out by two people. All information subject to change without notice. C -440 Copyright © DETROIT DIESEL CORPORATION...
  • Page 587 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. C -441 Copyright © DETROIT DIESEL CORPORATION...
  • Page 588 24. 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 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. C -443 Copyright © DETROIT DIESEL CORPORATION...
  • Page 590 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 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 without notice. C -445 Copyright © DETROIT DIESEL CORPORATION...
  • Page 592 Installing Piston With Connecting Rod With Oil Pan Installed Perform the following steps to install the piston with connecting rod with oil pan installed. All information subject to change without notice. C -446 Copyright © DETROIT DIESEL CORPORATION...
  • Page 593 2. Check distance between crankshaft web and connecting rod or between connecting rod and connecting rod, pressed towards each other. 3. The above-stated components must touch each other. All information subject to change without notice. C -447 Copyright © DETROIT DIESEL CORPORATION...
  • Page 594 Refer to section Connecting Rod Axial Clearance in Turnover Stand. 2. Before installing, spray cylinder liner and carbon scraper ring (marine only) with engine oil. All information subject to change without notice. C -448 Copyright © DETROIT DIESEL CORPORATION...
  • Page 595 SERIES 4000 12/16V SERVICE 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. C -449 Copyright © DETROIT DIESEL CORPORATION...
  • Page 596 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 CORPORATION...
  • Page 597 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. C -451 Copyright © DETROIT DIESEL CORPORATION...
  • Page 598 [a] Absolute TDC is reached when the dial gage shows the same values before and after TDC at the same angle. [b] To eliminate bearing clearance, the piston must always move in direction of TDC. All information subject to change without notice. C -452 Copyright © DETROIT DIESEL CORPORATION...

  • Page 599: C 037.05.12 After-Installation Operations

    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 35 After — Installation Operations All information subject to change without notice. C -453 Copyright © DETROIT DIESEL CORPORATION...
  • Page 600 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -454 Copyright © DETROIT DIESEL CORPORATION...
  • Page 601 After-Installation Operations ....... C -513 All information subject to change without notice. C -455 Copyright © DETROIT DIESEL CORPORATION...
  • Page 602 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -456 Copyright © DETROIT DIESEL CORPORATION...
  • Page 603 After-Installation Operations ........C -513 All information subject to change without notice. C -457 Copyright © DETROIT DIESEL CORPORATION...
  • Page 604 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -458 Copyright © DETROIT DIESEL CORPORATION...
  • Page 605 See 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. C -459 Copyright © DETROIT DIESEL CORPORATION...
  • Page 606 SERIES 4000 12/16V SERVICE 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 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. C -461 Copyright © DETROIT DIESEL CORPORATION...
  • Page 608 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 © DETROIT DIESEL CORPORATION...
  • Page 609 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 37 Before-Removal Operations All information subject to change without notice. C -463 Copyright © DETROIT DIESEL CORPORATION...

  • Page 610: C 041.05.05 Removal Of 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 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. C -465 Copyright © DETROIT DIESEL CORPORATION...
  • Page 612 3. Remove cylinder head gasket (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 4. Using appropriate tools, carefully lever 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. C -467 Copyright © DETROIT DIESEL CORPORATION...

  • Page 614: C 041.05.06 Disassembly Of Cylinder Head

    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 3. Place pressure plate (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. C -469 Copyright © DETROIT DIESEL CORPORATION...
  • Page 616 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 8. Remove valve 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. C -471 Copyright © DETROIT DIESEL CORPORATION...
  • Page 618 SERIES 4000 12/16V SERVICE 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 11. Remove base 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. C -473 Copyright © DETROIT DIESEL CORPORATION...
  • Page 620 13. Place valves in 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 18. 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.)) All information subject to change without notice. C -475 Copyright © DETROIT DIESEL CORPORATION...
  • Page 622 [b] Reuse cylinder heads if bores are within specifications. 22. Place cylinder head on hydraulic press. See Figure 357. 1. Removal Brass Drift 2. Valve Guide Figure 357 Removing Valve Guides All information subject to change without notice. C -476 Copyright © DETROIT DIESEL CORPORATION...
  • Page 623 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 overheating. All information subject to change without notice. C -477 Copyright © DETROIT DIESEL CORPORATION...

  • Page 624: C 041.05.08 Inspection And Repair

    [b] If cylinder head interfaces are not damaged or uneven, continue inspection. NOTE: Surface quality (roughness height, shaft height) of cylinder head interfaces must be maintained. NOTE: Do not remove material below minimum permissible height. All information subject to change without notice. C -478 Copyright © DETROIT DIESEL CORPORATION...
  • Page 625 1. Check that thread and bolt head mating surfaces are in perfect condition. [a] If thread and bolt head mating surfaces are not in perfect condition, replace bolts as necessary. All information subject to change without notice. C -479 Copyright © DETROIT DIESEL CORPORATION...
  • Page 626 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 © DETROIT DIESEL CORPORATION...
  • Page 627 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 notice. C -481 Copyright © DETROIT DIESEL CORPORATION...
  • Page 628 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 necessary. All information subject to change without notice. C -482 Copyright © DETROIT DIESEL CORPORATION...
  • Page 629 [b] If no pitting is found, continue inspection. NOTE: Valve keyways must not be damaged and valve seats must not be burnt. 5. Inspect valves for concentricity and dimensional accuracy. All information subject to change without notice. C -483 Copyright © DETROIT DIESEL CORPORATION...
  • Page 630 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 information subject to change without notice. C -484 Copyright © DETROIT DIESEL CORPORATION...
  • Page 631 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. C -485 Copyright © DETROIT DIESEL CORPORATION...
  • Page 632 [a] If surface cracks or broken coils are found, replace valve springs as necessary. [b] If no surface cracks or broken coils are found, continue inspection. 2. Visually inspect valve springs for indentations, flatness, burring and deformation. All information subject to change without notice. C -486 Copyright © DETROIT DIESEL CORPORATION...
  • Page 633 [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 notice. C -487 Copyright © DETROIT DIESEL CORPORATION...
  • Page 634 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 CORPORATION...
  • Page 635 6. Remove pressure test tool. 7. Replace cap plug if leaking. NOTE: The water for pressure testing must be treated with anti-corrosive agent. All information subject to change without notice. C -489 Copyright © DETROIT DIESEL CORPORATION...

  • Page 636: C 041.05.10 Assembly Of Cylinder Head

    14.00 mm (0.550 – 0.551). Installing Valve Guides Perform the following steps to install valve guides: NOTE: The water for pressure testing must be treated with anti-corrosive agent. All information subject to change without notice. C -490 Copyright © DETROIT DIESEL CORPORATION...
  • Page 637 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 assembly plate. All information subject to change without notice. C -491 Copyright © DETROIT DIESEL CORPORATION...
  • Page 638 SERIES 4000 12/16V SERVICE MANUAL 5. Measure 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 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 without notice. C -493 Copyright © DETROIT DIESEL CORPORATION...
  • Page 640 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 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. C -495 Copyright © DETROIT DIESEL CORPORATION...
  • Page 642 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 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. C -497 Copyright © DETROIT DIESEL CORPORATION...
  • Page 644 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 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. C -499 Copyright © DETROIT DIESEL CORPORATION...
  • Page 646 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 11. Install valve spring retainers. 12. Install pressure plate on valve spring retainer and bolt to base plate. 13. Install manual spindle in valve spring tensioner. All information subject to change without notice. C -501 Copyright © DETROIT DIESEL CORPORATION...
  • Page 648 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 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. C -503 Copyright © DETROIT DIESEL CORPORATION...
  • Page 650 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 DIESEL CORPORATION...
  • Page 651 [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 subject to change without notice. C -505 Copyright © DETROIT DIESEL CORPORATION...

  • Page 652: C 041.05.11 Installation Of Cylinder Head

    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 © DETROIT DIESEL CORPORATION...
  • Page 653 (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. C -507 Copyright © DETROIT DIESEL CORPORATION...
  • Page 654 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 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. C -509 Copyright © DETROIT DIESEL CORPORATION...
  • Page 656 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 CORPORATION...
  • Page 657 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. C -511 Copyright © DETROIT DIESEL CORPORATION...
  • Page 658 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 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 38 After-Installation Operations All information subject to change without notice. C -513 Copyright © DETROIT DIESEL CORPORATION...
  • Page 660 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -514 Copyright © DETROIT DIESEL CORPORATION...
  • Page 661 General View ..........C -647 All information subject to change without notice. C -515 Copyright © DETROIT DIESEL CORPORATION...
  • Page 662 After-Installation Operations ....... C -653 All information subject to change without notice. C -516 Copyright © DETROIT DIESEL CORPORATION...
  • Page 663 After-Installation Operations ........C -550 All information subject to change without notice. C -517 Copyright © DETROIT DIESEL CORPORATION...
  • Page 664 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -518 Copyright © DETROIT DIESEL CORPORATION...
  • Page 665 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. C -519 Copyright © DETROIT DIESEL CORPORATION...
  • Page 666 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 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. C -521 Copyright © DETROIT DIESEL CORPORATION...
  • Page 668 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 C 037.05.05. 6. Separate electrical plug-in connection. All information subject to change without notice. C -522 Copyright © DETROIT DIESEL CORPORATION...
  • Page 669 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. C -523 Copyright © DETROIT DIESEL CORPORATION...
  • Page 670 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 SERIES 4000 12/16V SERVICE 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. C -525 Copyright © DETROIT DIESEL CORPORATION...
  • Page 672 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 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. C -527 Copyright © DETROIT DIESEL CORPORATION...
  • Page 674 8. Install camshaft guide (3) 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 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). All information subject to change without notice. C -529 Copyright © DETROIT DIESEL CORPORATION...
  • Page 676 DDC specifications or replace camshaft. NOTE: Ensure parts are perfectly clean. Checking Hardness of Cam and Journal Perform the following steps to check hardness of cam and journal: All information subject to change without notice. C -530 Copyright © DETROIT DIESEL CORPORATION...
  • Page 677 [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 change without notice. C -531 Copyright © DETROIT DIESEL CORPORATION...
  • Page 678 [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 notice. C -532 Copyright © DETROIT DIESEL CORPORATION...
  • Page 679 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. C -533 Copyright © DETROIT DIESEL CORPORATION...
  • Page 680 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 notice. C -534 Copyright © DETROIT DIESEL CORPORATION...
  • Page 681 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. C -535 Copyright © DETROIT DIESEL CORPORATION...
  • Page 682 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 The 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. C -537 Copyright © DETROIT DIESEL CORPORATION...
  • Page 684 SERIES 4000 12/16V SERVICE 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 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. C -539 Copyright © DETROIT DIESEL CORPORATION...
  • Page 686 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 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. C -541 Copyright © DETROIT DIESEL CORPORATION...
  • Page 688 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 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. C -543 Copyright © DETROIT DIESEL CORPORATION...
  • Page 690 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 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. C -545 Copyright © DETROIT DIESEL CORPORATION...
  • Page 692 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 [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. C -547 Copyright © DETROIT DIESEL CORPORATION...
  • Page 694 Perform the following steps to measure intake valve stroke: 1. Start from cylinder A1, turning cylinder A1 to firing TDC. 2. Release locknuts (arrows) and insert adjusting screws until there is no more play. All information subject to change without notice. C -548 Copyright © DETROIT DIESEL CORPORATION...
  • Page 695 [c] If readings are not outside limits, continue to next step. 11. Remove magnetic-base indicator holder with dial gage and TDC indicator. 12. Set valve clearance on cylinder A1. Refer to section C 051.05.11. All information subject to change without notice. C -549 Copyright © DETROIT DIESEL CORPORATION...

  • Page 696: After-Installation Operations

    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 After-Installation Operations ........C -573 All information subject to change without notice. C -551 Copyright © DETROIT DIESEL CORPORATION...
  • Page 698 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -552 Copyright © DETROIT DIESEL CORPORATION...
  • Page 699 See Figure 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. C -553 Copyright © DETROIT DIESEL CORPORATION...
  • Page 700 Listed in Table 42 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 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 43 Before-Removal Operations All information subject to change without notice. C -555 Copyright © DETROIT DIESEL CORPORATION...
  • Page 702 5. On DDEC engines, use a dial gage in the A1 cylinder kit to determine TDC. Refer to section C 037.05.05. 6. Separate electrical plug-in connection. All information subject to change without notice. C -556 Copyright © DETROIT DIESEL CORPORATION...
  • Page 703 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. C -557 Copyright © DETROIT DIESEL CORPORATION...
  • Page 704 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 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. C -559 Copyright © DETROIT DIESEL CORPORATION...
  • Page 706 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 4. Measure camshaft against limit values. [a] If limit values are exceeded, replace components as necessary. [b] If limit values are not exceeded, continue inspection. NOTE: Ensure parts are perfectly clean. All information subject to change without notice. C -561 Copyright © DETROIT DIESEL CORPORATION...
  • Page 708 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 709 The 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. C -563 Copyright © DETROIT DIESEL CORPORATION...
  • Page 710 SERIES 4000 12/16V SERVICE 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 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. C -565 Copyright © DETROIT DIESEL CORPORATION...
  • Page 712 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 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. C -567 Copyright © DETROIT DIESEL CORPORATION...
  • Page 714 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 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. C -569 Copyright © DETROIT DIESEL CORPORATION...
  • Page 716 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 717 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. C -571 Copyright © DETROIT DIESEL CORPORATION...
  • Page 718 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: Camshaft Drive

    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 44 After-Installation Operations All information subject to change without notice. C -573 Copyright © DETROIT DIESEL CORPORATION...
  • Page 720 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -574 Copyright © DETROIT DIESEL CORPORATION...
  • Page 721 After-Installation Operations ........C -597 All information subject to change without notice. C -575 Copyright © DETROIT DIESEL CORPORATION...
  • Page 722 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -576 Copyright © DETROIT DIESEL CORPORATION...

  • Page 723: General View

    See Figure 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. C -577 Copyright © DETROIT DIESEL CORPORATION...

  • Page 724: Special Tools

    Listed in Table 45 are 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: Before-Removal Operations

    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 46 Before-Removal Operations All information subject to change without notice. C -579 Copyright © DETROIT DIESEL CORPORATION...
  • Page 726 4. Remove valve drive. Refer to section C 055.05.05. 5. On DDEC engines, use a dial gage in the A1 cylinder kit to determine TDC. Refer to section C 037.05.05. All information subject to change without notice. C -580 Copyright © DETROIT DIESEL CORPORATION...
  • Page 727 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. C -581 Copyright © DETROIT DIESEL CORPORATION...
  • Page 728 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 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. C -583 Copyright © DETROIT DIESEL CORPORATION...
  • Page 730 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: Inspection And Repair

    6. Inspect thread of hex bolts for ease of movement. [a] If threads are damaged, replace bolts as necessary. [b] If no damage is found, continue inspection. NOTE: Make sure parts are perfectly clean. All information subject to change without notice. C -585 Copyright © DETROIT DIESEL CORPORATION...
  • Page 732 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 DIESEL CORPORATION...
  • Page 733 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. C -587 Copyright © DETROIT DIESEL CORPORATION...
  • Page 734 SERIES 4000 12/16V SERVICE 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 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. C -589 Copyright © DETROIT DIESEL CORPORATION...
  • Page 736 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 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. C -591 Copyright © DETROIT DIESEL CORPORATION...
  • Page 738 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 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. C -593 Copyright © DETROIT DIESEL CORPORATION...
  • Page 740 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 741 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. C -595 Copyright © DETROIT DIESEL CORPORATION...
  • Page 742 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: After-Installation Operations

    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 47 After-Installation Operations All information subject to change without notice. C -597 Copyright © DETROIT DIESEL CORPORATION...
  • Page 744 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -598 Copyright © DETROIT DIESEL CORPORATION...
  • Page 745 After-Installation Operations ........C -644 All information subject to change without notice. C -599 Copyright © DETROIT DIESEL CORPORATION...
  • Page 746 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -600 Copyright © DETROIT DIESEL CORPORATION...

  • Page 747: General View

    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. C -601 Copyright © DETROIT DIESEL CORPORATION...
  • Page 748 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 See Figure 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. C -603 Copyright © DETROIT DIESEL CORPORATION...
  • Page 750 SERIES 4000 12/16V 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: Special Tools

    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. C -605 Copyright © DETROIT DIESEL CORPORATION...

  • Page 752: Before-Removal Operations

    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 49 Before-Removal Operations All information subject to change without notice. C -606 Copyright © DETROIT DIESEL CORPORATION...
  • Page 753 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. C -607 Copyright © DETROIT DIESEL CORPORATION...
  • Page 754 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 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. C -609 Copyright © DETROIT DIESEL CORPORATION...
  • Page 756 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 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. C -611 Copyright © DETROIT DIESEL CORPORATION...
  • Page 758 4. Remove rocker arm (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 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. C -613 Copyright © DETROIT DIESEL CORPORATION...
  • Page 760 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 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. C -615 Copyright © DETROIT DIESEL CORPORATION...
  • Page 762 1. Use brass drift 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: C 055.05.08 Inspection And Repair

    [b] If tapers and adjusting bolt slots are not worn or damaged, continue inspection. 10. Inspect heads and seating surfaces of nuts for damage. [a] If heads or seating surfaces of nuts are damaged, replace as necessary. All information subject to change without notice. C -617 Copyright © DETROIT DIESEL CORPORATION...
  • Page 764 16. Ensure that all components are perfectly clean and that flow through lube oil bores is unobstructed. Measuring Diameter of Bushing Bore in Rocker Arm Perform the following steps to measure diameter of bushing bore in rocker arm: All information subject to change without notice. C -618 Copyright © DETROIT DIESEL CORPORATION...
  • Page 765 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 notice. C -619 Copyright © DETROIT DIESEL CORPORATION...
  • Page 766 [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 notice. C -620 Copyright © DETROIT DIESEL CORPORATION...
  • Page 767 [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. C -621 Copyright © DETROIT DIESEL CORPORATION...
  • Page 768 [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 CORPORATION...
  • Page 769 [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. C -623 Copyright © DETROIT DIESEL CORPORATION...

  • Page 770: Assembly Of Rocker Arm Assembly

    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 without notice. C -624 Copyright © DETROIT DIESEL CORPORATION...
  • Page 771 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. C -625 Copyright © DETROIT DIESEL CORPORATION...
  • Page 772 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 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. C -627 Copyright © DETROIT DIESEL CORPORATION...
  • Page 774 5. Swing Arm 3. Brass Drift Figure 474 Inserting Pin and Roller 4. Heat swing arm to approximately 100 5. Insert roller (1) in swing arm (5). All information subject to change without notice. C -628 Copyright © DETROIT DIESEL CORPORATION...
  • Page 775 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. C -629 Copyright © DETROIT DIESEL CORPORATION...
  • Page 776 Inserting Rocker Arm Bushing 2. Heat rocker arm to approximately 200 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: C 055.05.11 Installation Of Valve Drive

    2. Secure valve bridge (1) in vice with aluminum jaws, release locknut and back off adjusting bolt by approximately 3 revolutions. 3. Ensure oil bore is perfectly clean. All information subject to change without notice. C -631 Copyright © DETROIT DIESEL CORPORATION...
  • Page 778 8. With valve bridge pressed down, install adjusting bolt (1) with Allen wrench (3) until adjusting bolt slightly contacts valve stem and a pressure point is noticeable. All information subject to change without notice. C -632 Copyright © DETROIT DIESEL CORPORATION...
  • Page 779 19. Match swing arms to left and right cylinder banks; carefully insert into camshaft chamber. 20. Screw in hex bolts (1) and tighten to specified torque. Refer to section A 003. All information subject to change without notice. C -633 Copyright © DETROIT DIESEL CORPORATION...
  • Page 780 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 SERIES 4000 12/16V SERVICE 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. C -635 Copyright © DETROIT DIESEL CORPORATION...
  • Page 782 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 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. C -637 Copyright © DETROIT DIESEL CORPORATION...
  • Page 784 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: All information subject to change without notice. C -638 Copyright © DETROIT DIESEL CORPORATION...
  • Page 785 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 notice. C -639 Copyright © DETROIT DIESEL CORPORATION...
  • Page 786 7. Tighten locknut with torque wrench to specification, holding valve bridge firmly in place with open-end wrench.Refer to section A 003. NOTE: Use engine oil as lubricant. All information subject to change without notice. C -640 Copyright © DETROIT DIESEL CORPORATION...
  • Page 787 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 subject to change without notice. C -641 Copyright © DETROIT DIESEL CORPORATION...
  • Page 788 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 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. C -643 Copyright © DETROIT DIESEL CORPORATION...

  • Page 790: After-Installation Operations

    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 50 After-Installation Operations All information subject to change without notice. C -644 Copyright © DETROIT DIESEL CORPORATION...

  • Page 791: Cylinder Head Cover

    After-Installation Operations ........C -653 All information subject to change without notice. C -645 Copyright © DETROIT DIESEL CORPORATION...
  • Page 792 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -646 Copyright © DETROIT DIESEL CORPORATION...

  • Page 793: General View

    See Figure 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. C -647 Copyright © DETROIT DIESEL CORPORATION...

  • Page 794: Special Tools

    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: C 056.05.04 Before-Removal Operations

    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. C -649 Copyright © DETROIT DIESEL CORPORATION...

  • Page 796: Removal Of The Rocker Cover

    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: C 056.05.08 Inspection And Repair

    4. Inspect threads of hex bolts for ease of movement. [a] If hex bolts do not move easily, replace as necessary. [b] If hex bolts move easily, continue inspection. 5. Replace gaskets during W6 maintenance. All information subject to change without notice. C -651 Copyright © DETROIT DIESEL CORPORATION...

  • Page 798: Installation Of The Rocker Cover

    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 engine start. All information subject to change without notice. C -652 Copyright © DETROIT DIESEL CORPORATION...
  • Page 799 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. C -653 Copyright © DETROIT DIESEL CORPORATION...
  • Page 800 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -654 Copyright © DETROIT DIESEL CORPORATION...
  • Page 801 After-Installation Operations ....... C -776 All information subject to change without notice. C -655 Copyright © DETROIT DIESEL CORPORATION...
  • Page 802 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -656 Copyright © DETROIT DIESEL CORPORATION...

  • Page 803: High-Pressure Fuel Pump

    Fuel that spills from the injectors flows through the return rails back to the fuel junction block to the fuel tank by a single return line. See Figure 492. All information subject to change without notice. C -657 Copyright © DETROIT DIESEL CORPORATION...
  • 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 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. C -659 Copyright © DETROIT DIESEL CORPORATION...
  • Page 806 SERIES 4000 12/16V SERVICE MANUAL 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 4. Inlet 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. C -661 Copyright © DETROIT DIESEL CORPORATION...
  • Page 808 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -662 Copyright © DETROIT DIESEL CORPORATION...
  • Page 809 After-Installation Operations ........C -685 All information subject to change without notice. C -663 Copyright © DETROIT DIESEL CORPORATION...
  • Page 810 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -664 Copyright © DETROIT DIESEL CORPORATION...

  • Page 811: General View

    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. C -665 Copyright © DETROIT DIESEL CORPORATION...
  • Page 812 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: Special Tools

    SERIES 4000 12/16V SERVICE MANUAL C 073.05.02 – SPECIAL TOOLS Not applicable. All information subject to change without notice. C -667 Copyright © DETROIT DIESEL CORPORATION...

  • Page 814: Before-Removal Operations

    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 54 Before-Removal Operations All information subject to change without notice. C -668 Copyright © DETROIT DIESEL CORPORATION...

  • Page 815: Removal Of The High-Pressure Fuel Pump

    Perform maintenance in a well ventilated work area with access to a fire extinguisher. 1. Disconnect DDEC Harness connection for solenoid controller at connection. See Figure 497. All information subject to change without notice. C -669 Copyright © DETROIT DIESEL CORPORATION...
  • Page 816 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 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. C -671 Copyright © DETROIT DIESEL CORPORATION...
  • Page 818 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 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. C -673 Copyright © DETROIT DIESEL CORPORATION...
  • Page 820 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: Disassembly Of The High-Pressure Fuel Pump

    C 073.05.06 – DISASSEMBLY OF THE HIGH-PRESSURE 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.

  • Page 822: Inspection And Repair

    [a] If weep hole is contaminated with oil and fuel discharge, clean as necessary. [b] If oil or fuel emerges from weep hole, replace high-pressure pump. All information subject to change without notice. C -676 Copyright © DETROIT DIESEL CORPORATION...
  • Page 823 [c] If weep hole is not 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. C -677 Copyright © DETROIT DIESEL CORPORATION...

  • Page 824: 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 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. C -679 Copyright © DETROIT DIESEL CORPORATION...
  • Page 826 4. Clean and check 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 SERIES 4000 12/16V SERVICE MANUAL 5. Carefully 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. C -681 Copyright © DETROIT DIESEL CORPORATION...
  • Page 828 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 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. C -683 Copyright © DETROIT DIESEL CORPORATION...
  • Page 830 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 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 55 After-Installation Operations All information subject to change without notice. C -685 Copyright © DETROIT DIESEL CORPORATION...
  • Page 832 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -686 Copyright © DETROIT DIESEL CORPORATION...

  • Page 833: C 073.05 M

    After-Installation Operations ........C -706 All information subject to change without notice. C -687 Copyright © DETROIT DIESEL CORPORATION...
  • Page 834 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -688 Copyright © DETROIT DIESEL CORPORATION...
  • Page 835 For an overview of the marine 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. C -689 Copyright © DETROIT DIESEL CORPORATION...

  • Page 836: C 073.05.04 M Before-Removal Operations

    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 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. C -691 Copyright © DETROIT DIESEL CORPORATION...
  • Page 838 (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 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. C -693 Copyright © DETROIT DIESEL CORPORATION...
  • Page 840 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 SERIES 4000 12/16V SERVICE MANUAL 6. 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. C -695 Copyright © DETROIT DIESEL CORPORATION...
  • Page 842 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 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. C -697 Copyright © DETROIT DIESEL CORPORATION...

  • Page 844: C 073.05.08 M Inspection And Repair

    [a] If wiring is worn or damaged, replace as necessary. [b] If wiring is not worn or damaged, continue inspection. 5. Replace O-ring after each removal. All information subject to change without notice. C -698 Copyright © DETROIT DIESEL CORPORATION...
  • Page 845 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. C -699 Copyright © DETROIT DIESEL CORPORATION...
  • Page 846 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 SERIES 4000 12/16V SERVICE MANUAL 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. C -701 Copyright © DETROIT DIESEL CORPORATION...
  • Page 848 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 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. C -703 Copyright © DETROIT DIESEL CORPORATION...
  • Page 850 (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 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. C -705 Copyright © DETROIT DIESEL CORPORATION...

  • Page 852: C 073.05.12 M After-Installation Operations

    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 CORPORATION...

  • Page 853: Injector

    After-Installation Operations ........C -728 All information subject to change without notice. C -707 Copyright © DETROIT DIESEL CORPORATION...
  • Page 854 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -708 Copyright © DETROIT DIESEL CORPORATION...

  • Page 855: General 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. C -709 Copyright © DETROIT DIESEL CORPORATION...

  • Page 856: Special Tools

    Listed in Table 58 are the 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: Before-Removal Operations

    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. C -711 Copyright © DETROIT DIESEL CORPORATION...
  • Page 858 7. Loosen DDEC injector harness terminal bolts on injector and remove DDEC injector harness terminals (arrows). See Figure 526. Figure 526 Removing DDEC Injector Harness Terminals All information subject to change without notice. C -712 Copyright © DETROIT DIESEL CORPORATION...
  • Page 859 8. Use a torque wrench 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. C -713 Copyright © DETROIT DIESEL CORPORATION...
  • Page 860 9. Install injector 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 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. C -715 Copyright © DETROIT DIESEL CORPORATION...
  • Page 862 SERIES 4000 12/16V SERVICE 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 [a] If injector hole tube is worn or damaged, replace as necessary. [b] If injector hole tube is not worn or damaged, continue inspection. 8. Replace C-E rings and O-rings at every assembly. All information subject to change without notice. C -717 Copyright © DETROIT DIESEL CORPORATION...
  • Page 864 SERIES 4000 12/16V SERVICE 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 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. C -719 Copyright © DETROIT DIESEL CORPORATION...
  • Page 866 2. 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 [a] Clean sealing surface on cylinder head or hole tube if necessary. [b] If sealing surface on cylinder head or hole tube does not require cleaning, continue inspection. All information subject to change without notice. C -721 Copyright © DETROIT DIESEL CORPORATION...
  • Page 868 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 Copyright © DETROIT DIESEL CORPORATION...
  • Page 869 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 seating area for proper installation. All information subject to change without notice. C -723 Copyright © DETROIT DIESEL CORPORATION...
  • Page 870 13. Tighten bolt of injector hold-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 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. C -725 Copyright © DETROIT DIESEL CORPORATION...
  • Page 872 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 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. C -727 Copyright © DETROIT DIESEL CORPORATION...
  • Page 874 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 notice. C -728 Copyright © DETROIT DIESEL CORPORATION...
  • Page 875 After-Installation Operations ........C -776 All information subject to change without notice. C -729 Copyright © DETROIT DIESEL CORPORATION...
  • Page 876 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -730 Copyright © DETROIT DIESEL CORPORATION...
  • Page 877 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. C -731 Copyright © DETROIT DIESEL CORPORATION...
  • Page 878 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 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. C -733 Copyright © DETROIT DIESEL CORPORATION...
  • Page 880 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 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. C -735 Copyright © DETROIT DIESEL CORPORATION...
  • Page 882 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 subject to change without notice. C -736 Copyright © DETROIT DIESEL CORPORATION...

  • Page 883: Removal Of The High-Pressure Fuel Rails

    SERIES 4000 12/16V SERVICE 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. C -737 Copyright © DETROIT DIESEL CORPORATION...
  • Page 884 Figure 542 Removing High-Pressure Line Between High-Pressure Pump and High-Pressure Rail 3. Unscrew and remove high-pressure line (1), “B” bank, on high-pressure pump and high-pressure rail. All information subject to change without notice. C -738 Copyright © DETROIT DIESEL CORPORATION...
  • Page 885 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. C -739 Copyright © DETROIT DIESEL CORPORATION...
  • Page 886 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 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. C -741 Copyright © DETROIT DIESEL CORPORATION...
  • Page 888 7. Loosen high-pressure fuel jumper lines at the 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 (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. C -743 Copyright © DETROIT DIESEL CORPORATION...
  • Page 890 10. Remove flow limiting 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 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. C -745 Copyright © DETROIT DIESEL CORPORATION...
  • Page 892 1. To 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 SERIES 4000 12/16V SERVICE 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. C -747 Copyright © DETROIT DIESEL CORPORATION...
  • Page 894 SERIES 4000 12/16V SERVICE 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 SERIES 4000 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. C -749 Copyright © DETROIT DIESEL CORPORATION...
  • Page 896 8. Ensure that high-pressure lines and high-pressure rail are perfectly clean. NOTE: Do not bend the injection line. 9. Replace sealing rings and O-rings at every assembly. All information subject to change without notice. C -750 Copyright © DETROIT DIESEL CORPORATION...

  • Page 897: C 077.05.10 Assembly Of The High-Pressure Rails

    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. C -751 Copyright © DETROIT DIESEL CORPORATION...
  • Page 898 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 4. Coat O-ring with petroleum jelly 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. C -753 Copyright © DETROIT DIESEL CORPORATION...
  • Page 900 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 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. C -755 Copyright © DETROIT DIESEL CORPORATION...
  • Page 902 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: C 077.05.11 Installation Of The High-Pressure Rails

    4. To secure connector on cylinder block, install hex bolts in first and last connector on each engine side. 5. Tighten to specification. Refer to section A 003. All information subject to change without notice. C -757 Copyright © DETROIT DIESEL CORPORATION...
  • Page 904 6. Carefully insert high-pressure rail in pre-assembled 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 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. C -759 Copyright © DETROIT DIESEL CORPORATION...
  • Page 906 10. Install flow limiting valve (1) in outlet 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 11. Pretighten all injectors, 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. C -761 Copyright © DETROIT DIESEL CORPORATION...
  • Page 908 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 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. C -763 Copyright © DETROIT DIESEL CORPORATION...
  • Page 910 SERIES 4000 12/16V SERVICE MANUAL 16. Tighten 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 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. C -765 Copyright © DETROIT DIESEL CORPORATION...
  • Page 912 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 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 change without notice. C -767 Copyright © DETROIT DIESEL CORPORATION...
  • Page 914 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 27. Tighten all hex bolts 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. C -769 Copyright © DETROIT DIESEL CORPORATION...
  • Page 916 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 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. C -771 Copyright © DETROIT DIESEL CORPORATION...
  • Page 918 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 35. Install pipe clamp 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. C -773 Copyright © DETROIT DIESEL CORPORATION...
  • Page 920 276 kPa (40 lb/in. ) 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 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. C -775 Copyright © DETROIT DIESEL CORPORATION...

  • Page 922: After-Installation Operations

    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 63 After-Installation Operations All information subject to change without notice. C -776 Copyright © DETROIT DIESEL CORPORATION...
  • Page 923 After-Installation Operations ....... C -839 All information subject to change without notice. C -777 Copyright © DETROIT DIESEL CORPORATION...
  • Page 924 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -778 Copyright © DETROIT DIESEL CORPORATION...
  • Page 925 After-Installation Operations ........C -790 All information subject to change without notice. C -779 Copyright © DETROIT DIESEL CORPORATION...
  • Page 926 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -780 Copyright © DETROIT DIESEL CORPORATION...
  • Page 927 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. C -781 Copyright © DETROIT DIESEL CORPORATION...
  • Page 928 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 notice. C -782 Copyright © DETROIT DIESEL CORPORATION...
  • Page 929 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. C -783 Copyright © DETROIT DIESEL CORPORATION...
  • Page 930 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 SERIES 4000 12/16V SERVICE MANUAL C 081.05.06 – 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. C -785 Copyright © DETROIT DIESEL CORPORATION...
  • Page 932 [a] If pump shaft driver is worn, rub down with an emery cloth or oilstone. [b] If damage is beyond repair; replace pump shaft driver. [c] If pump shaft driver is not worn, continue inspection. All information subject to change without notice. C -786 Copyright © DETROIT DIESEL CORPORATION...
  • Page 933 SERIES 4000 12/16V SERVICE MANUAL C 081.05.10 – 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. C -787 Copyright © DETROIT DIESEL CORPORATION...
  • Page 934 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 CORPORATION...
  • Page 935 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. C -789 Copyright © DETROIT DIESEL CORPORATION...
  • Page 936 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 After-Installation Operations ........C -810 All information subject to change without notice. C -791 Copyright © DETROIT DIESEL CORPORATION...
  • 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. C -793 Copyright © DETROIT DIESEL CORPORATION...
  • Page 940 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 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. C -795 Copyright © DETROIT DIESEL CORPORATION...
  • Page 942 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. All information subject to change without notice. C -796 Copyright © DETROIT DIESEL CORPORATION...
  • Page 943 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. C -797 Copyright © DETROIT DIESEL CORPORATION...
  • Page 944 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 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. C -799 Copyright © DETROIT DIESEL CORPORATION...
  • Page 946 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 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. C -801 Copyright © DETROIT DIESEL CORPORATION...
  • Page 948 [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 without notice. C -802 Copyright © DETROIT DIESEL CORPORATION...
  • Page 949 [a] If sealing and mating surfaces are damaged or defective, rub down with oilstone as necessary. [b] If sealing and mating surfaces are not damaged or defective, continue inspection. All information subject to change without notice. C -803 Copyright © DETROIT DIESEL CORPORATION...
  • Page 950 [a] 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 6. Coat O-rings (5) with petroleum jelly, and install in filter head (1). 7. Coat O-ring (4) with petroleum jelly, and install in the groove at the junction block. All information subject to change without notice. C -805 Copyright © DETROIT DIESEL CORPORATION...
  • Page 952 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 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. C -807 Copyright © DETROIT DIESEL CORPORATION...
  • Page 954 6. Install 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 SERIES 4000 12/16V SERVICE MANUAL 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. C -809 Copyright © DETROIT DIESEL CORPORATION...
  • Page 956 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 without notice. C -810 Copyright © DETROIT DIESEL CORPORATION...
  • Page 957 After-Installation Operations ........C -820 All information subject to change without notice. C -811 Copyright © DETROIT DIESEL CORPORATION...
  • Page 958 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -812 Copyright © DETROIT DIESEL CORPORATION...
  • Page 959 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. C -813 Copyright © DETROIT DIESEL CORPORATION...
  • Page 960 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 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. C -815 Copyright © DETROIT DIESEL CORPORATION...
  • Page 962 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 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 notice. C -817 Copyright © DETROIT DIESEL CORPORATION...
  • Page 964 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 © DETROIT DIESEL CORPORATION...
  • Page 965 7. 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. C -819 Copyright © DETROIT DIESEL CORPORATION...
  • Page 966 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 After-Installation Operations ........C -839 All information subject to change without notice. C -821 Copyright © DETROIT DIESEL CORPORATION...
  • Page 968 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -822 Copyright © DETROIT DIESEL CORPORATION...
  • Page 969 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. C -823 Copyright © DETROIT DIESEL CORPORATION...
  • 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 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 notice. C -825 Copyright © DETROIT DIESEL CORPORATION...
  • Page 972 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 information subject to change without notice. C -826 Copyright © DETROIT DIESEL CORPORATION...
  • 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. C -827 Copyright © DETROIT DIESEL CORPORATION...
  • Page 974 4. Remove fuel 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 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. C -829 Copyright © DETROIT DIESEL CORPORATION...
  • Page 976 8. Remove fuel return line (1) on high-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 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. C -831 Copyright © DETROIT DIESEL CORPORATION...
  • Page 978 SERIES 4000 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 [b] If damage is too extensive, replace parts as necessary. [c] If sealing and mating surfaces are not damaged or defective, continue inspection. 9. Replace sealing rings. All information subject to change without notice. C -833 Copyright © DETROIT DIESEL CORPORATION...
  • Page 980 SERIES 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 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 halves (1). See Figure 612. All information subject to change without notice. C -835 Copyright © DETROIT DIESEL CORPORATION...
  • Page 982 5. Install fuel return line (1) to return rail 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 6. Install the T-piece (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. C -837 Copyright © DETROIT DIESEL CORPORATION...
  • Page 984 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 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. C -839 Copyright © DETROIT DIESEL CORPORATION...
  • Page 986 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -840 Copyright © DETROIT DIESEL CORPORATION...
  • Page 987 After – Installation Operations (Marine) ....C -913 All information subject to change without notice. C -841 Copyright © DETROIT DIESEL CORPORATION...
  • Page 988 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -842 Copyright © DETROIT DIESEL CORPORATION...
  • Page 989 After-Installation Operations ........C -856 All information subject to change without notice. C -843 Copyright © DETROIT DIESEL CORPORATION...
  • Page 990 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -844 Copyright © DETROIT DIESEL CORPORATION...
  • Page 991 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. C -845 Copyright © DETROIT DIESEL CORPORATION...
  • Page 992 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 72 Before-Removal Operations All information subject to change without notice. C -846 Copyright © DETROIT DIESEL CORPORATION...
  • Page 993 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. C -847 Copyright © DETROIT DIESEL CORPORATION...
  • Page 994 See Figure 618. 1. Hex Nut 3. Exhaust Outlet (Y-pipe) 2. Washer 4. Bracket Figure 618 Removing Hex Bolt and Washer from Exhaust Outlet (Y-pipe) and Bracket All information subject to change without notice. C -848 Copyright © DETROIT DIESEL CORPORATION...
  • 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. C -849 Copyright © DETROIT DIESEL CORPORATION...
  • Page 996 SERIES 4000 12/16V SERVICE 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 [b] If threads show ease of movement, continue inspection. 7. Always replace nuts securing turbocharger, sealing rings and gaskets. 8. Major overhaul of turbocharger is scheduled during W6 maintenance. All information subject to change without notice. C -851 Copyright © DETROIT DIESEL CORPORATION...
  • 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 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. C -853 Copyright © DETROIT DIESEL CORPORATION...
  • Page 1000 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 © DETROIT DIESEL CORPORATION...
  • Page 1001 6. Install spacer bushings (3) and nuts. 7. Tighten hex nuts (2) on the turbocharger flange diagonally and evenly to specification. Refer to section A 003 . All information subject to change without notice. C -855 Copyright © DETROIT DIESEL CORPORATION...
  • Page 1002 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 73 After-Installation Operations All information subject to change without notice. C -856 Copyright © DETROIT DIESEL CORPORATION...
  • Page 1003 SERIES 4000 12/16V SERVICE MANUAL All information subject to change without notice. C -857 Copyright © DETROIT DIESEL CORPORATION...

Table of Contents

Save PDF