Detroit Diesel 16 V 4000 E20 Workshop Manual

Detroit Diesel 16 V 4000 E20 Workshop Manual

Detroit Diesel 16 V 4000 E20 Index:

• Title
• Table of Contents
• 1 General
  • 1.1 Important Information
    • 1.1.1 Reman assemblies – Prerequisites for maintenance tasks and general assembly instructions
      • REMAN assemblies
      • The following assemblies are only available through the exchange procedure
      • Requirements for maintenance tasks
      • General assembly instructions
      • Information on installation of Flexmaster pipe connection
  • 1.2 General Provisions
    • 1.2.1 General Instructions
      • General
      • Correct use
      • Modifications or conversions
      • Spare parts
      • Reworking components
    • 1.2.2 Personnel and organizational requirements
      • Personnel requirements
      • Organizational measures
      • Working clothes and protective equipment
    • 1.2.3 Safety precautions when working on the engine
      • Safety precautions when putting the equipment into operation
      • Safety requirements for operators
      • Engine operation
      • Maintenance and repair
      • Welding work
      • Hydraulic installation and removal
      • Working on electrical/electronic assemblies
      • Working with laser equipment
      • Operation of electrical equipment
    • 1.2.4 Auxiliary materials, fire prevention and environmental protection
      • Fire prevention
      • Noise
      • Environmental protection
      • Auxiliary materials
      • Lead
      • Acids and alkaline solutions
      • Painting
      • Liquid nitrogen
      • Compressed air
      • Used oil
    • 1.2.5 Standards for warning notices in the publication
    • 1.2.6 General information regarding the Tolerances and Wear Limits List
      • The tolerances and wear limits are intended as a guide for the examination of engine componentsas well as for engine inspection and repair.
    • 1.2.7 Engine side and cylinder designations
    • 1.2.8 Torque specifications for screws, nuts and bolts
      • Crankcase
      • Crank drive
      • Cylinder head
      • Valve gear
      • Fuel system – High-pressure
      • Exhaust turbocharger
      • Exhaust pipework
      • Starter
      • Lube oil system
      • Battery-charging generator
      • Auxiliary PTO
      • Monitoring, control and regulation devices
      • Tightening torques for setscrew and stud connections to works standard MTN 5008
      • When tightening mechanically, the permitted assembly tolerance is +15 %.
      • Tightening torques for stress bolt connections prescribed in standard MTN 5007
      • Tightening torques for plug screws as per MTN 5183-1 standard
      • Tightening torques for plug screws as per DIN 7604C (with long screwed plug)
      • Tightening torques for banjo screws as per MTN 5183-2 standard
      • Tightening torques for banjo screws made of steel
      • Tightening torques for banjo screws made of copper/aluminum alloys
      • Tightening torques for male connector as per MTN 5183-3 standard
      • Tightening torques for union nuts on screwed plugs ISO 6149-3
    • 1.2.9 Settings
      • Firing order for Series 4000 engines
      • Direction of rotation, viewed towards driving end
      • Valve clearance, engine cold (20 °C)
      • Valve timing with valve clearance adjusted
      • Cam and valve lift for camshaft adjustment
    • 1.2.10 Conversion tables
      • Length
      • Area
      • Volume
      • Speed
      • Mass
      • Force
      • Density
      • Torque
      • Pressure
      • Mass moment, 2nd grade
      • Energy
      • Power
      • Temperature
      • Fuel consumption
    • 1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil)
    • 1.2.12 Abbreviations
• 2 Task Schedules
  • 2.1 Engine – Checking condition before a major overhaul
  • 2.2 Preface
    • MTU maintenance concept
    • Notes on maintenance
    • Out-of-service periods
    • Application group
    • Load profile
    • Load profile table
  • 2.3 Maintenance schedule matrix
    • 0-10,500 Operating hours
    • 11,000-15,000 Operating hours
  • 2.4 Activities
  • 2.5 Engine – Removal
  • 2.6 Engine – Disassembly
  • 2.7 Engine – Assembly
  • 2.8 Engine – Installation
  • 2.9 Engine – Run-in procedure
    • Running in engine after replacing parts
    • Adjust engine operational data
  • 2.10 Putting the engine into operation
• 3 Job Descriptions
  • 3.1 Engine Casing and Add-on Components
    • 3.1.1 Engine layout
      • Illustration applies analogously to 8/12/16 V 4000 G, C and R
    • 3.1.2 Crankcase and attachments – Overview
      • Crankcase and attachments – Overview
    • 3.1.3 Crankcase – Overview
      • Crankcase with cover
      • Crankcase
      • Inspection port cover
      • Oil dipstick with guide tube
      • Oil filler neck
    • 3.1.4 Crankcase – Disassembly
    • 3.1.5 Crankcase – Cleaning
    • 3.1.6 Crankcase – Check
    • 3.1.7 Crankcase – Tolerances
      • Crankcase bore for crankshaft
      • Crankcase bore for camshaft
      • Crankcase bore for cylinder liner
      • Crankshaft bearing cap
      • Main bearing bore
      • Crankcase crankshaft bore coaxiality
      • Crankcase camshaft bore coaxiality
    • 3.1.8 Crankcase – Assembly
    • 3.1.9 Cylinder liner – Overview
      • Overview of cylinder liner with scraper ring
      • Cylinder liner with scraper ring in crankcase
    • 3.1.10 Cylinder liner – Removal
    • 3.1.11 Cylinder liner – Cleaning
    • 3.1.12 Cylinder liner – Check
    • 3.1.13 Cylinder liners – Tolerances
      • Reconditioning instructions:
    • 3.1.14 Cylinder liner – Installation
    • 3.1.15 Oil pan – Overview
      • Oil pan (shallow and deep version)
      • Oil pan with suction basket
      • View from free end
    • 3.1.16 Oil pan – Removal
    • 3.1.17 Oil pan – Cleaning
    • 3.1.18 Oil pan – Check
    • 3.1.19 Oil pan – Installation
    • 3.1.20 Oil pan – Tightening sequence for oil pans made of aluminium billet and aluminium castings
      • All applications with 4 engine mounting brackets
      • All applications with 2 engine mounting brackets or without engine mounting brackets
      • Oil pan screw joints
    • 3.1.21 Engine lifting equipment – Overview
      • Overview
      • Engine lifting equipment
    • 3.1.22 Engine lifting equipment – Removal
    • 3.1.23 Engine lifting equipment – Cleaning
    • 3.1.24 Engine lifting equipment – Check
    • 3.1.25 Engine suspension – Installation
    • 3.1.26 End housing driving end – Overview
      • End housing with externally mounted components
      • Guide bushing arrangement for end housing installation and removal
    • 3.1.27 End housing, driving end – Removal
    • 3.1.28 End housing, driving end – Dismantling
    • 3.1.29 End housing, driving end – Cleaning
    • 3.1.30 End housing, driving end – Check
    • 3.1.31 End housing driving end – Tolerances
    • 3.1.32 End housing, driving end – Assembly
    • 3.1.33 End housing, driving end – Installation
    • 3.1.34 Crankcase ventilation – Overview
      • Crankcase ventilation, free end, variant A
      • Crankcase ventilation, driving end, variant A
      • Crankcase ventilation variant B
    • 3.1.35 Crankcase ventilation – Removal
    • 3.1.36 Crankcase breather – Cleaning
    • 3.1.37 Oil separator – Check
    • 3.1.38 Oil separator – Disassembly
    • 3.1.39 Oil separator – Assembly
    • 3.1.40 Crankcase ventilation – Installation
  • 3.2 Gear Train
    • 3.2.1 Gearcase, free end – Overview
      • Arrangement of alignment tool for equipment carrier and equipment carrier cover
    • 3.2.2 Gearcase, free end – Removal
    • 3.2.3 Gearcase, free end – Disassembly
    • 3.2.4 Gearcase, free end – Cleaning
    • 3.2.5 Gearcase, free end – Check
    • 3.2.6 Gearcase, free end – Tolerances
      • Crankshaft bearing, free end, 8/12/16V
      • Crankshaft bearing, free end, 20V
    • 3.2.7 Gearcase, free end – Assembly
    • 3.2.8 Gearcase, free end – Installation
    • 3.2.9 Gear train, free end – Overview
      • 3.2.10 Gear train, free end – Removal
    • 3.2.11 Gear train, free end – Cleaning
    • 3.2.12 Gear train, free end – Check
    • 3.2.13 Gear train, free end – Tolerances
    • 3.2.14 Gear train, free end – Installation
    • 3.2.15 Bearing bush – Removal and installation
  • 3.3 Crank Drive
    • 3.3.1 Running gear – Overview
      • Running gear
    • 3.3.2 Crankshaft overview
      • Crankshaft, detail
      • Crankshaft
      • Crankshaft with bearing
    • 3.3.3 Crankshaft – Removal
    • 3.3.4 Crankshaft – Disassembly
    • 3.3.5 Crankshaft – Cleaning
    • 3.3.6 Crankshaft – Check
    • 3.3.7 Crankshaft – Tolerances
      • Crankshaft bearing shell
      • Conrod bearings
      • Crankshaft bearing – expansion dimension
      • Crankshaft axial play
      • Crankshaft bearing shells
      • Crankshaft gear, free end
      • Main bearing journal concentricity
    • 3.3.8 Crankshaft – Assembly
    • 3.3.9 Crankshaft – Balancing
    • 3.3.10 Main bearing shells – Check
      • Checking main bearing shells
      • Main bearing shells (grooved bearing), upper half
      • Assessment
      • Main bearing shell (sputtered bearing), lower half
      • Assessment
      • Damage to bearing
    • 3.3.11 Main bearing bore – Check
    • 3.3.12 Crankshaft – Installation
    • 3.3.13 PTO flange, driving end, flywheel – Overview
      • Layout for installation/removal jig for flywheel
    • 3.3.14 PTO flange, driving end, flywheel – Removal
    • 3.3.15 Radial-lip shaft seal, driving end – Removal
    • 3.3.16 PTO flange, driving end, flywheel – Cleaning
    • 3.3.17 PTO flange, driving end – Flywheel check
    • 3.3.18 Radial-lip shaft seal, driving end – Installation
    • 3.3.19 PTO flange, driving end, flywheel – Installation
    • 3.3.20 Crankshaft PTO, free end – Overview
      • Arrangement of drive flange installation/removal tool
    • 3.3.21 Vibration damper on PTO, free end – Removal
    • 3.3.22 Vibration damper on PTO, free end – Disassembly
      • Vibration damper – Disassembly
    • 3.3.23 Vibration damper on PTO, free end – Cleaning
    • 3.3.24 Vibration damper on PTO, free end – Check
    • 3.3.25 Vibration damper on PTO, free end – Tolerances
    • 3.3.26 Vibration damper on PTO, free end – Installation
    • 3.3.27 Pistons and conrods – Overview
      • Pistons and conrods
      • Piston details
    • 3.3.28 Piston and conrod – Removal
    • 3.3.29 Piston and conrod – Disassembly
    • 3.3.30 Piston – Cleaning
    • 3.3.31 Piston – Check
    • 3.3.32 Piston – Tolerances
      • Piston bearing
      • Piston rings
      • Piston clearance in cylinder liner
      • Piston crown mounting
    • 3.3.33 Conrod – Disassembly
    • 3.3.34 Conrod – Cleaning
    • 3.3.35 Conrod – Check
    • 3.3.36 Conrod – Tolerances
      • Conrod bearings
      • Conrod bearing, locating pin
      • Conrod screw length
      • Conrod bore parallelism
      • Small conrod bore
    • 3.3.37 Conrod – Assembly
    • 3.3.38 Conrod bearing shell – Assessment
      • Lower conrod bearing shell (grooved bearing) – Assessment
      • Assessment
      • Damage to bearing
      • Upper conrod bearing half shell (sputtered bearing) – Assessme
      • Assessment
    • 3.3.39 Piston – Assembly
    • 3.3.40 Piston and conrod – Installation
  • 3.4 Cylinder Head
    • 3.4.1 Cylinder head and attachments – Overview
      • Overview of cylinder head and attachments
    • 3.4.2 Valve-seat turning machine for cylinder head
      • Working principle of valve-seat turning machine
      • Installing the solid pilot
      • Mounting the supporting spider
      • Inserting the pilot into the valve guide
      • Locking the pilot
      • Setting up valve turning machine
      • Mounting the cutter
      • Placing the valve-turning machine on the pilot
      • Aligning the cutting edge with the valve-seat center
      • Connecting the machine to power supply
      • Valve seat turning
      • Positioning the cutter at the inner valve-seat edge
      • Setting cutting depth
      • Lubricating the valve seat
      • Valve seat turning
      • Repeating the cutting pass
      • Replacing the adapter head
      • Removing the adapter head
      • Mounting the adapter head
    • 3.4.3 Cylinder head – Removal
    • 3.4.4 Cylinder head – Disassembly
    • 3.4.5 Cylinder head – Cleaning
    • 3.4.6 Cylinder head – Check
    • 3.4.7 Cylinder head – Tolerances
      • Inlet and exhaust valve guides
      • Valve clearance
      • Inlet and exhaust valve seat ring
      • Exhaust valve seat
      • Inlet valve seat
      • Inlet valve elliptical chamfer
      • Exhaust valve
      • Inlet valve
      • Valve springs, exterior
      • Valve springs, interior
      • Cylinder head – Mating surface – Protective sleeve – Valve bridge
      • Cylinder head screws
    • 3.4.8 Cylinder head – Repair
    • 3.4.9 Cylinder head – Assembly
    • 3.4.10 Cylinder head – Installation
    • 3.4.11 Cylinder head – Plug repair
  • 3.5 Valve Gear
    • 3.5.1 Valve gear – Overview
      • Valve gear – Overview
    • 3.5.2 Camshaft overview
      • Overview of camshaft
    • 3.5.3 Camshaft – Removal
    • 3.5.4 Camshaft – Cleaning
    • 3.5.5 Camshaft running surfaces and swing followers – Visual check
    • 3.5.6 Camshaft – Check
    • 3.5.7 Camshaft – Tolerances
      • Concentricity of bearings
      • Axial play
    • 3.5.8 Camshaft – Installation
    • 3.5.9 Camshaft drive – Overview
      • Camshaft drive – Overview
    • 3.5.10 Camshaft drive – Removal
    • 3.5.11 Camshaft drive – Cleaning
    • 3.5.12 Camshaft drive – Check
    • 3.5.13 Camshaft drive – Installation
    • 3.5.14 Camshaft thrust bearing – Overview
      • Overview of camshaft thrust bearing
    • 3.5.15 Camshaft thrust bearing – Replacement
    • 3.5.16 Camshaft thrust bearing – Cleaning
    • 3.5.17 Camshaft thrust bearing – Check
    • 3.5.18 Valve drive – Overview
      • Swing follower, swing follower assembly
      • Rocker shaft support
      • Swing follower
      • Valve bridge
    • 3.5.19 Valve drive – Removal
    • 3.5.20 Valve drive – Disassembly
    • 3.5.21 Valve drive – Cleaning
    • 3.5.22 Valve drive – Check
    • 3.5.23 Valve drive – Tolerances
      • Rocker shaft support, inlet and exhaust
      • Swing follower support, inlet and exhaust
    • 3.5.24 Valve drive – Assembly
    • 3.5.25 Valve drive – Installation
    • 3.5.26 Valve drive – Removal
    • 3.5.27 Valve drive – Disassembly
    • 3.5.28 Valve drive – Cleaning
    • 3.5.30 Valve drive – Tolerances
      • Rocker shaft support, inlet and exhaust
      • Swing follower support, inlet and exhaust
    • 3.5.31 Valve drive – Assembly
    • 3.5.32 Valve drive – Installation
    • 3.5.33 Cylinder head cover – Overview
      • Overview of cylinder head cover
    • 3.5.34 Cylinder head cover – Removal
    • 3.5.35 Cylinder head cover – Cleaning
    • 3.5.36 Cylinder head cover – Check
    • 3.5.37 Cylinder head cover – Installation
  • 3.6 Fuel System – High-Pressure
    • 3.6.1 H.P. fuel system – overview
      • H.P. fuel system – overview
    • 3.6.2 H.P. pump – Overview
      • Front view of H.P. pump
    • 3.6.3 H.P. pump – Removal
    • 3.6.4 High-pressure pump – Disassembly
    • 3.6.5 H.P. pump – Check
    • 3.6.6 H.P. pump – Installation
    • 3.6.7 H.P. fuel pump – Control block replacement
    • 3.6.8 Fuel injector – overview
      • Fuel injector – overview
    • 3.6.9 Fuel injector – Removal
    • 3.6.10 Fuel injector disassembly
    • 3.6.11 Fuel injector cleaning
    • 3.6.12 Fuel injector inspection
    • 3.6.13 Fuel injector – Installation
    • 3.6.14 H.P. fuel line – Overview
      • H.P. line from H.P. accumulator to injector
      • H.P. line from H.P. fuel pump to H.P. accumulator
      • H.P. accumulator and attachments
      • H.P. accumulator, left engine side
      • H.P. accumulator, right engine side
    • 3.6.15 HP fuel line – Removal
    • 3.6.16 HP fuel line – Disassembly
    • 3.6.17 H.P. fuel line – Cleaning
    • 3.6.18 H.P. fuel line – Check
    • 3.6.19 HP fuel line – Assembly
    • 3.6.20 H.P. fuel line – Installation
    • 3.6.21 H.P. fuel system – Leak check
  • 3.7 Fuel System – Low-Pressure
    • 3.7.1 Low pressure fuel system – Overview
    • 3.7.2 Fuel delivery pump – Removal
    • 3.7.3 Fuel delivery pump – Disassembly
      • Disassembling fuel delivery pump
    • 3.7.4 Fuel delivery pump – Cleaning
    • 3.7.5 Fuel delivery pump – Check
    • 3.7.6 Fuel delivery pump – Installation
    • 3.7.7 Fuel lines from delivery pump to filter – Overview
    • 3.7.8 Fuel lines from pump to filter – Removal
    • 3.7.9 Fuel lines from pump to filter – Cleaning
    • 3.7.10 Fuel lines from pump to filter – Check
    • 3.7.11 Fuel lines from delivery pump to filter – Installation
    • 3.7.12 Fuel duplex filter – Overview
    • 3.7.13 Fuel duplex filter – Removal
    • 3.7.14 Fuel duplex filter – Disassembly
    • 3.7.15 Fuel duplex filter – Cleaning
    • 3.7.16 Fuel duplex filter – Check
    • 3.7.17 Fuel duplex filter – Assembly
    • 3.7.18 Fuel duplex filter – Installation
    • 3.7.19 Fuel lines from fuel filter to HP pump – Overview
    • 3.7.20 Fuel supply pipework from fuel filter to H.P. pump – Removal
    • 3.7.21 Fuel supply pipework from fuel filter to H.P. pump – Cleaning
    • 3.7.22 Fuel supply pipework from fuel filter to H.P. pump – Check
    • 3.7.23 Fuel supply pipework from fuel filter to H.P. pump – Installation
    • 3.7.24 Leak-off fuel line – Overview
    • 3.7.25 Leak-off fuel line – Removal
    • 3.7.26 Leak-off fuel line – Cleaning
    • 3.7.27 Leak-off fuel line – Check
    • 3.7.28 Leak-off fuel line – Installation
  • 3.8 Exhaust Turbocharger
    • 3.8.1 Exhaust turbochargers
      • Illustration applies analogously to 12V / 16V 4000 G
    • 3.8.2 Exhaust turbocharger – Overview
    • 3.8.3 Exhaust turbocharger – Removal
    • 3.8.4 Exhaust turbocharger – Disassembly
    • 3.8.5 Exhaust turbochargers – Cleaning
    • 3.8.6 Exhaust turbocharger – Check
    • 3.8.7 Exhaust turbocharger – Assembly
    • 3.8.8 Exhaust turbochargers – Installation
  • 3.9 Charge-Air Cooling
    • 3.9.1 Charge-air cooling – Overview
      • Intercooler and attachments
    • 3.9.2 Intercooler – Removal
    • 3.9.3 Intercooler – Disassembly
      • Intercooler – Disassembly
    • 3.9.4 Intercooler – Cleaning
      • Air-side cleaning
      • Water-side cleaning
      • Intercooler flushing
      • Intercooler drying and preservation
    • 3.9.5 Intercooler – Check
    • 3.9.6 Charge-air cooler – Installation
  • 3.10 Air Intake/Air Supply
    • 3.10.1 Air intake / air supply – Overview
    • 3.10.2 Intake air system to cylinders, left – Overview
    • 3.10.3 Air supply system to cylinders, left – Removal
    • 3.10.4 Air supply system to cylinders, left – Cleaning
    • 3.10.5 Air supply system to cylinders, left – Check
    • 3.10.6 Air supply system to cylinders, left – Installation
    • 3.10.7 Air supply system to cylinders, right – Overview
    • 3.10.8 Air supply system to cylinders, right – Removal
    • 3.10.9 Air supply system to cylinders, right – Cleaning
    • 3.10.10 Air supply system to cylinders, right – Check
    • 3.10.11 Air supply system to cylinders, right – Installation
    • 3.10.12 Air ducts from turbochargers to intercooler – Overview
      • Air supply, variant A
      • Illustration applies analogously to 8/12/16 V 4000 G
      • Air supply, variant B
      • Illustration applies analogously to 8/12/16 V 4000 G
    • 3.10.13 Air ducts from exhaust turbochargers to intercooler – Removal
    • 3.10.14 Air ducts from turbochargers to intercooler – Cleaning
    • 3.10.15 Air ducts from turbochargers to intercooler – Check
    • 3.10.16 Air ducts from turbochargers to intercooler – Installation
  • 3.11 Exhaust Pipework
    • 3.11.1 Exhaust system – Overview
      • Illustration applies analogously to 8/12/16 V 4000 G
    • 3.11.2 Exhaust pipework after cylinder head – Overview
      • Exhaust pipework, 12 V plug connection – Overview
      • Exhaust pipework, 12 V screwed joint – Overview
      • Exhaust pipework, 16 V – Overview
    • 3.11.3 Exhaust pipework after cylinder head – Removal
    • 3.11.4 Exhaust pipework after cylinder head – Cleaning
    • 3.11.5 Exhaust pipework after cylinder head – Check
    • 3.11.6 Exhaust pipework after cylinder head – Installation
  • 3.12 Starter
    • 3.12.1 Electric starter – Overview
    • 3.12.2 Starter – Removal
    • 3.12.3 Starter – Disassembly
      • Remove starter (→ Page 550).
      • Starter – Disassembly
      • See separate publication No. M060715.
    • 3.12.4 Starter – Cleaning
    • 3.12.5 Starter – Inspection
    • 3.12.6 Starter – Installation
  • 3.13 Lube Oil System, Lube Oil Circuit
    • 3.13.1 Lube oil pump with drive – Overview
    • 3.13.2 Lube oil pump with drive – Removal
    • 3.13.3 Lube oil pump with drive – Disassembly
      • Remove lube oil pump with drive (→ Page 557).
    • 3.13.4 Lube oil pump with drive – Cleaning
    • 3.13.5 Lube oil pump with drive – Check
    • 3.13.6 Lube oil pump with drive – Installation
    • 3.13.7 Oil filter – Overview
      • Oil filter assembly
    • 3.13.8 Oil filter with oil filter housing – Removal
    • 3.13.9 Oil filter housing – Disassembly
    • 3.13.10 Oil filter housing – Cleaning
    • 3.13.11 Oil filter housing – Check
    • 3.13.12 Oil filter housing – Assembly
    • 3.13.13 Oil filter with oil filter housing – Installation
    • 3.13.14 Centrifugal oil filter– Overview
      • Centrifugal oil filter with attachments
      • Centrifugal oil filter with flange
      • Centrifugal oil filter assembly
    • 3.13.15 Centrifugal oil filter – Removal
    • 3.13.16 Centrifugal oil filter – Disassembly
    • 3.13.17 Centrifugal oil filter – Cleaning
    • 3.13.18 Centrifugal oil filter – Check
    • 3.13.19 Centrifugal oil filter – Bearing clearance check
    • 3.13.20 Centrifugal oil filter – Assembly
    • 3.13.21 Centrifugal oil filter – Installation
    • 3.13.22 Oil cooler – Overview
      • Oil cooler with attachments
    • 3.13.23 Oil cooler – Removal
    • 3.13.24 Oil cooler – Cleaning
    • 3.13.25 Oil cooler – Check
    • 3.13.26 Oil cooler – Installation
    • 3.13.27 Oil system in crankcase – Overview
      • Oil system
    • 3.13.28 Oil system in crankcase – Removal
    • 3.13.29 Oil system in crankcase – Cleaning
    • 3.13.30 Oil system in crankcase – Check
    • 3.13.31 Oil system in crankcase – Installation
    • 3.13.32 Turbocharger oil supply – Overview
      • Exhaust turbocharger oil supply
    • 3.13.33 Turbocharger oil supply – Removal
    • 3.13.34 Turbocharger oil supply – Cleaning
    • 3.13.35 Turbocharger oil supply – Check
    • 3.13.36 Turbocharger oil supply system – Installation
  • 3.14 Engine Coolant System
    • 3.14.1 Coolant system – Overview
      • Engine coolant circuit
      • (applicable to 8/12/16 V 4000 Gx1)
    • 3.14.2 Engine coolant pump – Overview
    • 3.14.3 Engine coolant pump – Removal
    • 3.14.4 Engine coolant pump – Disassembly
    • 3.14.5 Engine coolant pump – Cleaning
    • 3.14.6 Engine coolant pump – Check
    • 3.14.7 Engine coolant pump – Tolerances
    • 3.14.8 Engine coolant pump – Assembly
    • 3.14.9 Engine coolant pump – Installation
    • 3.14.10 Coolant supply for engine coolant pump, intake side – Overview
      • Overview drawing
    • 3.14.11 Coolant supply for engine coolant pump, intake side – Removal
    • 3.14.12 Coolant supply for engine coolant pump, intake side – Removal
    • 3.14.13 Coolant supply for engine coolant pump, intake side – Check
    • 3.14.14 Coolant supply for engine coolant pump, intake side – Installation
    • 3.14.15 Coolant pipework after cylinder – Overview
      • Coolant pipework after cylinder – Overview
      • Also applies analogously to 12 V.
    • 3.14.16 Coolant pipework after cylinder – Removal
    • 3.14.17 Coolant pipework after cylinder – Cleaning
    • 3.14.18 Coolant pipework after cylinder – Check
    • 3.14.19 Coolant pipework after cylinder – Installation
    • 3.14.20 Engine coolant and charge air coolant ventilation – Overview
      • Coolant vent lines
      • Applies analogously to 8/12/16 V 4000 G
    • 3.14.21 Engine coolant ventilation and charge-air cooling – Removal
    • 3.14.22 Engine coolant ventilation and charge air cooling – Cleaning
    • 3.14.23 Engine coolant and charge air coolant ventilation – Check
    • 3.14.24 Engine coolant ventilation and charge air cooling – Installation
    • 3.14.25 Charge-air coolant pump – Overview
      • Charge-air coolant pump – Overview
    • 3.14.26 Charge-air coolant pump – Removal
    • 3.14.27 Charge-air coolant pump – Disassembly
    • 3.14.28 Charge-air coolant pump – Cleaning
    • 3.14.29 Charge-air coolant pump – Check
    • 3.14.30 Charge-air coolant pump – Tolerances
    • 3.14.31 Charge-air coolant pump – Assembly
    • 3.14.32 Charge-air coolant pump – Installation
    • 3.14.33 Coolant pipework from/to intercooler – Overview
      • Coolant pipework
    • 3.14.34 Coolant pipework from/to intercooler – Removal
    • 3.14.35 Coolant pipework from/to intercooler – Cleaning
    • 3.14.36 Coolant pipework from/to intercooler – Check
    • 3.14.37 Coolant pipework from/to intercooler – Installation
    • 3.14.38 Coolant pipework with thermostat — Overview
      • Coolant pipework with thermostat
    • 3.14.39 Coolant pipework with thermostat – Removal
    • 3.14.40 Coolant pipework with thermostat – Cleaning
    • 3.14.41 Coolant pipework with thermostat – Check
    • 3.14.42 Coolant pipework with thermostat – Installation
  • 3.15 Power Supply – Engine Side
    • 3.15.1 Battery-charging generator — Overview
      • Overview battery-charging generator with drive (version A)
      • Overview battery-charging generator with drive (version B)
      • Generator drive
    • 3.15.2 Battery-charging generator – Removal
    • 3.15.3 Battery-charging generator – Disassembly
      • Remove battery-charging generator (→ Page 700).
      • Battery-charging generator – Disassembly
      • See separate publication No. M060715
    • 3.15.4 Battery-charging generator – Cleaning
    • 3.15.5 Battery-charging generator – Check
    • 3.15.6 Battery-charging generator – Installation
  • 3.16 Mounting/Support
    • 3.16.1 Engine mounting – Overview
      • Engine mounting bracket
    • 3.16.2 Engine mounting – Removal
    • 3.16.3 Engine mounting – Cleaning
    • 3.16.4 Engine mounting – Check
    • 3.16.5 Engine mounting – Installation
  • 3.17 Monitoring, Control and Regulation
    • 3.17.1 Monitoring, control and regulation devices – Overview
      • DDEC engine control unit
    • 3.17.2 Wiring and engine wiring harnesses – Overview
      • DDEC engine wiring harness
      • DDEC engine wiring harness (applies analogously to 12V)
      • Series 4000 system cable
      • Series 4000 system cable
    • 3.17.3 Engine wiring harnesses – Removal
    • 3.17.4 Engine wiring harness – Check
    • 3.17.5 Engine wiring harnesses – Installation
    • 3.17.6 Sensors and actuators – Overview
      • Sensors, actuators
      • Sensors and actuators left engine side, overview
      • Sensors and actuators right engine side, overview
    • 3.17.7 Sensors, actuators and injectors – Removal
    • 3.17.8 Sensors, actuators and injectors – Check
    • 3.17.9 Sensors, actuators and injectors – Installation
• 4 Special Tools
  • 4.1 Standard tools – Overview
  • 4.2 Special tools – Overview
  • 4.3 General workshop equipment – Overview
  • 4.4 Measuring tools – General overview
• 5 Annex
  • 5.1 Manufacturer’s documentation
    • See manufacturer’s documentation.
  • 5.2 MTU contact/service partner
  • 5.3 Index

Detroid Diesel