Table of Contents
1 Safety
1.1 Important requirements for all products 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Crankshaft transport locking device 8
1.5 Safety requirements for startup and
operation 11
1.6 Safety requirements for maintenance and
repair work 12
1.7 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 15
1.8 Standards for safety notices in the text 17
2 General Information
2.1 Engine side and cylinder designations 18
2.2 Engine layout 19
2.3 Sensors, actuators and injectors – Overview 21
3 Technical Data
3.1 16V 4000 R43 engine data 24
3.2 16 V 4000 R43L engine data 28
3.3 16 V 4000 R43R engine data 31
3.4 Firing order 34
3.5 Main engine dimensions 35
4 Operation
4.1 Putting the engine into operation after
extended out-of-service periods (>3 months) 36
4.2 Putting the engine into operation after
scheduled out-of-service-period 37
4.3 Starting the engine in manual mode 38
4.4 Stopping the engine in manual mode 39
4.5 Preparing the engine for extended out-of-
service period 40
4.6 Plant – Cleaning 41
5 Maintenance
5.1 Maintenance task reference table [QL1] 42
6 Troubleshooting
6.1 Troubleshooting 44
6.2 Fault messages on PAU display 47
6.3 Fault messages of engine governor ADEC
(ECU 7) for Series 4000, rail applications 48
7 Task Description
7.1 Engine 75
7.1.1 Engine – Barring manually 75
7.1.2 Cranking engine with starting system 77
7.1.3 Engine – Performing test run 78
7.2 Cylinder Liner 79
7.2.1 Cylinder liner – Endoscopic examination 79
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 81
7.3 Crankcase Breather 83
7.3.1 Crankcase breather – Oil separator element
replacement 83
7.4 Valve Drive 85
7.4.1 Valve gear – Lubrication 85
7.4.2 Valve clearance – Check and adjustment 86
7.4.3 Cylinder head cover – Removal and
installation 90
7.5 Injection Pump / HP Pump 91
7.5.1 HP pump – Relief bore check 91
7.5.2 HP pump – Filling with engine oil 92
7.6 Injection Valve / Injector 93
7.6.1 Injector – Replacement 93
7.6.2 Injector – Removal and installation 94
7.7 Fuel System 99
7.7.1 Fuel system – Venting 99
7.8 Fuel Filter 100
7.8.1 Fuel filter – Replacement 100
7.8.2 Fuel prefilter – Draining 101
7.8.3 Fuel prefilter – Filter element replacement 102
7.8.4 Intermediate fuel filter – Replacement 103
7.9 Exhaust Turbocharger 104
7.9.1 Exhaust turbocharger – Turbine housing
check 104
7.9.2 Compressor wheel – Cleaning 107
7.10 Charge-Air Cooling 111
7.10.1 Intercooler – Checking condensate drain for
coolant leakage and obstruction 111
7.11 Air Filter 112
7.11.1 Air filter element and (optional) dust bowl ‒
Cleaning 112
7.11.2 Air filter ‒ Replacement 113
7.11.3 Air filter element – Removal and installation
(optional) 114
7.12 Starting Equipment 115
7.12.1 Starter – Condition check 115
7.13 Air Intake 116
7.13.1 Service indicator – Signal ring position check 116
MS15042/00E 2014-10 | Table of Contents | 3
DCL-ID: 0000035416 - 001