Series 40E – Section 3.3 Oil Filter and Header

Section 3.3
Oil Filter and Header

Use the following procedures to remove and install the oil filter and header.‪

Section 3.3.1
Removal of Oil Filter and Header

Follow these steps to remove the oil filter and header.‪

  1. Using an open end wrench, loosen and remove oil feed supply tube nut located on top of the oil filter header. Remove and discard tube nut O-ring. Remove cap fitting on the header. See Figure "Oil Filter and Header Removal" .
    Click to see this graphic in a separate window

    1. Oil Filter Header‪

    3. Oil Feed Supply Tube‪

    2. Oil Feed Supply Tube Nut‪

    Figure 1. Oil Filter and Header Removal

  2. With oil and coolant drained from the engine, remove the oil filter using an appropriate filter wrench. Discard the filter. See Figure "Oil Filter Removal" .
    Click to see this graphic in a separate window

    1. Oil Filter‪

    2. Oil Filter Header‪

    Figure 2. Oil Filter Removal

  3. Remove one bolt and retainer plate securing the water coolant supply tube from the crankcase. See Figure "Removal of Water Coolant Supply Tube " .

    Note: Remove oil cooler and water coolant supply tube as an assembly.

    Click to see this graphic in a separate window

    1. Mounting Bolts‪

    3. Oil Cooler Assembly‪

    2. Oil Cooler Filter Header‪

    Figure 3. Removal of Water Coolant Supply Tube

  4. Remove mounting hardware securing oil cooler assembly to the crankcase.
  5. Remove the oil cooler and water coolant supply tube as an assembly from the crankcase. Discard the O-rings, gaskets and seals.

Section 3.3.2
Leakage Test

Check oil cooler assembly for leaks using an Air Pressure Test as follows:‪

  1. Fasten oil cooler leakage test plate, J43097, to oil cooler headers using new oil cooler gaskets.
  2. Install oil filter.
  3. Install air pressure gage to oil cooler filter header at turbocharger supply fitting location. See Figure "Oil Cooler Filter Header" .
    Click to see this graphic in a separate window

    1. Pressure Test Plate Mounting Bolts (7)‪

    4. Air Hose‪

    2. Oil Cooler Front Header‪

    5. Air Pressure Gage‪

    3. Oil Cooler Filter Header‪

    6. Pressure Test Plate‪

    Figure 4. Oil Cooler Filter Header

  4. Immerse assembly in a container of clean "tap" water.
  5. Apply 690 kPa (100 psi) air pressure while immersed.
  6. Inspect header castings, O-ring seals and 1/4 NPTF water side opening for moving or growing bubbles. Replace components as required.

Section 3.3.3
Disassembly of Oil Cooler

Disassemble oil cooler assembly as follows:‪

  1. With non-metallic hammer, gently rap front of oil filter header to loosen O-rings. Twist headers and separate from cooler bundle.
  2. Remove, inspect and install oil temperature control thermostat located in filter/oil cooler header. Install with new O-ring.

    Note: Oil pressure regulator valve may be removed by depressing plunger and trapping a length of copper wire when released. Valve may then be removed by copper wire.

  3. Remove, inspect and install pressure regulator valve located in crankcase.
  4. Remove oil cooler rear and front header from the oil cooler bundle

    Note: In the event of bearing failure, oil cooler bundle must be replaced because failed bearing debris cannot be removed from the cooler bundle.

Cleaning of Oil Cooler

Clean oil cooler assembly as follows:‪

  1. Immerse oil cooler, front and filter header in a suitable solvent. Flush and drain cooler to remove residue.

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.‪

  2. Dry all components thoroughly with filtered compressed air.
Inspection and Repair of Oil Cooler

Inspect the oil cooler as follows:‪

  1. Visually inspect oil cooler for blocked tubes and corrosion where tubes are assembled to the bundle. Replace oil cooler tube bundle if required.
  2. Visually inspect header for blocked orifices or damaged threads at oil filter threaded insert.
  3. Remove any debris which may be blocking oil flow passages.

Section 3.3.4
Assembly of Oil Cooler

Assemble the oil cooler using the following procedure:‪

Note: Use new O-rings when assembling oil cooler. Do not nick, cut or distort O-rings during assembly.

  1. Install O-rings onto oil cooler bundle.
  2. Using lubriplate, lubricate the oil cooler bundle, headers and O-rings on the cooler bundle. See Figure "Oil Cooler Installation" .
    Click to see this graphic in a separate window

    1. Oil Cooler Filter Header‪

    3. Oil Cooler Front Header‪

    2. Oil Cooler Bundle‪

    Figure 5. Oil Cooler Installation

  3. Carefully press assembly together assuring that locating clip of oil cooler headers (front and rear) align in slots of oil cooler bundle and header is not cocked. This procedure can be accomplished by using body weight to press the assembly together.

Section 3.3.5
Installation of Oil Cooler Assembly

Install the oil cooler assembly as follows:‪

  1. Install the water outlet tube in the front cover.

    Note: Install oil cooler assembly using a new square cut O-ring at front header and O-ring gasket at rear filter cooler header.

  2. Install the filter header/oil cooler assembly to the crankcase. Secure with appropriate bolts and nuts and torque to specifications.

    Note: Ensure the oil pressure relief valve is installed into the crankcase.

  3. Secure the water inlet tube to crankcase. Install the retainer plate and tighten the bolt. See Figure "Walter Inlet Tube" .
    Click to see this graphic in a separate window

    1. Oil Pressure Regulating Valve‪

    3. Air Cooler Assembly‪

    2. Water Coolant Supply Tube‪

    Figure 6. Walter Inlet Tube

  4. Install the new oil filter as follows:
    1. Lubricate new filter gasket with clean engine oil.
    2. Hand tighten filter one full turn after gasket first contacts the filter header. See Figure "Oil Filter Installation" .
    3. Click to see this graphic in a separate window

      1. Oil Filter‪

      2. Oil Filter Header‪

      Figure 7. Oil Filter Installation

  5. Prime the lubricating system. Refer to "3.3.6 Prime Lubricating System" .

Section 3.3.6
Prime Lubricating System

When the engine has been reassembled, it is recommended the engine be lubricated with oil before starting. This prevents damage to internal parts. The following procedure is the preferred method for priming the lubricating system.‪

Note: Install a new lube oil filter.


To prevent engine from accidentally starting, do not rotate any diesel engine when priming with oil.‪

  1. Use the following procedure to pressure prime the lubrication system with oil prior to starting:
    1. Inject sufficient oil into the engine to fill the oil filters and charge the entire system.
    2. After priming, check the oil level before the engine is put back into service.
  2. Crankcase refill capacities:
    1. 26.4 L (28 qt) with filter change
    2. 22.7 L (24 qt) without filter change
    3. NOTICE:

      To prevent engine damage, ensure the engine is well oiled during assembly. Do not use this procedure if the engine has not been well oiled.‪

  3. Using the cranking motor, spin but DO NOT start the engine until oil pressure is read on the oil pressure gage.

    Note: Engines equipped with a bypass filtering system require additional oil.

  4. When oil pressure is read, you may start the engine.

Series 40E Service Manual - 6SE410
Generated on 10-13-2008

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