Detroit Diesel MBE 4000 Service Manual
  1. Manuals
  2. Brands
  3. Detroit Diesel Manuals
  4. Engine
  5. MBE4000
  6. Service manual

Detroit Diesel MBE 4000 Service Manual

Hide thumbs Also See for MBE 4000:
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
Table of Contents

Advertisement

Quick Links

Download this manual See also: Service Information
www.rtrucks.ru
www.rtrucks.ru
www.rtrucks.ru
www.rtrucks.ru
www.rtrucks.ru
www.rtrucks.ru

Advertisement

Table of Contents
loading
Need help?

Need help?

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

Questions and answers

Related Manuals for Detroit Diesel MBE 4000

Summary of Contents for Detroit Diesel MBE 4000

  • Page 1 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 2 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 3 (compare Examples 1 and 2). ENGINE EXHAUST Consider the following before servicing engines: All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 4 If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 5: Table Of Contents

    EGR CAMSHAFT ..................1-181 ADDITIONAL INFORMATION ..............1-183 FUEL SYSTEM INJECTOR UNIT PUMP ................EGR INJECTOR UNIT PUMP ..............2-11 FUEL INJECTOR LINE ................2-13 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 6 EGR EXHAUST MANIFOLD ..............7-14 EGR COOLER AND COOLER SUPPORT BRACKET ......7-26 EGR CONTROL VALVE, GAS OUTLET PIPE, AND GAS MIXER ..7-43 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 7 PREPARING ENGINE FOR STORAGE ........... 14-3 MECHANICAL TROUBLESHOOTING 15.1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM ....................15-3 15.2 GENERAL TROUBLESHOOTING ............15-4 INDEX ....................Index-1 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 8 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 9: General Information

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru GENERAL INFORMATION Section Page SCOPE AND USE OF THIS MANUAL ............GENERAL DESCRIPTION ................. ELECTRONIC ENGINE CONTROL SYSTEM ..........ENGINE BRAKING POWER ............... GENERAL SPECIFICATIONS AND ENGINE VIEWS ........ ENGINE MODEL AND SERIAL NUMBER ..........EXHAUST GAS RECIRCULATION (EGR) SYSTEM ........SAFETY INSTRUCTIONS AND PRECAUTIONS ........
  • Page 10 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 11: Scope And Use Of This Manual

    Basic maintenance and overhaul procedures are common to all MBE 4000 engines, and apply to all engine models. This manual is divided into numbered sections. Section one covers the engine (less major assemblies).

  • Page 12: Electronic Engine Control System

    J1587 and J1939 datalinks, where it can be read by minidiag2, Nexiq™ ® Diagnostic Data Reader (DDR), or Detroit Diesel Diagnostic Link (DDDL) PC software. The DDEC-ECU monitors both the engine and the datalink. When a malfunction or other problem is detected, the system selects an appropriate response;...
  • Page 13 Figure 1 DDEC-ECU Control Unit Location NOTE: To obtain a replacement DDEC-ECU, all the data given on the DDEC-ECU label are required. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 14 Other electronic control units (for example, the antilock brake system) The DDEC-ECU control unit (data such as oil pressure and coolant temperature) All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 15: Engine Braking Power

    For a general view of the MBE 4000 engine, showing major components, see Figure 3 for the left-hand side, and see Figure 4 for the right-hand side. For a general view of the MBE 4000 engine, showing ports and fluid lines, see Figure 5 for the left-hand side and see Figure 6 for the right-hand side.
  • Page 16 5. Engine Trim Cover 13. Fuel Pump 6. Crankcase Breather 14. Air Conditioner Compressor 7. Air Compressor Figure 3 Left Side, Major Engine Components All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 17 4. Exhaust Manifold 12. Oil Dipstick 5. Cylinder Head Cover 13. Turbocharger 6. Fan 7. Belt Tensioner Figure 4 Right Side, Major Engine Components All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 18 3. Charge Air Inlet 7. Electronic Engine Harness Connector 4. Open Breather Tube 8. Fuel Feed Line Figure 5 Left Side, Ports and Lines All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 19 3. Constant-Throttle Inlet 7. Oil Fill Cap 4. Exhaust Brake Valve Outlet 8. Coolant Pump Inlet Pipe Figure 6 Right Side, Ports and Lines All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 20 2. TDC Sensor (on camshaft) 6. Fuel Temperature Sensor 3. Crank Angle Position Sensor 7. Oil Pressure/Temperature Sensor 4. Coolant Temperature Sensor Figure 7 Sensor Locations All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 21 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru The general specifications for the MBE 4000 engine are listed in Table 1. Description 6–Cylinder Engines Engine Type Vertical, inline cylinder block with turbocharger and charge-air cooler Cooling System Liquid Circuit Combustion Principle 4–Stroke direct-injection diesel...

  • Page 22: Engine Model And Serial Number

    OM 460 LA is the production code. The engine serial number contains the type reference followed by a sequential manufacturing number. See Figure 9. Figure 8 Location of Engine Type Plate All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 23 DDEC-ECU label. The ten-digit number is derived from the fourteen-digit number. See Figure 10. Figure 10 Engine Serial Number All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 24: Exhaust Gas Recirculation (Egr) System

    Reed Valves EGR Charge Air Mixer The MBE 4000 engines for on-highway EPA 2004 regulation applications use a cooled EGR system. Part of the exhaust gasses from the front three cylinders are routed from the exhaust manifold through the EGR cooler, past control and reed valves, and are mixed with the intake manifold charge air.
  • Page 25 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru For an general view of the MBE 4000 engine with an EGR system, See Figure 12 for a right side view and see Figure 13 for a left side view. 1. Oil Filter 8. EGR Cooler ®...
  • Page 26 7. Crankcase Breather (Hengst filter) 4. EGR Modulated Control Valve 8. EGR Mixer Figure 13 EGR Engine with EGR Components and Revised Parts (Left View) All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 27 EGR modulated control valve and the mixer and then back to the cylinder. EGR Control Valves There are two EGR valves on the MBE 4000 EGR engine — the EGR shutoff valve and the EGR modulated control valve. The EGR shutoff valve is a pneumatically driven butterfly valve, located at the inlet of the EGR cooler.

  • Page 28: Safety Instructions And Precautions

    SAFETY INSTRUCTIONS AND PRECAUTIONS The following safety measures are essential when working on the MBE 4000 engine. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: Proper service and repair are important to the service technician and the safe, reliable operation of the engine.
  • Page 29 To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 30 After servicing or adjusting the engine: Reinstall all safety devices, guards or shields Ensure that all tools and servicing equipment are removed from the engine All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 31 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru Welding Wear welding goggles and gloves when welding or using an acetylene torch. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 32 Use proper shielding around hydraulic lines when welding to prevent hydraulic line damage. Ensure that a metal shield separates the acetylene and oxygen that must be chained to a cart. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 33 Check for frayed cords prior to using the tool. Be sure all electric tools are grounded. Defective electrical equipment can cause severe injury. Improper use of electrical equipment can cause severe injury. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 34 If injured by escaping fluid, see a doctor at once. Serious infection or reaction can result without immediate medical treatment. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 35 This will reduce the likelihood of a dangerous spark. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 36 Apply baking soda or lime to help neutralize the acid. Flush your eyes with water. Get medical attention immediately. Always disconnect the battery cable before working on the electrical system. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 37 Disconnect the batteries or disable an air starter when working on the engine to prevent accidental starting. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 38 PERSONAL INJURY To avoid injury, use care when working around moving belts and rotating parts on the engine. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 39 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. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...

  • Page 40: English To Metric Conversion

    To get equivalent number of: Pound-inch (lb·in.) 0.11298 Newton-meters (N·m) Pound-foot (lb·ft) 1.3558 Newton-meters (N·m) Multiply Power To get equivalent number of: All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 41: Decimal And Metric Equivalents

    Kilometers/hour (km/hr) Table 2 English to Metric Conversion Table DECIMAL AND METRIC EQUIVALENTS Listed in Table 3 are the decimal and metric equivalents. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 42 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 3 Conversion Chart-Customary and Metric Units All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 43: Torque Specifications

    Listed in Table 4, listed in Table 5, listed in Table 6, listed in Table 7, and listed in Table 8 are the torque specifications for the MBE 4000 engine. Torque Values for U.S. Customary Thread Fasteners with Lubricated* or Plated Threads†...
  • Page 44 † Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed). Table 5 Torque Specifications Table Two All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 45 † Use one of the previous tables if either the male or female threads (bolt and nut) are plated or lubricated. Coat all plated and unplated fasteners with oil before installation. Table 6 Torque Specifications Table Three All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 46 † Use one of the previous tables if either the male or female threads (bolt and nut) are plated or lubricated. Coat all plated and unplated fasteners with oil before installation. Table 7 Torque Specifications Table Four All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 47 † Use one of the previous tables if either the male or female threads (bolt and nut) are plated or lubricated. Coat all plated and unplated fasteners with oil before installation. Table 8 Torque Specifications Table Five All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 48 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 49: Engine

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru ENGINE Section Page CYLINDER HEAD COVER ..............CYLINDER HEAD ..................CYLINDER BLOCK .................. 1-24 EGR CYLINDER HEAD AND BLOCK ............. 1-40 EGR FRONT AND REAR LIFTER BRACKETS ........1-43 ENGINE BRAKE ..................1-45 FRONT RADIAL SEAL ................1-51 REAR RADIAL SEAL ................
  • Page 50 1.23 EGR CAMSHAFT ..................1-181 ADDITIONAL INFORMATION ..............1-183 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 51: Cylinder Head Cover

    4. Cylinder Head Figure 1-1 Cylinder Head Cover 1.1.1 Removal of Cylinder Head Cover Perform the following steps to remove the cylinder head cover: All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 52 2. Place the cylinder head cover in position on the cylinder head. 3. Install the cylinder head cover bolts. Tighten the bolts 20 N·m (15 lb·ft). All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...

  • Page 53: Cylinder Head

    CYLINDER HEAD The MBE 4000 engine has individual heads for each cylinder. To remove one head, follow these instructions, step by step. To remove all the heads, repeat each step in these instructions, as applicable, for all six cylinders.
  • Page 54 6. Fuel Return Line 13. Exhaust Manifold Mounting Bolt 7. Cylinder Head Bolt 14. Guide Pin Figure 1-3 Exploded View of Cylinder Head All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 55 4. Remove the engine trim cover to gain access to the fuel injector lines. 5. Remove the charge-air intake manifold. Refer to section 6.1.1. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 56 7. Remove the high-pressure injector line from the head and unit pump. 8. To prevent any dirt from entering, cover the openings in the unit pump and the transfer tube. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 57 When all the bolts are loose, remove the bolts from the cylinder head. See Figure 1-5. Figure 1-5 Loosening the Head Bolts All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 58 2. Position the cylinder head on the head gasket. Make sure the head is seated onto the guide pins. All information subject to change without notice. 1-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 59 Maximum shaft length 212.0 mm (8.35 inches) Table 1-3 Cylinder Head Bolt Lengths 4. Lubricate the cylinder head bolts with engine oil. All information subject to change without notice. 1-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 60 6. Replace the seal rings and connect the fuel return line to the cylinder head. 7. Replace the seal rings and install the constant-throttle line on the cylinder head. All information subject to change without notice. 1-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 61 19. Check that the coolant drain plug is tight and not leaking. 20. Fill the radiator with coolant. Refer to section 4.1.1. 21. Install the cylinder head cover. Refer to section 1.1.2. All information subject to change without notice. 1-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 62 2. Remove the nozzle holder. Refer to section 2.4.1. 3. Remove the intake and exhaust valves. Refer to section 1.19.5. 4. Remove the constant-throttle valve. Refer to section 1.6.1. All information subject to change without notice. 1-14 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 63 Deviation of Head Mating Surface When New 113.85-114.15 (4.482-4.494) Overall Height of Cylinder Head After Machining 113.5 (4.46) Table 1-6 Cylinder Head Specifications All information subject to change without notice. 1-15 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 64 [e] Repeat this procedure at each spot marked by an arrow (each corner of the cylinder head). All information subject to change without notice. 1-16 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 65 4. Install the intake and exhaust valves. Refer to section 1.19.6. 5. Install the nozzle holder. Refer to section 2.4.2. 6. Install the cylinder head. Refer to section 1.2.2. All information subject to change without notice. 1-17 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 66 3. Adjust the valve lash. Refer to section 1.19.3. NOTE: To do this procedure, coolant temperature must be between 155 and 205 F (70 to 95 C). All information subject to change without notice. 1-18 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 67 4. Turn on the ignition keyswitch and run the engine until it reaches operating temperature. 5. Shut down the engine. All information subject to change without notice. 1-19 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 68 4. High-Pressure Fuel Line 9. Retaining Bolt 5. Seal Ring 10. Constant Throttle Valve Cover Figure 1-11 Removing the Injector Nozzle All information subject to change without notice. 1-20 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 69 [c] Tighten the bolt attaching the hold-down to the cylinder head. NOTE: Follow the equipment manufacturer's operating instructions to connect the compression tester. All information subject to change without notice. 1-21 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 70 Pressure in kPa (psi) Minimum Compression Pressure Valve 2800 (406) Permissible Difference Between Individual Cylinders 400 (58) Table 1-7 Compression Testing All information subject to change without notice. 1-22 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 71 7. Install the cylinder head cover. Refer to section 1.1.2. 8. Repeat this procedure for each cylinder. 9. Remove the chocks from the tires. All information subject to change without notice. 1-23 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 72: Cylinder Block

    If the same liner is used again, it must be installed at an offset of 90 degrees from its last position. 1. Cylinder Block 2. Cylinder Liner Figure 1-14 Mark the Cylinder Liner All information subject to change without notice. 1-24 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 73 5. Threaded end of Spindle 2. Hold-down bolt 6. Hold-down bolt 3. Washer 7. Cylinder Liner 4. Spindle Nut Figure 1-15 Cylinder Liner Removal All information subject to change without notice. 1-25 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 74 See Figure 1-16. 1. Block 3. Cylinder Liner Collar 2. Cylinder Liner 4. Collar Seat Insert Figure 1-16 Cylinder Liner Collar Seat All information subject to change without notice. 1-26 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 75 7. Check the condition of the cylinder liner collar. Make sure that the height of the collar is within the specifications given. Discard the liner if the collar is not within specifications listed in Table 1-8. All information subject to change without notice. 1-27 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 76 Table 1-9. NOTE: The cylinder liner collar and collar seat must remain completely free of oil. All information subject to change without notice. 1-28 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 77 [b] Cylinder liners with tolerance code B require a piston of either code BA or BC. [c] Cylinder liners with tolerance code C require a piston of code BC. All information subject to change without notice. 1-29 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 78 If installing a new liner, use the first reference mark. If installing the old liner, use the second reference mark, offset 90 degrees from the first one. All information subject to change without notice. 1-30 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 79 [c] If the O-rings are damaged, replace them. [d] Check the out-of-round again until it meets specifications. 8. Install the piston. Refer to section 1.17.2. All information subject to change without notice. 1-31 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 80 Minor fading of the honing pattern at the top ring inversion area is not sufficient cause to reject the liner. Figure 1-21 Intact Honing Pattern All information subject to change without notice. 1-32 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 81 3. Do an external visual check of the cylinder liner for signs of cavitation and corrosion. Discard the liner if any damage is noted. All information subject to change without notice. 1-33 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 82 A to Axis B Table 1-10 Cylinder Liner Measurements NOTE: This measurement serves as a baseline against which to measure the actual wear. All information subject to change without notice. 1-34 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 83 [b] Make the second measurement 90 degrees away, along the side-to-side axis. [c] When finished, set the dial gauge to zero. All information subject to change without notice. 1-35 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 84 2. Clean the contact surfaces of the cylinder block, the cylinder liner, and the measuring plate. All information subject to change without notice. 1-36 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 85 See Figure 1-26. 1. Cylinder Head Bolts Figure 1-26 Measuring Plate Installation 4. Tighten the cylinder head bolts 50 N·m (37 lb·ft). All information subject to change without notice. 1-37 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 86 Support the dial gauge. See Figure 1-27. 1. Dial Gauge 3. Feeler 2. Slot (4 qty.) Figure 1-27 Dial Gauge Installation All information subject to change without notice. 1-38 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 87 7. Remove the bolts, spacers and measuring plate (J 46071 or 402 589 00 21 00), as installed. 8. Install the cylinder head. Refer to section 1.2.2. All information subject to change without notice. 1-39 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 88: Egr Cylinder Head And Block

    EGR CYLINDER HEAD AND BLOCK There are several minor changes in the cylinder liner, block and engine lifter brackets between the MBE 4000 EGR engine and the non-EGR engine. 1.4.1 EGR Cylinder Head Installation Be aware of the following notice when installing the cylinder head on an EGR engine:...
  • Page 89 EGR engine is in the area previously hardened in the non-EGR cylinder liner. Its purpose is to inhibit coke formation. All information subject to change without notice. 1-41 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 90 EGR cooler.See Figure 1-31. 1. Opening near the air compressor housing 2. Flange for attaching coolant inlet pipe Figure 1-31 EGR Cylinder Block Changes All information subject to change without notice. 1-42 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 91: Egr Front And Rear Lifter Brackets

    See Figure 1-32. 1. Front Lifter Bracket Mounting Bolts 2. Front Lifter Bracket Figure 1-32 Removal / Installation of Front Lifter Bracket All information subject to change without notice. 1-43 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 92 3. Install the rear lifter bracket using two mounting bolts. See Figure 1-33. 4. Torque the two bolts to 200 N·m (147.5 lb·ft). All information subject to change without notice. 1-44 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 93: Engine Brake

    Remove the constant-throttle valve as follows: 1. Remove the cylinder head. Refer to section 1.2.1. 2. Remove the injector nozzle. Refer to section 2.4.1. All information subject to change without notice. 1-45 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 94 Insert a spacer beneath the valve head to prevent the valve from opening while doing the rest of the removal procedures. See Figure 1-35. All information subject to change without notice. 1-46 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 95 4. Piston Seal 10. Valve 5. Collets 11. Spacer 6. Spring Retainer Figure 1-35 Constant-Throttle Valve (cutaway view, with spacer installed) All information subject to change without notice. 1-47 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 96 6. Inspect the piston and piston seal for damage and signs of wear. If necessary, replace the piston and piston seal. All information subject to change without notice. 1-48 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 97 NOTE: Always replace the valve stem seal whenever the constant-throttle valve is removed. 11. Repeat this procedure for each constant-throttle valve. All information subject to change without notice. 1-49 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 98 10. Install the injector nozzle. Refer to section 2.4.2. 11. Install the cylinder head. Refer to section 1.2.1. 12. Repeat this procedure for each constant-throttle valve. All information subject to change without notice. 1-50 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 99: Front Radial Seal

    6. Check the seal for wear at the places where it contacts the crankshaft. NOTE: When drilling holes for screws, make sure to coat the drill bit with grease to catch the shavings. All information subject to change without notice. 1-51 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 100 5. Install the three drive belts. Refer to section 8.1.1. 6. Install the support angle bracket fairing. Install the bumper beam. All information subject to change without notice. 1-52 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 101 7. Check the engine oil pressure at idle. Engine oil pressure at idle should be at least 50 kPa (7 psi). 8. Close the hood, and remove the chocks from the tires. All information subject to change without notice. 1-53 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 102: Rear Radial Seal

    1. Remove the flywheel. Refer to section 1.12.1. See Figure 1-39. 1. Flywheel 3. Flywheel Housing 2. Rear Radial Seal 4. End of Crankshaft Figure 1-39 Rear Radial Seal Location All information subject to change without notice. 1-54 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 103 2. Place the receptacle,(J 45393 or 457 589 02 15 00), on the end of the crankshaft. Put the new radial seal in place on the rear seal installer, (J 45393 or 457 589 02 15 00). All information subject to change without notice. 1-55 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 104 3. Check the sealing lip on the radial seal to make sure it is positioned correctly. 4. Install the flywheel. Refer to section 1.12.2. All information subject to change without notice. 1-56 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 105: Crankshaft Assembly

    7. Main Bearing Cap (center) 4. Lower Bearing Shell(s) 8. Main Bearing Cap Bolt Figure 1-42 Crankshaft, Main Bearings, and Main Bearing Caps All information subject to change without notice. 1-57 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 106 5. Remove the flywheel and flywheel housing. Refer to section 1.12.1. 6. Remove the front cover housing. Refer to section 1.10.1. 7. Remove the pistons. Refer to section 1.17.1. All information subject to change without notice. 1-58 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 107 2. Crankshaft Gear Figure 1-43 Aligning the Marked Gear Teeth 9. Remove the crankshaft gear from the crankshaft. Refer to section 1.9.3. All information subject to change without notice. 1-59 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 108 Removal Order, Main Bearing Cap Bolts 11. Loosen the main bearing caps with a plastic hammer, if necessary. Remove the main bearing caps. All information subject to change without notice. 1-60 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 109 Then lift the crankshaft out of the block. See Figure 1-45. 1. Crankshaft 3. Hoisting Chain 2. Flexible Straps 4. Engine Stand Figure 1-45 Attaching the Hoist All information subject to change without notice. 1-61 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 110 Clean the crankshaft, bearings, and bearing seats with a chamois. 2. Lubricate the bearing surfaces with a light coating of clean engine oil. All information subject to change without notice. 1-62 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 111 See Figure 1-44. NOTE: Make sure the numbers on the bearing caps are in ascending order, starting from the front of the engine. All information subject to change without notice. 1-63 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 112 14. Install the flywheel and flywheel housing. Refer to section 1.12.2. 15. Install the front cover housing. Refer to section 1.10.2. All information subject to change without notice. 1-64 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 113 If it doesn't, either replace the crankshaft, or have it re-hardened. [a] Place a hard base underneath the bearing journal to be tested. All information subject to change without notice. 1-65 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 114 If, for any one journal, the two measurements differ by more than 0.02 mm (0.0008 inch), replace the crankshaft. Refer to section 1.9.1. All information subject to change without notice. 1-66 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 115 Undersize - 0.75 (0.030) 103.230-103.250 (4.0642-4.0650) 93.230-93.250 (3.6705-3.6712) Undersize - 1.00 (0.040) 102.980-103.000 (4.0543-4.0551) 92.980-93.000 (3.6606-3.6614) Table 1-14 Crankshaft Journal Diameters All information subject to change without notice. 1-67 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 116 Undersize - 0.50 (0.020) 46.24-46.31 (1.820-1.823) 46.500-46.562 (1.8307-1.8331) Undersize - 1.00 (0.040) 46.74-46.81 (1.840-1.843) 47.000-47.062 (1.8504-1.8528) Table 1-16 Bearing Shell and Bearing Journal Width All information subject to change without notice. 1-68 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 117 11. Measure the fillet radius of the main journals and the connecting-rod journals as listed in Table 1-13. See Figure 1-49. Figure 1-49 Measuring the Fillet Radius All information subject to change without notice. 1-69 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 118 [a] When the main bearing caps have been installed, measure the radial play (radial runout) of the crankshaft. Refer to section 1.9.2.2. All information subject to change without notice. 1-70 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 119 1. Crankcase Race 3. Cylinder Block 2. Upper Bearing Shell 4. Bearing Shells Locking Lug Figure 1-51 Installing the Upper Bearing Shell All information subject to change without notice. 1-71 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 120 Installing the Lower Bearing Shell NOTE: The guide pins on the bearing cap ensure correct seating of the cap on the crankcase race. All information subject to change without notice. 1-72 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 121 Installing the Bearing Caps NOTE: Make sure the numbers on the bearing caps are in ascending order, starting from the front of the engine. All information subject to change without notice. 1-73 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 122 [a] Measure vertically from the top to the bottom of the bore. (see Figure 1-55, A.) [b] Measure 30 degrees counterclockwise from the separation point of the bearing shells. (see Figure 1-55, B.) All information subject to change without notice. 1-74 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 123 New bearing shells are supplied ready for installation. Do not machine them or remove any material from them. Refer to section 1.9.2. All information subject to change without notice. 1-75 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 124 Crankshaft Radial Play [a] For the main bearing shell, note the inside diameter of the bearing shell. Example: = 4.0875 inches. All information subject to change without notice. 1-76 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 125 2. Check the width of the center main bearing journal. If damage or cracks are present, replace the crankshaft. See Figure 1-57. Figure 1-57 Measuring the Width of the Center Journal All information subject to change without notice. 1-77 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 126 = 1.8120 inches. [b] For the center main bearing shell, note the width (thickness) of the bearing shell. Example: W =1.8030 inches. All information subject to change without notice. 1-78 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 127 [a] Set up a dial gauge and a dial gauge holder on the front end of the crankshaft. Set the dial gauge to 5 mm (0.2 inch) preload. All information subject to change without notice. 1-79 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 128 3. Crankshaft Gear 2. Guide Pin Figure 1-60 Removing the Crankshaft Gear 5. Remove the crankshaft from the engine. Refer to section 1.9.1. All information subject to change without notice. 1-80 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 129 7. Press the gear onto the end of the crankshaft. Make sure the chamfer on the gear is facing outward. See Figure 1-60. 8. Install the crankshaft. Refer to section 1.9.2. 9. Install the engine. All information subject to change without notice. 1-81 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 130: Front Cover Housing

    2. Tilt the hood. 3. Remove the front engine mounting bolts attaching the front cover housing to the front crossmember. All information subject to change without notice. 1-82 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 131 Tighten the front engine mounting bolts 325 N·m (240 lb·ft). 10. Close the hood, and remove the chocks from the tires. All information subject to change without notice. 1-83 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 132: Crankshaft Vibration Damper

    3. Oil Deflector 2. Mounting Bolt 4. End of Crankshaft Figure 1-62 Vibration Damper Removal 5. Remove the oil deflector from the crankshaft. All information subject to change without notice. 1-84 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 133 Tighten the inspection cover bolts 25 N·m (18 lb·ft). 5. Install the drive belts on their pulleys, as removed. Refer to section 8.1. All information subject to change without notice. 1-85 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 134: Flywheel

    (J 46167 or 407 589 00 63 00). Insert the pin and make sure the tool is blocked. Refer to section 1.15.2. All information subject to change without notice. 1-86 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 135 See Figure 1-64. 1. Flywheel Mounting Bolt (10 qty.) 2. Flywheel Figure 1-64 Flywheel (exploded view) All information subject to change without notice. 1-87 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 136 See Figure 1-65. 1. Bolt used as a handle 2. Flywheel Mounting Bolt Figure 1-65 Flywheel Removal All information subject to change without notice. 1-88 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 137 [b] Using the two bolts as handles, dislodge the flywheel from the crankshaft flange and remove it from the flywheel housing. [c] After removing the flywheel, remove the bolts from the clutch bolt holes. All information subject to change without notice. 1-89 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 138 Refer to section 1.13.1. 1.12.2 Flywheel Installation Install the flywheel as follows: 1. Grease the ring gear with a suitable heavy-duty grease. All information subject to change without notice. 1-90 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 139 Verify the alignment of the crankshaft dowel with the guide hole in the flywheel. 4. With a light coating of engine oil, lubricate the threads of the ten multipoint socket-head flywheel bolts. All information subject to change without notice. 1-91 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 140 1. Remove the flywheel. Refer to section 1.12.1. 2. Thoroughly clean the flywheel and check it for cracks, scoring, burned areas, or rough spots. All information subject to change without notice. 1-92 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 141 If the width of the flywheel between the friction surface and the mounting flange is less than 60 mm (2.4 inches), replace the flywheel. All information subject to change without notice. 1-93 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 142 See Figure 1-70for the locations on the flywheel to coordinate with the specifications in the table. Figure 1-69 Machining the Flywheel Friction Surface All information subject to change without notice. 1-94 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 143 2. Check the radial and lateral deviation from true of the flywheel. The deviation from true must not exceed 0.2 mm (0.008 inch). 3. Install the flywheel. Refer to section 1.12.2. All information subject to change without notice. 1-95 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 144: Ring Gear

    Ring Gear Replacement Replace the flywheel ring gear as follows: 1. Remove the flywheel from the crankshaft flange. Refer to section 1.12.1. All information subject to change without notice. 1-96 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 145 2. Heat the ring gear on the flywheel with a torch and press the gear off. See Figure 1-72. Figure 1-72 Heating the Ring Gear All information subject to change without notice. 1-97 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 146 (A) from the flywheel shoulder diameter (B). [d] Make sure that the amount of interference fit lies between 0.295 and 0.645 mm (0.0116 and 0.0254 inch). All information subject to change without notice. 1-98 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 147 With the ring gear pressed onto the flywheel, make sure the radial run-out of the ring gear does not exceed 0.5 mm (0.02 inch). 8. Install the flywheel on the crankshaft flange. Refer to section 1.12.2. All information subject to change without notice. 1-99 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 148: Pilot Bearing

    Pilot Bearing Removal 1.14.2 Pilot Bearing Installation Install the pilot bearing as follows: 1. Lubricate the new bearing with longlife grease. All information subject to change without notice. 1-100 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 149 3. Flywheel 2. Pilot Bearing Figure 1-76 Pilot Bearing Installation 3. Install the clutch on the flywheel. 4. Install the transmission. All information subject to change without notice. 1-101 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 150: Engine Cranking Tool

    Engine Cranking Tool Installation 2. Remove the pin from the engine cranking tool (J 46167 or 407 589 00 63 00). All information subject to change without notice. 1-102 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 151 The engine cranking tool must be removed from the timing case before starting the engine. Failure to do so could damage the flywheel ring gear. All information subject to change without notice. 1-103 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 152: Flywheel Housing

    3. Camshaft (TDC) Sensor 8. Starter 4. Flywheel Housing 9. Rear Radial Seal 5. Gasket Figure 1-78 Flywheel Housing Assembly (exploded view) All information subject to change without notice. 1-104 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 153 11. Install the camshaft (TDC) sensor. Refer to section 1.22.3. 12. Install the crank angle position sensor. Refer to section 2.6.3. 13. Install the engine. All information subject to change without notice. 1-105 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 154: Piston, Piston Ring, And Connecting Rod

    1. Remove the engine from the vehicle. NOTE: The MBE 4000 engine has individual heads for each cylinder. To remove one piston, do these procedures step by step. To remove all the pistons, repeat each step in these instructions, as applicable, for all six pistons.
  • Page 155 6. Be sure the connecting rods and the bearing caps are marked so that they can be matched for installation. See Figure 1-80. 1. Bearing Cap 2. Connecting Rod Figure 1-80 Checking Rod and Bearing Cap Markings All information subject to change without notice. 1-107 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 156 7. Remove and inspect the oil spray nozzles. See Figure 1-81. Refer to section 3.2.1. Replace them if damaged. 1. Oil Spray Nozzle 2. Cylinder Liner Figure 1-81 Location of Oil Spray Nozzle All information subject to change without notice. 1-108 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 157 13. Remove the wrist-pin snap rings. Push the wrist pin out and remove the piston from the connecting rod. 1.17.2 Piston Installation Install the piston assembly as follows: All information subject to change without notice. 1-109 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 158 [a] Lubricate the wrist pin with a light coating of clean engine oil. [b] Insert the wrist pin into the wrist pin bore. [c] Secure the wrist pin with the two snap rings. All information subject to change without notice. 1-110 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 159 4. Offset the ring gaps alternately by 120 degrees. 5. Position a ring compressor loosely over the piston. Tighten the ring compressor on the piston. All information subject to change without notice. 1-111 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 160 [b] Lubricate the bearing surface with a light coating of clean engine oil. 7. Lubricate the cylinder liners with a light coating of clean engine oil. All information subject to change without notice. 1-112 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 161 [a] Be sure that the locking lug in the bearing shell is fully seated in the groove of the cap. [b] Lubricate the bearing surface with a light coating of clean engine oil. All information subject to change without notice. 1-113 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 162 If it is necessary to turn the crankshaft and the flywheel has been removed, install the flywheel guide studs in the crankshaft gear. All information subject to change without notice. 1-114 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 163 Refer to section 3.1.2. 19. Install the oil pan. Refer to section 3.1.2. 20. Install each cylinder head, as removed. Refer to section 1.2.2. All information subject to change without notice. 1-115 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 164 3. Double Chamfered Oil Control Ring with Garter Spring (Groove III) 2. Taper Face Ring with Internal Angle (Groove II) 4. Piston Figure 1-89 Piston Rings All information subject to change without notice. 1-116 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 165 Check the end gap of the upper two piston rings first. The garter spring must be removed from the third (lowest) piston ring before you can measure its end gap. All information subject to change without notice. 1-117 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 166 [b] Remove the spring garter from the third (lowest) ring, then measure its gap in the same way as the other two rings. All information subject to change without notice. 1-118 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 167 Install the rings in the reverse order of their removal; from the bottom to the top of the piston. All information subject to change without notice. 1-119 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 168 7. Install the piston. Refer to section 1.17.2. 1.17.3.1 Piston Inspection Inspect the piston as follows: 1. Remove the piston. Refer to section 1.17.1. All information subject to change without notice. 1-120 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 169 3. Inspect the cylinder liner and piston for damage and signs of wear. Replace any piston with damage to the snap ring grooves, cracks in the piston wall, or signs of seizing and/or erosion. All information subject to change without notice. 1-121 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 170 6. Check the connecting rod for any unusual condition. Refer to section 1.17.3.2. 7. Measure the diameters of the bearing shell bore and crankshaft journals. Refer to section 1.17.3.3 for instructions. All information subject to change without notice. 1-122 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 171 2. Inspect the connecting rod for blue discoloration (indicates bearing damage), scoring, notches, and cracks. If any of these conditions are found, replace the connecting rod. All information subject to change without notice. 1-123 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 172 Checking the connecting rod for a twisted or bent condition in the next step requires machine shop equipment such as a caliper gauge with a round scale. All information subject to change without notice. 1-124 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 173 [a] On each side of the connecting rod, measure the length of the connecting rod (Dimension A in see Figure 1-98) : the distance from the center bearing bore (big-end All information subject to change without notice. 1-125 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 174 1. Remove the piston. Refer to section 1.17.1. 2. Using a chamois cloth, clean the bearing bores in both the connecting rod and the bearing cap. All information subject to change without notice. 1-126 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 175 108 N·m (80 lb·ft) 68.5 mm (2.70 in) Stage 2 additional 90 degrees Table 1-29 Tightening Stages, Connecting Rod Stretch Bolts All information subject to change without notice. 1-127 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 176 [a] Measure the bearing journal in the vertical plane and note the reading. [b] Measure the bearing journal in the horizontal plane and note the reading. All information subject to change without notice. 1-128 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 177 8. Place the connecting rod in a vise with protective jaws. To prevent the rod from twisting excessively, position the rod in the vise as close as possible to the big-end bore. All information subject to change without notice. 1-129 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 178 10. Using a quick-release caliper (internal measurement 80-120 mm), dial gauge, and holder, measure the inside diameter of the bearing bore (with the shells installed) at three points. All information subject to change without notice. 1-130 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 179 To obtain a correct value for connecting-rod radial play, the diameters of each bearing bore and its corresponding journal must belong to the same repair stage (both must be "standard," "undersize 0.1 mm," etc.). All information subject to change without notice. 1-131 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 180 In the above example, both measurements belonged to repair stage "undersize 0.1 mm." 12. Remove the bearing cap from the connecting rod. 13. Install the piston. Refer to section 1.17.2. All information subject to change without notice. 1-132 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 181 2. Check the bushing bore in the connecting rod. If surface material is missing from the bushing bore, replace the connecting rod. All information subject to change without notice. 1-133 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 182 7. Measure the inside diameter of the bushing. If the measurement is shorter than 52.05 mm (2.049 in.), machine the inside contact surface of the bushing until the measurement is correct. All information subject to change without notice. 1-134 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 183: Egr Piston, Piston Ring, And Connecting Rod

    1. Cylinder Liner 3. Installed Piston 2. Carbon Scraper Ring 4. Installed Carbon Scraper Ring Figure 1-104 Removing Carbon Scraper Ring All information subject to change without notice. 1-135 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 184 There are NO arrows on the top of the EGR piston to direct the installation. The piston can be installed in any direction and it will be correct. All information subject to change without notice. 1-136 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 185 5. Check carbon scraper ring for correct fit after installation. 6. Follow remaining steps for piston installation in a non-EGR engine . Refer to section 1.17.2. All information subject to change without notice. 1-137 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 186: Valves

    3. Select the first cylinder. Using the engine cranking tool (J 46167 or 407 589 00 63 00), turn the flywheel until the piston in that cylinder is at ignition TDC (top dead center). All information subject to change without notice. 1-138 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 187 4. Adjust the valve lash. See Figure 1-106. Refer to section 1.19.3. 1. Rocker Arm 3. Valve Spring Retainer 2. Valve Bridge Figure 1-106 Valve Lash and Valve Lift All information subject to change without notice. 1-139 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 188 15 mm (0.60 inch) to provide adequate travel for checking the intake valve lift. [b] Set the scale on the dial gauge to "0" (zero). All information subject to change without notice. 1-140 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 189 3. Exhaust Rocker Arm Figure 1-108 Checking Valve Lift, Exhaust Valves [a] Turn the flywheel in a counterclockwise direction until both valves are closed. All information subject to change without notice. 1-141 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 190 Each Cylinder in Firing Order); By type of valve, depending on crankshaft position (see Method Two—Adjust All Valves Using Two Crankshaft Positions). All information subject to change without notice. 1-142 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 191 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru See Figure 1-109 for the cylinder and valve layout on MBE 4000 engines. Figure 1-109 Cylinder and Valve Layout 1.19.2.1 Method One — Adjust Each Cylinder in Firing Order Method one allows you to adjust each cylinder in the order in which fuel is injected. The crankshaft must be repositioned after each cylinder is adjusted as listed in Table 1-35.
  • Page 192 2. Cylinder Head Cover 4. Cylinder Head Figure 1-110 Cylinder Head Cover, (exploded view) 2. Remove the inspection cover on the flywheel housing. All information subject to change without notice. 1-144 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 193 6. For each valve, measure the valve lash with a feeler gauge between the rocker arm and valve bridge. It should be possible to pull the feeler gauge through with no more than light resistance. All information subject to change without notice. 1-145 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 194 2. Cylinder Head Cover 4. Cylinder Head Figure 1-112 Cylinder Head Cover, (exploded view) 2. Remove the inspection cover on the flywheel housing. All information subject to change without notice. 1-146 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 195 3. Fit the engine cranking tool (J 46167 or 407 589 00 63 00) into the inspection hole on the flywheel housing. See Figure 1-113 . 1. Inspection Cover 2. Cranking Device Figure 1-113 Placement of the Cranking Tool All information subject to change without notice. 1-147 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 196 6. Using the cranking tool, turn the crankshaft until cylinder #6 is at the ignition TDC position (all valves are closed) and cylinder #1 is at the valve overlap position (all valves are open). All information subject to change without notice. 1-148 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 197 If the value measured is outside the range given in the "Check For" column listed in Table 1-36, adjust the valve lash. 1.19.3 Valve Lash Adjusting Adjust the valve lash as follows: All information subject to change without notice. 1-149 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 198 Measuring Valve Standback Measure the valve standback as follows: 1. Remove the cylinder head from the engine. Refer to section 1.2.1. All information subject to change without notice. 1-150 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 199 Setting the Dial Gauge Preload NOTE: Before doing this procedure, make sure the valve head is making contact with the valve seat. All information subject to change without notice. 1-151 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 200 0.7 mm (0.03 inch), or more than 1.1 mm (0.04 inch), the valve standback is not within specifications. All information subject to change without notice. 1-152 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 201 Remove the intake and exhaust valves as follows: NOTE: The MBE 4000 engine has individual heads for each cylinder. To replace the valves on one head, follow these instructions, step by step. To replace all the valves, repeat these instructions for all six cylinder heads.
  • Page 202 4. Attach the valve spring adaptor and remover, (J 46173), to the cylinder head. See Figure1-118. 1. Valve 2. Cylinder Head Figure 1-118 Valve Removal All information subject to change without notice. 1-154 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 203 7. Turn over the cylinder head and remove the valves. NOTE: Mark the valves in order for ease of installation. All information subject to change without notice. 1-155 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 204 8. With the cylinder head again in the upright position, remove and discard the valve stem seals. See Figure 1-120. 1. Valve Stem Seal 3. Cylinder Head 2. Valve Guide Figure 1-120 Valve Stem Seals All information subject to change without notice. 1-156 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 205 12. Check the following critical valve dimensions, and repair as necessary. See Figure 1-122 to determine the dimensions given in the table. Listed in Table 1-42 are the dimensions. Valve stem diameter (A) All information subject to change without notice. 1-157 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 206 Table 1-42 Valve Removal/Installation Specifications in mm (inches) 13. Check the condition of the valve seat insert. Repair the valves if necessary. All information subject to change without notice. 1-158 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 207 1. Remove the cylinder head from the engine. Refer to section 1.2.1. NOTE: Use care during removal to not damage the valve guides and valve stems. All information subject to change without notice. 1-159 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 208 8. Install the collets, spring retainer, valve spring and spring base, as removed. 9. Repeat the procedure for the other valves. 10. Install the cylinder head. Refer to section 1.2.2. All information subject to change without notice. 1-160 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 209: Egr Valves

    EGR valves. Valve stem diameter (A) Valve seat diameter at the contact surface of the cylinder head (B) Valve head diameter (C) All information subject to change without notice. 1-161 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 210 Valve length (G) 145.0 (5.71) 145.0 (5.71) 145.0 (5.71) Table 1-44 Valve Removal/Installation Specifications in mm (in.) for non-EGR and EGR engines All information subject to change without notice. 1-162 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 211 7. Install the valve stem sealing ring in the valve guide and then install the valve in the head. Repeat procedure for all remaining valves. All information subject to change without notice. 1-163 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 212 14. Install the keeper, spring retainer, valve spring and spring seat, as removed. 15. Repeat the procedure for the other valves. All information subject to change without notice. 1-164 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 213 (G) Relative position (H) to 4.00-4.15 (0.157-0.163) 3.80-3.95 (0.15-0.16) 4.00-4.15 (0.157-0.163) diameter G Table 1-45 Valve Seat Specifications for EGR Engine All information subject to change without notice. 1-165 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 214: Rocker Arm

    3. Inspect the rocker arm assembly for wear. If necessary, disassemble the rocker arm assembly and replace any worn parts. Refer to section 1.21.2. All information subject to change without notice. 1-166 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 215 5. Intake Rocker Arm 2. Washer 6. Locknut 3. Exhaust Rocker Arm 7. Adjusting Screw 4. Rocker Support Figure 1-129 Rocker Arm Components All information subject to change without notice. 1-167 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 216 1. Install a valve bridge on each set of valves, both intake and exhaust. 2. Lubricate each pushrod with a light coating of engine oil. All information subject to change without notice. 1-168 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 217 [c] Tighten each mounting bolt 60 N·m (44 lb·ft). Final angular tightening: 90 degrees. 5. Adjust the valve lash. 6. Install the cylinder head cover on each cylinder head. Refer to section 1.1.2. All information subject to change without notice. 1-169 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 218: Camshaft And Camshaft Sensor

    3. Remove the unit pumps. Refer to section 2.1.1. 4. Remove the vibration damper. Refer to section 1.11.1. 5. Remove the fan support. All information subject to change without notice. 1-170 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 219 6. Remove the eight mounting bolts attaching the camshaft front cover to the cylinder block. See Figure 1-130. Figure 1-130 Removing the Camshaft Front Cover All information subject to change without notice. 1-171 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 220 9. Turn the engine on the stand until it is upside down. 10. Remove the oil pan. Refer to section 3.1.1. 11. Remove the flywheel housing. Refer to section 1.16.1. All information subject to change without notice. 1-172 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 221 Attaching the Camshaft Guide Tool 13. From the gear end (rear of the engine), carefully remove the camshaft from the block. See Figure 1-132. All information subject to change without notice. 1-173 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 222 [a] Measure the outside diameter of each tappet. [b] Measure the diameter of the tappet housing in the cylinder block. 16. Inspect the camshaft. Refer to section 1.22.2.1. All information subject to change without notice. 1-174 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 223 [d] Carefully insert the camshaft into the block. 4. Install the flywheel housing. Refer to section 1.16.2. 5. Install the oil pan. Refer to section 3.1.2. All information subject to change without notice. 1-175 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 224 NOTE: To get a correct hardness reading, it is critical to place a hard base below the cam or bearing journal. All information subject to change without notice. 1-176 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 225 A hard base should be placed below the cam or bearing journal to be inspected. See Figure 1-135. 1. Camshaft Figure 1-135 Inspecting Cam Hardness All information subject to change without notice. 1-177 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 226 6. Measure the cam rise of the exhaust valve cams. See Figure 1-136, Ref. E. 7. Measure the cam rise of the unit pump valve cams. See Figure 1-136, Ref. U. All information subject to change without notice. 1-178 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 227 Cam Gear to Crank Gear 0.074–0.176 (0.0029–0.0069) Gear Back Lash Cam Gear to Air Compressor Gear 0.082–0.168 (0.0032–0.0066) Table 1-50 Camshaft Specifications All information subject to change without notice. 1-179 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 228 3. Install a new sensor in the flywheel housing. 4. Connect the electrical connector. NOTE: Be sure that the correct electrical connector is connected to the sensor. All information subject to change without notice. 1-180 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 229 The holes in the camshaft journal must be lined up with the holes in the camshaft bushing. 1. Bushing Groove Figure 1-138 Camshaft Bushing Installation All information subject to change without notice. 1-181 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 230 1.23 EGR CAMSHAFT www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 1-182 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 231 Piston, Piston Ring and Connecting Rod ............1-191 Valves ......................1-193 Rocker Arm ....................1-196 Camshaft and Camshaft Sensor ..............1-197 Sensor and Fittings ..................1-198 All information subject to change without notice. 1-183 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 232: Specifications

    The torque specifications for the cylinder head cover are listed in Table 1-51. Description Torque Value Cylinder Head Cover Bolts 20 N·m (15 lb·ft) Table 1-51 Cylinder Head Cover Torque Values All information subject to change without notice. 1-184 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 233: Cylinder Head

    Engine at Idle Speed 50 kPa (7 psi) Engine at Max. rpm 250 kPa (36 psi) Table 1-56 Oil Pressure Readings All information subject to change without notice. 1-185 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 234 Table 1-59 Compression Pressure Test Data Description N·m (lb·ft) Tensioning Arm Bolts 50 (37) Table 1-60 Tensioning Arm Bolt Torque Values All information subject to change without notice. 1-186 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 235: Cylinder Block

    Cylinder Liner Protrusion From Block 0.245–0.315 (0.0096–0.0124) Difference Between the Four Measuring Points Max.: 0.02 (0.0007) Table 1-64 Specifications for Measuring Cylinder Liner Protrusion All information subject to change without notice. 1-187 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 236: Crankshaft Assembly

    Undersize - 0.50 (0.020) 46.24-46.31 (1.820-1.823) 46.500-46.562 (1.8307-1.8331) Undersize - 1.00 (0.040) 46.74-46.81 (1.840-1.843) 47.000-47.062 (1.8504-1.8528) Table 1-67 Bearing Shell and Bearing Journal Width All information subject to change without notice. 1-188 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 237 71.20 mm (2.803 in.) Stage 1 150 (111) (2.754 - 2.756 in.) Stage 2 Additional 90 Table 1-71 Torque Values for Crankshaft Counterweight Bolts All information subject to change without notice. 1-189 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 238: Flywheel And Flywheel Housing

    Flywheel Housing Mounting Bolts (to cylinder block) 70 (52) Vibration Damper Mounting Bolts (to crankshaft) 200 (148) Table 1-74 Torque Values for Flywheel and Flywheel Housing All information subject to change without notice. 1-190 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 239: Piston, Piston Ring And Connecting Rod

    Piston Compression Height 79.50-79.55 (3.130-3.132) Wrist Pin Bore Diameter 52.03-52.04 (2.0484-2.0488) Wrist Pin Diameter 51.992-51.998 (2.0469-2.0472) Table 1-78 Piston Inspection Specifications All information subject to change without notice. 1-191 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 240 Undersize - 0.75 (0.030) 93.304-93.346 (3.6764-6.6750) Undersize - 1.00 (0.040) 93.054-93.096 (3.6635-3.6652) Table 1-82 Bearing Bore Inside Diameter with Bearing Shells Installed All information subject to change without notice. 1-192 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 241: Valves

    Table 1-90. The measurements for valve seat specifications for an EGR engine are listed in Table 1-91. All information subject to change without notice. 1-193 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 242 Outside Diameter of Spring Coil 28.9 (1.14) Inside Diameter of Spring Coil 24.5-24.9 (0.96-0.98) Table 1-88 Spring Specifications, Intake and Exhaust Valves All information subject to change without notice. 1-194 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 243 (G) Relative position (H) to 4.00-4.15 (0.157-0.163) 3.80-3.95 (0.15-0.16) 4.00-4.15 (0.157-0.163) diameter G Table 1-91 Valve Seat Specifications for EGR Engine All information subject to change without notice. 1-195 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 244: Rocker Arm

    Bushing Inside Diameter (when installed) 25.005-25.021 mm (0.9844-0.9851 in) Shaft Diameter 24.967-24.980 mm (0.9830-0.9835 in) Table 1-94 Rocker Arm Bushing Specifications All information subject to change without notice. 1-196 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 245: Camshaft And Camshaft Sensor

    Valve Tappet Specifications Fastener Type N·m (lb·ft) Camshaft Front Cover 50 (37) Fuel Pump Drive Gear 60 (44) Table 1-97 Camshaft Torque Values All information subject to change without notice. 1-197 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 246: Sensor And Fittings

    Coolant Temperature Sensor to the Engine Block 30 (22) Trim Cover Bolts 12 (9) Table 1-98 Sensor and Fittings Torque Values All information subject to change without notice. 1-198 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 247: Aadditional Information

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru FUEL SYSTEM Section Page INJECTOR UNIT PUMP ................EGR INJECTOR UNIT PUMP ..............2-11 FUEL INJECTOR LINE ................2-13 FUEL INJECTOR NOZZLE ..............2-18 EGR FUEL INJECTOR NOZZLE ............. 2-24 PROTECTIVE SLEEVE ................2-25 DDEC ELECTRONIC CONTROL UNIT ........... 2-29 FUEL HEAT EXCHANGER ..............
  • Page 248 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 249: Injector Unit Pump

    Unscrewing the fuel filter cap releases pressure in the fuel system, causing fuel to flow through the return lines and back into the tank. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 250 5. Disconnect the fuel line at the fuel gallery inlet. Have a suitable container ready to catch any fuel that comes out of the cylinder block or fuel line. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 251 7. Remove the end cover from the lower right side of the flywheel housing, then attach the engine cranking tool (J 46167 or 407 589 00 63 00). All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 252 9. Using the cranking tool (J 46167 or 407 589 00 63 00), rotate the crankshaft until the cam pushes the unit pump upwards. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 253 See arrow in see Figure 2-5. Figure 2-5 Releasing a Locked-up Pump All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 254 Injector Unit Pump Installation Install the injector unit pump as follows: 1. Lubricate two new O-rings with a light coating of engine oil. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 255 6. Remove the engine cranking tool and replace the inspection cover on the flywheel housing. Tighten the inspection cover mounting bolts 25 N·m (18 lb·ft). All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 256 12. Start the engine and check for leaks. Tighten connections as needed. 13. Install the engine trim cover. All information subject to change without notice. 2-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 257: Egr Injector Unit Pump

    3. Enter the unit pump identification Number found on the top of the unit pump. 4. Press enter. 5. Press double-arrow back key. All information subject to change without notice. 2-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 258 EGR INJECTOR UNIT PUMP www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru 6. Turn off key and unplug minidiag2. 7. Install the unit pump. Refer to section 2.1.2. All information subject to change without notice. 2-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 259: Fuel Injector Line

    Perform the following procedures for removal and installation of the fuel injector line. 2.3.1 Fuel Injector Line Removal Remove the fuel injector line as follows: All information subject to change without notice. 2-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 260 1. Remove the engine trim cover. NOTE: The MBE 4000 engine has individual heads for each cylinder. To remove the injector line for one cylinder, do these procedures step by step. To remove all the injector lines, repeat each step in these instructions, as applicable, for all six cylinders.
  • Page 261 4. Using the injector line torque wrench adaptor (J 45062), loosen the injector line nuts at the transfer tube and at the injector unit pump. All information subject to change without notice. 2-15 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 262 3. Using the injector line torque wrench adaptor, (J 45062), tighten the injector line nuts at the transfer tube and at the unit pump. The final torque on the bolt must be 30 N·m (22 lb·ft). All information subject to change without notice. 2-16 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 263 6. Run the engine and check for leaks. Tighten the connections as needed. 7. Shut down the engine and install the engine trim cover. All information subject to change without notice. 2-17 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 264: Fuel Injector Nozzle

    1. Remove the engine trim cover. NOTE: The MBE 4000 engine has individual heads for each cylinder. To remove the injector nozzle for one cylinder, do these procedures step by step. To remove all the injector nozzles, repeat each step in these instructions, as applicable, for all six cylinders.
  • Page 265 Fuel Injection System (exploded view) 5. Remove the thrust bolt and the transfer tube. Discard the old O-ring. 6. Remove the tensioning arm. All information subject to change without notice. 2-19 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 266 10. Cap off or cover the openings in the fuel lines to prevent contamination of the fuel. 2.4.2 Fuel Injector Nozzle Installation Install the fuel injector nozzle as follows: All information subject to change without notice. 2-20 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 267 3. Install a new seal ring on the nozzle. NOTE: Take care that the nozzle is installed correctly and is aligned properly with respect to the transfer tube. All information subject to change without notice. 2-21 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 268 5. Install the retaining bolt in the tensioning arm. Tighten the bolt 50 N·m (37 lb·ft). NOTE: The tensioning arm insures the correct positioning of the nozzle. All information subject to change without notice. 2-22 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 269 9. Install the charge-air manifold. Refer to section 6.1.2. 10. Install the cylinder head cover(s), as removed. Refer to section 1.1.2. 11. Install the engine trim cover. All information subject to change without notice. 2-23 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 270: Egr Fuel Injector Nozzle

    EGR engine. Verify correct nozzle before insertion into engine. NOTE: There is no fuel return hole on EPA 04 EGR fuel nozzles. All information subject to change without notice. 2-24 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 271: Protective Sleeve

    1. Drain the engine coolant into a clean container. If the coolant is clean, save it for later use. 2. Remove the injector nozzle. All information subject to change without notice. 2-25 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 272 3. Using the claw-foot wrench (904 589 00 07 00), remove the protective sleeve from the cylinder head. See Figure 2-15. 1. Protective Sleeve 2. O-ring Figure 2-15 Pulling the Protective Sleeve All information subject to change without notice. 2-26 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 273 5. Fill the cooling system with clean coolant. 2.6.3 Crank Angle Position Sensor Replacement Replace the crank angle position sensor as follows: All information subject to change without notice. 2-27 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 274 3. Install a new sensor in the flywheel housing. 4. Connect the electrical connector. NOTE: Be sure that the correct electrical connector is connected to the sensor. All information subject to change without notice. 2-28 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 275: Ddec Electronic Control Unit

    2.7.1 DDEC Electronic Control Unit Removal Remove the DDEC-ECU Control Unit as follows: 1. Disconnect the batteries. 2. Open the hood. All information subject to change without notice. 2-29 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 276 6. Engine Wiring Harness 13. Heat Exchanger Case Bolt 7. Fuel Feed Line 14. DDEC-ECU Case Bolt Figure 2-18 DDEC-ECU Control Unit All information subject to change without notice. 2-30 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 277 DDEC-ECU unit. See Figure 2-19. 1. Vehicle Electrical Connector 2. Vehicle Wiring Harness Figure 2-19 Vehicle Electrical Connector All information subject to change without notice. 2-31 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 278 (6 lb·ft). 4. Connect the vehicle wiring harness to the DDEC-ECU. Pull down on the locking unit to lock it in place. All information subject to change without notice. 2-32 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 279 Do not modify or tamper with the exhaust system or emission control system. 8. Close the hood. Then check for normal operation. All information subject to change without notice. 2-33 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 280: Fuel Heat Exchanger

    Do not smoke when refueling. 1. Disconnect the batteries. 2. Open the hood. All information subject to change without notice. 2-34 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 281 4. Remove the mounting bolts attaching the fuel heat exchanger to the DDEC-ECU control unit. Then remove the fuel heat exchanger. NOTE: Do not disassemble the fuel heat exchanger. It cannot be serviced. All information subject to change without notice. 2-35 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 282 50 N·m (37 lb·ft). 3. Close the hood. 4. Connect the batteries. 5. Prime the fuel system. Refer to section 2.9.2. All information subject to change without notice. 2-36 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 283: Fuel Filter

    1. Disconnect the batteries. 2. Open the fuel fill cap to release pressure in the fuel system. Replace and tighten the cap. All information subject to change without notice. 2-37 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 284 10. Fuel Return Line 4. O-ring 5. Fuel Filter Cap 11. Fuel Drain Line 6. Banjo Bolt Figure 2-22 Removing the Filter Housing All information subject to change without notice. 2-38 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 285 [a] Make sure that all high-pressure lines have been tightened to 30 N·m (22 lb·ft) and all banjo bolts to 50 N·m (37 lb·ft). All information subject to change without notice. 2-39 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 286 Tighten the high-pressure lines and repeat the priming procedure. 7. With the engine running, check the fuel filter for leaks. Shut down the engine. All information subject to change without notice. 2-40 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 287: Egr Fuel Filter

    1. Fuel Filter-to-Bracket Threaded Mounting Bolts 3. Bracket Mounting Bolts 2. Fuel Filter Mounting Bracket Figure 2-23 Removal or Installation of EGR Fuel Filter Bracket All information subject to change without notice. 2-41 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 288 3. Attach fuel inlet, fuel outlet, and fuel drain connection hoses to the fuel filter. All information subject to change without notice. 2-42 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 289: Fuel Pump

    Do not smoke when refueling. 1. Disconnect the batteries. All information subject to change without notice. 2-43 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 290 4. Slowly remove the fuel pump from the engine, taking care not to damage the splined shaft on the fuel pump. 5. Discharge the fuel pump gasket. All information subject to change without notice. 2-44 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 291 [c] Install and tighten the three socket-head bolts that attach the fuel pump to the cylinder block. Tighten the socket-head bolts 25 N·m (18 lb·ft). All information subject to change without notice. 2-45 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 292 5. With the engine running, check the fuel pump and the rest of the fuel system for leaks. Shut down the engine. All information subject to change without notice. 2-46 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 293 30 N·m (22 lb·ft) Table 2-2 Torque Specifications for Fuel Line Nuts 5. Perform a fuel pressure test. Refer to section 2.12.1. All information subject to change without notice. 2-47 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 294 4. Fuel Outlet Line 2. Fuel Filter Housing 5. Unit Pump 3. Mechanical Gauge Figure 2-26 Gauge Installation – After the Fuel Filter All information subject to change without notice. 2-48 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 295 Mercedes-Benz kit or SPX kit. This fitting is a component and it can be ordered from Canton PDC under part number 915039012205. All information subject to change without notice. 2-49 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 296 (29 psi). Check the fuel pump assembly (bearing and/or driven gear). Check to see if the fuel system is drawing air. All information subject to change without notice. 2-50 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 297 Check the fuel pressure valve for a blocked or restricted regulator orifice. 2.12.2 Performing a Fuel System Test using minidiag2 To perform a fuel system test using minidiag2, perform the following steps: All information subject to change without notice. 2-51 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 298 This test measures the percentage of fuel delivery for each cylinder in order to maintain a smooth operation at idle. Operational range for this test: from -3% (negative) to 3% (positive). All information subject to change without notice. 2-52 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 299 Refer to section 2.1.1 for unit pump removal and refer to section 2.1.2 for unit pump installation. If the condition follows the unit pump, replace the unit pump. All information subject to change without notice. 2-53 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 300 2. Fuel Pump Drive Gear Splines Figure 2-28 Checking Fuel Pump Drive Gear 4. Remove the fuel pump drive gear cover. All information subject to change without notice. 2-54 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 301 9. Apply Loctite 574 sealant and install the cover. Torque 50 N·m (37 lb·ft). 10. Install new gasket and the fuel pump. Torque to the fuel pump bolts will be 25 N·m (18 lb·ft). All information subject to change without notice. 2-55 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 302 2.12 FUEL SYSTEM INSPECTION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 2-56 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 303 27 (20) 25 (18) 30 (22) Transfer Tube Thrust Bolt 40 (30) 36 (27) 45 (33) Table 2-5 Injector Lines Torque Values All information subject to change without notice. 2-57 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 304 Turbo Brake Control, switch to Bat- (PV6) Turbo Brake Voltage Supply (PV6) Table 2-7 Current Harness Connector A460 150 01 33 All information subject to change without notice. 2-58 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 305 Fuel Pump Driven Gear Bolt 30 (22) Fuel Temperature Sensor to Engine Block 30 (22) Table 2-10 Fuel System Torque Values All information subject to change without notice. 2-59 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 306 Figure 2-30 DDEC-ECU Control Unit Wiring All information subject to change without notice. 2-60 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 307 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru Figure 2-31 DDEC-ECU Control Unit Wiring, VCU Interface All information subject to change without notice. 2-61 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 308 Figure 2-32 DDEC-ECU Control Unit Wiring, Proportioning Valves and Oil System Sensors All information subject to change without notice. 2-62 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 309 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru Figure 2-33 DDEC-ECU Control Unit Wiring, Miscellaneous Sensors All information subject to change without notice. 2-63 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 310: Fuel System Inspection

    Maximum difference between fuel filter housing 0.3 bar (4 psi) inlet and outlet pressure Table 2-12 Fuel System Specifications for Pressure All information subject to change without notice. 2-64 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 311: Additional Information

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru LUBRICATION SYSTEM Section Page OIL PAN ....................OIL SPRAY NOZZLE ................EGR CAMSHAFT LUBRICATION SPRAYER .......... 3-13 OIL PUMP ....................3-14 EGR OIL PUMP AND PICK UP TUBE ............. 3-21 OIL FILTER ....................3-23 OIL HEAT EXCHANGER AND FILTER HOUSING ........3-26 OIL PRESSURE AND TEMPERATURE SENSOR ........
  • Page 312 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 313: Oil Pan

    3. Loosen all front suspension shackle bolts. 4. Remove the front spring bolts and shock absorber bolts. Using the floor jack, lower the axle to the ground. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 314 18. Fill Tube Flatwasher 9. Oil Fill Tube Retainer 19. Fill Tube Bolt 10. Oil Fill Retainer Bolt Figure 3-2 Oil Pan Removal and Installation All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 315 10. Remove and discard the oil pan gasket. Save the bolts. 11. Thoroughly clean the pan. Remove all traces of gasket material from the pan and from the block. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 316 Tighten the drain plug 80 N·m (59 lb·ft). 8. Install the standoff bracket, as removed. Tighten the locknuts until firm. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 317 Do not modify or tamper with the exhaust system or emission control system. 13. Start the engine and check for leaks. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 318 Oil Dipstick NOTE: Do not fill beyond the maximum fill level on the dipstick, since overfilling may result in high oil consumption. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 319: Oil Spray Nozzle

    (J 46167 or 407 589 00 63 00). See Figure 3-6. Rotate the crankshaft to gain access to the nozzles. 1. Inspection Cover Figure 3-6 Installing the Engine Cranking Tool All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 320 Remove the oil spray nozzle from the engine. See Figure 3-7. 1. Oil Spray Nozzle 2. Hollow-Core Bolt Figure 3-7 Removing the Oil Spray Nozzle All information subject to change without notice. 3-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 321 [c] Set the nozzle so that the tip of the nozzle fits, without tension, into the cup of the setting rod. If necessary, bend the nozzle gently until it fits easily. All information subject to change without notice. 3-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 322 2. Install the oil pan. Refer to section 3.1.2. 3. Fill the crankcase to the specified oil level. Do not overfill the crankcase. All information subject to change without notice. 3-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 323: Egr Camshaft Lubrication Sprayer

    1. Install the lubrication sprayer to block with injector unit pump lubricator bolt. 2. Torque bolt to 20 N·m (15 lb·ft). All information subject to change without notice. 3-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 324: Oil Pump

    [b] Remove the two bolts attaching the sump pipe to the oil pump. Discard the gasket. [c] Remove the sump pipe and bracket from the oil pan. All information subject to change without notice. 3-14 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 325 4. Remove the bolt attaching the oil pump to the cylinder block. Remove the oil pump from the oil pan. 5. Thoroughly clean the contact surfaces of the oil pump and cylinder block. All information subject to change without notice. 3-15 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 326 Replace any worn or damaged parts. NOTE: If either the idler gear or pump drive gear needs replacing, replace both gears as a set. All information subject to change without notice. 3-16 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 327 1. Heat the drive wheel to approximately 176 F (80 C) in a hot water tank. All information subject to change without notice. 3-17 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 328 4. Seat the idler gear in the pump housing. 5. Install the face plate on the pump housing. Tighten the mounting bolts 25 N·m (18 lb·ft). All information subject to change without notice. 3-18 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 329 [g] Repeat this procedure for the idler gear. 7. Install the oil pump in the cylinder block. Refer to section 3.4.4. All information subject to change without notice. 3-19 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 330 7. Start the engine and check for leaks. 8. Check the engine oil level and add oil if necessary. All information subject to change without notice. 3-20 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 331: Egr Oil Pump And Pick Up Tube

    There are larger internal gears compared to the EPA 98 non-EGR version which has smaller internal gears. See Figure 3-16. Figure 3-16 Comparison on Oil Pump Internal Gears All information subject to change without notice. 3-21 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 332 EGR engine. See Figure 3-17. Figure 3-17 Oil Pick Up Tube in the EPA 04 EGR Engine All information subject to change without notice. 3-22 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 333: Oil Filter

    1. Clean the outside of the oil filter housing, then unscrew the oil filter cap from the housing. See Figure 3-18. Figure 3-18 Oil Filter Cap NOTE: Use care to prevent foreign objects from entering the filter housing. All information subject to change without notice. 3-23 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 334 5. Insert a new filter element into the housing. 6. Install the cap on the filter and tighten the cap nut 25 N·m (18 lb·ft). All information subject to change without notice. 3-24 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 335 7. Start the engine and check for leaks. 8. Check the engine oil level and add oil if necessary. All information subject to change without notice. 3-25 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 336: Oil Heat Exchanger And Filter Housing

    Drain the oil remaining in the filter into a clean container. 5. Disconnect the wiring harness from the oil pressure/temperature sensor. All information subject to change without notice. 3-26 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 337 Figure 3-20 Heat Exchanger Housing Removal NOTE: The oil filter housing and the heat exchanger housing are made from the same casting. All information subject to change without notice. 3-27 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 338 2. Install the oil heat exchanger and new gaskets on the heat exchanger housing. Tighten the heat exchanger bolts 25 N·m (18 lb·ft). All information subject to change without notice. 3-28 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 339 [a] Clean the mating surfaces of the heat exchanger housing and the cylinder block. Remove any bits of adhering gasket material. [b] Replace the heat exchanger housing gasket. All information subject to change without notice. 3-29 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 340 9. Connect the coolant pump shunt line to the coolant pump inlet pipe. 10. Fill the cooling system. Refer to section 4.1.1. All information subject to change without notice. 3-30 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 341 Minimum Pressure At idling rpm 50 kPa (7 psi) At maximum rpm 250 kPa (36 psi) Table 3-3 Engine Oil Pressures All information subject to change without notice. 3-31 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 342: Oil Pressure And Temperature Sensor

    2. Connect the wiring harness at the oil temperature sensor. 3. Using a new O-ring (if necessary), install the oil filter cap. Tighten the nut 25 N·m (18 lb·ft). All information subject to change without notice. 3-32 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 343 4. Start the engine. Check the gauge for the correct oil pressure; check the lubrication system for leaks. 5. Check and add engine oil as needed. All information subject to change without notice. 3-33 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 344 OIL PRESSURE AND TEMPERATURE SENSOR www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 3-34 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 345: Aadditional Information

    3.A ADDITIONAL INFORMATION Description Page SPECIFICATIONS ..................... 3-36 Lubrication System ..................3-36 Oil Pump ......................3-37 Oil Heat Exchanger ..................3-38 All information subject to change without notice. 3-35 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 346 35 (26) Sump Pipe Bracket Bolt 50 (37) Sump Pipe Mounting Bolt (to oil pump) 25 (18) Table 3-5 Torque Values All information subject to change without notice. 3-36 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 347 (inch) Projection of Pump Drive Gear 0.5 (0.02) Pump/Idler Gear End Play 0.050-0.128 (0.0020-0.005) Table 3-8 Oil Pump Installation Specifications All information subject to change without notice. 3-37 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 348 Minimum Pressure At idling rpm 50 kPa (7 psi) At maximum rpm 250 kPa (36 psi) Table 3-9 Engine Oil Pressures All information subject to change without notice. 3-38 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 349 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru COOLING SYSTEM Section Page COOLING SYSTEM ................. COOLANT PUMP ..................EGR COOLANT PUMP ................4-20 FRONT IDLER AND TENSIONER SUPPORT ........4-22 THERMOSTAT ..................4-25 EGR THERMOSTAT HOUSING ............... 4-30 COOLANT TEMPERATURE SENSOR ............ 4-32 ADDITIONAL INFORMATION ..............4-35 www.rtrucks.ru www.rtrucks.ru...
  • Page 350 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 351: Cooling System

    1. Cap 3. Low-Coolant- Level Probe 2. Surge Tank Figure 4-1 Surge Tank 2. Open the water regulating valve for the heating system. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 352 3. Drain the coolant from the radiator. See Figure 4-2. Cooling system capacity is listed in Table 4-1. Figure 4-2 Coolant Drain Plug All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 353 Make sure the coolant can flow unobstructed into the receptacle. [b] Open the coolant drain plug located on the bottom of the radiator. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 354 [b] Add coolant up to the maximum fill level on the surge tank. 8. Check the coolant level and check the cooling system for leaks. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 355 [c] Check the coolant level and add more coolant if necessary. 9. Shut down the engine. 10. Close and tighten the cap on the surge tank. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 356: Coolant Pump

    2. Remove the fan. 3. Release the tension on the main drive belt and the fan belt and set the belts aside All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 357 See Figure 4-4. 7. Remove the upper alternator mounting bolt, loosening the alternator enough to tilt it out of the way. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 358 11. On both the coolant pump and the cylinder block, clean the sealing surfaces (where the gasket was attached) of any adhering bits of gasket material. All information subject to change without notice. 4-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 359 2. Using a puller, pull the coolant pump hub away from the bearing. See Figure 4-5. 1. Puller 3. Coolant Pump Housing 2. Hub Figure 4-5 Pulling the Hub All information subject to change without notice. 4-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 360 2. Snap Ring 5. Sleeve Seal 3. Drive Shaft and Bearing Assembly 6. Impeller Figure 4-6 Coolant Pump Assembly (exploded view) All information subject to change without notice. 4-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 361 Inspect the coolant pump unit as follows: 1. Check all coolant pump components for signs of damage. Replace any damaged components. All information subject to change without notice. 4-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 362 1. Press the drive shaft and bearing assembly into the coolant pump housing. See Figure 4-8. 1. Drive Shaft 2. Coolant Pump Housing Figure 4-8 Installing the Drive Shaft All information subject to change without notice. 4-14 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 363 [b] Press the hub onto the drive shaft, while holding the bearing and drive shaft assembly to prevent it from turning. Make sure the hub is flush with the end of the drive shaft. All information subject to change without notice. 4-15 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 364 See Figure 4-9. 1. Sleeve Seal 3. Coolant Pump Housing 2. Drive Shaft Figure 4-9 Installing the Sleeve Seal All information subject to change without notice. 4-16 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 365 Pressing in the Impeller NOTE: Secure both the drive shaft and hub to prevent them from turning while the impeller is being installed. All information subject to change without notice. 4-17 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 366 Tighten the inlet pipe mounting bolts 50 N·m (37 lb·ft). All information subject to change without notice. 4-18 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 367 9. Install the fan. 10. Fill the engine with coolant, as removed, and check for leaks. All information subject to change without notice. 4-19 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 368: Egr Coolant Pump

    EGR coolant inlet pipe connection. See Figure 4-12. 1. EGR Coolant Pump 2. EGR Coolant Pipe Inlet Figure 4-12 EGR Coolant Pump All information subject to change without notice. 4-20 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 369 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru This page intentionally left blank. All information subject to change without notice. 4-21 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 370: Front Idler And Tensioner Support

    (towards the rear of the engine). 4. Remove the belt tensioner from the front idler and tensioner support. All information subject to change without notice. 4-22 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 371 1. Install the front idler and tensioner support on the cylinder block. Tighten the mounting bolts 60 N·m (44 lb·ft). 2. Install the belt tensioner on the support. All information subject to change without notice. 4-23 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 372 4. Release the tension on the main belt tensioner and install the main drive belt. Release the tension on the fan belt tensioner and install the fan belt. 5. Connect the batteries. All information subject to change without notice. 4-24 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 373: Thermostat

    4. O-ring 2. Thermostat Housing 5. Thermostat 3. Upper Coolant Tube 6. Coolant Pump Housing Figure 4-14 Thermostat Removal or Installation All information subject to change without notice. 4-25 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 374 Refer to section 4.1.1. 4.5.2.1 Thermostat Checking Check the thermostat as follows: 1. Remove the thermostat from the coolant pump. Refer to section 4.5.1. All information subject to change without notice. 4-26 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 375 3. Heat the water with a suitable heating element. Stir the water occasionally to help equalize the temperature. All information subject to change without notice. 4-27 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 376 If the main valve is not completely open, replace the thermostat. See Figure 4-16. 1. Thermostat 3. Short Circuit Valve 2. Main Valve Figure 4-16 Thermostat Lift All information subject to change without notice. 4-28 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 377 O-ring(s) on the coolant pump, as removed. 8. Fill the engine with coolant, as removed, and check for leaks and proper operation. All information subject to change without notice. 4-29 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 378: Egr Thermostat Housing

    4. Remove any other hose or fitting connections. 4.6.2 EGR Thermostat Housing Cover Installation Install the EGR thermostat housing cover as follows: All information subject to change without notice. 4-30 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 379 2. Install EGR modulated valve to thermostat housing cover using four bolts. 3. Attach reed valve housing bracket to thermostat cover. 4. Install any other hose or fitting connections. All information subject to change without notice. 4-31 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 380: Coolant Temperature Sensor

    2. Remove the engine trim panel. All information subject to change without notice. 4-32 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 381 2. Connect the electrical connector to the sensor. Make sure the connection is secure. 3. Install the engine trim panel. 4. Fill the engine with coolant, and check for leaks and proper operation. All information subject to change without notice. 4-33 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 382 COOLANT TEMPERATURE SENSOR www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 4-34 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 383: Aadditional Information

    Description Page SPECIFICATIONS ..................... 4-36 Cooling System Overview ................4-37 Coolant Pump ....................4-38 Thermostat ..................... 4-39 Coolant Sensor ....................4-39 All information subject to change without notice. 4-35 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 384 SPECIFICATIONS This section contains the specifications for servicing the engine. All information subject to change without notice. 4-36 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 385 Water Percentage by Volume Corrosion-Inhibiting Antifreeze to F ( C) Percentage by Volume -34 (-37) -49 (-45) Maximum 60 Table 4-8 Coolant Mixing Ratio All information subject to change without notice. 4-37 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 386 Gap between the Impeller and the 0.6 - 1.0 Coolant Pump Housing (0.023 - 0.039) Table 4-11 Critical Dimension for Coolant Pump Assembly All information subject to change without notice. 4-38 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 387 The sensor torque value is listed in Table 4-13. Description Torque, N·m (lb·ft) Coolant Temperature Sensor to the Engine Block 30 (22) Table 4-13 Torque Value All information subject to change without notice. 4-39 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 388 All information subject to change without notice. 4-40 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 389: Fuel, Lubricating Oil, And Coolant

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru FUEL, LUBRICATING OIL, AND COOLANT Section Page FUEL ......................LUBRICATING OIL ................... COOLANT ....................ADDITIONAL INFORMATION ..............5-13 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 390 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 391: Fuel

    In most cases, winter-grade fuel can be used without problems at cold outside temperatures. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 392 Do not add anything to cold-resistant winter-grade diesel fuels. The fuel's low-temperature flow characteristics could actually deteriorate with additives. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 393: Lubricating Oil

    When topping off, use only engine oils of the correct API designation and SAE rating. 5.2.1 Synthetic Oils Synthetic oil may be used in MBE 4000 engines, provided they are of the correct API designation and viscosity, as required for non-synthetic oil. Synthetic oil offers improved low-temperature flow properties and high-temperature resistance to oxidation.
  • Page 394 SAE viscosity class which corresponds to the outside temperatures anticipated during this period of operation. See Figure 5-2. Figure 5-2 Engine Oil Temperature Ranges All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 395: Coolant

    5.3.1 Fully Formulated Antifreeze Antifreeze approved for use in the MBE 4000 engine is a mixture of glycol compound (ethylene glycol), and corrosion inhibitors. Antifreeze containing glycol compounds and corrosion inhibitors is known as fully-formulated antifreeze.
  • Page 396 The concentrations of some inhibitors will gradually deplete during normal engine operation. SCAs replenish the protection for cooling system components. The coolant must be maintained with the proper concentration of SCA. Detroit Diesel Power Cool maintenance SCAs are recommended. All information subject to change without notice.
  • Page 397 Recycled Antifreeze Recycled antifreeze that complies with TMC RP-329 Type “A” (for ethylene glycol) is approved for use in MBE 4000 engines. The antifreeze must be recycled by distillation, reverse osmosis, or ion exchange. Other recycled antifreeze, especially any antifreeze recycled by means of filtration processes, is not approved.
  • Page 398 This can cause deposits or dropout in the cooling system. The following types of corrosion inhibitors are approved for use in MBE 4000 engines: Supplemental Coolant Additives (SCAs) Nitrated Organic Acid Technology (NOAT) Inhibitors Corrosion inhibitors are very important in maintaining engine life. All corrosion inhibitors protect against corrosion caused by acid, and cavitation of wet cylinder liners.
  • Page 399 5.3.6 Non-Approved Coolants The following types of coolant are not approved for use in MBE 4000 engines: Antifreeze or coolant containing phosphate can cause dropout, overheating, and damage to coolant pump seals. Automotive coolants offer no protection against liner pitting, and generally contain high levels of phosphate and silicate.
  • Page 400 COOLANT www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 5-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 401: Aadditional Information

    MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru 5.A ADDITIONAL INFORMATION Description Page SPECIFICATIONS ..................... 5-14 Coolant ......................5-14 All information subject to change without notice. 5-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 402: Coolant

    F ( C) Antifreeze % by Volume –34 (–37) –62 (–52) The cooling mix ratio is Max. 60 Table 5-4 Coolant Mixing Ratio All information subject to change without notice. 5-14 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 403: Additional Information

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru AIR INTAKE SYSTEM Section Page INTAKE MANIFOLD ................. CHARGE PRESSURE/TEMPERATURE SENSOR ......... TURBOCHARGER ................... ADDITIONAL INFORMATION ..............6-17 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 404 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 405: Intake Manifold

    3. Remove the bolts from the engine trim cover. Move the side panels down and out of the way to expose the manifold mounting bolts. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 406 5. Install the charge air inlet pipe, with a new gasket, on the charge air manifold. 6. Lower the hood and remove the chocks from the rear tires. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...

  • Page 407: Charge Pressure/Temperature Sensor

    2. Connect the electrical connector. 3. Install the #2 cylinder head cover. 4. Lower the hood and remove the chocks from the rear tires. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 408: Turbocharger

    Do not modify or tamper with the exhaust system or emission control system. 2. Place the transmission in neutral and start the engine. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 409 6. Check the exhaust system for leaks. To find leaks, check for color changes to the pipe caused by heating around the leak area. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru...
  • Page 410 3. Check both wheels for damage to the blade caused by dirt, debris, and other foreign matter in the turbocharging air system. See Figure 6-5 for the turbocharger wheel and see Figure 6-6 for the compressor wheel. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 411 1. Turbocharger Housing 3. Blade 2. Rotor Shaft Figure 6-5 Turbocharger Wheel 1. Turbocharger Housing 3. Blade 2. Rotor Shaft Figure 6-6 Compressor Wheel All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 412 Neither turbo wheel nor compressor wheel should rub against the housing. [b] If there is friction or contact with either side of the housing, replace the turbocharger. All information subject to change without notice. 6-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 413 Remove the turbocharger as follows: 1. Apply the parking brakes, shut down the engine, and chock the rear tires. Tilt the hood. All information subject to change without notice. 6-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 414 6. Return Line Mounting Bolt 3. Oil Supply Line 7. Oil Return Line 4. Air Cleaner Inlet Figure 6-9 Turbocharger Air Outlet All information subject to change without notice. 6-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 415 [a] Remove the two bolts attaching the oil return line to the turbocharger. Discard the gasket. [b] Remove the banjo bolt attaching the oil return line to the cylinder block. Discard the two seal rings. All information subject to change without notice. 6-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 416 2. Using new nuts, install the exhaust brake valve housing on the turbocharger (if removed). Tighten the nuts 50 N·m (37 lb·ft). All information subject to change without notice. 6-14 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 417 6. Refill the oil inlet port and connect the oil supply line. listed in Table 6-1 are the torque values. [a] Install a new gasket where the end flange of the supply line meets the turbocharger. All information subject to change without notice. 6-15 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 418 13. Check for oil leaks. Correct any if found. 14. Lower the hood and remove the chocks from the rear tires. All information subject to change without notice. 6-16 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 419: Aadditional Information

    MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru 6.A Additional Information Description Page SPECIFICATIONS ..................... 6-18 Charge Air Cooler ................... 6-18 Turbocharger ....................6-18 All information subject to change without notice. 6-17 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 420 35 (26) Turbocharger Oil Return Line Connection 50 (37) Turbocharger Oil Return Line Banjo Bolt 120 (88) Table 6-3 Turbocharger Torque Values All information subject to change without notice. 6-18 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 421: Exhaust System

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru EXHAUST SYSTEM Section Page EXHAUST MANIFOLD ................EXHAUST BRAKE ASSEMBLY ............... EGR EXHAUST MANIFOLD ..............7-14 EGR COOLER AND COOLER SUPPORT BRACKET ......7-26 EGR CONTROL VALVE, GAS OUTLET PIPE, AND GAS MIXER ..7-43 ® EPV (ELECTRONIC PROPORTIONAL VALVE) AND WABCO SOLENOID VALVE ...................
  • Page 422 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 423: Exhaust Manifold

    Remove the exhaust manifold as follows: 1. Disconnect the batteries and tilt the hood. 2. Remove the turbocharger from the exhaust manifold. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 424 [a] Remove each mounting bolt and spacer from the exhaust manifold and each cylinder head. [b] Remove the spacer from each mounting bolt. [c] Remove the exhaust manifold. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 425 7. Start the engine and make sure there is oil pressure. Shut down the engine and check for leaks. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 426 To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles. 4. Remove the exhaust brake compressed-air line from the exhaust brake cylinder. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 427 6. Remove the locknuts that attach the brake valve housing to the studs on the turbocharger. Remove the housing from the engine. 7.2.2 Exhaust Brake Disassembly Disassemble the exhaust brake unit as follows: All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 428 8. Adjusting-Lever Hexnut 18. Shaft 9. Adjusting Lever 19. Front Bushing (integral to shaft) 10. Adjusting Lever Bolt Figure 7-3 Exhaust Brake Assembly All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 429: Exhaust Brake Assembly

    8. Using a suitable drift, press the rear bushing out of the brake valve housing. 7.2.3 Exhaust Brake Assembly Assemble the exhaust brake unit as follows: All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 430 [a] Choose a feeler gauge equal to dimension B, 2.6 mm (0.10 inch). [b] Insert the feeler gauge into the bore in the brake valve housing until it is touching the rear bushing. All information subject to change without notice. 7-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 431 8. Install the exhaust brake cylinder on the bracket. [a] Install the bolt, washers, spacer, and a new locknut on the cylinder and bracket, as removed. All information subject to change without notice. 7-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 432 [g] Tighten the locknut 25 N·m (18 lb·ft). 9. Install the exhaust brake assembly on the engine. All information subject to change without notice. 7-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 433 5. Slide the exhaust pipe and clamp over the end of the housing. Tighten the clamp. 6. Install the air cleaner. 7. Connect the batteries, lower the hood, and remove the chocks from the rear tires. All information subject to change without notice. 7-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 434: Egr Exhaust Manifold

    Upper or main heat shield must remain on the exhaust manifold assembly until the assembly is removed due to inaccessibility of some of the heat shield mounting bolts. All information subject to change without notice. 7-14 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 435 NOTE: Stud and stud bracket should be loose enough to allow removal of the exhaust manifold inlet pipe. All information subject to change without notice. 7-15 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 436 4. Loosen and remove bolt from positioning clamp which holds the gas inlet pipe to the throttle valve. See Figure 7-8. Figure 7-8 Removing or Installing Positioning Clamp to Throttle Inlet Pipe All information subject to change without notice. 7-16 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 437 See Figure 7-9. Figure 7-9 Exhaust Manifold Gas Inlet Pipe Removal All information subject to change without notice. 7-17 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 438 (not shown in graphic). See Figure 7-10. Figure 7-10 Removing or Installing Three-piece Exhaust Manifold Assembly All information subject to change without notice. 7-18 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 439 Removing Upper Heat Shield 8. Remove the stud and M8 nut and collar still attached to the center exhaust manifold piece. All information subject to change without notice. 7-19 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 440 9. Remove the two side pieces of the exhaust manifold from the center piece. See Figure 7-12. Figure 7-12 Three Piece Exhaust Manifold Assembly All information subject to change without notice. 7-20 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 441 NOTE: EGR cooler and cooler bracket will need to be removed before removing the exhaust manifold gaskets. Refer to section 7.4.1. All information subject to change without notice. 7-21 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 442 1. Install the exhaust manifold guide studs to the cylinder head and mount the two exhaust manifold gaskets. The rear gasket will overlap the front in the center of block. See Figure 7-14. All information subject to change without notice. 7-22 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 443 1. Stud 3. Exhaust Manifold Center Piece 2. M8 Nut with Collar Figure 7-15 Installing Stud in Exhaust Manifold Center Piece All information subject to change without notice. 7-23 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 444 9. Torque remaining five mounting bolts (captured bolt and washer type) of the upper heat shield to the exhaust manifold. Torque to 25 N·m (19 lb·ft). All information subject to change without notice. 7-24 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 445 [e] Apply 25 N·m (19 lb·ft) tightening torque to nut on resting face on pipe (internal). See Step Five in see Figure 7-17. All information subject to change without notice. 7-25 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 446: Egr Cooler And Cooler Support Bracket

    2. Remove the bolt attaching the coolant outlet pipe bracket to the pipe. Remove the bracket. 3. Remove the two bolts attaching the coolant outlet pipe flange to the coolant pump. Discard the gasket. All information subject to change without notice. 7-26 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 447 6. Remove the three bolts from the front bracket that holds and stabilizes the reed valve housing to the thermostat housing. See Figure 7-19. All information subject to change without notice. 7-27 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 448 Also, do not remove the two EGR cooler-to-sheet metal support bolts at this time. They will all be removed once the EGR cooler as an assembly is taken off of the engine. All information subject to change without notice. 7-28 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 449 11. Remove the air line mounting bolts. Loosen and remove the air supply line from the EGR shut off valve. See Figure 7-21. All information subject to change without notice. 7-29 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 450 The oil filter and oil filter cover should be removed for good clearance when removing and installing the EGR cooler assembly. All information subject to change without notice. 7-30 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 451 Before removing the eight bolts from the EGR cooler support, insert the four guide studs into the exhaust manifold gasket holes to support the gaskets once the cooler support is removed. All information subject to change without notice. 7-31 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 452 See Figure 7-24. 1. M10 x 65 mm bolts 2. M10 x 45 mm bolts Figure 7-24 Removing the EGR Cooler Support All information subject to change without notice. 7-32 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 453 2. EGR Cooler Flange Bolts Figure 7-25 Removing the EGR Cooler Flange 16. Remove the two EGR cooler-to-sheet metal support bolts. See Figure 7-25. All information subject to change without notice. 7-33 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 454 Exhaust manifold gaskets will have to be installed before EGR cooler support or cooler can be installed. Refer to section 7.3.2. All information subject to change without notice. 7-34 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 455 Installation of Coolant Outlet Pipe NOTE: Coolant outlet pipe must be installed to coolant pump before the EGR cooler support and cooler are installed. All information subject to change without notice. 7-35 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 456 Assemble and attach the EGR reed valve housing to the cooler before mounting the cooler to the cooler support. 3. Insert the reed valves into the EGR reed valve housing flange. All information subject to change without notice. 7-36 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 457 5. Attach the EGR cooler to the front sheet metal support with two bolts. Torque to 25 N·m (19 lb·ft). See Figure 7-29. All information subject to change without notice. 7-37 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 458 The oil filter and oil filter cover should be removed for good clearance when removing and installing the EGR cooler assembly. All information subject to change without notice. 7-38 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 459 13. Install the EGR air temperature sensor into reed valve housing flange. Torque to 25 N·m (19 lb·ft). Using plastic ties, attach remainder of sensor to reed valve-housing bracket. See Figure 7-32. All information subject to change without notice. 7-39 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 460 1. EGR Air Temperature Sensor 2. Reed Valve Housing Bracket Figure 7-32 Installing the EGR Air Temp. Sensor and Housing Bracket All information subject to change without notice. 7-40 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 461 1. EGR Cooler 3. Clamps (4 Qty.) 2. Tightening Tool for Clamps 4. Clamp Bolts Figure 7-33 Installing Tightening Clamps on the Cooler All information subject to change without notice. 7-41 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 462 16. Tighten EGR shutoff valve using two bolts. Torque to 35 N·m (26 lb·ft). 17. Install and attach air supply line using two mounting bolts. All information subject to change without notice. 7-42 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 463: Egr Control Valve, Gas Outlet Pipe, And Gas Mixer

    2. Loosen the wiring harness terminal from the back cover mounting bracket by punching the push-mount cable tie out of the drilled hole in the mounting bracket. Remove the two All information subject to change without notice. 7-43 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 464 Remove back bracket. 1. EGR Control Valve Back Mounting Bracket 2. Push-Mount Cable Tie Figure 7-36 Removing the Back Control Valve Cover Bracket All information subject to change without notice. 7-44 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 465 5. Remove the three bolts that attach the gas outlet pipe mounting bracket to the intake manifold and to the outlet pipe. See Figure 7-37. All information subject to change without notice. 7-45 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 466 Removing the Symmetric Membrane on Gas Outlet Pipe Side 7. Remove membrane from the EGR control valve. 8. Disconnect wiring harness terminal from valve connector. See Figure 7-39. All information subject to change without notice. 7-46 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 467 10. Pull the EGR control valve out of the reed valve housing flange. 11. Remove symmetric membrane from the housing flange. See Figure 7-38. All information subject to change without notice. 7-47 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 468 4. Metal Gasket Figure 7-40 Removal of Gas Mixing Pipe 13. Remove the turbo boost/air temperature sensor attached to the gas mixer. All information subject to change without notice. 7-48 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 469 4. Using two bolts, install the back control valve bracket that holds the wiring harness terminal in place. Torque to 25 N·m (19 lb·ft). All information subject to change without notice. 7-49 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 470 14. Install the air inlet pipe to the gas mixer using four nuts. Torque to 50 N·m (37 lb·ft). See Figure 7-41. 15. Install the turbo boost/air intake temperature sensor to the gas mixer. All information subject to change without notice. 7-50 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 471: Epv (Electronic Proportional Valve) And Wabco

    Perform the following steps to remove the EPV valve, Wabco air solenoid valve and all the corresponding connections: 1. Disconnect wiring harness from the EPV valve and the Wabco solenoid valve. All information subject to change without notice. 7-51 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 472 7. Remove the two M8 x 50 mm bolts that hold the Wabco solenoid valve on the right side of bracket. All information subject to change without notice. 7-52 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 473 N·m (19 lb·ft) tightening torque. 4. Install large hollow screw in threaded connection. Torque to 50 N·m (37 lb·ft). See Figure 7-43. All information subject to change without notice. 7-53 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 474 7. Fit the pipe between inlet connection installed at EPV valve and turbo brake actuator. 8. Connect wiring harness to EPV valve and Wabco valve. All information subject to change without notice. 7-54 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 475: Hengst Breather Filter

    1. Filter Piping 3. Hengst Filter 2. Filter Piping Bracket 4. Plastic Clamps Figure 7-44 Removal of Hengst Filter and Related Parts All information subject to change without notice. 7-55 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 476 6. Remove the two M8 x 25 mm bolts holding the breather filter to the block. 7. Remove the breather filter. 7.7.2 Installation of Hengst Filter Perform the following steps to install the Hengst filter: All information subject to change without notice. 7-56 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 477 Bolt down with two hex head bolts. See Figure 7-46. 1. Filter Cap 4. Breather 2. Spring and Diaphragm 5. Assembly Bolt 3. Centrifugal Filter Figure 7-46 Hengst Filter Assembly All information subject to change without notice. 7-57 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 478 5. Install pipe, connecting it at the Hengst filter mouth. 6. Install three plastic clamps at pipe bracket. See Figure 7-47. All information subject to change without notice. 7-58 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 479: Aadditional Information

    MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru 7.A ADDITIONAL INFORMATION Description Page SPECIFICATIONS ..................... 7-60 Exhaust Manifold .................... 7-60 Exhaust Brake Assembly ................7-60 All information subject to change without notice. 7-59 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 480 Bracket Mounting Bolt 35 (25) Exhaust Brake Cylinder Locknut 25 (18) Valve Mounting Bolts 30 (22) Table 7-7 Exhaust Brake Assembly Torque Values All information subject to change without notice. 7-60 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 481: Electrical Equipment

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru ELECTRICAL EQUIPMENT Section Page DRIVE BELTS ..................ADDITIONAL INFORMATION ..............8-15 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 482 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 483 There are three idler pulleys on the MBE 4000 engine, one on the main drive belt and two on the fan belt. One of the fan belt idler pulleys has a ribbed belt contact surface; the others are smooth.
  • Page 484 [b] Pull the socket wrench (swivel the tensioner pulley counterclockwise) to remove the tension from the belt. [c] Hold the tensioner pulley in this position for the next step. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 485 8.1.2 Main Drive Belt Installation Install the main drive belt as follows: All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 486 Remove the fan belt as follows: 1. Disconnect the batteries. 2. Release the tension on the fan drive belt. See Figure 8-1. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 487 6. Inspect the following parts and replace any that are damaged or worn: vibration damper fan pulley belt tensioner tensioner pulley idler pulley 8.1.4 Fan Belt Installation Install the fan belt as follows: All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 488 Install the air conditioner (A/C) compressor belt as follows: NOTE: The A/C compressor belt is installed only on vehicles with air conditioning. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 489 6. Inspect the following parts and replace any that are damaged or worn: vibration damper A/C compressor pulley belt tensioner tensioner pulley idler pulley All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 490 5. Check the A/C compressor belt to make sure it is in the correct position and properly aligned on the pulleys. 6. Connect the batteries. All information subject to change without notice. 8-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 491 2. Release the tensioning pulley. 3. Remove the mounting bolt that fastens the belt tensioner and tensioner pulley to the cylinder block. All information subject to change without notice. 8-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 492 4. Fan Idler Pulley #2 2. Main Drive Belt Idler Pulley 5. Fan Idler Pulley #1 3. Coolant Pump Inlet Pipe Figure 8-9 Idler Pulleys All information subject to change without notice. 8-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 493 The A/C compressor belt tensioner is attached to the A/C compressor pad. 1. Remove the A/C compressor. 2. Remove the belt tensioner from the pad. All information subject to change without notice. 8-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 494 2. Install the mounting bolts and tighten them 150 N·m (110 lb·ft). 3. Install the belt tensioner on the pad. 4. Install the A/C compressor. All information subject to change without notice. 8-14 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 495 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru 8.A ADDITIONAL INFORMATION Description Page SPECIFICATIONS ..................... 8-16 Drive Belts ...................... 8-16 All information subject to change without notice. 8-15 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 496 50 (37) Idler Pulley, Mounting Bolt 45 (33) A/C Compressor Pad, Mounting Bolt 150 (110) Table 8-1 Drive Belts Torque Values All information subject to change without notice. 8-16 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 497: Power Take-Off

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru POWER TAKE-OFF Section Page POWER TAKE-OFF ................. www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 498 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 499 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru POWER TAKE-OFF Power take-off is not applicable for the MBE 4000 engine. All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 500 POWER TAKE-OFF www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 501: Special Equipment

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru SPECIAL EQUIPMENT Section Page 10.1 AIR COMPRESSOR ................10-3 10.A ADDITIONAL INFORMATION ..............10-11 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 502 All information subject to change without notice. 10-2 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 503 Wear adequate protective clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure. 1. Drain the coolant. All information subject to change without notice. 10-3 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 504 Do not remove the power steering lines. Tie up the lines and move the pump out of the way. 3. Remove the cross plate between the compressor and the power steering pump. All information subject to change without notice. 10-4 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 505 [b] Remove the unloader line. Check the fittings for damage and replace if necessary. [c] Loosen the hose clamp and remove the intake (suction) air line. All information subject to change without notice. 10-5 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 506 1. Hollow-Core Banjo Bolt 4. Air Compressor 2. Seal Ring 5. Coolant Return Line 3. Coolant Delivery Line Figure 10-3 Air Compressor Coolant Lines All information subject to change without notice. 10-6 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 507 This locks the driveshaft to allow removal of the drive nut. 4. Remove the drive gear from the air compressor. All information subject to change without notice. 10-7 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 508 7. Release the air compressor from the vise. 10.1.2 Air Compressor Installation Install the air compressor as follows: 1. Install the air compressor. All information subject to change without notice. 10-8 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 509 7. Install the two bolts attaching the power steering pump to the air compressor. Tighten the bolts 40 N·m (30 lb·ft). 8. Fill the radiator with coolant. All information subject to change without notice. 10-9 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 510 10.1 AIR COMPRESSOR www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 10-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 511 MBE 4000 SERVICE MANUAL www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru 10.A ADDITIONAL INFORMATION Description Page SPECIFICATIONS ..................... 10-12 Air Compressor ....................10-12 All information subject to change without notice. 10-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 512: Air Compressor

    Approved Brand ® Loctite Pipe Thread Sealant ® Henkel 790 Pipegrip (49-00094-108) ® Perma-Lok LH-150 Table 10-3 Approved Pipe Thread Sealants All information subject to change without notice. 10-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 513: Operation And Verification

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru OPERATION AND VERIFICATION Section Page 11.1 PREPARATION FOR A FIRST TIME START ........... 11-3 11.2 STARTING THE ENGINE ................. 11-7 11.3 RUNNING THE ENGINE ................11-10 11.4 STOPPING THE ENGINE ................ 11-12 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 514 All information subject to change without notice. 11-2 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 515: Preparation For A First Time Start

    No. 955 Quaker State No. NYK-77 Table 11-1 Approved Electrical Lubricants 11.1.2 Checking the Oil Level Check the oil level as follows: All information subject to change without notice. 11-3 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 516 1. Check the oil level using the oil dipstick. See Figure 11-1. 1. Maximum Fill Level 2. Minimum Fill Level Figure 11-1 Oil Dipstick All information subject to change without notice. 11-4 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 517 Work in the cleanest conditions possible. Prevent water from entering the fuel tank. 11.1.5 Priming the Fuel System Prime the fuel system as follows: All information subject to change without notice. 11-5 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 518 4. If the engine still does not start, open the high-pressure lines and bleed the air from the fuel system while cranking. Tighten the high-pressure lines and repeat the priming procedure. All information subject to change without notice. 11-6 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 519: Starting The Engine

    Checking the Coolant Level (Hot Check) Check the coolant levels as follows: 1. Allow the engine to run for approximately five minutes at a moderate speed. All information subject to change without notice. 11-7 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 520 1. Chock the tires, place the transmission in neutral, and set the parking brake. 2. Turn on the ignition switch and start the engine All information subject to change without notice. 11-8 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 521 4. Monitor the oil pressure gauge immediately after starting the engine. NOTE: Do not place the engine under full load until it reaches operating temperature. All information subject to change without notice. 11-9 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 522: Running The Engine

    11.3.4 Changing the Idle Speed The rpm range of the MBE 4000 engine is 600 to 850 rpm if the parameters in the VCU are set to the default range. Change the idling speed as follows: All information subject to change without notice.
  • Page 523 When in emergency running mode, the engine operates at a constant 1300 rpm. This allows you to move the vehicle to a service location. All information subject to change without notice. 11-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 524: Stopping The Engine

    2. Turn off the ignition switch and shut down the engine. All information subject to change without notice. 11-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 525: Engine Tune-Up

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru ENGINE TUNE-UP Section Page 12.1 VALVE LASH CHECKING ................ 12-3 12.2 ADJUSTING VALVE LASH ............... 12-10 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 526 All information subject to change without notice. 12-2 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 527: Valve Lash Checking

    Using Two Crankshaft Positions).See Figure 12-1 for the cylinder and valve layout on MBE 4000 engines. Figure 12-1 Cylinder and Valve Layout All information subject to change without notice. 12-3 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 528 2. Cylinder Head Cover 4. Cylinder Head Figure 12-2 Cylinder Head Cover, (exploded view) 2. Remove the inspection cover on theflywheel housing. All information subject to change without notice. 12-4 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 529 6. For each valve, measure the valve lash with a feeler gauge between the rocker arm and valve bridge. It should be possible to pull the feeler gauge through with no more than light resistance. All information subject to change without notice. 12-5 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 530 2. Cylinder Head Cover 4. Cylinder Head Figure 12-4 Cylinder Head Cover, (exploded view) 2. Remove the inspection cover on the flywheel housing. All information subject to change without notice. 12-6 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 531 3. Fit the engine cranking tool (J 46167 or 407 589 00 63 00) into the inspection hole on the flywheel housing. See Figure 12-5. 1. Inspection Cover Figure 12-5 Placement of Engine Cranking Tool All information subject to change without notice. 12-7 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 532 MBE 4000 — Valve MBE 4000 — Overlap * I= Intake Valve and E= Exhaust Valve Table 12-3 Valve Adjustment (Method Two) All information subject to change without notice. 12-8 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 533 If the value measured is outside the range given in the "Check For" column listed in Table 12-2, adjust the valve lash. All information subject to change without notice. 12-9 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 534: Adjusting Valve Lash

    5. Remove the cranking tool (J 46167 or 407 589 00 63 00) from the inspection hole in the flywheel housing. 6. Replace the end cover on the inspection hole and tighten the bolts 25 N·m (18 lb·ft). All information subject to change without notice. 12-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 535: Preventive Maintenance

    www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru PREVENTIVE MAINTENANCE Section Page 13.1 SCHEDULED INTERVALS ............... 13-3 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 536 All information subject to change without notice. 13-2 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 537: Scheduled Intervals

    Examples of Long-Haul usage are: regional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage. All information subject to change without notice. 13-3 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 538 (in miles or kilometers) for each maintenance operation. The schedule of actual distances is based on the intervals given in the Maintenance Schedule Table. All information subject to change without notice. 13-4 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 539 M1, M2 and M3 140,000 234,000 150,000 250,000 M1 and M2 160,000 267,000 Table 13-2 Maintenance Intervals for Schedule I, Severe Service All information subject to change without notice. 13-5 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 540 M1, M2 and M3 210,000 350,000 225,000 375,000 M1, M2 and M4 240,000 400,000 Table 13-3 Maintenance Intervals for Schedule II, Short Haul All information subject to change without notice. 13-6 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 541 Each maintenance operation set is listed in a separate Maintenance Operations Table. All information subject to change without notice. 13-7 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 542 Table 13-6 Required Maintenance Operations Sets, Schedule II and III 13.1.2 Fuel/Water Separator Pre-Filter Element Cleaning Clean the pre-filter element as follows: All information subject to change without notice. 13-8 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 543 [a] Lubricate the other O-ring with a light coating of engine oil. [b] Insert the lubricated O-ring into the open end of the pre-filter element. All information subject to change without notice. 13-9 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 544 50 times. NOTE: There should be a strong resistance in the hand pump, caused by the pressure build-up within the fuel system. All information subject to change without notice. 13-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 545 Change the main fuel filter element as follows: 1. Open the fuel filler cap to release pressure in the fuel system. Replace and tighten the cap. All information subject to change without notice. 13-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 546 [a] Make sure that all high-pressure lines have been tightened to 25 N·m (18 lb·ft) and all banjo bolts to 50 N·m (37 lb·ft). All information subject to change without notice. 13-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 547 The engine should start within four 30-second attempts. 10. Start the engine. Check the fuel filter housing for leaks. All information subject to change without notice. 13-13 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 548 To ensure the engine is protected and the oil stays clean until the next oil change, use only oils of API classification CH4. Drain oil as follows: All information subject to change without notice. 13-14 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 549 Change the engine oil only when the engine is at a temperature of approximately 140 F (60 C). 2. Using a 36-mm socket, unscrew the oil filter cap. See Figure 13-4. Figure 13-4 Oil Filter Cap All information subject to change without notice. 13-15 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 550 [b] Carefully unscrew the oil drain plug on the oil pan and allow the oil to drain out. [c] Discard the O-ring on the oil drain plug. Figure 13-5 Engine Oil Drain Plug All information subject to change without notice. 13-16 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 551 7. Screw the cap onto the oil filter housing. Tighten the cap 45 N·m (33 lb·ft). 8. Install the oil drain plug, using a new O-ring. Tighten the plug 80 N·m (60 lb·ft). All information subject to change without notice. 13-17 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 552 Do not modify or tamper with the exhaust system or emission control system. 10. Start the engine with the accelerator pedal in the idle position. Monitor the oil pressure gauge. All information subject to change without notice. 13-18 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 553 2. Before adding coolant, use a suitable tester to check the concentration of corrosion-inhibiting antifreeze. If the concentration is lower than 50 percent by volume, All information subject to change without notice. 13-19 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 554 500 Hours or three months, whichever comes first Applications Stand-by Generator Set 200 Hours or yearly, whichever comes first Table 13-8 Required Coolant Inhibitor Test Intervals All information subject to change without notice. 13-20 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 555 Nitrite Interval Checks 13.1.7 Inhibitor Level Checking Use Detroit Diesel PowerTrac 3–way Coolant Test Strips to measure nitrite and glycol concentrations. Cavitation/corrosion protection is indicated on the strip by the level of nitrite concentration. Freeze/boil-over protection is determined by glycol concentration.
  • Page 556 1. Open the cap on the surge tank slowly, to allow excess pressure to escape. Set the cap aside. 2. Open the water regulating valve for the heating system. All information subject to change without notice. 13-22 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 557: System

    Antifreeze quantity at 60% 26.6 (25.2) *Does not include capacity of cooling system. †With 1200 sq. in. radiator. Table 13-10 Coolant Capacity All information subject to change without notice. 13-23 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 558 7. Add coolant in the specified concentration until the maximum mark on the surge tank is reached. The coolant system capacity is listed in Table 13-10. All information subject to change without notice. 13-24 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 559 3. Check the outside of the radiator and condenser for blockage by dirt or debris. Make sure the fins are not damaged, and straighten them if necessary. All information subject to change without notice. 13-25 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 560 13.1 SCHEDULED INTERVALS www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru All information subject to change without notice. 13-26 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 561 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru ENGINE STORAGE Section Page 14.1 PREPARING ENGINE FOR STORAGE ........... 14-3 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 562 All information subject to change without notice. 14-2 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 563 Collect the used coolant, cleaning solutions, and washing liquids. Dispose of them in accordance with applicable laws regarding the protection of the environment. All information subject to change without notice. 14-3 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 564 1. Fill the cooling system with a 5% solution (1.6 ounces per quart of water—50 grams per liter) of a mildly alkaline cleaning agent, such as sodium carbonate. All information subject to change without notice. 14-4 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 565 For types of coolant, 14.1.4 Storage Required protective measures for the MBE 4000 engine depend on the following: The length of time that the engine will be out of service The climate and conditions where the engine is stored After cleaning, engines should, whenever possible, be placed in a dry, well-ventilated place.
  • Page 566 If the engine is to be out of service for over 18 months, the oil must be changed before the engine can be brought back into service. All information subject to change without notice. 14-6 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 567 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru MECHANICAL TROUBLESHOOTING Section Page 15.1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM ....................15-3 15.2 GENERAL TROUBLESHOOTING ............15-4 www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 568 All information subject to change without notice. 15-2 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 569 To read the complete fault code, bring the vehicle to an authorized dealer. Complete fault codes can be read using minidiag2. All information subject to change without notice. 15-3 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 570: General Troubleshooting

    Change the engine oil, using the correct type of oil. The transmission fluid does not meet the correct Change the transmission fluid, using the correct type specifications. of fluid. All information subject to change without notice. 15-4 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 571 There are other problems in the fuel system. Bring the vehicle to an authorized dealer for service. All information subject to change without notice. 15-5 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 572 Replace the fan hub The parameter settings in the PLD or VCU control unit Have an authorized dealer reprogram the control unit. are incorrect. All information subject to change without notice. 15-6 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 573 Bring the vehicle to an authorized dealer for service. There is internal damage to the engine. Bring the vehicle to an authorized dealer for service. All information subject to change without notice. 15-7 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 574 Problem—The Engine Is in Emergency Running Mode (constant speed 1,300 rpm) Cause Remedy The PLD or VCU control unit is damaged. Bring the vehicle to an authorized dealer for service. All information subject to change without notice. 15-8 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 575 Have an authorized dealer replace the air compressor. The cylinder head gasket is leaking. Have an authorized dealer replace the head gasket. All information subject to change without notice. 15-9 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 576 Check the intake air preheater, and replace it, if The intake air preheater is malfunctioning. necessary. The valves are not adjusted properly. Check the valve lash. All information subject to change without notice. 15-10 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 577 Components of the PLD and/or VCU control unit are Bring the vehicle to an authorized dealer for service. damaged or not working properly. All information subject to change without notice. 15-11 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 578 Replace the belt. The alternator is damaged (has a damaged rectifier or Have an authorized dealer replace the alternator. voltage regulator). All information subject to change without notice. 15-12 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

  • Page 579: Index

    Coolant Pump Inspection, 4-13 Coolant Pump Installation, 4-18 Coolant Pump Removal, 4-8 Coolant Temperature Sensor, 4-32 Coolant Temperature Sensor Assembly, 4-33 All information subject to change without notice. Index-1 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 580 Air Conditioner Compressor Belt Installation, 8-10 Air Conditioner Compressor Belt Removal, 8-8 Air Conditioner Compressor Pad Installation, 8-14 Air Conditioner Compressor Pad Removal, 8-13 All information subject to change without notice. Index-2 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 581 EGR Front and Rear Lifter Brackets, 1-43 Installation, 1-44 Removal, 1-43 EGR Fuel Filter, 2-41 EGR Fuel Filter Bracket Installation, 2-42 EGR Fuel Filter Bracket Removal, 2-41 All information subject to change without notice. Index-3 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 582 Exhaust Brake Assembly Removal, 7-6 Exhaust Brake Disassembly, 7-7 Exhaust Manifold, 7-3 Exhaust Manifold Installation, 7-5 Exhaust Manifold Removal, 7-3 Flywheel, 1-86 Flywheel Inspection, 1-92 All information subject to change without notice. Index-4 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 583 Fuel Injector Nozzle Installation, 2-20 Fuel Injector Nozzle Removal, 2-18 Fuel Pump, 2-43 Fuel Pump Installation, 2-45 Fuel Pump Removal, 2-43 Fuel System Inspection, 2-47 All information subject to change without notice. Index-5 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 584 Oil Heat Exchanger and Filter Housing Installation, 3-28 Oil Heat Exchanger and Filter Housing Removal, 3-26 Oil Pan, 3-3 Oil Pan Installation, 3-6 Oil Pan Removal, 3-3 All information subject to change without notice. Index-6 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 585 Priming the Fuel System, 11-5 Preparing Engine, 14-3 Cleaning the Cooling System, 14-3 Cleaning the Engine, 14-3 Degreasing the Cooling System, 14-4 Storage, 14-5 All information subject to change without notice. Index-7 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 586 Main Fuel Filter Element Changing, 13-11 Maintenance Schedule Types, 13-3 Maintenance Operation Sets, 13-7 Maintenance Schedule and Interval Operations, 13-4 Starting the engine, 11-7 All information subject to change without notice. Index-8 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...
  • Page 587 Method Two — Adjust All Valves Using Two Crankshaft Positions, 1-146 Valve Lift Checking, 1-138 Valve Removal, 1-153 Valve Stem Seal Replacement, 1-159 All information subject to change without notice. Index-9 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION www.rtrucks.ru www.rtrucks.ru www.rtrucks.ru...

Table of Contents

Save PDF