Detroit Diesel EPA04 MBE 4000 Workshop Manual
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Detroit Diesel EPA04 MBE 4000 Workshop Manual

Detroit Diesel EPA04 MBE 4000 Workshop Manual

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Summary of Contents for Detroit Diesel EPA04 MBE 4000

  • Page 3 □ 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 4 MBE 4000 SERVICE MANUAL All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 5: Table Of Contents

    CAMSHAFT AND CAMSHAFT POSITION SENSOR ......1-171 1.24 EGR CAMSHAFT ..................1-181 ADDITIONAL INFORMATION ..............1-183 FUEL SYSTEM INJECTOR UNIT PUMP ................EGR INJECTOR UNIT PUMP ..............2-15 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 6 5-13 AIR INTAKE SYSTEM INTAKE MANIFOLD ................. CHARGE PRESSURE/TEMPERATURE SENSOR ......... TURBOCHARGER ................... ADDITIONAL INFORMATION ..............6-17 EXHAUST SYSTEM EXHAUST MANIFOLD ................EXHAUST BRAKE ASSEMBLY ............... All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 7 17.4 RESTRICTED AIR CLEANER ELEMENT ..........17-15 17.5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING INTAKE MANIFOLD ................. 17-16 17.6 FAULTY EXHAUST SYSTEM ..............17-18 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 8 MBE 4000 SERVICE MANUAL 17.7 HIGH INLET AIR TEMPERATURE ............17-20 17.8 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER ... 17-22 INDEX ....................Index-1 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 9: General Information

    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 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 11: Scope And Use Of This Manual

    The valves are controlled by mushroom tappets, pushrods, and rocker arms. The intake and exhaust valves are opened and closed by a valve-guided bridge. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 14 □ The operator (accelerator pedal position, engine brake switch) □ 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 15: Engine Braking Power

    filter. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 16 5. Engine Trim Cover 12. Fuel Filter 6. Crankcase Breather 13. Fuel Pump 7. Air Compressor 14. Air Conditioner Compressor Figure 3 Left Side, Major Engine Components All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 17 11. Oil Heat Exchanger 4. Exhaust Manifold 5. Cylinder Head Cover 12. Oil Dipstick 6. Fan 13. Turbocharger 7. Belt Tensioner Figure 4 Right Side, Major Engine Components All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 18 6. Hydraulic Line (to power steering pump) 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 19 6. Dipstick 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 21: 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. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 22 MBE 4000 SERVICE MANUAL Figure 8 Location of Engine Type Plate Figure 9 Engine Type Plate Detail All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 23: Exhaust Gas Recirculation (Egr) System

    The addition of cooled exhaust gasses back into the combustion airflow reduces the peak in cylinder combustion temperature. Less oxides of nitrogen (NOx) are produced at lower combustion temperatures. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 24 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. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 25 12. EGR Gas Outlet Pipe (Cold Pipe) 6. EGR Shutoff Valve 13. Alternator 7. EGR Air Cylinder 14. Belt Tensioner Figure 12 EGR Engine with EGR Components and Revised Parts (Right View) All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 26 EGR shutoff valve and through the cooler and reed valves, past the EGR modulated control valve and the mixer and then back to the cylinder. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 27: Safety Instructions And Precautions

    “Cautions” and “Notices” are not exhaustive, because it is impossible to warn personnel of the possible hazardous consequences that might result from failure to follow these instructions. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 28 Glasses Select appropriate safety glasses for the job. It is especially important to wear safety glasses when using tools such as hammers, chisels, pullers or punches. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 29 □ Ensure that all tools and servicing equipment are removed from the engine Welding Wear welding goggles and gloves when welding or using an acetylene torch. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 30 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 31 Improper use of electrical equipment can cause severe injury. Recommendations regarding the use of compressed air are indicated throughout the manual. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 32 Keep the hose and nozzle or the funnel and container in contact with the metal of the fuel tank when refueling to avoid the possibility of an electric spark igniting the fuel. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 33 Do not smoke when refueling. Batteries Electrical storage batteries emit highly flammable hydrogen gas when charging and continue to do so for some time after receiving a steady charge. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 34 To avoid injury from harmful vapors or skin contact, do not use carbon tetrachloride as a cleaning agent. Exercise caution against burns when using oxalic acid to clean the cooling passages of the engine. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 35 Follow the instructions on the container or by the manufacturer of the starting aid. Fluoroelastomer (Viton) Use Under normal design conditions, fluoroelastomer (VITON) parts, such as O-rings and seals, are perfectly safe to handle. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 36: English To Metric Conversion

    To get equivalent number of: Pound (lb) 0.4536 Kilograms (kg) Ton (ton) 907.18 Kilograms (kg) Ton (ton) 0.907 Tonne (t) Multiply Force To get equivalent number of: All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 37: Decimal And Metric Equivalents

    Miles/hour (mile/hr) 1.6093 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 38 61/64 0.953125 24.20937 15/32 0.46875 11.90625 31/32 0.96875 24.60625 31/64 0.484375 12.30312 63/64 0.984375 25.00312 0.500 12.70000 1.00 25.40000 Table 3 Conversion Chart-Customary and Metric Units All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 39: Torque Specifications

    † Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed). Table 4 Torque Specifications Table One All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 40 † 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 41 † 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 42 † 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 43 † 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 44 MBE 4000 SERVICE MANUAL All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 45: Engine

    ENGINE Section Page CYLINDER HEAD COVER ..............CYLINDER HEAD ..................CYLINDER BLOCK .................. 1-22 EGR CYLINDER HEAD AND BLOCK ............. 1-44 EGR FRONT AND REAR LIFTER BRACKETS ........1-47 ENGINE BRAKE ..................1-49 FRONT RADIAL SEAL ................1-56 REAR RADIAL SEAL ................1-60 CRANKSHAFT SEAL WEAR SLEEVE ............
  • Page 46 1.23 CAMSHAFT AND CAMSHAFT POSITION SENSOR ......1-171 1.24 EGR CAMSHAFT ..................1-181 ADDITIONAL INFORMATION ..............1-183 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 47: Cylinder Head Cover

    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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 48: Cylinder Head

    8. Constant-Throttle Line 4. Seal Ring 9. Spacer 14. Guide Pin 5. Hollow Core (Banjo) Bolt 10. Exhaust Port Gasket Figure 1-2 Exploded View of Cylinder Head All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 49 Wear adequate protective clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure. 1. Drain the coolant from the radiator. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 50 [c] Turn the wrench on the high-pressure line fitting while holding the other wrench on the thrust bolt. 7. Remove the high-pressure fuel line from the transfer-tube and unit pump. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 51 This would damage the injector nozzles, which protrude slightly. 15. Remove the cylinder head and set it on wooden blocks or on its side. 16. Remove the head gasket. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 52 1. Remove the cylinder head. 2. Remove the nozzle holder. 3. Remove the intake and exhaust valves. Refer to section 1.20.5. 4. Remove the constant-throttle valve. Refer to section 1.6.1. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 53 Overall Height of Cylinder Head After Machining 113.5 (4.46) Table 1-3 Cylinder Head Specifications [d] Place the straightedge diagonally across the cylinder head. Repeat the procedure above. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 54 [d] Check the reading on the dial gauge. If the reading is larger than 0.1 mm (0.004 in.), machine the cylinder head. [e] Repeat this procedure at each spot marked by an arrow (each corner of the cylinder head). All information subject to change without notice. 1-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 55 1. Remove the exhaust brake compressed-air line from the exhaust brake cylinder. 2. Remove the v-band clamp connecting the exhaust pipe to the brake valve housing. 3. Remove the turbocharger. All information subject to change without notice. 1-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 56 10. With the shutoff valve on the regulator in the off position, set the regulator to zero pressure by pulling up on the adjusting knob and turning counter-clockwise. All information subject to change without notice. 1-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 57 24. Slide the exhaust pipe and clamp over the end of the housing. Tighten the clamp. 1.2.2 Cylinder Head Installation Install the cylinder head as follows: All information subject to change without notice. 1-13 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • 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. 1-14 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 59 Shaft length when new 210.0 (8.27 ) Maximum shaft length 212.0 (8.35) Table 1-4 Cylinder Head Bolt Lengths 4. Lubricate the cylinder head bolts with engine oil. All information subject to change without notice. 1-15 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 60 7. Replace the seal rings and connect the fuel injector spill line to the cylinder head. Torque banjo bolt to 15 N·m (11 lb·ft). 8. Connect the coolant line to the cylinder head. Torque banjo bolt to 35 N·m (26 lb·ft). All information subject to change without notice. 1-16 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 61 19. Check that the coolant drain plug is tight and not leaking. 20. Fill the radiator with coolant. 21. Install the cylinder head cover. 22. Install the engine trim cover. NOTE: Prime the fuel system. All information subject to change without notice. 1-17 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 62 3. Adjust the valve lash. Refer to section 1.20.3. NOTE: To do this procedure, coolant temperature must be between 70 - 95°C (155 - 205°F). All information subject to change without notice. 1-18 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 63 6. Remove the injector nozzle. See Figure 1-12. 1. O-ring (transfer-tube) 5. Seal Ring 9. Retaining Bolt 2. Transfer-Tube 6. O-ring (nozzle) 10. Constant Throttle Valve Cover All information subject to change without notice. 1-19 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 64 Refer to section 1.2.1. Description Pressure: 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. 1-20 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 65 5. Install the injector nozzle. 6. Install the cylinder head cover. Refer to section 1.1.2. 7. Repeat this procedure for each cylinder. 8. Remove the chocks from the tires. All information subject to change without notice. 1-21 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 66: Cylinder Block

    [b] Install the cylinder liner removal tool in the cylinder liner to be removed with bridge resting on deck of cylinder block and lip of tool resting on the top of the cylinder liner. See Figure 1-15. All information subject to change without notice. 1-22 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 67 Remove the cylinder liner and tool. See Figure 1-15. [e] Remove the tool from the liner. 1. Lower Nut 2. Resting Bridge 3. Upper Nut Figure 1-15 Cylinder Liner Removal Tool J-45876 All information subject to change without notice. 1-23 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 68 5. Upper O-ring 2. Block 6. Lower O-ring 3. Cylinder Liner A. Specified in Measuring Cylinder Liner Protrusion Table 4. Liner D-Ring Figure 1-17 Cylinder Liner O-rings All information subject to change without notice. 1-24 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 69 Cylinder Liner Bore Inspection and Measurement Inspection Inspect the cylinder liner bore as follows: 1. Check the wall of the cylinder liner for signs of excessive wear or deformation. All information subject to change without notice. 1-25 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 70 3. Do an external visual check of the cylinder liner for signs of cavitation and corrosion. Discard the liner if any damage is noted. Measurement All information subject to change without notice. 1-26 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 71 Max.: 0.08 (0.003) Axis 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. 1-27 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 72 See Figure 1-22. The specifications are listed in Table 1-10. 1. Cylinder Liner 2. Measuring Point 2 (upper reversal point of the first piston ring) Figure 1-22 Measuring Points All information subject to change without notice. 1-28 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 73 See Figure 1-23. 1. Cylinder Head Bolts Figure 1-23 Measuring Plate Installation 4. Tighten the cylinder head bolts 50 N·m (37 lb·ft). All information subject to change without notice. 1-29 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 74 The feeler must touch the contact surface of the cylinder block with some preload. Support the dial gauge. See Figure 1-24. 1. Dial Gauge 3. Feeler 2. Slot (4 qty.) Figure 1-24 Dial Gauge Installation All information subject to change without notice. 1-30 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 75 [e] Compare the four measurements. If any measurement differs from any one of the others by more than 0.02 mm (0.0008 in.), replace the cylinder liner and repeat All information subject to change without notice. 1-31 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 76 Do not smoke when refueling. 1. Drain all fuel from engine. 2. Remove all six electronic unit pumps from the engine block. All information subject to change without notice. 1-32 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 77 4. Block the fuel gallery inlet and outlet with special plugs from kit (J–45982). See Figure 1-26. 5. Install the pressure gauge assembly J-45982–7 (pressure gauge, pressure regulator, and shut off valve) from kit (J–45982). See Figure 1-27. All information subject to change without notice. 1-33 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 78 10. Watch the pressure for 30 seconds. If the pressure holds at 200 kPa (29 psi), the fuel gallery is properly sealing. In case of a pressure drop, the engine block should not be reused. All information subject to change without notice. 1-34 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 79 3. Install the oil cooler/filter housing cover plate, from the kit, on the right hand side of the engine block using supplied hardware. See Figure 1-28. All information subject to change without notice. 1-35 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 80 6. Install the pressure gauge assembly J-45982–7 (pressure gauge, pressure regulator, and shut off valve) from kit (J–45982). See Figure 1-30. 1. Pressure Gauge Assembly J-45987–2 Figure 1-30 Installing Pressure Gauge Assembly All information subject to change without notice. 1-36 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 81 A. Specified in Measuring Cylinder Liner Protrusion Table 3. Cylinder Liner Figure 1-31 Cylinder Liner Collar Seat 1. Remove the cylinder heads, pistons, liners, and other hardware. All information subject to change without notice. 1-37 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 82 9. Raise the depth stop adjustment collars and lower the tapered cutter plate into the bore. Rotate the tool and allow it to center itself in the bore. See Figure 1-32. All information subject to change without notice. 1-38 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 83 Continue backing off the adjustment in 0.0508 mm (0.002 in.) increments for the balance of the cutting operation until the collars come together. All information subject to change without notice. 1-39 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 84 The cylinder liner collar and collar seat must remain completely free of oil. 4. Install a new seat insert, clean and dry, into the block counterbore. See Figure 1-34. All information subject to change without notice. 1-40 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 85 [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. 1-41 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 86 O-rings, being careful to keep turning the installation tool until the cylinder liner is properly seated. [c] Remove the installation tool from the cylinder liner. All information subject to change without notice. 1-42 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 87 [c] If the O-rings are damaged, replace them. [d] Check the out-of-round again until it meets specifications. 10. Install the piston. Refer to section 1.18.1. All information subject to change without notice. 1-43 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 88: Egr Cylinder Head And Block

    4. Carbon Scraper Ring located in groove in cylinder liner Figure 1-38 Installed Carbon Scraper Ring NOTE: All remaining installation procedures for the cylinder head are identical to a non-EGR engine. All information subject to change without notice. 1-44 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 89 See Figure 1-38. The carbon scraper ring for the 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. 1-45 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 90 EGR cooler. See Figure 1-40. 1. Opening near the air compressor housing 2. Flange for attaching coolant inlet pipe Figure 1-40 EGR Cylinder Block Changes All information subject to change without notice. 1-46 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 91: Egr Front And Rear Lifter Brackets

    Removal / Installation of Front Lifter Bracket 2. Remove the bolt from the air compressor coolant line bracket on the rear lifting bracket. See Figure 1-42. All information subject to change without notice. 1-47 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 92 4. Install the bolt securing the air compressor coolant line bracket to the rear lifting bracket. Torque the bolt to 30 N·m (22 lb·ft). See Figure 1-42. All information subject to change without notice. 1-48 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 93: Engine Brake

    Constant Throttle Valve Removal Remove the Constant Throttle Valve (CTV) as follows: 1. Remove the cylinder head. Refer to section 1.2.1. 2. Remove the injector nozzle. All information subject to change without notice. 1-49 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 94 NOTE: Insert a spacer beneath the valve head to prevent the valve from opening while doing the rest of the removal procedures. See Figure 1-44. All information subject to change without notice. 1-50 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 95 5. Using needle-nose pliers, remove the piston. Pull the piston and piston seal out of the valve bore. See Figure 1-45. 1. Needle-Nose Pliers 2. Piston Figure 1-45 Removing the Piston All information subject to change without notice. 1-51 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 96 Insert a spacer beneath the valve head to prevent the valve from opening while installing the valve spring and piston. 2. Insert a suitable spacer about 6.0 mm (0.25 in.) in height. See Figure 1-44. All information subject to change without notice. 1-52 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 97 Perform the following to remove the CTV solenoid: 1. Remove the lower exhaust manifold heat shield. 1. EPV Harness Connector 2. Wirinig Harness Bracket Figure 1-47 CTV Solenoid Removal All information subject to change without notice. 1-53 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 98 1. Install a new O-ring on the CTV solenoid and lubricate with clean engine oil. 2. Position the CTV solenoid into the oil cooler housing and start threads by hand. All information subject to change without notice. 1-54 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 99 EPV solenoid. Secure harness with nylon tie straps. 5. Install the removed lower exhaust manifold heat shield. Torque the bolts to 25 N·m (18 lb·ft). All information subject to change without notice. 1-55 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 100: Front Radial Seal

    4. Remove the vibration damper from the engine through the opening in the bumper. Refer to section 1.12.1. 5. Check the seal for wear at the places where it contacts the crankshaft. All information subject to change without notice. 1-56 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 101 Refer to section 1.9.1. 1.7.2 Front Radial Seal Installation Install the front radial seal as follows: NOTE: The radial seal does not need to be lubricated. All information subject to change without notice. 1-57 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 102 3. Install the vibration damper on the crankshaft. Refer to section 1.12.2. 4. Install the three drive belts. 5. Install the support angle bracket fairing. Install the bumper beam. All information subject to change without notice. 1-58 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 103 50 kPa (7 psi). Looks for any oil leaks, repair as necessary. 7. Close the hood, and remove the chocks from the tires. All information subject to change without notice. 1-59 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 104: Rear Radial Seal

    2. Drill 3.174 mm (0.125 in.) pilot holes and use the sheet metal screws and the rear seal puller J–46188 (part of service kit J–47273), remove the rear radial seal from the flywheel housing. Discard the seal. See Figure 1-51. All information subject to change without notice. 1-60 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 105 [c] Position the rear seal installer on the receptacle, and drive the seal in until it bottoms out. 3. To replace an oversize rear crankshaft seal do the following: [a] Install the crankshaft rear seal wear sleeve. Refer to section 1.9.4. All information subject to change without notice. 1-61 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 106 [g] Remove the tool and visually check the seal and sealing lip for correct installation. [h] Install the flywheel. Refer to section 1.13.2. All information subject to change without notice. 1-62 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 107: Crankshaft Seal Wear Sleeve

    7. Assemble the front seal wear sleeve removal tool (J-45989, part of service kit J–47273). See Figure 1-54. 1. Seal Wear Sleeve Figure 1-54 Front Seal Wear Sleeve Removal Tool J-45989 All information subject to change without notice. 1-63 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 108 2. Install the seal wear sleeve with the rounded edge toward the inside of the seal wear sleeve installer tool (J–47271, part of toolset J-47273). Heat the tool and sleeve together in an oven to a maximum of 150°C (302°F). All information subject to change without notice. 1-64 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 109 Perform the following to remove the rear crankshaft seal wear sleeve: 1. Remove the flywheel. Refer to section 1.13.1. 1. Flywheel Figure 1-56 Rear Seal Wear Sleeve Removal All information subject to change without notice. 1-65 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 110 2. Install the seal wear sleeve with the rounded edge toward the inside of the seal wear sleeve installer tool (J–47271, part of toolset J-47273). Heat the tool and sleeve together in an oven to a maximum of 150°C (302°F). All information subject to change without notice. 1-66 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 111 5. Wait until the seal wear sleeve cools to room temperature before installing the oversize radial seal. Refer to section 1.7.2 to install the front oversize radial seal. All information subject to change without notice. 1-67 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 112: Crankshaft Assembly

    4. Lower Bearing Shell(s) 8. Main Bearing Cap Bolt Figure 1-58 Crankshaft, Main Bearings, and Main Bearing Caps 1.10.1 Crankshaft Removal Remove the crankshaft as follows: All information subject to change without notice. 1-68 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 113 5. Remove the flywheel and flywheel housing. Refer to section 1.13.1. 6. Remove the front cover housing. Refer to section 1.11.1. 7. Remove the pistons. Refer to section 1.18.1. All information subject to change without notice. 1-69 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 114 Figure 1-60 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. 1-70 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 115 Then lift the crankshaft out of the block. See Figure 1-61. 1. Crankshaft 3. Hoisting Chain 2. Flexible Straps 4. Engine Stand Figure 1-61 Attaching the Hoist All information subject to change without notice. 1-71 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 116 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. 1-72 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 117 If, for any one journal, the two measurements differ by more than 0.02 mm (0.0008 in.), replace the crankshaft. Refer to section 1.10.1. All information subject to change without notice. 1-73 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 118 2. Hardness Tester Figure 1-63 Journal Measurements Type of Journal Width: mm (in.) 46.000-46.250 Main Journal (1.8110-1.8209) 44.5-44.6 Connecting-Rod Journal (1.752-1.756) Table 1-15 Crankshaft Bearing Journal Width All information subject to change without notice. 1-74 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 119 11. Measure the fillet radius of the main journals and the connecting-rod journals as listed in Table 1-13. See Figure 1-64. Figure 1-64 Measuring the Fillet Radius All information subject to change without notice. 1-75 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 120 Refer to section 1.10.1.2. [b] With the crankshaft fully installed, measure the end play (lateral runout) of the crankshaft. Refer to section 1.10.1.3. All information subject to change without notice. 1-76 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 121 fit into the slots in the crankcase races. See Figure 1-66. 1. Crankcase Race 3. Cylinder Block 2. Upper Bearing Shell 4. Bearing Shells Locking Lug Figure 1-66 Installing the Upper Bearing Shell All information subject to change without notice. 1-77 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 122 Figure 1-67 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. 1-78 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 123 See Figure 1-69. Refer to section 1.10.2 for instructions and tightening torques. 1. Cylinder Block 2. Main Bearing Cap 3. Bearing-Cap Bolt 4. Crankshaft Gear Figure 1-69 Installing the Main Bearing Caps All information subject to change without notice. 1-79 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 124 Bearing Shell and Bearing Journal Diameter NOTE: New bearing shells are supplied ready for installation. Do not machine them or remove any material from them. Refer to section 1.10.2. All information subject to change without notice. 1-80 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 125 [a] For the main bearing shell, note the inside diameter of the bearing shell. Example: = 4.0875 inches. [b] For the main bearing journal, note the outside diameter of the journal. Example: = 4.0850 inches. All information subject to change without notice. 1-81 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 126 12. Install the engine in the vehicle. 1.10.1.3 Crankshaft End Play Checking Check the crankshaft end play as follows: 1. Remove the crankshaft. Refer to section 1.10.1. All information subject to change without notice. 1-82 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 127 To obtain a correct value for crankshaft end play, the width of each bearing shell and its corresponding journal must belong to the same repair stage (both must be "Standard," "Undersize - 0.020 inch," etc.). All information subject to change without notice. 1-83 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 128 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 1-20 Bearing Shell and Bearing Journal Width 5. Install the crankshaft. Refer to section 1.10.2. All information subject to change without notice. 1-84 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 129 [c] Move the crankshaft all the way aft. Note the end play on the dial gauge. [d] If the end play does not correspond to the calculated amount (in the example above: 0.0090 in.), replace the crankshaft. All information subject to change without notice. 1-85 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 130 Make sure the locking lugs are fully seated in the grooves of the bearing caps. Refer to section 1.10.1.2. 5. Screw a crankshaft and flywheel guide pin into each end of the crankshaft. All information subject to change without notice. 1-86 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 131 9. Measure the shaft length of the main bearing-cap bolts. Replace any bolts that exceed the maximum shaft length of 156.0 mm (6.14 in.). See Figure 1-75. 1. Main Bearing-Cap Bolt Figure 1-75 Measuring a Main Bearing-Cap Bolt All information subject to change without notice. 1-87 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 132 The brackets are designed to lift vertically. 17. Remove the engine from the stand. 18. Install the engine in the vehicle. All information subject to change without notice. 1-88 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 133 6. Rotate the crankshaft until the marked gear tooth on the crankshaft gear is aligned between the two similarly marked teeth on the camshaft gear. See Figure 1-76. All information subject to change without notice. 1-89 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 134 10. Attach the rear engine mounts to the flywheel housing. Refer to the applicable vehicle service manual. 11. Remove the jack stands supporting the engine. 12. Install the oil pan. All information subject to change without notice. 1-90 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 135: Front Cover Housing

    Remove and discard the cover housing gasket. 7. Remove the front radial seal from the front cover housing. All information subject to change without notice. 1-91 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 136 7. Install the front engine mounting bolts attaching the front cover housing to the front crossmember. Tighten the front engine mounting bolts to 325 N·m (240 lb·ft). 8. Close the hood, and remove the chocks from the tires. All information subject to change without notice. 1-92 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 137: Crankshaft Vibration Damper

    The vibration damper has a crankshaft pulley bolted to it to accommodate two additional drive belts. It is not necessary to disassemble the vibration damper unless the crankshaft pulley is damaged and needs to be replaced. All information subject to change without notice. 1-93 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 138 3. Install the lower mounting bolts on the bottom of the front fairing/bumper, as removed. 4. Remove the engine barring tool from the flywheel housing. Refer to section 1.16.2. 5. Install the drive belts on their pulleys, as removed. All information subject to change without notice. 1-94 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 139: Flywheel

    4. Flywheel Figure 1-80 Flywheel and Components 1.13.1 Flywheel Removal Remove the flywheel as follows: 1. Remove the transmission. 2. Remove the clutch from the flywheel. All information subject to change without notice. 1-95 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 140 flywheel, one from each side of the bolt circle. See Figure 1-82. 1. Flywheel Mounting Bolt (10 qty.) 2. Flywheel Figure 1-82 Flywheel (exploded view) All information subject to change without notice. 1-96 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 141 [a] On opposite sides of the bolt circle, screw a bolt into each of two threaded clutch bolt holes. [b] Using the two bolts as handles, dislodge the flywheel from the crankshaft flange and remove it from the flywheel housing. All information subject to change without notice. 1-97 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 142 Inspect the flywheel as follows: 1. Remove the flywheel. Refer to section 1.13.1. 2. Thoroughly clean the flywheel and check it for cracks, scoring, burned areas, or rough spots. All information subject to change without notice. 1-98 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 143 finish could cause difficulties in clutch disengagement. See Figure 1-87 for the locations on the flywheel to coordinate with the specifications in the table. All information subject to change without notice. 1-99 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 144 70 (2.8) Peak-to-Valley Height (R ) of Clutch Friction Surface 0.016 (0.0006) Flywheel Permissible Deviation From True 0.2 (0.008) (radial and lateral) Table 1-22 Flywheel Specifications All information subject to change without notice. 1-100 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 145 2. Check the radial and lateral deviation from true of the flywheel. The deviation from true must not exceed 0.2 mm (0.008 in.). 3. Install the flywheel. Refer to section 1.13.2. 1.13.2 Flywheel Installation Install the flywheel as follows: All information subject to change without notice. 1-101 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 146 2. Using a suitable lifting device install the flywheel over the guide pins (J–46172). Align the dowel on the crankshaft with the guide hole in the flywheel (arrow). See Figure 1-89. All information subject to change without notice. 1-102 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 147 7. If removed, install the pilot bearing and spacer in the flywheel. Refer to section 1.15.2. 8. Install the crank angle position sensor into the flywheel housing. 9. Install the clutch and the transmission. All information subject to change without notice. 1-103 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 148: Ring Gear

    Location of Flywheel Ring Gear 1.14.1 Ring Gear Replacement Replace the flywheel ring gear as follows: 1. Remove the flywheel from the crankshaft flange. Refer to section 1.13.1. All information subject to change without notice. 1-104 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 149 2. Heat the ring gear on the flywheel with a torch and press the gear off. See Figure 1-91. Figure 1-91 Heating the Ring Gear All information subject to change without notice. 1-105 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 150 (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 in.). All information subject to change without notice. 1-106 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 151 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 in.). 8. Install the flywheel on the crankshaft flange. Refer to section 1.13.2. All information subject to change without notice. 1-107 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 152: Pilot Bearing

    The flats on the hex-head bolts must be parallel to the pilot bearing bore in order to have sufficient clearance to remove the pilot bearing. 1. Flywheel 2. M16 x 1.5 x 70mm Hex-Head Bolt Figure 1-94 Flywheel Bolt Positioning All information subject to change without notice. 1-108 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 153 9. Attach a suitable slide hammer (J-6471–02), with 5/8–18 male threads, to the extractor and remove the bearing. See Figure 1-96. 1. Flywheel 2. M16 x 1.5 x 70 mm Bolt Figure 1-96 Pilot Bearing Removal All information subject to change without notice. 1-109 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 154 4. Install two standard flywheel bolts, finger tight, perpendicular to the M16 x 1.5 x 70mm bolts. Remove the special bolts. 5. Install the remaining eight flywheel bolts. All information subject to change without notice. 1-110 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 155 8. Install the clutch on the flywheel. Refer to the appropriate vehicle service manual. 9. Install the transmission. Refer to the appropriate vehicle service manual. All information subject to change without notice. 1-111 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 156: Engine Barring Tool

    The inspection cover bolts are not long enough to install the engine barring tool. Longer ones will be needed. 4. As needed, insert the pin to lock the tool and block movement of the flywheel ring gear. All information subject to change without notice. 1-112 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 157 1. Remove the two bolts and the barring tool from the flywheel housing. It is not necessary to remove the pin. 2. Install the inspection cover on the flywheel housing with the two bolts. Tighten the bolts 25 N·m (18 lb·ft). All information subject to change without notice. 1-113 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 158: Flywheel Housing

    7. Remove the flywheel housing mounting bolts. Then remove the flywheel housing from the cylinder block. See Figure 1-99. 8. Remove and discard the flywheel housing gasket. All information subject to change without notice. 1-114 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 159 8. Install the rear engine mounts onto the flywheel housing. Refer to appropriate vehicle service manual. 9. Install the oil pan and new gasket. 10. Install the transmission and clutch. Refer to appropriate vehicle service manual. All information subject to change without notice. 1-115 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 160: Piston, Piston Ring, And Connecting Rod

    4. Install the engine barring tool (J–46392). Refer to section 1.16.1. All information subject to change without notice. 1-116 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 161 6. Remove and inspect the oil spray nozzles. See Figure 1-102. Replace them if damaged. 1. Oil Spray Nozzle 2. Cylinder Liner Figure 1-102 Location of Oil Spray Nozzle All information subject to change without notice. 1-117 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 162 12. Remove the wrist-pin snap rings. Push the wrist pin out and remove the piston from the connecting rod. 1.18.1.1 Piston Inspection Inspect the piston as follows: 1. Remove the piston. Refer to section 1.18.1. All information subject to change without notice. 1-118 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 163 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. 1-119 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 164 8. Check the length of the connecting rod stretch bolts. See Figure 1-106. Replace any bolts that exceed the maximum length of 68.5 mm (2.70 in.). 1. Shank Figure 1-106 Measuring a Stretch Bolt All information subject to change without notice. 1-120 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 165 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. 1-121 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 166 [b] Measure the difference in axial parallelism (Dimension B in see Figure 1-108) between the bearing bore and the inner surface of the bushing, at 50 mm (2 in.) from All information subject to change without notice. 1-122 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 167 1. Remove the piston. Refer to section 1.18.1. 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. 1-123 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 168 Torque Value: N·m ( lb·ft) 68.5 (2.70) Stage 1 108 (80) 68.5 (2.70) Stage 2 additional 90 degrees Table 1-28 Tightening Stages, Connecting Rod Stretch Bolts All information subject to change without notice. 1-124 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 169 [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. 1-125 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 170 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. 1-126 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 171 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. 1-127 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 172 Install the piston assembly as follows: 1. Position the connecting rod in the piston so that the longer end side is on the unit pump side. All information subject to change without notice. 1-128 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 173 Ring Gaps Offset 120 Degrees [a] Lubricate the piston with a light coating of clean engine oil. [b] Install each piston ring in the appropriate groove on the piston. All information subject to change without notice. 1-129 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 174 [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. 1-130 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 175 [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. 1-131 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 176 14. Rotate the crankshaft to make sure it turns freely. NOTE: If it is necessary to turn the crankshaft and the flywheel has been removed, install the flywheel guide pins in the crankshaft gear. All information subject to change without notice. 1-132 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 177 18. Install the oil spray nozzles, as removed. Be sure they are seated and aligned correctly. 19. Install the oil pan. 1.18.3 Piston Ring Replacement Replace the piston ring as follows: 1. Remove the piston. Refer to section 1.18.1. All information subject to change without notice. 1-133 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 178 3. Clean all the carbon from the ring grooves. Be sure the grooves are not damaged and that there are no burrs or combustion residue in the grooves. All information subject to change without notice. 1-134 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 179 Checking the Ring End Gap [b] Remove the spring garter from the third (lowest) ring. Measure its gap in the same way as the other two rings. All information subject to change without notice. 1-135 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 180 Be careful not to over-expand the rings during installation. See Figure 1-123. 1. Ring Expansion Stop Knob 2. Piston Diameter (mm) Figure 1-123 Piston Ring Pliers (J-46072) All information subject to change without notice. 1-136 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 181 Piston Rings Offset 120 Degrees 8. Install the piston. Refer to section 1.18.2. 1.18.4 Connecting Rod Bushing Replacement Replace the connecting rod bushing as follows: All information subject to change without notice. 1-137 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 182 57.080-57.100 (2.2472-2.2480) Inside Diameter of Bushing Bore 57.000-57.019 (2.2441-2.2448) Bushing Interference Fit 0.061-0.100 (0.0024-0.0039) Maximum Permissible Out-of-Round in Bushing Bore 0.01 (0.0004) Table 1-35 Bushing Specifications All information subject to change without notice. 1-138 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 183 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. 1-139 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 184: Egr Piston, Piston Ring, And Connecting Rod

    2. Push the piston and connecting rod assembly out of the cylinder liner. 3. Follow remaining steps for non-EGR engine piston removal. Refer to section 1.18.1. All information subject to change without notice. 1-140 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 185 4. After piston is installed, install carbon scraper ring in the cylinder liner groove. See Figure 1-126. 5. Check carbon scraper ring for correct fit after installation. All information subject to change without notice. 1-141 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 186 EGR PISTON, PISTON RING, AND CONNECTING ROD 6. Follow remaining steps for piston installation in a non-EGR engine . Refer to section 1.18.2 step 9. All information subject to change without notice. 1-142 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 187: Valves

    4. Adjust the valve lash. See Figure 1-128. Refer to section 1.20.3. 1. Rocker Arm 2. Valve Bridge 3. Valve Spring Retainer Figure 1-128 Valve Lash and Valve Lift All information subject to change without notice. 1-143 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 188 11.546 mm (0.4546 in.) at its highest point, the intake valves are lifting OK. Check the exhaust valves.If the intake valve lift fails to All information subject to change without notice. 1-144 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 189 11.963 mm (0.4710 in.) at its highest point, the exhaust valve is lifting OK. Check the next cylinder.If the exhaust valve lift fails to All information subject to change without notice. 1-145 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 190 □ In order, according to the timing sequence used for fuel injection (see Method One—Adjust 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. 1-146 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 191 Cylinders Cylinders Cylinders Cylinders Cylinders Position Ignition TDC Valve Overlap Table 1-37 Valve Adjustment (Method One) NOTE: Clean each cylinder head cover before removing it. All information subject to change without notice. 1-147 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 192 The bolts from the inspection cover are not long enough to secure the engine barring tool properly. Use bolts of sufficient length to secure the barring tool. 1. Inspection Cover 2. Cranking Device Figure 1-133 Placement of the Barring Tool All information subject to change without notice. 1-148 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 193 Method Two — Adjust All Valves Using Two Crankshaft Positions Method two allows you to adjust all the valves using just two crankshaft positions. NOTE: Clean each cylinder head cover before removing it. All information subject to change without notice. 1-149 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 194 3. Fit the engine barring tool (J–46392) into the inspection hole on the flywheel housing. See Figure 1-135. 1. Inspection Cover 2. Cranking Device Figure 1-135 Placement of the Barring Tool All information subject to change without notice. 1-150 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 195 8. 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. 1-151 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 196 3. Check the valve lash again. Adjust again if necessary. 4. Install the cylinder head covers. Refer to section 1.1.2. 5. Remove the barring tool from the inspection hole in the flywheel housing. All information subject to change without notice. 1-152 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 197 4. Dial Gauge Holder Figure 1-138 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. 1-153 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 198 [d] For used heads, if the gauge reads more than 1.6 mm (0.06 in.), inspect valve and valve seats. Listed in Table 1-44 are the specifications. 4. Install the cylinder head. Refer to section 1.2.2. All information subject to change without notice. 1-154 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 199 3. Place the cylinder head on wooden blocks. 4. Attach the valve spring adaptor and remover (J–46173), to the cylinder head. See Figure1-140. 1. Valve 2. Cylinder Head Figure 1-140 Valve Removal All information subject to change without notice. 1-155 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 200 6. Relieve the pressure on the adaptor/remover. Remove the valve spring retainers, valve springs, and spacer washers. 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. 1-156 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 201 Measuring the Inside Diameter of the Valve Guide Description Specification: mm (in.) Normal 9.000-9.022 (0.3543-0.3552) Wear Limit 9.050 (0.3563) Table 1-43 Inside Diameter of Valve Guide All information subject to change without notice. 1-157 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 202 Valve seat width at the valve head (E) □ Valve seat angle (F) □ Valve length (G) □ Figure 1-144 Critical Dimensions, Valve Stem and Head All information subject to change without notice. 1-158 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 203 Always replace the valve stem seal if the valve has been removed. Check the seal to make sure it is correctly seated on the valve guide. Refer to section 1.20.7. 3. Install new valve stem seals. Refer to section 1.20.7. All information subject to change without notice. 1-159 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 204 4. Lubricate the valve stem and valve stem seal installer/protector (J–46174) with a light coating of clean engine oil. NOTE: The installer prevents the groove on the valve stem from damaging the seal. All information subject to change without notice. 1-160 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 205 8. Install the valve keepers, 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. 1-161 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 206: Egr Valves

    □ Valve head diameter (C) □ Valve seat height (D) □ Valve seat width at the valve head (E) □ Valve seat angle (F) □ All information subject to change without notice. 1-162 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 207 1. Install the valve stem sealing ring in the valve guide in the cylinder head. 2. Lubricate each valve with a light coating of engine oil. All information subject to change without notice. 1-163 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 208 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. 1-164 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 209 14. Install the keeper, spring retainer, valve spring and spring seat, as removed. 15. Repeat the procedure for the other valves. 16. Install the cylinder head on the EGR engine. Refer to section 1.4.1. All information subject to change without notice. 1-165 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 210 38.99-39.0 (1.535-1.535) 38.99-39.01(1.535-1.536) diameter (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 1-47 Valve Seat Specifications for EGR Engine All information subject to change without notice. 1-166 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 211: Rocker Arm

    [d] Remove the rocker arm assembly from the cylinder head. 3. Inspect the rocker arm assembly for wear. If necessary, disassemble the rocker arm assembly and replace any worn parts. Refer to section 1.22.2. All information subject to change without notice. 1-167 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 212 [a] Remove the intake rocker arm and washer. [b] Remove the exhaust rocker arm and washer. [c] Remove the adjusting screw and locknut from both intake and exhaust rocker arms. All information subject to change without notice. 1-168 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 213 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. 1-169 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 214 [c] Tighten each mounting bolt 60 N·m (44 lb·ft). Final angular tightening: 90 degrees. 5. Adjust the valve lash. Refer to section 1.20.3. 6. Install the cylinder head cover on each cylinder head. Refer to section 1.1.2. All information subject to change without notice. 1-170 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 215: Camshaft And Camshaft Position Sensor

    3. Install the engine on an engine stand. 4. Remove the electronic unit pumps (EUP). 5. Remove the vibration damper. Refer to section 1.12.1. All information subject to change without notice. 1-171 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 216 3. Cover Mounting Bolt 5. Front of Camshaft 2. Front Camshaft Cover 4. Fuel Pump Drive Gear 6. Fuel Pump Driven Gear Figure 1-153 Camshaft Assembly All information subject to change without notice. 1-172 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 217 Figure 1-154 Attaching the Camshaft Guide Tool 14. From the gear end (rear of the engine), carefully remove the camshaft from the block. See Figure 1-154. All information subject to change without notice. 1-173 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 218 [a] Measure the outside diameter of each tappet. [b] Measure the diameter of the tappet housing in the cylinder block. 17. Inspect the camshaft. Refer to section 1.23.1.1. All information subject to change without notice. 1-174 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 219 A hard base should be placed below the cam or bearing journal to be inspected. See Figure 1-156. 1. Camshaft 2. Hardness Tester Figure 1-156 Inspecting Cam Hardness All information subject to change without notice. 1-175 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 220 6. Measure the cam rise of the exhaust valve cams. See Figure 1-157, Ref. E. 7. Measure the cam rise of the unit pump valve cams. See Figure 1-157, Ref. U. All information subject to change without notice. 1-176 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 221 [a] Lubricate the cams and camshaft journals with a light coating of clean engine oil. [b] Attach the camshaft guide tool (J-46183) to the camshaft. All information subject to change without notice. 1-177 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 222 11. Install the vibration damper. Refer to section 1.12.2. 12. Lubricate the pushrods with a light coating of clean engine oil. Install the pushrods and the rocker arm assembly. Refer to section 1.22.4. All information subject to change without notice. 1-178 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 223 2. Crankshaft Position Sensor Figure 1-159 Camshaft Sensor Installation 2. Remove the sensor from the access hole in the flywheel housing by pulling the sensor outward. All information subject to change without notice. 1-179 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 224 4. Connect the electrical connector to the CMP sensor. NOTE: Be sure that the correct electrical connector is connected to the sensor. All information subject to change without notice. 1-180 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 225: Egr Camshaft

    The holes in the camshaft journal must be lined up with the holes in the camshaft bushing. 1. Bushing Groove Figure 1-160 Camshaft Bushing Installation All information subject to change without notice. 1-181 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 226 1.24 EGR CAMSHAFT All information subject to change without notice. 1-182 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 227: Aadditional Information

    Table 1-58. Cylinder head torque values are listed in Table 1-59. Cylinder head specifications are listed in Table 1-60. The specifications for compression testing are listed in Table 1-61 and listed in Table 1-62. All information subject to change without notice. 1-183 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 228 Inspection Cover on Flywheel Housing 25 N·m (18 lb·ft) Rocker Arm Mounting Bolts 60 N·m (44 lb·ft); then another 90° Table 1-59 Cylinder Head Torque Values All information subject to change without notice. 1-184 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 229: Cylinder Head

    400 (58) Table 1-61 Compression Pressure Test Data Description Torque Value: N·m (lb·ft) Tensioning Arm Bolts 50 (37) Table 1-62 Tensioning Arm Bolt Torque Values All information subject to change without notice. 1-185 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 230: Cylinder Block

    Specification: mm (in.) 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 1-66 Specifications for Measuring Cylinder Liner Protrusion All information subject to change without notice. 1-186 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 231: Crankshaft Assembly

    46.000-46.062 (1.8110-1.8135) 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 1-69 Bearing Shell and Bearing Journal Width All information subject to change without notice. 1-187 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 232: Flywheel And Flywheel Housing

    1-75. Listed in Table 1-76 are the torque values for the flywheel and the flywheel housing. The tightening stages for the flywheel mounting bolts are listed in Table 1-77. All information subject to change without notice. 1-188 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 233 Tightening Stage Torque Value: N·m (lb·ft) 77.0 (3.03) Stage 1 200 (147.5) 77.0 (3.03) Stage 2 90 degrees Table 1-77 Tightening Stages, Flywheel Mounting Bolts All information subject to change without notice. 1-189 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 234: Piston, Piston Ring And Connecting Rod

    Max. Shaft Length: mm (in.) Tightening Stage Torque Value: N·m (lb·ft) Stage 1 100-115 (74-85) 68.5 (2.70) Stage 2 additional 90-100° Table 1-81 Tightening Stages, Connecting Rod Stretch Bolts All information subject to change without notice. 1-190 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 235 Undersize 0.25 (0.010) 93.730-93.750 (3.6901-3.6909) Undersize 0.50 (0.020) 93.480-93.500 (3.6803-3.6811) Undersize 0.75 (0.030) 93.230-93.250 (3.6705-3.6712) Undersize 1.00 (0.040) 92.980-93.000 (3.6606-3.6614) Table 1-85 Bearing Journal Specifications All information subject to change without notice. 1-191 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 236: Valves

    Specification: mm (in.) Intake Normal 0.7-1.1 (0.03-0.04) Intake Wear Limit 1.6 (0.06) Exhaust Normal 0.7-1.1 (0.03-0.04) Exhaust Wear Limit 1.6 (0.06) Table 1-88 Valve Protrusion Limits All information subject to change without notice. 1-192 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 237 38.99-39.0 (1.535-1.535) 38.99-39.01(1.535-1.536) diameter (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 1-93 Valve Seat Specifications for EGR Engine All information subject to change without notice. 1-193 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 238: Rocker Arm

    Table 1-95 Rocker Arm Specifications Description Specification: mm (in.) Bushing Inside Diameter (when installed) 25.005-25.021 (0.9844-0.9851) Shaft Diameter 24.967-24.980 (0.9830-0.9835) Table 1-96 Rocker Arm Bushing Specifications All information subject to change without notice. 1-194 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 239: Camshaft And Camshaft Sensor

    Table 1-98 Valve Tappet Specifications Fastener Type N·m (lb·ft) Camshaft Front Cover 50 (37) Fuel Pump Drive Gear 60 (44) Table 1-99 Camshaft Torque Values All information subject to change without notice. 1-195 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 240: Sensor And Fittings

    Fuel Temperature Sensor to Engine Block 30 (22) Coolant Temperature Sensor to the Engine Block 30 (22) Trim Cover Bolts 12 (106 lb·in.) Table 1-100 Sensor and Fittings Torque Values All information subject to change without notice. 1-196 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 241: Fuel System

    FUEL SYSTEM Section Page INJECTOR UNIT PUMP ................EGR INJECTOR UNIT PUMP ..............2-15 HIGH PRESSURE FUEL LINE AND TRANSFER TUBE ......2-16 FUEL INJECTOR NOZZLE ..............2-26 EGR FUEL INJECTOR NOZZLE ............. 2-34 PROTECTIVE SLEEVE ................2-35 DDEC-ELECTRONIC CONTROL UNIT ........... 2-39 FUEL HEAT EXCHANGER ..............
  • Page 242 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 243: Injector Unit Pump

    Main Fuel Filter (exploded view) NOTE: 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 244 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 245 This step is necessary to prevent fuel from contaminating the engine oil in the block. 7. Remove the end cover from the lower right side of the flywheel housing, then attach the engine barring tool (J-46392). All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 246 2. Head of Unit Pump Figure 2-4 Loosen the Mounting Bolts 9. Using the engine barring tool (J-46392), rotate the crankshaft until the cam pushes the unit pump upwards. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 247 11. Remove both mounting bolts completely. Carefully pull the unit pump out of the cylinder block. See Figure 2-6. 1. Mounting Bolt 3. Cylinder Block 2. Unit Pump Figure 2-6 Removing the Unit Pump All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 248 This service kit is used to repair fuel leakage at the solenoid. For this type of complaint, total replacement of the unit pump is no longer necessary. Perform the following steps to install the unit pump repair kit. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 249 9. Cross Piece 4. Seal 10. O-ring 5. Intermediate Plate 11. O-ring 6. Magnet Figure 2-7 Unit Pump Components 2. Wipe the pump clean, removing excess fuel. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 250 Clean the model plate and remove paint from the screw heads contact area. 7. Remove the two spacer seals and clean the intermediate plate. Do not damage sealing surfaces. All information subject to change without notice. 2-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 251 13. Place the intermediate plate on the unit pump body. Observe the identification mark on the cross piece and anchor plate for the unit pump body. The cutouts (see arrows D of Figure All information subject to change without notice. 2-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 252 Refer to section 2.1.3 for installation procedures. 2.1.3 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. 2-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 253 7. Connect the fuel line at the fuel gallery inlet. Tighten the fitting to 50 N·m (37 lb·ft). 8. Install the fuel lines and pressure limiting valve on the fuel gallery outlet. Tighten all fasteners to 50 N·m (37 lb·ft). All information subject to change without notice. 2-13 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 254 11. Prime the fuel system. 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. 2-14 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 255: 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. 6. Turn off key and unplug minidiag2. 7. Install the unit pump. Refer to section 2.1.3. All information subject to change without notice. 2-15 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 256: High Pressure Fuel Line And Transfer Tube

    Any repair to the fuel system requires the fuel tank cap to be removed, to release any trapped air pressure in the fuel tank. 2.3.1 Removal of High Pressure Fuel Line and Transfer Tube Remove as follows: All information subject to change without notice. 2-16 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 257 4. To prevent the transfer tube from rotating during the high pressure fuel line disassembly, secure the transfer tube thrust nut using a 24 mm fuel line wrench (J-47484 or J-45063) All information subject to change without notice. 2-17 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 258 Remove and discard the transfer tube and the O-ring. See Figure 2-13. 2.3.2 Installation of High Pressure Fuel Injector Lines Installation steps are as follows: All information subject to change without notice. 2-18 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 259 2. Apply a light coat of clean engine oil to the transfer tube O-ring and install the transfer tube into the cylinder head. 3. Using a 24 mm socket, torque the thrust nut to 45 N·m (33 lb·ft). All information subject to change without notice. 2-19 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 260 Ensure that the damper is not touching any other fuel lines or other engine or vehicle components. Figure 2-15 Orientation of Fuel Line All information subject to change without notice. 2-20 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 261 1/3 of a full turn, or through two nut flats. Lack of space in some All information subject to change without notice. 2-21 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 262 120 degrees can be measured by turning the nut so that the nut edge which had been marked has been turned through 1/3 of a full turn, or through two nut flats. Lack of All information subject to change without notice. 2-22 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 263 60 degrees, or one nut flat each. See Figure 2-18. Figure 2-18 Turning Fuel Line Nut 120 Degrees At Transfer Tube End All information subject to change without notice. 2-23 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 264 Correct High Pressure Fuel Line Installations 10. Install the intake manifold. 11. Install the cylinder head covers. 12. Prime the fuel system. Refer to section 11.1.5. All information subject to change without notice. 2-24 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 265 14. Shut down the engine. All information subject to change without notice. 2-25 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 266: Fuel Injector Nozzle

    □ Wear adequate protective clothing (face shield, insulated gloves and apron, etc.). □ To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during operation. All information subject to change without notice. 2-26 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 267 If the transfer tube is stuck in the cylinder head, use the injector unit pump puller (J–46375) to remove the transfer tube. 6. Remove the tensioning arm. All information subject to change without notice. 2-27 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 268 [b] Use the slide hammer on the puller tool and remove and discard the heat isolator. 11. Cap off or cover the openings on the unit pump and nozzle to prevent contamination. All information subject to change without notice. 2-28 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 269 2. Lubricate a new nozzle O-ring with a light coating of engine oil and install it on the nozzle. 3. Using the heat isolator installer (J-46384), press the new heat isolator onto the nozzle. [a] Position the new heat isolator over the nozzle. All information subject to change without notice. 2-29 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 270 [b] Place the receptacle from the heat isolator installer over the head of the nozzle holder and the pressure-fit cap over the heat isolator. See Figure 2-23 and see Figure 2-24. Figure 2-23 Heat Isolator Installer Components (J-46393) All information subject to change without notice. 2-30 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 271 Check that the heat isolator is firmly pressed onto the nozzle. NOTE: Take care that the nozzle holder is installed correctly and is aligned properly with respect to the transfer tube. All information subject to change without notice. 2-31 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 272 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. 2-32 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 273 8. Install the injector line. Refer to section 2.3.2. 9. Install the charge-air manifold. 10. Install the cylinder head cover(s), as removed. 11. Install the engine trim covers. All information subject to change without notice. 2-33 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 274: Egr Fuel Injector Nozzle

    EPA 98 injector nozzles may not be used in an EPA 04 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. 2-34 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 275: Protective Sleeve

    [b] Loosen the protective sleeve with a ratchet by turning in a counterclockwise direction until the threads of the sleeve are disengaged from the cylinder head. All information subject to change without notice. 2-35 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 276 [d] Pull upward while rotating the injector sleeve puller counterclockwise to remove it from the cylinder head. 1. Protective Sleeve 2. O-ring Figure 2-28 Pulling the Protective Sleeve All information subject to change without notice. 2-36 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 277: Protective Sleeve

    45 N·m (33 lb·ft). 4. Install the nozzle. Refer to section 2.4.2. Use Detroit Diesel POWER Trac® 3–way Coolant Test Strips to measure nitrite and glycol concentrations. If the test indicates the coolant is acceptable reuse the coolant. If the test indicates the coolant is not within specifications, discard the coolant and replace with new.
  • Page 278 3. Install a new sensor in the flywheel housing. Push the sensor in until it is fully seated. 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. 2-38 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 279: Ddec-Electronic Control Unit

    Perform the following procedures for removal and installation of the DDEC-ECU. 2.7.1 DDEC-Electronic Control Unit Removal Remove the DDEC-ECU as follows: 1. Disconnect the batteries. 2. Open the hood. All information subject to change without notice. 2-39 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 280 12. Fuel Heat Exchanger 13. Heat Exchanger Case Bolt 6. Engine Wiring Harness 7. Fuel Feed Line 14. DDEC-ECU Case Bolt Figure 2-31 DDEC-ECU Control Unit All information subject to change without notice. 2-40 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 281 4. Lift up the slide on the locking unit to release the vehicle wiring harness connector and disconnect it from the DDEC-ECU unit. See Figure 2-32. 1. Vehicle Electrical Connector 2. Vehicle Wiring Harness Figure 2-32 Vehicle Electrical Connector All information subject to change without notice. 2-41 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 282 3. Install the fuel heat exchanger on the DDEC-ECU and tighten the mounting bolts to 8 N·m (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. 2-42 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 283 □ 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. 2-43 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 284: Fuel Heat Exchanger

    flames, sparks, and electrical resistance heating elements. Do not smoke when refueling. 1. Disconnect the batteries. 2. Open the hood. All information subject to change without notice. 2-44 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 285 NOTE: Do not disassemble the fuel heat exchanger. It cannot be serviced. 2.8.2 Fuel Heat Exchanger Installation Install the fuel heat exchanger as follows: All information subject to change without notice. 2-45 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 286 2. Connect the fuel lines to the fuel heat exchanger. Use new seal rings. Tighten the fuel lines to 50 N·m (37 lb·ft). 3. Close the hood. 4. Connect the batteries. 5. Prime the fuel system. All information subject to change without notice. 2-46 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 287: Fuel Filter

    filter. See Figure 2-35. 1. Filter Housing Cap 3. Fuel Filter Element 2. O-ring 4. Filter housing Figure 2-35 Removing the Fuel Filter All information subject to change without notice. 2-47 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 288 6. Crank the engine for 30 seconds at a time, but no longer. Before cranking the engine again, wait at least two minutes. The engine should start within four 30-second attempts. All information subject to change without notice. 2-48 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 289 filter. Engines built before March 2005 require the installation of a fuel priming valve before using the Diesel Fuel System Primer tool (J-47912). All information subject to change without notice. 2-49 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 290: Fuel Filter Housing

    3. Using a 36-mm socket, unscrew the cap on the fuel filter. Lift both the cap and the filter element a short distance above the filter housing. See Figure 2-36 for non-EGR engines All information subject to change without notice. 2-50 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 291 14. Fuel Drain Line 6. Banjo Bolt 7. Priming Nipple Valve 15. Bolts 8. Dust Cover 16. Bolts Figure 2-36 Non-EGR Engine Fuel Filter Housing All information subject to change without notice. 2-51 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 292 14. Fuel Filter Housing Mounting Bracket 7. Priming Nipple Valve 15. Fuel Filter Housing-to-Bracket Mounting Bolts 8. Dust Cover 16. Fuel Drain Line Figure 2-37 EGR Engine Fuel Filter Housing All information subject to change without notice. 2-52 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 293 4. Install the return line, as removed. Install new seal rings on the banjo fitting. Tighten the banjo bolt to 40–50 N·m (30–37 lb·ft). 5. Install a new filter element. Refer to section 2.9.2. All information subject to change without notice. 2-53 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 294: Fuel Filter Bracket

    2. Remove the two filter bracket mounting bolts from bracket and block and remove the filter bracket. See Figure 2-38. 1. Fuel Filter Housing Mounting Bracket 2. Bolts Figure 2-38 Non-EGR Fuel Filter Bracket All information subject to change without notice. 2-54 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 295 1. Install the fuel filter bracket to the block using the three 8 mm x 90 mm fuel filter bracket mounting bolts. Torque the bolts to 25 N·m (18 lb·ft). See figure 2-39. All information subject to change without notice. 2-55 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 296 2.11 FUEL FILTER BRACKET 2. Install the fuel filter housing to the mounting bracket. Refer to section 2.10.2. All information subject to change without notice. 2-56 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 297: Fuel Pump

    1. Disconnect the batteries. 2. Open the fuel tank fill cap to release the pressure in the fuel system. Replace and tighten the cap. All information subject to change without notice. 2-57 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 298 5. Slowly remove the fuel pump from the engine, taking care not to damage the spline shaft on the fuel pump. 6. Discharge the fuel pump gasket. 2.12.2 Fuel Pump Installation Install the fuel pump as follows: All information subject to change without notice. 2-58 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 299 2. Install the fuel lines, as removed. Install new seal rings on the banjo fittings. Tighten the banjo bolts to 40-50 N·m (30-37 lb·ft). 3. Connect the batteries. All information subject to change without notice. 2-59 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 300 4. Prime the fuel system. 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. 2-60 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 301: Fuel Pump Drive

    6. Remove the fuel pump driven gear bolt while holding the fuel pump drive splines with locking tool (J-46187). See Figure 2-42. Figure 2-42 Fuel Pump Gear Locking Device J-46187 All information subject to change without notice. 2-61 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 302 Figure 2-43 Removing/Installing Fuel Pump Drive Assembly 8. Remove the snap ring from the front of the cylinder block and inside the drive assembly bore. All information subject to change without notice. 2-62 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 303 See Figure 2-44. 1. Torque Wrench 3. Fuel Pump 2. Fuel Pump Drive Gear Splines 4. Fuel Pump Gasket Figure 2-45 Torquing Fuel Pump Drive Gear All information subject to change without notice. 2-63 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 304 9. Install the air conditioner compressor pad. 10. Install idler pulley. 11. Install the alternator and electrical connections. 12. Install the crankshaft vibration damper on the crankshaft. All information subject to change without notice. 2-64 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 305: Fuel System Inspection

    45 (33) High Pressure Line Nuts 30 (22) Table 2-2 Torque Specifications for Fuel Line Nuts 5. Perform a fuel pressure test. Refer to section 2.14.1. All information subject to change without notice. 2-65 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 306 1. Fuel Pump 4. Fuel Outlet Line 2. Fitting 5. Mechanical Gauge 3. Fuel Filter Housing Figure 2-47 Gauge Installation – Before the Fuel Filter All information subject to change without notice. 2-66 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 307 For results out of specs on the fuel pressure test, check the following appropriate steps: 1. At idle rpm, with fuel pressure lower than 2 bar (29 psi), check the following: All information subject to change without notice. 2-67 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 308 Check the fuel pressure valve for a blocked or restricted regulator orifice. □ 2.14.2 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. 2-68 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 309 Operational range for this test: from -3% (negative) to 3% (positive). Identify the cylinder with the biggest absolute value – highest positive or lowest negative. The troubleshooting steps for both conditions are: All information subject to change without notice. 2-69 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 310 Checking the Fuel Pump Driven Gear Bolt Torque This procedure describes how to check the fuel pump driven gear bolt torque. Insufficient torque on the bolt will impact engine performance. All information subject to change without notice. 2-70 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 311 4. Remove the crankshaft vibration damper from the engine through the opening in the bumper. 5. Remove the idler pulley. 6. Remove the air conditioner compressor pad. 7. Remove the camshaft gear cover. See Figure 2-49. All information subject to change without notice. 2-71 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 312 15. Install the crankshaft vibration damper on the crankshaft. 16. Install the fuel pump and a new fuel pump gasket. Torque the fuel pump bolts to 25 N·m (18 lb·ft). All information subject to change without notice. 2-72 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 313 Injector Line Nuts 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. 2-73 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 314 Compression Brake Voltage Supply (PV2) 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. 2-74 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 315 Fuel Spill Line Banjo Bolt 15 (11) 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. 2-75 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 316 Figure 2-50 55-Pin Connector Wiring Diagram for EPA98 Engine All information subject to change without notice. 2-76 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 317 MBE 4000 SERVICE MANUAL Figure 2-51 55-Pin Connector Wiring Diagram for EPA04 (EGR) Engine All information subject to change without notice. 2-77 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 318 5.5 – 6.5 (80 – 94) Maximum difference between fuel filter housing 0.3 (4.0) inlet and outlet pressure Table 2-12 Fuel System Specifications for Pressure All information subject to change without notice. 2-78 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 319: Additional Information

    LUBRICATION SYSTEM Section Page LUBRICATION SYSTEM DESCRIPTION ..........OIL PAN ....................PISTON OIL SPRAY NOZZLE(S) ............3-11 CAMSHAFT LUBRICATION SPRAYER ........... 3-17 OIL PUMP AND SUMP PIPE ..............3-19 OIL FILTER ....................3-27 OIL HEAT EXCHANGER/FILTER HOUSING .......... 3-29 OIL PRESSURE/TEMPERATURE SENSOR ........... 3-34 ADDITIONAL INFORMATION ..............
  • Page 320 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 321: Lubrication System Description

    A mechanical oil separator pulls any oil droplets out of the crankcase vapor and returns the oil back into the oil pan. The clean air is then returned to the atmosphere. See Figure 3-1. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 322 7. Piston Oil Spray Nozzle(s) 3. Oil Filter 8. Oil Pump 4. Oil Cooler Element 9. Crankshaft 5. Turbocharger Oil Return Line Figure 3-1 Engine Oil Flow Diagram All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 323: 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 324 8. Oil Fill Tube 18. Fill Tube Flatwasher 9. Oil Fill Tube Retainer 19. Fill Tube Bolt 10. Oil Fill Retainer Bolt Figure 3-3 Oil Pan Removal and Installation All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 325 11. Thoroughly clean the pan. Remove all traces of gasket material from the pan and from the block. 3.2.2 Oil Pan Installation Install the oil pan as follows: 1. Position a new gasket on the cylinder block. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 326 Installing the Oil Fill Tube and Dipstick Guide Tube [a] Connect the oil fill tube clamp to the coolant inlet pipe using the oil fill tube clamp bolt. Tighten to 10 N·m (7 lb·ft). All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 327 Install the front suspension. 12. Tighten the shackle bolts and adjust the suspension. 13. Remove the stands and lower the vehicle to the ground. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 328 2. Minimum Fill Level Figure 3-7 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. 3-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 329: Piston Oil Spray Nozzle(S)

    2. Remove the inspection cover on the flywheel housing and install the engine cranking tool (J–46392). See Figure 3-8. Rotate the crankshaft to gain access to the nozzle(s). 1. Inspection Cover Figure 3-8 Installing the Engine Cranking Tool All information subject to change without notice. 3-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 330 Piston cooling nozzle tool J–47301 is used to check the proper alignment of the piston oil spray nozzles for non-EGR and EGR engines built before March 2005. EGR engines All information subject to change without notice. 3-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 331 MBE 4000 SERVICE MANUAL built starting March 2005 do not use this tool. For identification of the oil spray nozzles see Figure 3-10. Figure 3-10 Piston Cooling Nozzles All information subject to change without notice. 3-13 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 332 3.0 mm (0.118 in.) for EGR engines. 3.3.2 Piston Oil Spray Nozzle(s) Installation Install the piston oil spray nozzle(s) as follows: All information subject to change without notice. 3-14 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 333 Do not bend the nozzles to align. 3. Install the oil pan. Refer to section 3.2.2. All information subject to change without notice. 3-15 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 334 Figure 3-13 Installing the Engine Cranking Tool 5. Fill the crankcase to the specified oil level listed in Table 3-4. Do not overfill the crankcase. All information subject to change without notice. 3-16 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 335: Camshaft Lubrication Sprayer

    Figure 3-14 Camshaft Lubrication Sprayer Camshaft Lubrication Sprayer Removal 3.4.1 Remove the camshaft lubrication sprayer(s) as follows: 1. Remove the oil pan. Refer to section 3.2.1. All information subject to change without notice. 3-17 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 336 4. Install the oil pan. Refer to section 3.2.2. 5. Fill the crankcase to the specified oil level. Do not overfill the crankcase. The correct oil fill capacity is listed in Table 3-4. All information subject to change without notice. 3-18 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 337: Oil Pump And Sump Pipe

    EGR engine. See Figure 3-17. Oil Pick Up Tube in the EPA 04 (EGR) Engine Figure 3-17 Perform the following procedures for removal of the oil pump. All information subject to change without notice. 3-19 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 338 5. Thoroughly clean the contact surfaces of the oil pump and cylinder block. 3.5.2 Oil Pump Disassembly Disassemble the oil pump unit as follows: 1. Remove the oil pump from the cylinder block. Refer to section 3.5.1. All information subject to change without notice. 3-20 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 339 Clearance of Pump/Idler Gear to Walls of Pump Housing 0.030-0.122 (0.0012-0.0048) Gear Backlash (clearance between gear cogs) 0.312-0.476 (0.0123-0.0187) Table 3-1 Oil Pump Inspection Limits All information subject to change without notice. 3-21 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 340 To avoid injury from burning, use lifting tools and heat-resistant gloves when handling heated components. 1. Heat the drive wheel to approximately 80°C (176°F) in a hot water tank. All information subject to change without notice. 3-22 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 341 4. Seat the idler gear in the pump housing. 5. Install the face plate on the pump housing. Tighten the mounting bolts to 25 N·m (18 lb·ft). All information subject to change without notice. 3-23 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 342 Oil Pump and Sump Pipe Installation Install the oil pump and Sump Pipe as follows: 1. Coat the contact surface between the block and the oil pump with Loctite® 574. All information subject to change without notice. 3-24 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 343 6. Install the oil pan with a new gasket. Refer to section 3.2.2. 7. Fill the engine oil circuit. The correct oil fill capacity is listed in Table 3-4. All information subject to change without notice. 3-25 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 344 □ Do not modify or tamper with the exhaust system or emission control system. 8. Start the engine and check for leaks. 9. Check the engine oil level and add oil if necessary. All information subject to change without notice. 3-26 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 345: Oil Filter

    1. Clean the outside of the oil filter housing, then unscrew the oil filter cap from the housing. See Figure 3-23. Figure 3-23 Oil Filter Cap NOTE: Use care to prevent foreign objects from entering the filter housing. All information subject to change without notice. 3-27 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 346 □ Do not modify or tamper with the exhaust system or emission control system. 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. 3-28 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 347: Oil Heat Exchanger/Filter Housing

    4. Remove the oil filter cap. Inspect the O-ring and filter for damage and replace them if necessary. 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. 3-29 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 348 8. Cylinder Block Figure 3-25 Oil Heat Exchanger/Filter Housing Removal NOTE: The oil filter housing and the heat exchanger housing are part of the same casting. All information subject to change without notice. 3-30 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 349 2. Install the oil heat exchanger and new gaskets on the heat oil exchanger/filter housing. Tighten the heat exchanger bolts to 25 N·m (18 lb·ft). All information subject to change without notice. 3-31 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 350 3. Oil Filter Element 2. O-ring Figure 3-28 Oil Filter Assembly 5. Install the oil filter cap. Tighten the cap nut to 25 N·m (18 lb·ft). All information subject to change without notice. 3-32 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 351 Table 3-3. Engine Speed Minimum Pressure – kPa (psi) At idling rpm 50 (7.0) At maximum rpm 250 (36.0) Table 3-3 Engine Oil Pressures All information subject to change without notice. 3-33 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 352: Oil Pressure/Temperature Sensor

    2. Connect the wiring harness at the oil pressure/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. 3-34 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 353 4. Start the engine. Check the gauge for the correct oil pressure listed in Table 3-9; and check the lubrication system for leaks. 5. Check and add engine oil as needed. All information subject to change without notice. 3-35 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 354 OIL PRESSURE/TEMPERATURE SENSOR All information subject to change without notice. 3-36 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 355 All Engines – L (qts) Oil Pan Capacity 40 (42) Engine Oil Fill Capacity * 43.5 (46.0) *In standard oil pan, including oil filter. Table 3-4 Lubricating Oil Capacity All information subject to change without notice. 3-37 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 356 Main Oil Gallery - Engine Right Hand Side Bottom 60 (44) Plug after the Oil Filter Housing - M16 x 1.5 Table 3-6 Torque Values All information subject to change without notice. 3-38 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 357: Oil Heat Exchanger/Filter Housing

    The minimum engine oil pressure is listed in Table 3-9. Engine Speed Minimum Pressure – kPa (psi) At idling rpm 50 (7.0) At maximum rpm 250 (36.0) Table 3-9 Engine Oil Pressures All information subject to change without notice. 3-39 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 358 All information subject to change without notice. 3-40 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 359: Additional Information

    COOLING SYSTEM Section Page COOLING SYSTEM ................. COOLANT PUMP ..................EGR COOLANT PUMP ................4-18 FRONT IDLER AND TENSIONER SUPPORT ........4-19 THERMOSTAT ..................4-22 EGR THERMOSTAT HOUSING .............. 4-27 COOLANT TEMPERATURE SENSOR ............ 4-29 ADDITIONAL INFORMATION ..............4-31...
  • Page 360 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 361 2. Open the water regulating valve for the heating system. 3. Drain the coolant from the radiator. See Figure 4-2. Cooling system capacity is listed in Table 4-1. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 362 21.0 (22.2) Antifreeze quantity at 55 percent 23.1 (24.4) * Does not include capacity of cooling system. †With 1200 sq. ft. radiator. Table 4-1 Cooling System Capacity All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 363 [a] Tighten the coolant drain plug 30 N·m (22 ft·lb). [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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 364 [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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 365: Coolant Pump

    1. Drain the coolant from the engine. Refer to section 4.1.1. 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 366 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 367 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 368 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. 4-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 369 4. Coolant Pump Housing 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. 4-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 370 4.2.2.1 Coolant Pump Inspection 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. 4-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 371 [b] Place the coolant pump pressure piece, (J 45388 ), over the outer bearing race. [c] Place the receptacle, (J 45388 ), under the coolant pump housing. All information subject to change without notice. 4-13 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 372 4. Using the coolant pump bearing drift (352 589 08 15 00), press the sleeve seal into the coolant pump housing. 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. 4-14 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 373 Figure 4-10 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. 4-15 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 374 5. Install the coolant pump pulley and the mounting bolts attaching the coolant pump pulley to the coolant pump. Tighten the bolts 25 N·m (18 lb·ft). All information subject to change without notice. 4-16 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 375 8. Release the belt tensioners for the main drive and fan belts. Route the two belts around their pulleys and restore the belt tension. 9. Install the fan. 10. Fill the engine with coolant, as removed, and check for leaks. All information subject to change without notice. 4-17 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 376: Egr Coolant Pump

    (refer to section 4.2.1), but the pump design is different to accommodate the 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. 4-18 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 377: Front Idler And Tensioner Support

    3. Remove the upper alternator mounting bolt and the lower alternator mounting bolt. Slide the alternator backwards (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. 4-19 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 378 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. 4-20 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 379 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. 4-21 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 380: Thermostat

    2. Remove the upper coolant tube from the thermostat housing. See Figure 4-14. 1. Mounting Bolt 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. 4-22 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 381 5. Fill the engine with coolant, and check for leaks and proper operation. 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. 4-23 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 382 2 – 3°F (1 – 2°C) per minute. [b] In about five minutes, the main valve should begin to open. All information subject to change without notice. 4-24 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 383 [a] At the temperature of 92°C (198°F), check that the short circuit valve is fully closed. [b] Check the minimum lift of the short circuit valve at the closing temperature. All information subject to change without notice. 4-25 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 384 7. Install the original or replacement thermostat(s), as necessary, the upper coolant hose inlet, and 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. 4-26 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 385: Egr Thermostat Housing

    3. Remove the two bolts that attach the reed valve housing bracket to thermostat cover. Remove bracket. 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. 4-27 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 386 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. 4-28 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 387: Coolant Temperature Sensor

    3. Locate the temperature sensor behind the engine harness, between unit pumps #2 and #3. See Figure 4-19. 1. Cylinder Block 3. Coolant Temperature Sensor 2. High-Pressure Fuel Line 4. Engine Harness Figure 4-19 Coolant Temperature Sensor Location All information subject to change without notice. 4-29 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 388 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. 4-30 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 389 Cooling System Overview ................4-32 Coolant Pump ....................4-33 Thermostat ..................... 4-34 Coolant Sensor ....................4-34 SPECIFICATIONS This section contains the specifications for servicing the engine. All information subject to change without notice. 4-31 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 390: Description

    Antifreeze Protection Down 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. 4-32 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 391: Coolant Pump

    (in.) Gap between the Impeller and the 0.6 - 1.0 (0.023 - 0.039) Coolant Pump Housing Table 4-11 Critical Dimension for Coolant Pump Assembly All information subject to change without notice. 4-33 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 392: Thermostat

    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. 4-34 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 393: Additional Information

    FUEL, LUBRICATING OIL, AND COOLANT Section Page FUEL ......................LUBRICATING OIL .................. COOLANT ....................ADDITIONAL INFORMATION ..............5-13...
  • Page 394 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 395: Fuel

    Avoid breakdowns caused by this problem (for example, blocked filters) by using cold-resistant winter-grade diesel fuel with improved low-temperature flow characteristics. In most cases, winter-grade fuel can be used without problems at cold outside temperatures. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 396 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 397: Lubricating Oil

    Review carefully the product information published by the synthetic oil manufacturer. Performance additive systems often respond differently in synthetic oil. Use of synthetic oil does not change the recommended oil change service interval. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 398 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 399: Coolant

    If water quality is inadequate, the water must undergo suitable treatment. The following types of water are preferred for use in coolant: □ Distilled water □ Water purified by reverse osmosis □ De-ionized water All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 400 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 401 SCA can result in damage to the cooling system and related components. Over-concentration of SCA inhibitor can result in poor heating transfer and lead to engine damage. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 402 If the gel is allowed to dry, it is necessary to disassemble the engine and clean it with a caustic solution, or physically clean the individual components. All information subject to change without notice. 5-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 403 60 percent of normal. If the engine is shut down or out of use for an extended period of time, store the batteries out of the vehicle in a heated area if possible. Ensure good ventilation when recharging. All information subject to change without notice. 5-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 404 COOLANT All information subject to change without notice. 5-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 405: Aadditional Information

    Corrosion - Inhibiting to °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. 5-13 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 406 All information subject to change without notice. 5-14 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 407: Air Intake System

    AIR INTAKE SYSTEM Section Page INTAKE MANIFOLD ................. CHARGE PRESSURE/TEMPERATURE SENSOR ......... TURBOCHARGER ................... ADDITIONAL INFORMATION ..............6-17...
  • Page 408 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 409: 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. 4. Remove the mounting bolts attaching the manifold to the cylinder heads. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 410 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 411: Charge Pressure/Temperature Sensor

    1. Install the pressure/temperature sensor. Tighten the fasteners 10 N·m (7 lb·ft). 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 412: Turbocharger

    3. Check the turbocharger for unusual noises and excessive vibration. NOTE: Unusual noises and excessive vibration can be caused by damage to the turbocharger wheels, or by leaks in the charge-air piping. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 413 7. Shut down the engine. 6.3.1.1 Checking Turbocharger Radial and Axial Play Check the turbocharger radial and axial play as follows: All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 414 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 415 MBE 4000 SERVICE MANUAL 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 416 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 417 6.3.2 Turbocharger Removal 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 418 5. Turbocharger Outlet Pipe 2. Bracket 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 419 [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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 420 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 421 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 422 12. Start the engine and allow it to run at idle speed for three to four minutes before accelerating. 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 423 50 (37) Turbo Outlet Hose Clamps 6 (4) Turbo Outlet Pipe Mounting Bolts (to bracket) 50 (37) Table 6-2 Torque Values for Charge Air Cooler All information subject to change without notice. 6-17 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 424 Turbocharger Oil Supply Line Banjo Bolt 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 425: Additional Information

    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 ..7-47 EPV (ELECTRONIC PROPORTIONAL VALVE) AND WABCO® AIR SOLENOID VALVE ...................
  • Page 426 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 427: Exhaust Manifold

    Remove the exhaust manifold as follows: 1. Disconnect the batteries and tilt the hood. 2. Remove the turbocharger from the exhaust manifold. Refer to section 6.3.2. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 428 [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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 429 □ Do not modify or tamper with the exhaust system or emission control system. 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 430: Exhaust Brake Assembly

    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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 431 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 432 17. Brake Valve Housing 7. Spacer 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 433 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 434 [a] Choose a feeler gauge equal to dimension B, 2.6 mm (0.10 in.). [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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 435 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 436 [f] Using high temperature resisting grease, fit the ball socket onto the ball stud, and install the locking element. [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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 437 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 438: 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 439 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 440 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 441 (see arrows in graphic). Remove the fey rings (four per groove) on the gas inlet pipe leading to the exhaust manifold center piece. See Figure 7-9. Figure 7-9 Exhaust Manifold Gas Inlet Pipe Removal All information subject to change without notice. 7-17 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 442 first lowering the left side, then the right side out from under the heat exchanger bracket (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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 443 2. Lower or Front Heat Shield Figure 7-11 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 444 EGR EXHAUST MANIFOLD 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 445 11. Remove exhaust manifold three-piece gasket from cylinder heads. See Figure 7-14. 1. Three-Piece Gasket 2. Guide Studs Figure 7-14 Removal of Exhaust Manifold Gaskets All information subject to change without notice. 7-21 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 446 The exhaust manifold gasket studs are to be removed after installing the EGR cooler support bracket. 1. Three-Piece Gasket 2. Guide Studs Figure 7-15 Installation of Exhaust Manifold Gaskets All information subject to change without notice. 7-22 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 447 3. Install the fey rings (2 in each groove) in the two grooves of each exhaust manifold end piece. See Figure 7-17. 1. Fey Rings (2 per groove) 2. Exhaust Manifold Grooves Figure 7-17 Installing or Removing Rings in Exhaust Manifold Grooves All information subject to change without notice. 7-23 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 448 Attach a nut to the outer edge of bracket also. 14. Adjust 219 mm (8.62 in.) dimension on stud by doing the following: All information subject to change without notice. 7-24 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 449 See Step Four in Figure 7-18. [e] Apply 25 N·m (18 lb·ft) tightening torque to nut on resting face on pipe (internal). See Step Five in Figure 7-18. All information subject to change without notice. 7-25 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 450: 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 451 Removing EGR Air Temperature Sensor 6. Remove the three bolts from the front bracket that holds and stabilizes the reed valve housing to the thermostat housing. See Figure 7-20. All information subject to change without notice. 7-27 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 452 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 453 See Figure 7-22. 11. Remove the air line mounting bolts. Loosen and remove the air supply line from the EGR shut off valve. See Figure 7-22. All information subject to change without notice. 7-29 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 454 Removing Clamps on the Cooler NOTE: 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 455 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 456 See Figure 7-25. 1. M10 x 65 mm Bolts 2. M10 x 45 mm Bolts Figure 7-25 Removing the EGR Cooler Support All information subject to change without notice. 7-32 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 457 1. EGR Cooler-to- Sheet Metal Support Bolts 2. EGR Cooler Flange Bolts Figure 7-26 Removing the EGR Cooler Flange 16. Remove the two EGR cooler-to-sheet metal support bolts. See Figure 7-26. All information subject to change without notice. 7-33 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 458 Install the EGR cooler and the EGR cooler support bracket as follows: NOTE: 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 459 Figure 7-28 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 460 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 461 Installing the EGR Cooler Flange 5. Attach the EGR cooler to the front sheet metal support with two bolts. Torque to 25 N·m (19 lb·ft). See Figure 7-30. All information subject to change without notice. 7-37 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 462 See Figure 7-31. NOTE: 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 463 13. Install the EGR air temperature sensor into reed valve housing flange. Torque to 25 N·m (18 lb·ft). Using plastic ties, attach remainder of sensor to reed valve-housing bracket. See Figure 7-33. All information subject to change without notice. 7-39 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 464 Take care to install it properly. 1. EGR Air Temperature Sensor 2. Reed Valve Housing Bracket Figure 7-33 Installing the EGR Air Temperature Sensor and Housing Bracket All information subject to change without notice. 7-40 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 465 Torque to 10 N·m (7 lb·ft). See Figure 7-34. 1. EGR Cooler 3. Clamps (4 Qty.) 2. Clamping Pieces (4) 4. Clamp Bolts Figure 7-34 Installing Clamps on the Cooler All information subject to change without notice. 7-41 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 466 □ Black traces of a liquid on the rear right side of engine block, near the shutoff-valve. □ Black soot on the inside surface of the heat shield and the mounting bracket for the EGR shutoff-valve. All information subject to change without notice. 7-42 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 467 EGR cooler, the water/coolant traces in the EGR components are always associated with coolant consumption. Check the Amber Warning Lamp (AWL) for low coolant level. All information subject to change without notice. 7-43 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 468 Make sure that they also are inspected for leaks during the coolant system pressure test. 7.4.2.2 EGR Cooler Leak Test Perform the following steps to conduct a cooler leak test: All information subject to change without notice. 7-44 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 469 276 kPa (40 psi) air pressure. 3. Pressurize the EGR cooler to 90 kPa (13 psi). When adjusting the pressure, do not exceed 103 kPa (15 psi). All information subject to change without notice. 7-45 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 470 6. In the event of a failed EGR cooler, a steady stream of small air bubbles will come out of the highest end of the EGR cooler. 7. Replace the EGR cooler. All information subject to change without notice. 7-46 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 471: 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. 7-47 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 472 3. Remove the two bolts from gas outlet pipe attaching the pipe to the gas mixer. See Figure 7-41. 1. Gas Outlet Pipe Flange 2. Gas Outlet Pipe Mounting Bracket Figure 7-41 Removal of EGR Gas Outlet Pipe All information subject to change without notice. 7-48 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 473 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 7-43. All information subject to change without notice. 7-49 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 474 Removal or Installation of EGR Control Valve 10. Pull the EGR control valve out of the reed valve housing flange. 11. Remove symmetric membrane from the housing flange. See Figure 7-42. All information subject to change without notice. 7-50 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 475 2. EGR Gas Mixer 4. Metal Gasket Figure 7-44 Removal of Gas Mixing Pipe 13. Remove the air temperature/pressure sensor attached to the gas mixer. All information subject to change without notice. 7-51 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 476 5. Connect wiring harness terminal to valve connector. 6. Insert a second membrane into the right side of the EGR control valve housing using industrial petroleum jelly. All information subject to change without notice. 7-52 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 477 14. Install the air inlet pipe to the gas mixer using four nuts. Torque to 50 N·m (37 lb·ft). See Figure 7-45. 15. Install the turbo boost/air intake temperature sensor to the gas mixer. All information subject to change without notice. 7-53 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 478: Epv (Electronic Proportional Valve) And Wabco® Air Solenoid Valve

    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. 7-54 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 479 6. Remove the two M8 x 50 mm bolts that hold the EPV valve on the left side of bracket. 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. 7-55 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 480 3. Mount the EPV valve on left side of bracket using two M8 x 50 mm bolts. Torque to 25 N·m (18 lb·ft) tightening torque. 4. Install large hollow screw in threaded connection. Torque to 50 N·m (37 lb·ft). See Figure 7-47. All information subject to change without notice. 7-56 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 481 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. 7-57 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 482: Hengst Breather Filter

    Figure 7-48 Removal of Hengst Filter and Related Parts NOTE: If only removing the centrifugal filter, go to step 2. Remaining steps are not necessary. All information subject to change without notice. 7-58 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 483 If breather contains the former style of seal ring, remove it from the groove in the breather housing. Discard gasket, seal ring, and washer. See Figure 7-51. All information subject to change without notice. 7-59 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 484 8. Clean any residual oil from the seal ring groove in the breather housing and from the mounting surface at the flywheel housing using a common solvent. All information subject to change without notice. 7-60 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 485 11. Remove the engine block breather tube housing and seal ring. Discard seal ring. 7.7.2 Installation of Hengst Filter Perform the following steps to install the Hengst filter: All information subject to change without notice. 7-61 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 486 3. Engine Block Breather Tube Housing Figure 7-53 Engine Block Breather Tube Housing NOTE: If installing centrifugal filter only, go to step 2. Remaining steps are not necessary. All information subject to change without notice. 7-62 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 487 1. Filter Cap 4. Breather Housing 2. Spring and Diaphragm 5. Assembly Bolt 3. Centrifugal Filter Figure 7-54 Hengst Filter Assembly 3. Install cap on centrifugal filter. All information subject to change without notice. 7-63 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 488 See Figure 7-55. 7. Insert the upper opening of the breather housing onto the engine block breather tube housing. All information subject to change without notice. 7-64 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 489 10. Connect filter pipe to the top of the Hengst filter. 11. Secure filter pipe with three plastic clamps to pipe bracket. See Figure 7-56. All information subject to change without notice. 7-65 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 490 HENGST BREATHER FILTER All information subject to change without notice. 7-66 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 491 15 (11) Bracket Mounting Bolt 35 (26) 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. 7-67 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 492 All information subject to change without notice. 7-68 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 493: Aadditional Information

    ELECTRICAL EQUIPMENT Section Page DRIVE BELTS ..................ADDITIONAL INFORMATION ..............8-15...
  • Page 494 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 495 Remove the main drive belt as follows: NOTE: There are three v-ribbed drive belts on the MBE 4000 engine. Be sure to remove and install the correct belt(s). 1. Disconnect the batteries. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 496 [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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 497 □ coolant-pump pulley □ belt tensioner □ tensioner pulley □ idler pulley □ 8.1.2 Main Drive Belt Installation Install the main drive belt as follows: All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 498 8.1.3 Fan Belt Removal 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 499 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 500 Air Conditioner Compressor Belt Removal 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 501 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. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 502 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 503 A/C compressor belt, as desired. Refer to section 8.1.1. 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 504 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 505 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 506 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 507: Drive Belts

    Socket-Head Mounting Bolt Belt Tensioner 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. 8-15 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 508 All information subject to change without notice. 8-16 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 509: Power Take-Off

    POWER TAKE-OFF Section Page FRONT ENGINE POWER TAKE-OFF (FEPTO) ........REAR ENGINE POWER TAKE-OFF (REPTO) ........
  • Page 510 All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 511: Front Engine Power Take-Off (Fepto)

    3. To gain access to the vibration damper, remove the lower mounting bolts from the bottom of the front fairing/bumper. 1. Bolts 2. Plate (Hub) Figure 9-1 FEPTO Plate (Hub) Removal All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 512 (J–46172). See Figure 9-2. 6. Remove the remaining six bolt securing the intermediate pulley and remove the pulley. 9.1.2 INSTALLATION OF FEPTO COMPONENTS Install the FEPTO components as follows: All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 513 Torque the bolts in a criss-cross pattern to 200 N·m (148 lb·ft). Ensure all bolts have been tighten. 5. Remove the guide pins from the front of the crankshaft. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 514 FEPTO Plate (Hub) Installation 7. Install the drive belts on their pulleys, as removed. 8. Install the lower mounting bolts of the front fairing/bumper, as removed. All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 515: Rear Engine Power Take-Off (Repto)

    flange of the driven unit (i.e. hydraulic pump). The torsional coupling is a rubber element design to reduce the unwanted stresses reaching the engine. The torsional coupling is available as a service part from Detroit Diesel Corporation. See Figure 9-6. 1. Flywheel Housing 4.
  • Page 516 REAR ENGINE POWER TAKE-OFF (REPTO) All information subject to change without notice. DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 517: Special Equipment

    SPECIAL EQUIPMENT Section Page 10.1 AIR COMPRESSOR FLANGE ..............10-3 10.2 AIR COMPRESSOR ................10-5 10.A ADDITIONAL INFORMATION ..............10-11...
  • Page 518 All information subject to change without notice. 10-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 519: Air Compressor Flange

    3. Remove the cross plate between the compressor and the power steering pump. 4. Discard the O-ring between the power steering pump and the air compressor. All information subject to change without notice. 10-3 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 520 4. Install the two bolts attaching the power steering pump to the air compressor. Torque to 40 N·m (30 lb·ft). All information subject to change without notice. 10-4 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 521: Air Compressor

    Figure 10-2 Power Steering Pump Removal NOTE: Do not remove the power steering lines. Tie up the lines and move the pump out of the way. All information subject to change without notice. 10-5 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 522 5. Remove the engine trim cover. NOTE: The bottom of the engine trim cover overhangs the coolant delivery line fasteners, making them difficult to remove. All information subject to change without notice. 10-6 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 523 See Figure 10-4. 1. Hollow-Core Banjo Bolt 4. Air Compressor 2. Seal Ring 5. Coolant Return Line 3. Coolant Delivery Line Figure 10-4 Air Compressor Coolant Lines All information subject to change without notice. 10-7 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 524 Make sure the locking device is tightly secured and cannot slip or slide out of the vise. [b] Using an impact wrench, remove the drive nut from the drive gear. All information subject to change without notice. 10-8 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 525 Be sure the correct mounting bolt is mounted at each location. The outboard upper mounting bolt is installed from the rear. 3. Install the two coolant lines. [a] Replace the seal rings on the coolant lines. All information subject to change without notice. 10-9 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 526 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. 10-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 527: A Additional Information

    Air Governor Torque Values Protectant Material Approved Brand Loctite® 567 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. 10-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 528 All information subject to change without notice. 10-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 529: Operation And Verification

    OPERATION AND VERIFICATION Section Page 11.1 PREPARATION FOR A FIRST TIME START ........... 11-3 11.2 STARTING THE ENGINE ................ 11-8 11.3 RUNNING THE ENGINE ................. 11-11 11.4 STOPPING THE ENGINE ................ 11-13...
  • Page 530 All information subject to change without notice. 11-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 531 No. 71032; No. 71306 Texaco, Inc. 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 532: Preparation For A First Time Start

    2. If necessary, top off by filling engine oil through the oil fill cap until the maximum fill level on the oil dipstick has been reached. See Figure 11-2. 1. Oil Dipstick 2. Oil Fill Cap Figure 11-2 Oil Fill Cap All information subject to change without notice. 11-4 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 533 □ Do not modify or tamper with the exhaust system or emission control system. 2. If equipped with a hand pump on the fuel/water separator, work the hand pump until resistance is felt. All information subject to change without notice. 11-5 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 534 DDC does not recommend opening the high-pressure lines and bleeding the air from the fuel system while cranking. Figure 11-3 Diesel Fuel System Primer Tool J-47912 6. Fill the fuel system primer three-fourths full with fuel oil. All information subject to change without notice. 11-6 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 535 12. Slowly release the pressure on the diesel fuel system primer (J-47912) by slightly turning the pumping handle counter-clockwise. 13. With the engine running, check the fuel filter for leaks. Repair any leaks found. 14. Shut down the engine. All information subject to change without notice. 11-7 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 536: 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. 11-8 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 537 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. 11-9 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 538 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. 11-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 539: Running The Engine

    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: 1. Turn the cruise control switch to the OFF position. All information subject to change without notice. 11-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 540 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. 11-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 541: Stopping The Engine

    1. If the engine has been running at full output or the coolant temperature has been high, allow the engine to idle for one to two minutes without load. 2. Turn off the ignition switch and shut down the engine. All information subject to change without notice. 11-13 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 542 11.4 STOPPING THE ENGINE All information subject to change without notice. 11-14 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 543: Engine Tune-Up

    ENGINE TUNE-UP Section Page 12.1 VALVE LASH CHECKING ................ 12-3 12.2 ADJUSTING VALVE LASH ..............12-9...
  • Page 544 All information subject to change without notice. 12-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 545: Valve Lash Checking

    □ By type of valve, depending on crankshaft position (see Method Two—Adjust All Valves 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 546 1. Socket-Head Bolt 3. Gasket 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 547 Intake 0.30 to 0.60 (0.012 to 0.024) 0.40 (0.016) Exhaust 0.50 to 0.80 (0.020 to 0.032) 0.60 (0.024) Table 12-2 Valve Lash Checking and Adjustment All information subject to change without notice. 12-5 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 548 3. Gasket 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 549 When the piston in cylinder #1 or #6 is at ignition TDC, there will be a small bevelled alignment mark visible through the inspection hole. See Figure 12-6. Figure 12-6 Flywheel Alignment Mark All information subject to change without notice. 12-7 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 550 Valve Lash Checking and Adjustment 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. 12-8 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 551: Adjusting Valve Lash

    5. Remove the cranking tool (J 46392) 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. 12-9 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 552 12.2 ADJUSTING VALVE LASH All information subject to change without notice. 12-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 553: Preventive Maintenance

    PREVENTIVE MAINTENANCE Section Page 13.1 SCHEDULED INTERVALS ..............13-3...
  • Page 554 All information subject to change without notice. 13-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 555: Scheduled Intervals

    60,000 miles (100,000 kilometers), with minimal city or stop-and-go operation. 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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 556 (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 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 557 195,000 325,000 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. 13-5 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 558 Each Maintenance Operations Sets Table (M1 through M3) lists the descriptions of only those maintenance operations that must be performed at that maintenance operation set. Each maintenance operation set is listed in a separate Maintenance Operations Table. All information subject to change without notice. 13-6 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 559 † For Schedule II and III, the valve lash checking and adjusting must be done first at 60,000 and then every M4. 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. 13-7 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 560 [c] Screw the pre-filter element onto the separator head and tighten firmly, using hands only. NOTE: Do not use tools to tighten the pre-filter element. All information subject to change without notice. 13-8 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 561 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. 13-9 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 562 9. Bleed the fuel system. [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. 13-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 563 [c] Crank the engine for 30 seconds at a time, but no longer. Wait at least two minutes, then crank again. 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. 13-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 564 1. Chock the tires, place the transmission in neutral, and set the parking brake. NOTE: Change the engine oil only when the engine is at a temperature of approximately 140°F (60°C). All information subject to change without notice. 13-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 565 [a] Place a suitable receptacle beneath the oil drain plug on the underside of the oil pan. [b] Carefully unscrew the oil drain plug on the oil pan and allow the oil to drain out. All information subject to change without notice. 13-13 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 566 5. Replace the O-ring on the cap. See Figure 13-6. 6. Install the new filter into the cap. Make sure the filter element is securely in place. All information subject to change without notice. 13-14 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 567 □ 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. 13-15 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 568 fill level on the oil dipstick. 13.1.5 Coolant Concentration and Inhibitor Level Checking Check the coolant concentration as follows: All information subject to change without notice. 13-16 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 569 Coolant inhibitor level should be checked at the intervals listed in Table 13-8. If topping off is needed, add coolant which is identical to the initial fill coolant. All information subject to change without notice. 13-17 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 570 500 Hours or three months, whichever comes first all Other 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. 13-18 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 571 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 572 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. 13-20 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 573 Antifreeze quantity at 50% 21.0 (22.2) Antifreeze quantity at 60% 25.2 (26.6) *Does not include capacity of cooling system. †With 1200 sq. in. radiator. Table 13-10 Coolant Capacity All information subject to change without notice. 13-21 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 574 Make sure the heater valve is still open. 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. 13-22 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 575 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. 13-23 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 576 13.1 SCHEDULED INTERVALS All information subject to change without notice. 13-24 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 577: Engine Storage

    ENGINE STORAGE Section Page 14.1 PREPARING ENGINE FOR STORAGE ..........14-3...
  • Page 578 All information subject to change without notice. 14-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 579 Work from the rear of the radiator (in the opposite direction of the normal cooling air flow). All information subject to change without notice. 14-3 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 580 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 All information subject to change without notice. 14-4 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 581 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. 14-5 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 582 14.1 PREPARING ENGINE FOR STORAGE All information subject to change without notice. 14-6 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 583: Troubleshooting The Electronic Engine Control System

    TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM Section Page 15.1 ELECTRONIC ENGINE CONTROL SYSTEM ......... 15-3...
  • Page 584 All information subject to change without notice. 15-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 585: Electronic Engine Control System

    To read the complete fault code, refer to the MBE Electronic Controls Troubleshooting Guide (6SE422) or bring the vehicle to an authorized repair facility. Complete fault codes can be read using minidiag2. All information subject to change without notice. 15-3 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 586 15.1 ELECTRONIC ENGINE CONTROL SYSTEM All information subject to change without notice. 15-4 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 587: General Mechanical Troubleshooting

    GENERAL MECHANICAL TROUBLESHOOTING Section Page 16.1 MECHANICAL TROUBLESHOOTING ............ 16-3...
  • Page 588 All information subject to change without notice. 16-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 589: Mechanical 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. 16-3 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 590 Bring the vehicle to an authorized dealer for service. position sensor are damaged. There are other problems in the fuel system. Bring the vehicle to an authorized dealer for service. All information subject to change without notice. 16-4 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 591 The engine performs poorly, or does not develop full The remedies are listed in "The Engine Performs Poorly, Does Not Develop Full Power." power. All information subject to change without notice. 16-5 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 592 The fan is not operating properly. Bring the vehicle to an authorized dealer and have the parameter settings reprogrammed in the engine control unit (PLD) or vehicle control unit (VCU). All information subject to change without notice. 16-6 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 593 Correct the oil level. The oil has not been changed within the recommended Change the oil. interval. The oil is not of the recommended quality. Change the oil. All information subject to change without notice. 16-7 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 594 The valve stem seals are loose or damaged. Have an authorized dealer replace the seals. The piston rings are worn. Have an authorized dealer replace the piston rings. All information subject to change without notice. 16-8 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 595 The poly-V belt is worn or damaged. 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. 16-9 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 596 16.1 MECHANICAL TROUBLESHOOTING All information subject to change without notice. 16-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 597: Low Power Concern

    LOW POWER CONCERN Section Page 17.1 FACTORS THAT AFFECT WHEEL HORSEPOWER ......17-3 17.2 LOW HORSEPOWER INTERVIEW ............17-6 17.3 AERATED FUEL ..................17-13 17.4 RESTRICTED AIR CLEANER ELEMENT ..........17-15 17.5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING INTAKE MANIFOLD .................
  • Page 598 All information subject to change without notice. 17-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 599: Factors That Affect Wheel Horsepower

    Air flow must not be inhibited by a plugged filter, or inadequate inlet air duct shrouding. Faulty Turbocharger A turbocharger that has wheel rubbing, oil leaks, bent blades, etc. will not provide adequate air supply. All information subject to change without notice. 17-3 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 600 Air system leaks will result in insufficient air for optimum combustion. Biodiesel Should not be higher than 5%. Refer to Engine Requirements – Lubricating Oil, Fuel and Filters, (7SE270), available from authorized Detroit Diesel distributors. Charge Air Cooler Leak Air system leaks will result in insufficient air for optimum combustion.
  • Page 601 Make sure the foot pedal has complete travel. The foot pedal position can be monitored on DDDL (accelerator pedal pos.) Table 17-1 Factors Affecting Wheel Horsepower All information subject to change without notice. 17-5 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 602: Low Horsepower Interview

    To determine if low horsepower is causing a power concern, use the driver questionnaire, the troubleshooting tree, and the low power troubleshooting chart. 17.2.1 Driver Questionnaire This section should serve as a guideline for the technician. All information subject to change without notice. 17-6 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 603 MBE 4000 SERVICE MANUAL For an example of the driver questionnaire see Figure 17-1. Figure 17-1 Driver Questionnaire All information subject to change without notice. 17-7 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 604 1. If the problem is repeatable, take the vehicle for a drive with Detroit Diesel Diagnostic Link (DDDL) connected and note the conditions when the problem occurs. Be prepared to take snapshot data using DDDL.
  • Page 605 10. If the problem occurs at a specific engine rpm, unplug the oil, coolant, and air temperature sensors, and note any changes to the problem. Gather this data and contact the DDC Customer Support Center at 313-592-5800. All information subject to change without notice. 17-9 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 606 17.2 LOW HORSEPOWER INTERVIEW 17.2.2 Troubleshooting Tree Following is the troubleshooting tree for low horsepower: Figure 17-2 Troubleshooting Tree All information subject to change without notice. 17-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 607 HP data. Record data on AFA claim. NOTE: Service information letter instructions published following the date of this document take precedence. All information subject to change without notice. 17-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 608 Always On refer to section 17.1 Debris in Fuel Tank — — - Air Vent Plugged refer to section 17.1 Table 17-2 Low Power Troubleshooting Chart All information subject to change without notice. 17-12 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 609: Aerated Fuel

    4. Verify aerated fuel resolution; refer to section 17.3.1.1. 17.3.1.1 Test the Engine with Aerated Fuel Resolution Perform the following steps to determine if aerated fuel resolution resolved lack of power condition: All information subject to change without notice. 17-13 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 610 Shut down the engine. [b] If lack of power occurred during the test drive, shut down the engine and . refer to section 17.4. All information subject to change without notice. 17-14 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 611: Restricted Air Cleaner Element

    Shut down the engine. [b] If lack of power occurred during the test drive, shut down the engine. Check the charge air cooler; refer to section 17.5. All information subject to change without notice. 17-15 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 612: Restricted Or Cracked Charge Air Cooler Or Leaking Intake Manifold

    Perform the following steps to repair the air intake manifold: 1. Remove the air intake manifold; refer to MBE 4000 Service Manual (6SE412), Air system chapter 6.1. All information subject to change without notice. 17-16 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 613 Shut down the engine. [b] If lack of power occurred during the test drive, shut down the engine. Check the exhaust system; refer to section 17.6. All information subject to change without notice. 17-17 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 614: Faulty Exhaust System

    1. Visually inspect the engine exhaust system; refer to OEM guidelines. 2. Repair or replace defective exhaust system components; refer to OEM guidelines. 3. Verify exhaust system resolution; refer to section 17.6.1.1. All information subject to change without notice. 17-18 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 615 Shut down the engine. [b] If lack of power occurred during the test drive, shut down the engine. Check for high inlet air temperature; refer to section 17.7. All information subject to change without notice. 17-19 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

  • Page 616: High Inlet Air Temperature

    Engine exhaust is toxic. 1. Start and run the engine. 2. Test drive the vehicle to ensure lack of power has been resolved. All information subject to change without notice. 17-20 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 617 [a] If no lack of power occurred during the test drive, no further troubleshooting is required. Shut down the engine. [b] If lack of power occurred during the test drive, shut down the engine, contact the Detroit Diesel Customer Support Center (313–592–5800). All information subject to change without notice. 17-21 DDC-SVC-MAN-0023 Copyright ©...

  • Page 618: Verification Of Power With Chassis Dynamometer

    For direct engine cooling, Detroit Diesel recommends the use of a 368 m3 /min (13,000 ft3 /min) or greater capacity barrel-type ram air fan. This should be portable so that it can be conveniently placed three to five feet (approximately one to two meters) in front of the truck and aimed directly...
  • Page 619 □ When loading the vehicle on the dynamometer, make sure the vehicle is positioned onto the rollers as straight as possible. □ For direct engine cooling, Detroit Diesel recommends the use of a 368 m3 /min (13,000 ft3 /min) or greater capacity barrel-type ram air fan. This should be portable so that it can be conveniently placed three to five feet (approximately one to two meters) in front...
  • Page 620 435 bhp @ 1900 (1550 lb-ft @ 1100 RPM) 450 bhp @ 1900 (1550 lb-ft @ 1100 RPM) Table 17-3 Minimum Acceptable Wheel HP Model 460 All information subject to change without notice. 17-24 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 621 Batteries, 5-11 Corrosion Inhibitors, 5-9 Dropout, 5-10 Disposal, 5-11 Fully Formulated Antifreeze, 5-7 Non-approved Coolants, 5-11 Recycled Antifreeze, 5-9 Supplemental Coolant Additives, 5-8 Water, 5-7 All information subject to change without notice. Index-1 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 622 Cylinder Liner Removal, 1-22 Cylinder Block Leak Test, 1-35 Cylinder Liner Bore Inspection and Measurement, 1-25 Fuel System Leak Test, 1-32 Measurement, 1-29 Installation, 1-40 Cylinder Head, 1-4 All information subject to change without notice. Index-2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 623 Installation, 7-52 Removal, 7-47 EGR Coolant Pump, 4-18 EGR Cooler and Cooler Support Bracket, 7-26 EGR Cooler and Support Bracket Installation, 7-34 EGR Cooler Inspection, 7-42 All information subject to change without notice. Index-3 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 624 Engine Brake, 1-49 Constant Throttle Valve Installation, 1-52 Constant Throttle Valve Removal, 1-49 Constant Throttle Valve Solenoid Installation, 1-54 Constant Throttle Valve Solenoid Removal, 1-53 All information subject to change without notice. Index-4 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 625 Front Idler and Tensioner Support, 4-19 Front Idler and Tensioner Support Installation, 4-20 Front Idler and Tensioner Support Removal, 4-19 Front Radial Seal, 1-56 Front Radial Seal Installation, 1-57 All information subject to change without notice. Index-5 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 626 Performing a Fuel System Test using minidiag2, 2-68 Checking the Fuel Pump Driven Gear Bolt Torque, 2-70 Idle Smoothly Balance Troubleshooting, 2-69 Impact Delay Time Troubleshooting, 2-70 All information subject to change without notice. Index-6 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 627 Low Power Troubleshooting Chart, 17-11 Troubleshooting Tree, 17-10 Lubricating Oil, 5-5 Low Viscosity Engine Oil, 5-6 Synthetic Oils, 5-5 Lubrication system Description, 3-3 mechanical troubleshooting, 16-3 Oil Filter, 3-27 All information subject to change without notice. Index-7 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 628 Piston Ring Replacement, 1-133 Preparation, 11-3 Adding Fuel, 11-5 Checking the Batteries, 11-3 Checking the Coolant Level (Cold Check), 11-5 Checking the Oil Level, 11-3 All information subject to change without notice. Index-8 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 629 Rocker Arm Installation, 1-169 Rocker Arm Removal, 1-167 Running the Engine, 11-11 Battery Charge, 11-11 Changing the Idle Speed, 11-11 Emergency Running Mode, 11-12 Excessive Idling, 11-11 All information subject to change without notice. Index-9 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 630 Valve Lash checking, 12-3 Method One — Adjust Each Cylinder in Firing Order, 12-4 Method Two — Adjust All Valves Using Two Crankshaft Positions, 12-6 Valves, 1-143 All information subject to change without notice. Index-10 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...
  • Page 631 Valve Lift Checking, 1-143 Valve Removal, 1-155 Valve Stem Seal Replacement, 1-160 verification, 17-22 Chassis Dynamometer Room Ventilation Recommendations, 17-22 Chassis Dynamometer Test and Run-in Procedure, 17-22 All information subject to change without notice. Index-11 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION...

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