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MBE 4000 SERVICE MANUAL REVISION NOTIFICATION Modifications to this manual are announced in the form of Service Information Bulletins. The bulletins include attachment pages and are posted on the World Wide Web (www.detroitdiesel.com/svc/sibindex.htm). Revisions to this manual will be sent marked with a revision bar (see Example 2). Sections containing revisions will have a third line in the page footer (compare Examples 1 and 2). ENGINE EXHAUST Consider the following before servicing engines: All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION i

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MBE 4000 SERVICE MANUAL PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Always start and operate an engine in a well ventilated area. 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. ii 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION

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MBE 4000 SERVICE MANUAL TABLE OF CONTENTS GENERAL INFORMATION ...................................................................... 1 SCOPE AND USE OF THIS MANUAL ..................................................... 3 GENERAL DESCRIPTION ...................................................................... 3 ELECTRONIC ENGINE CONTROL SYSTEM ......................................... 4 ENGINE BRAKING POWER .................................................................... 7 GENERAL SPECIFICATIONS AND ENGINE VIEWS ............................. 7 ENGINE MODEL AND SERIAL NUMBER ...............................................

14 EXHAUST GAS RECIRCULATION (EGR) SYSTEM ............................... 16 SAFETY INSTRUCTIONS AND PRECAUTIONS .................................... 20 ENGLISH TO METRIC CONVERSION .................................................... 32 DECIMAL AND METRIC EQUIVALENTS ................................................ 33 TORQUE SPECIFICATIONS ................................................................... 35 1 ENGINE 1.1 CYLINDER HEAD COVER ...................................................................... 1-3 1.2 CYLINDER HEAD ....................................................................................

1-5 1.3 CYLINDER BLOCK .................................................................................. 1-24 1.4 EGR CYLINDER HEAD AND BLOCK ..................................................... 1-40 1.5 EGR FRONT AND REAR LIFTER BRACKETS ....................................... 1-43 1.6 ENGINE BRAKE ...................................................................................... 1-45 1.7 FRONT RADIAL SEAL ............................................................................. 1-51 1.8 REAR RADIAL SEAL ............................................................................... 1-54 1.9 CRANKSHAFT ASSEMBLY .....................................................................

1-57 1.10 FRONT COVER HOUSING ..................................................................... 1-82 1.11 CRANKSHAFT VIBRATION DAMPER ..................................................... 1-84 1.12 FLYWHEEL .............................................................................................. 1-86 1.13 RING GEAR ............................................................................................. 1-96 1.14 PILOT BEARING ...................................................................................... 1-100 1.15 ENGINE CRANKING TOOL .....................................................................

1-102 1.16 FLYWHEEL HOUSING ............................................................................. 1-104 1.17 PISTON, PISTON RING, AND CONNECTING ROD ............................... 1-106 1.18 EGR PISTON, PISTON RING, AND CONNECTING ROD ...................... 1-135 1.19 VALVES .................................................................................................... 1-138 1.20 EGR VALVES ........................................................................................... 1-161 1.21 ROCKER ARM ......................................................................................... 1-166 1.22 CAMSHAFT AND CAMSHAFT SENSOR ................................................

1-170 1.23 EGR CAMSHAFT ..................................................................................... 1-181 1.A ADDITIONAL INFORMATION .................................................................. 1-183 2 FUEL SYSTEM 2.1 INJECTOR UNIT PUMP ........................................................................... 2-3 2.2 EGR INJECTOR UNIT PUMP .................................................................. 2-11 2.3 FUEL INJECTOR LINE ............................................................................ 2-13 All information subject to change without notice. 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION iii

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MBE 4000 SERVICE MANUAL 2.4 FUEL INJECTOR NOZZLE ...................................................................... 2-18 2.5 EGR FUEL INJECTOR NOZZLE ............................................................. 2-24 2.6 PROTECTIVE SLEEVE ........................................................................... 2-25 2.7 DDEC ELECTRONIC CONTROL UNIT ................................................... 2-29 2.8 FUEL HEAT EXCHANGER ...................................................................... 2-34 2.9 FUEL FILTER ...........................................................................................

2-37 2.10 EGR FUEL FILTER .................................................................................. 2-41 2.11 FUEL PUMP ............................................................................................. 2-43 2.12 FUEL SYSTEM INSPECTION ................................................................. 2-47 2.A ADDITIONAL INFORMATION .................................................................. 2-57 3 LUBRICATION SYSTEM 3.1 OIL PAN ................................................................................................... 3-3 3.2 OIL SPRAY NOZZLE ...............................................................................

3-9 3.3 EGR CAMSHAFT LUBRICATION SPRAYER .......................................... 3-13 3.4 OIL PUMP ................................................................................................ 3-14 3.5 EGR OIL PUMP AND PICK UP TUBE ..................................................... 3-21 3.6 OIL FILTER .............................................................................................. 3-23 3.7 OIL HEAT EXCHANGER AND FILTER HOUSING .................................. 3-26 3.8 OIL PRESSURE AND TEMPERATURE SENSOR .................................. 3-32 3.A ADDITIONAL INFORMATION ..................................................................

3-35 4 COOLING SYSTEM 4.1 COOLING SYSTEM ................................................................................. 4-3 4.2 COOLANT PUMP .................................................................................... 4-8 4.3 EGR COOLANT PUMP ............................................................................ 4-20 4.4 FRONT IDLER AND TENSIONER SUPPORT ........................................ 4-22 4.5 THERMOSTAT ......................................................................................... 4-25 4.6 EGR THERMOSTAT HOUSING ...............................................................

4-30 4.7 COOLANT TEMPERATURE SENSOR .................................................... 4-32 4.A ADDITIONAL INFORMATION .................................................................. 4-35 5 FUEL, LUBRICATING OIL, AND COOLANT 5.1 FUEL ........................................................................................................ 5-3 5.2 LUBRICATING OIL ................................................................................... 5-5 5.3 COOLANT ................................................................................................ 5-7 5.A ADDITIONAL INFORMATION ..................................................................

5-13 6 AIR INTAKE SYSTEM 6.1 INTAKE MANIFOLD ................................................................................. 6-3 6.2 CHARGE PRESSURE/TEMPERATURE SENSOR ................................. 6-5 6.3 TURBOCHARGER ................................................................................... 6-6 6.A ADDITIONAL INFORMATION .................................................................. 6-17 7 EXHAUST SYSTEM 7.1 EXHAUST MANIFOLD ............................................................................. 7-3 7.2 EXHAUST BRAKE ASSEMBLY ...............................................................

7-6 7.3 EGR EXHAUST MANIFOLD .................................................................... 7-14 7.4 EGR COOLER AND COOLER SUPPORT BRACKET ............................ 7-26 7.5 EGR CONTROL VALVE, GAS OUTLET PIPE, AND GAS MIXER .......... 7-43 All information subject to change without notice. iv 6SE412 0403 Copyright © 2004 DETROIT DIESEL CORPORATION

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