Detroit Diesel MBE 4000 Service Manual (EN)

EPA07 MBE 4000 SERVICE MANUAL ABSTRACT This manual provides instruction for servicing the MBE 4000 Diesel Engine. Specifically, a basic overview of each major component and the system, along with the recommendations for removal, cleaning, inspection, criteria for replacement, repair, installation, and mechanical troubleshooting are contained in this manual. TRADEMARK INFORMATION Loctite® is a registered trademark of Loctite Corporation. Wabco® is a registered trademark of American Standard, Inc. Hengst® is a registered trademark of Walter Hengst GMBH & Co. Perma-Lok® is a registered trademark of National Starch and Chemical Investment Holding Corporation.

Henkel® is a registered trademark of Henkel Corporation. Diagnostic Link® is a registered trademark of Detroit Diesel Corporation. POWER COOL ® is a registered trademark of Detroit Diesel Corporation. ENGINE EXHAUST Consider the following before servicing engines: 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.

PERSONAL INJURY REVISION NOTIFICATION Modifications to this manual are announced in the form of Service Information Bulletins. The bulletins are posted on the World Wide Web (www.detroitdiesel.com/public/sibs/sibnav.asp). All information subject to change without notice. DDC-SVC-MAN-0026 Copyright © 2011 DETROIT DIESEL CORPORATION i

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EPA07 MBE 4000 SERVICE MANUAL All information subject to change without notice. ii DDC-SVC-MAN-0026 Copyright © 2011 DETROIT DIESEL CORPORATION

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EPA07 MBE 4000 SERVICE MANUAL TABLE OF CONTENTS GENERAL INFORMATION ...................................................................... 1 SCOPE AND USE OF THIS MANUAL .................................................... 3 GENERAL DESCRIPTION ...................................................................... 3 AFTERTREATMENT SYSTEM ................................................................ 4 ELECTRONIC ENGINE CONTROL SYSTEM ......................................... 4 ENVIRONMENTAL CONDITIONS ........................................................... 7 SAFETY INSTRUCTIONS AND PRECAUTIONS ....................................

8 CPC VEHICLE INTERFACE HARNESS .................................................. 18 ENGINE BRAKING POWER .................................................................... 19 1 ENGINE 1.1 ENGINE TRIM COVERS AND FRAMES ................................................. 1-3 1.2 CYLINDER HEAD COVER ...................................................................... 1-6 1.3 CYLINDER HEAD .................................................................................... 1-8 1.4 CYLINDER BLOCK .................................................................................. 1-21 1.5 FRONT AND REAR ENGINE LIFTING BRACKETS ...............................

1-42 1.6 ENGINE BRAKE ...................................................................................... 1-44 1.7 FRONT RADIAL SEAL ............................................................................. 1-51 1.8 REAR RADIAL SEAL ............................................................................... 1-54 1.9 CRANKSHAFT WEAR SLEEVE .............................................................. 1-57 1.10 CRANKSHAFT ASSEMBLY ..................................................................... 1-63 1.11 FRONT COVER HOUSING .....................................................................

1-86 1.12 CRANKSHAFT POSITION SENSOR ...................................................... 1-88 1.13 CRANKSHAFT VIBRATION DAMPER AND PULLEY ............................. 1-89 1.14 FLYWHEEL .............................................................................................. 1-91 1.15 RING GEAR ............................................................................................. 1-100 1.16 PILOT BEARING ...................................................................................... 1-104 1.17 ENGINE BARRING TOOL .......................................................................

1-108 1.18 FLYWHEEL HOUSING ............................................................................ 1-110 1.19 PISTON, PISTON RING, AND CONNECTING ROD ............................... 1-112 1.20 VALVES .................................................................................................... 1-138 1.21 ROCKER ARM ......................................................................................... 1-154 1.22 CAMSHAFT AND GEAR ASSEMBLY ...................................................... 1-158 1.A ADDITIONAL INFORMATION ..................................................................

1-169 2 FUEL SYSTEM 2.1 ELECTRONIC UNIT PUMP ..................................................................... 2-3 2.2 FUEL RETURN AND NOZZLE SPILL LINE ............................................ 2-17 2.3 FUEL OVERFLOW VALVE ...................................................................... 2-19 2.4 HIGH PRESSURE FUEL LINE AND TRANSFER TUBE ......................... 2-20 2.5 FUEL INJECTOR HARNESS ADAPTOR FRAME ................................... 2-30 2.6 FUEL INJECTOR ..................................................................................... 2-32 2.7 PROTECTIVE SLEEVE ...........................................................................

2-41 All information subject to change without notice. DDC-SVC-MAN-0026 Copyright © 2011 DETROIT DIESEL CORPORATION iii

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EPA07 MBE 4000 SERVICE MANUAL 2.8 MOTOR CONTROL MODULE ................................................................. 2-44 2.9 FUEL FILTER ........................................................................................... 2-47 2.10 FUEL FILTER HOUSING ......................................................................... 2-50 2.11 FUEL FILTER BRACKET ......................................................................... 2-53 2.12 FUEL HAND PRIMER PUMP .................................................................. 2-55 2.13 FUEL PUMP .............................................................................................

2-57 2.14 FUEL PUMP DRIVE ................................................................................. 2-60 2.15 FUEL DOSER VALVE (FDV) .................................................................... 2-63 2.16 DOSER BLOCK ASSEMBLY ................................................................... 2-68 2.17 FUEL DOSER VALVE COOLANT LINES ................................................ 2-71 2.A ADDITIONAL INFORMATION .................................................................. 2-73 3 LUBRICATION SYSTEM 3.1 LUBRICATION SYSTEM DESCRIPTION ................................................

3-3 3.2 OIL PAN ................................................................................................... 3-5 3.3 PISTON OIL SPRAY NOZZLE ................................................................. 3-8 3.4 CAMSHAFT LUBRICATION NOZZLE ..................................................... 3-12 3.5 OIL PUMP AND SUCTION PIPE ............................................................. 3-15 3.6 OIL FILTER .............................................................................................. 3-22 3.7 OIL COOLER/FILTER HOUSING ............................................................ 3-24 3.8 ENGINE OIL PRESSURE/TEMPERATURE SENSOR ............................

3-31 3.9 OIL FILL-TUBE AND OIL DIPSTICK ....................................................... 3-33 3.A ADDITIONAL INFORMATION .................................................................. 3-37 4 COOLING SYSTEM 4.1 COOLING SYSTEM ................................................................................. 4-3 4.2 COOLANT PUMP .................................................................................... 4-8 4.3 FRONT IDLER AND TENSIONER SUPPORT ........................................ 4-18 4.4 THERMOSTAT ......................................................................................... 4-19 4.5 ENGINE COOLANT TEMPERATURE SENSOR .....................................

4-23 4.6 CYLINDER HEAD COOLANT VENT LINE ............................................. 4-25 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 AIR INTAKE ELBOW AND GRID HEATER .............................................. 6-3 6.2 INTAKE THROTTLE VALVE AND ADAPTOR .......................................... 6-8 6.3 GAS MIXER HOUSING ........................................................................... 6-10 6.4 AIR INTAKE MANIFOLD .......................................................................... 6-13 6.5 ELECTROSTATIC OIL SEPARATOR, CRANKCASE SEPARATOR, AND OIL SEPARATOR DRAIN LINE ................................................................ 6-16 6.6 INTAKE AIR TEMPERATURE/PRESSURE SENSOR .............................

6-23 6.7 TURBOCHARGER ................................................................................... 6-25 6.8 WASTEGATE ACTUATOR ....................................................................... 6-35 All information subject to change without notice. iv DDC-SVC-MAN-0026 Copyright © 2011 DETROIT DIESEL CORPORATION

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