Mercedes \ Detroit Diesel MBE 4000 EPA 04 Workshop Service Repair Manual

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 ............................................... 13
EXHAUST GAS RECIRCULATION (EGR) SYSTEM ............................... 15
SAFETY INSTRUCTIONS AND PRECAUTIONS .................................... 19
ENGLISH TO METRIC CONVERSION .................................................... 28
DECIMAL AND METRIC EQUIVALENTS ................................................ 29
TORQUE SPECIFICATIONS ................................................................... 31
1 ENGINE
1.1 CYLINDER HEAD COVER ...................................................................... 1-3
1.2 CYLINDER HEAD .................................................................................... 1-4
1.3 CYLINDER BLOCK .................................................................................. 1-22
1.4 EGR CYLINDER HEAD AND BLOCK ..................................................... 1-44
1.5 EGR FRONT AND REAR LIFTER BRACKETS ....................................... 1-47
1.6 ENGINE BRAKE ...................................................................................... 1-49
1.7 FRONT RADIAL SEAL ............................................................................. 1-56
1.8 REAR RADIAL SEAL ............................................................................... 1-60
1.9 CRANKSHAFT SEAL WEAR SLEEVE .................................................... 1-63
1.10 CRANKSHAFT ASSEMBLY ..................................................................... 1-68
1.11 FRONT COVER HOUSING ..................................................................... 1-91
1.12 CRANKSHAFT VIBRATION DAMPER .................................................... 1-93
1.13 FLYWHEEL .............................................................................................. 1-95
1.14 RING GEAR ............................................................................................. 1-104
1.15 PILOT BEARING ...................................................................................... 1-108
1.16 ENGINE BARRING TOOL ....................................................................... 1-112
1.17 FLYWHEEL HOUSING ............................................................................ 1-114
1.18 PISTON, PISTON RING, AND CONNECTING ROD ............................... 1-116
1.19 EGR PISTON, PISTON RING, AND CONNECTING ROD ...................... 1-140
1.20 VALVES .................................................................................................... 1-143
1.21 EGR VALVES ........................................................................................... 1-162
1.22 ROCKER ARM ......................................................................................... 1-167
1.23 CAMSHAFT AND CAMSHAFT POSITION SENSOR .............................. 1-171
1.24 EGR CAMSHAFT ..................................................................................... 1-181
1.A ADDITIONAL INFORMATION .................................................................. 1-183
2 FUELSYSTEM
2.1
INJECTOR UNIT PUMP ........................................................................... 2-3
2.2 EGR INJECTOR UNIT PUMP .................................................................. 2-15
2.3 HIGH PRESSURE FUEL LINE AND TRANSFER TUBE ......................... 2-16
2.4 FUEL INJECTOR NOZZLE ...................................................................... 2-26
2.5 EGR FUEL INJECTOR NOZZLE ............................................................. 2-34
2.6 PROTECTIVE SLEEVE ........................................................................... 2-35
2.7 DDEC-ELECTRONIC CONTROL UNIT ................................................... 2-39
2.8 FUEL HEAT EXCHANGER ...................................................................... 2-44
2.9 FUEL FILTER ........................................................................................... 2-47
2.10 FUEL FILTER HOUSING ......................................................................... 2-50
2.11 FUEL FILTER BRACKET ......................................................................... 2-54
2.12 FUEL PUMP ............................................................................................. 2-57
2.13 FUEL PUMP DRIVE ................................................................................. 2-61
2.14 FUEL SYSTEM INSPECTION ................................................................. 2-65
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(S) ............................................................ 3-11
3.4 CAMSHAFT LUBRICATION SPRAYER ................................................... 3-17
3.5 OIL PUMP AND SUMP PIPE ................................................................... 3-19
3.6 OIL FILTER .............................................................................................. 3-27
3.7 OIL HEAT EXCHANGER/FILTER HOUSING .......................................... 3-29
3.8 OIL PRESSURE/TEMPERATURE SENSOR ........................................... 3-34
3.A ADDITIONAL INFORMATION .................................................................. 3-37
4 COOLING SYSTEM
4.1 COOLING SYSTEM ................................................................................. 4-3
4.2 COOLANT PUMP .................................................................................... 4-7
4.3 EGR COOLANT PUMP ............................................................................ 4-18
4.4 FRONT IDLER AND TENSIONER SUPPORT ........................................ 4-19
4.5 THERMOSTAT ......................................................................................... 4-22
4.6 EGR THERMOSTAT HOUSING .............................................................. 4-27
4.7 COOLANT TEMPERATURE SENSOR .................................................... 4-29
4.A ADDITIONAL INFORMATION .................................................................. 4-31
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 .......... 7-47
7.6 EPV (ELECTRONIC PROPORTIONAL VALVE) AND WABCO® AIR
SOLENOID VALVE ................................................................................... 7-54
7.7 HENGST BREATHER FILTER ................................................................. 7-58
7.A ADDITIONAL INFORMATION .................................................................. 7-67
8 ELECTRICAL EQUIPMENT
8.1 DRIVE BELTS .......................................................................................... 8-3
8.A ADDITIONAL INFORMATION .................................................................. 8-15
9 POWERTAKE-OFF
9.1 FRONT ENGINE POWER TAKE-OFF (FEPTO) ...................................... 9-3
9.2 REAR ENGINE POWER TAKE-OFF (REPTO) ........................................ 9-7
10 SPECIAL EQUIPMENT
10.1 AIR COMPRESSOR FLANGE ................................................................. 10-3
10.2 AIR COMPRESSOR ................................................................................ 10-5
10.A ADDITIONAL INFORMATION .................................................................. 10-11
11 OPERATION AND VERIFICATION
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
12 ENGINE TUNE-UP
12.1 VALVE LASH CHECKING ........................................................................ 12-3
12.2 ADJUSTING VALVE LASH ...................................................................... 12-9
13 PREVENTIVE MAINTENANCE
13.1 SCHEDULED INTERVALS ...................................................................... 13-3
14 ENGINE STORAGE
14.1 PREPARING ENGINE FOR STORAGE .................................................. 14-3
15 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM
15.1 ELECTRONIC ENGINE CONTROL SYSTEM ......................................... 15-3
16 GENERAL MECHANICAL TROUBLESHOOTING
16.1 MECHANICAL TROUBLESHOOTING .................................................... 16-3
17 LOW POWER CONCERN
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 ................................................................................. 17-16
17.6 FAULTY EXHAUST SYSTEM .................................................................. 17-18
17.7 HIGH INLET AIR TEMPERATURE .......................................................... 17-20
17.8 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER ........... 17-22
INDEX .................................................................................................
Index-1