Mercedes / Detroit Diesel MBE 4000 EPA 07 Workshop Service Repair Manual

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 .................................................. 19
ENGINE BRAKING POWER .................................................................... 20
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 FUELSYSTEM
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
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 CYLINDERHEADCOOLANTVENT 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 AIRINTAKESYSTEM
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
6.A ADDITIONAL INFORMATION .................................................................. 6-41
7 EXHAUST SYSTEM
7.1 EXHAUST MANIFOLD ASSEMBLY ......................................................... 7-3
7.2 BRAKE GATE .......................................................................................... 7-11
7.3 ELECTRONIC PROPORTIONAL VALVE ................................................ 7-26
7.A ADDITIONAL INFORMATION .................................................................. 7-29
8 EXHAUST GAS RECIRCULATION COMPONENTS
8.1 EGR GAS INLET PIPE ............................................................................ 8-3
8.2 EGR COOLER GAS OUTLET PIPE ........................................................ 8-7
8.3 EGR COOLER AND SUPPORT BRACKET ............................................ 8-9
8.4 EGR COOLER HEAT SHIELD AND MOUNTING BRACKET .................. 8-18
8.5 EGR COOLER COOLANT INLET TUBE ................................................. 8-19
8.6 EGR COOLER COOLANT RETURN TUBE ............................................ 8-21
8.7 EGR CONTROL VALVE ........................................................................... 8-23
8.A ADDITIONAL INFORMATION .................................................................. 8-25
9 ELECTRICAL EQUIPMENT
9.1 DRIVE BELTS .......................................................................................... 9-3
9.2 ALTERNATOR/AIR CONDITIONING COMPRESSOR BRACKET .......... 9-12
9.A ADDITIONAL INFORMATION .................................................................. 9-15
10 POWER TAKE-OFF
10.1 FRONT POWER TAKE-OFF .................................................................... 10-3
10.2 REAR ENGINE POWER TAKE-OFF ....................................................... 10-7
11 SPECIAL EQUIPMENT
11.1 AIR COMPRESSOR FLANGE ................................................................. 11-3
11.2 AIR COMPRESSOR ................................................................................ 11-5
11.A ADDITIONAL INFORMATION .................................................................. 11-11
12 OPERATION AND VERIFICATION
12.1 PREPARATION FOR A FIRST TIME START ........................................... 12-3
12.2 STARTING THE ENGINE ........................................................................ 12-8
12.3 RUNNING THE ENGINE ......................................................................... 12-11
12.4 STOPPING THE ENGINE ........................................................................ 12-13
12.A ADDITIONAL INFORMATION .................................................................. 12-15
13 ENGINE TUNE-UP
13.1 CHECKING THE VALVE LASH ................................................................ 13-3
13.2 ADJUSTING THE VALVE LASH .............................................................. 13-9
13.A ADDITIONAL INFORMATION .................................................................. 13-11
14 PREVENTIVE MAINTENANCE
14.1 SCHEDULED INTERVALS ...................................................................... 14-3
15 ENGINE STORAGE
15.1 PREPARING ENGINE FOR STORAGE .................................................. 15-3
INDEX .................................................................................................
Index-1