Mercedes Detroit Diesel MBE 4000 EPA 07 Workshop Service Repair Manual
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This is the COMPLETE Official Service Repair Manual for the Detriot Diesel Engine.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Engine.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
This Manual contains information and data to this model. has specs, diagrams, and actual real photo illustrations, and schemes, which give you complete step by step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. all pages are printable, so run off what you need and take it with you into the garage or workshop.
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 ………………………………………….. 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
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
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