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2.9 FUEL SYSTEM INSPECTION
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1. Figure 2 27 PLD Control Unit Wiring All information subject to change without notice 6SE412 0206 Copyright O 2003 DETROIT DIESEL CORPORATION AB PLD CONTROL UNIT PLD CONTROL UNIT tte PEDICONTROUUNIT op gc A S 2857 CONTROL UNIT LOGIC CONTROL UNIT LOGIC TARTI PROPORTIONING VALVES SIGNAL ACQUISTION AND ANALYSIS leg POWER SUPPLY CANINTERFACE 63 125 PERFORMANCE FINAL STAGE OIL LEVEL OIL PRESSURE 50 i 279 266 233 232 j 91 31 30 30 15 iow ano ew roe Prope prore propa _ E AGND 5 AGND
2. E SV E AGND v E xA i i d Ld s 18 5 6 7 16 36 16 1 4 1 53 3 os 22 1 er Y fare CES rs fe y sec Vil fe fe E 8 m 8 83 ol 5 8 S 8 Sg 2 z 3 39 5 NA i Fi 2 ig Fig 3 9 GU BLU PED dew gan wer ELO Gov OR WETBOC BLK Wet Reo WAP SPN BEN BATTERY REAME a7 3 3 Q ENGINE FRONTWALL AIR CONNECTOR ix INTAKE 2 wt 4 HEATER 20 Ate aA NE 1 I d veu vou 8 15 AMP CIRCUIT A B xt BREAKER n y 3 ee MUR EA Yel Y70 49 B14 B110 BRAKE VALVE FAN CONSTANT OIL LEVEL OIL PRESSURE SOLENOID SOLENOID THROTTLE SENSOR TEMPERATURE SENSOR z 1 4 L 1 d A6 PLD CONTROL UNIT PLD CONTROL UNIT A6 arma atc a RUNES es ceti ia esee Li AYE ate ca n S PED CONTROLUN TS AS m CONTROL UNIT LOGIC CONTROL UNIT LOGIC i I I SIGNAL ACQUISTION AND ANALYSIS TEMPERATURE SENSOR SIGNAL SIGNAL pour pu d Eod loen TION AND ANALYSIS CRANE RECOGNITION 186 UNIT PUMPS PERFORMANCE FINAL STAGE PRESSURE 177 i 842 175 TDC as osv amo 2 7 284 e 178 197 6851 A o Bd E o B D F 33833 4 8 T Y Y Y T 5 05 0 5 0 5 05 0 5 0 5 0 5 0 5 05
3. brake is set and the wheels are blocked 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 2 Start the engine and warm it up to working temperatures 80 95 176 203 F 3 Check the fuel pressure at two points idle speed and rated speed 4 Compare the test results with the fuel systems specifications for pressure listed in Table 2 3 If any of the readings are out of spec follow the proper troubleshooting steps mmm Fuel Pressure Test at idle rpm 2 bar 29 psi minimum Fuel Pressure Test at rated rpm 5 5 6 5 bar 80 95 psi Maximum difference between fuel filter housing 0 3 bar 4 psi inlet and outlet pressure Table 2 3 Fuel System Specifications for Pressure 2 9 1 1 Fuel Pressure Test Troubleshooting Procedures For results out of specs on the fuel pressure test check the following appropriate steps 1 At idle rpm with fuel pressure lower than 2 bar 29 psi check the following Check the pressure valve at the end of the fuel gallery Look for opening pressure 2 bar 29 psi Check the fuel pump assembly bearing and or driven gear Check to see if the fuel system is d
4. 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 NOTE Before running the test warm the engine to normal operating temperatures 80 95 C 176 203 F 1 Plug your minidiag2 into the truck diagnostic connector and follow the instructions in the minidiag2 Supplement Manual to connect to the VCU PLD MR system 2 After establishing the connection with the truck choose option 4 Routines Under Routines section select option 4 Idle Smoothly Balance All information subject to change without notice 6SE412 0206 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 03 2 45 2 9 FUEL SYSTEM INSPECTION 4 Check each cylinder value for this routine and compare your results with the troubleshooting and proceed as described for any results out of spec Refer to section 2 9 2 1 5 Still connected to truck look for option 5 Impact Time Delay under the Routines section 6 Select it and check each cylinder value for this routine and compare your results with the troubleshooting and proceed as described for results out of spec 2 9 2 1 Idle Smoothly Balance Troubleshooting This test measures the percentage of fuel delivery for each cylinder in order t
5. 075 075 075 075 15 15 15 15 15 15 15 1 5 1 5 15 15 15 GAY mED GRY RED RED GAY gay RED Gay RED BED WHT GN MO WHT BBY ED YET GR e GEN GRN GEN G N BLU WO mu VEL Fig 4 ew Fig 5 sb o gb Y6 ye 0 yu Ye NO 1 NO NO 2 NO 5 NO 6 NO 4 R UNIT PUMPS E H 6 CYLINDER In i LAZ ty fel eo uL p B111 B12 B65 B10 815 816 CHARGE AIR PRESSURE OIL PRESSURE COOLANT FUEL CRANK ANGLE TDC TEMPERATURE SENSOR SENSOR TEMPERATURE TEMPERATURE POSITIONSENSOR SENSOR SENSOR SENSOR L 2 From Bulletin 6 4000 03 2 55 PLD CONTROL UNIT 285 CONTROL UNIT LOGIC CAN INT STARTER CONTROL 273 POWER SUPPLY 50 279 30 HIGH LOW 50 50 Y ENGINE FRONTWALL BATTERY gt gt gt 0 2 15 CIRCUIT BREAKER 03 12 2001 Figure 2 28 PLD Control Unit Wiring VCU Interface All information subject to change without notice 2 56 From Bulletin 6 MBE4000 03 6SE412 0206 Copyright 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL PLD CONTROL UNIT A6 CONTROL UNIT L
6. 206 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 03 2 41 2 9 FUEL SYSTEM INSPECTION 2 9 1 Performing a Fuel Pressure Test Perform the following steps to conduct a fuel pressure test 1 Install the pressure gauge on the fuel system There are two possible setups for this installation Setup 1 has the gauge installed after the fuel filter See Figure 2 23 Setup 2 has the gauge installed before the fuel filter See Figure 2 24 43558 1 Fitting 4 Fuel Outlet Line 2 Fuel Filter Housing 5 Unit Pump 3 Mechanical Gauge Figure 2 23 Gauge Installation After the Fuel Filter All information subject to change without notice 2 42 From Bulletin 6 MBE4000 03 65 412 0206 Copyright 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 1 Fuel Pump 4 Fuel Outlet Line 2 Fitting 5 Mechanical Gauge 3 Fuel Filter Housing Figure 2 24 Gauge Installation Before the Fuel Filter NOTE The fitting applied in both setups is not a special tool and it is not included in the Mercedes Benz kit or SPX kit This fitting is a component and it can be ordered from Canton PDC under part number 915039012205 All information subject to change without notice 6 412 0206 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 03 2 43 2 9 FUEL SYSTEM INSPECTION To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking
7. 94 p 178 175 176 235 1 Y v v v 23 39 48 Y Y 2 Ki E 2 wu ow zo cl Pu SEEMS EE CHARGE AIR PHESSURE OIL PRESSURE BUGLE CRANK ANGLE TDC TEMPERATURE SENSOR SENSOR TEMPERATURE SENSOR SENSOR Figure 2 30 PLD Control Unit Wiring Miscellaneous Sensors All information subject to change without notice 2 58 From Bulletin 6 MBE4000 03 6SE412 0206 Copyright 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL Fuel System Inspection The torque specifications for fuel line nuts are listed in Table 2 11 The fuel system specifications for pressure are listed in Table 2 12 Transfer Tube Nut 45 N m 33 Ib ft High Pressure Line Nuts 30 22 lb ft Table 2 11 Torque Specifications for Fuel Line Nuts mem Fuel Pressure Test at idle rpm 2 bar 29 psi minimum Fuel Pressure Test at rated rpm 5 5 6 5 bar 80 95 psi Maximum difference between fuel filter housing 0 3 bar 4 psi inlet and outlet pressure Table 2 12 Fuel System Specifications for Pressure All information subject to change without notice 6SE412 0206 Copyright O 2003 DETROIT DIESEL CORPORATION From Bulleti
8. MBE 4000 SERVICE MANUAL 2 9 FUEL SYSTEM INSPECTION Perform the following steps to inspect the fuel system for damage A CAUTION To avoid injury from penetrating fluids do not put your hands in front of fluid under pressure Fluids under pressure can penetrate skin and clothing A CAUTION To avoid injury from fire keep all potential ignition sources away from diesel fuel open flames sparks and electrical resistance heating elements Do not smoke when refueling NOTE For additional safety precautions refer to the General Information section of the MBE 4000 Service Manual 6SE412 1 Check fuel delivery lines looking for deformation or bent lines creating restriction and or obstruction of the flow 2 Check suction lines and connections looking for damage or under torque allowing air to enter the fuel system Check the fuel tank installation Look for bent blocked lines and leaks 4 Check high pressure lines for leaks Look for connector nut leaks at the unit pump and at the transfer tube on the cylinder head In the event of leaks disassemble and inspect the high pressure lines transfer tube For proper torque specifications see those listed in Table 2 2 Transfer Tube Nut 45 N m 33 Ib ft High Pressure Line Nuts 30 22 lb ft Table 2 2 Torque Specifications for Fuel Line Nuts 5 Perform a fuel pressure test Refer to section 2 9 1 All information subject to change without notice 6SE412 0
9. OGIC PROPORTIONING VALVES SIGNAL ACQUISTION AND ANALYSIS 185 PERFORMANCE FINAL STAGE OIL LEVEL OIL PRESSURE PROP DVB 266 293 232 i PROP1 PROP2 PROP3 PROP4 RETURN RETURN E AGND 5V AGND E 45M E AGND 5V E l1 v Y Y 4 4 v 4 Y 51 50 41 43 12 52 38 49 6 15 32 13 28 22 11 27 Y Y Y Y Y Y 3 Fig 4 05 0 5 0 75 075 0 75 0 5 0 5 05 05 5 0 5 0 5 RED RED BLU BLU RED BRN WHT YEL WHT BRN GRY GRY WHT BLK WHT RED WHT RED BLK WHT BRN BRN A X A E 1 2 1 2 3 1 2 1 2 3 1 4 2 m AN ROM EST SC X L Y91 Y70 Y49 B14 B110 BRAKE VALVE FAN CONSTANT OIL LEVEL OIL PRESSURE SOLENOID SOLENOID THROTTLE SENSOR TEMPERATURE SENSOR 42118 Figure 2 29 PLD Control Unit Wiring Proportioning Valves and Oil System Sensors All information subject to change without notice 6 412 0206 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 03 2 57 PLD CONTROL UNIT CONTROL UNIT LOGIC SIGNAL ACQUISTION AND ANALYSIS Oil PRESSURE AMBIENT TEMPERATURE SENSOR SIGNAL SIGNAL CHARGER ee 7 ACQUISTION AND ANALYSIS CRANK COGNITION CE enol 21 171 2
10. eplace the injector nozzle holder If the pressure is within the spec proceed to the next step 3 Runa compression test using minidiag2 ProLink reader or DDDL 5 0 refer to the Diagnostic Tool Manual for instructions to run this test The readings must be 7596 or higher For readings lower than 75 remove the oil pan and cylinder head and check for damaged components All information subject to change without notice 2 46 From Bulletin 6 MBE4000 03 6SE412 0206 Copyright O 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 2 9 2 2 Impact Delay Time Troubleshooting This test measures the reaction time of the unit pumps The operation range is from 1 2 to 2 1 milliseconds Perform the following troubleshooting procedure for values out of the operating range 1 Check the engine harness from the PLD MR to the suspected unit pump connectors and wire Look for bad or loose connections and broken wires If there are none proceed to the next step 2 Swap the suspect unit pump with one operating properly and run the test again Refer to section 2 1 1 for unit pump removal and refer to section 2 1 2 for unit pump installation If the condition follows the unit pump replace the unit pump 2 9 2 3 Checking the Fuel Pump Driven Gear Bolt Torque This procedure describes how to check the fuel pump assembly for any play or wear on the fuel pump shaft drive gear mounting bolt Any play in this component has a big impact on engine per
11. formance 1 Remove the fuel pump 2 Set the torque wrench to 30 N m 22 lb ft All information subject to change without notice 6SE412 0206 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 03 2 47 2 9 FUEL SYSTEM INSPECTION NOTICE Do not apply a torque over 30 N m 22 lb ft Excessive torque can cause the bolt gear failure 3 Turn the torque wrench as shown by the arrow in until the torque wrench clicks This resistance ensures that the fuel pump drive gear is in good condition In the event of NO resistance found with shaft turning freely proceed to the next step See Figure 2 25 J 46187 or ALLEN KEY WRENCH 12 mm 43793 1 Torque wrench 3 Fuel Pump 2 Fuel Pump Drive Gear Splines Figure 2 25 Checking Fuel Pump Drive Gear 4 Remove the fuel pump drive gear cover All information subject to change without notice 2 48 From Bulletin 6 MBE4000 03 65 412 0206 Copyright 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 5 Remove the bolt and gear See Figure 2 26 1 Cover 3 Fuel Pump Shaft 2 Drive Gear Mounting Bolt 4 Fuel Pump Drive Gear Figure 2 26 Removing Installing Fuel Pump Drive Gear and Bolt 6 Check the mounting between bolt gear and shaft Look for damaged parts Replace any damaged part in order to avoid it coming loose again 7 Install gear and bolt Apply Loctite 271 sealant to the bolt For the correct tightening of the bolt
12. ge Supply PV2 Turbo Brake Control switch to Bat G 40 PV6 Table 2 7 Current Harness Connector A460 150 01 33 All information subject to change without notice 6SE412 0206 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 03 2 53 Fuel and Fuel Control The fuel control torque values are listed in Table 2 8 Listed in Table 2 9 and listed in Table 2 10 are the fuel system torque values See Figure 2 27 for a harness drawing of the wiring from the PLD pump and nozzle control unit For a detailed partial harness drawing showing the interface between the PLD and the vehicle control unit VCU through the electronic engine frontwall connector see Figure 2 28 For a detailed partial harness drawing showing the PLD wiring to the proportioning valves and the oil system sensors see Figure 2 29 For a detailed partial harness drawing showing the PLD wiring to the other system sensors including charge air coolant fuel crank angle position and TDC top dead center see Figure 2 30 Fastener Type N m lb ft Fuel Heat Exchanger Mounting Bolts 8 6 Table 2 8 Fuel Control Torque Values Table 2 9 Fuel System Torque Values Table 2 10 Fuel System Torque Values All information subject to change without notice 2 54 From Bulletin 6 MBE4000 03 6SE412 0206 Copyright O 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL
13. install the special tool J 36187 to the fuel pump spline and block the shaft movement See Figure 2 25 8 Torque bolt to 30 22 lb ft 9 Apply Loctite 574 sealant and install the cover Torque 50 N m 37 lb ft 10 Install new gasket and the fuel pump Torque to the fuel pump bolts will be 25 18 Ib ft All information subject to change without notice 6SE412 0206 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 03 2 49 29 FUEL SYSTEM INSPECTION All information subject to change without notice 2 50 From Bulletin 6 MBE4000 03 65 412 0206 Copyright 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 2 A ADDITIONAL INFORMATION Description Page SPECIFICATIONS eite noinen reat ie Siecle that 2 52 FS iio i c C 2 52 Engine Brake heran nd cdam fusis acto Hos 2 53 Fuel Fuel Control ces ede ethos eeu do ure eR 2 54 Fuel System Inspection acuerda EO pns gx de dh 2 59 i All information subject to change without notice 6SE412 0206 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 03 2 51 SPECIFICATIONS This section contains the specifications for servicing the engine Fuel Injectors The fuel injection system torque values are listed in Table 2 4 The torque values for the injector lines are listed in Table 2 5 Table 2 4 Fuel Injection Sy
14. n 6 MBE4000 03 2 59 All information subject to change without notice 2 60 From Bulletin 6 MBE4000 03 65 412 0206 Copyright 2003 DETROIT DIESEL CORPORATION
15. o maintain a smooth operation at idle Operational range for this test from 3 negative to 396 positive Identify the cylinder with the biggest absolute value highest positive or lowest negative The troubleshooting steps for both conditions are For Highest Positive 1 Check torque at all the transfer tubes nuts 45 N m 33 Ib ft Run the test again If the results are out of operational range proceed to next step 2 Find the cylinder with the result closest to zero Swap the injector nozzle holder and the transfer tube between this cylinder and the cylinder with the highest result Run the test again If the highest result follows the injector nozzle holder replace the nozzle holder If not proceed to the next step NOTE After removing the injector nozzle holders and transfer tubes check the coupling area between both components and the seal rings If any defect or damage is found replace the damaged parts 3 Return both injector nozzle holders and transfer tubes to their original positions and run the impact delay time and compression test routines For Lowest Negative 1 Check torque at all the transfer tubes nuts 45 N m 33 Ib ft Run the test again If the results are out of the operational range proceed to the next step 2 Find the cylinder with the lowest result remove the injector nozzle holder and check the opening pressure If the pressure is lower than the minimum spec 275 bar 3989 psi r
16. rawing air 2 Atrated rpm for fuel pressure lower than 5 5 bar 80 psi check the following O Check the water separator filter condition Check for restriction at the check valve on the PLD MR heat exchange plate All information subject to change without notice 2 44 From Bulletin 6 MBE4000 03 6SE412 0206 Copyright 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL Check the main fuel filter condition looking for saturation or any damaged seal allowing flow of fuel from the pressure side to the return side Check for leaks at the suction lines from the tank Check the fuel pump assembly bearing and or driven gear Look for leaks and or a damaged fuel pump Check for restriction at the check valve on the fuel filter return line to tank 3 Atrated rpm for fuel pressure higher than 6 5 bar 95 psi check the following Check the return line and injector spill line looking for restrictions or bent lines Check the fuel pressure valve for a blocked or restricted regulator orifice 2 9 2 Performing a Fuel System Test using minidiag2 To perform a fuel system test using minidiag2 perform the following steps To avoid injury when working near or on an operating engine remove loose items of clothing jewelry tie back or contain long hair that could be caught in any moving part causing injury Diesel engine exhaust and some of its constituents are known
17. stem Torque Values Fastener Type lb ft Using a 12 in torque Using a 24 in torque Required Torque on wrench wrench Fastener Injector Line Nuts 27 20 25 18 30 22 Transfer Tube Thrust Bolt 40 30 36 27 45 33 Table 2 5 Injector Lines Torque Values All information subject to change without notice 2 52 From Bulletin 6 MBE4000 03 65 412 0206 Copyright 2003 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL Engine Brake Harness The former 8 pin Engine Harness Connector is identified with part number A460 150 00 33 and it is used in the engines that have one solenoid air valve for the engine brakes Beginning with the engine serial number 739080 these current engines will have an 8 pin Engine Harness Connector with part number A460 150 01 33 The changes in the harness connections between the former and current 8 pin harness connector are Listed in Table 2 6and listed in Table 2 7 e id Fan and Wastegate E Flap Voltage 12 Supply PV1 3 4 Exhaust Flap Wastegate Control switch to Bat PV1 Fan and Wastegate E Flap Voltage Supply PV1 3 4 Turbo Brake Control switch to Bat G 40 PV6 Table 2 6 Former Harness Connector A460 150 00 33 8 Pin Engine Harness Connector PLD MR 55 Pin Connector Compression Brake Control switch to Bat PV2 Fan and Wastegate E Flap Voltage Supply PV1 3 4 Exhaust Flap Wastegate Control switch to Bat PV1 Compression Brake Volta
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