5 COOLING SYSTEM
Contents
1. 1 Thermostat 3 Short Circuit Valve 2 Main Valve Figure 5 13 Thermostat Valves All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 29 5 6 THERMOSTAT 4 Check all the test values listed in Table 5 2 If any of the values are not met replace the thermostat a ee a O a Main Valve Starts To Open 81 to 85 C 178 to 1857 Short Circuit Valve Fully Closed 92 C 198 F Pe Main Valve Minimum Lift A Lo ee 8 mm 0 3 in Table 5 2 Thermostat Test Values a At the temperature of 85 C 185 F check that the main valve has started to open b At the temperature of 92 C 198 F check that the short circuit valve is fully closed c At the opening temperature of 95 C 203 F check that the main valve is fully open d Check the minimum lift of the main valve at the opening temperature 5 Install the original or replacement thermostat s as necessary 6 Install the upper coolant hose inlet and new O ring s on the coolant pump 7 Fill the engine with the removed coolant and check for leaks and proper operation Rev 0304 All information subject to change without notice 5 30 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 5 6 2 Thermostat Installation Install the thermostat as follows 1 Install a new O ring on each thermostat 2 Instal2. EGR Engine Install the coolant pump as follows see Figure 5 6 for component location 1 Install two new seals on rear of coolant pump 5 and oil filter assembly See Figure 5 6 NOTE One lower bolt near the damper must be installed in rear coolant pump and oil filter assembly prior to installation due to interference by damper NOTE The oil filter is part of the coolant pump housing and must installed as an assembly 2 Secure the coolant pump housing and oil filter assembly to the cylinder block with six bolts Tighten bolts to 31 35 N m 23 26 Ib ft NOTE The belt tensioner has two locating pins on the rear that must align with corresponding holes in the cylinder block 3 Install the hexagon socket head bolt in the belt tensioner 7 and secure to cylinder block Tighten bolt to 50 N m 37 lb ft See Figure 5 6 4 Install the banjo bolt and two new washers and secure water tube to the coolant pump Install a new seal ring on the heater supply tube 8 and secure tube to coolant pump with three bolts Tighten bolts to 31 35 N m 23 26 lb ft See Figure 5 6 6 Install a new gasket and secure the thermostat housing to the coolant pump with three bolts Tighten bolts to 31 35 N m 23 26 lb ft 7 Connect temperature sensor electrical connector at thermostat housing 8 Install the banjo bolt and two new washer and secure tube on rear of oil filter housing going to turbocharger 9 Install engine valve cover Refer
3. Cylinder 6 Cylinder Description L at L at Total Total capacity 19 20 23 24 Antifreeze quantity at 50 9 5 10 0 11 5 12 0 Antifreeze quantity at 55 10 5 11 1 12 7 13 4 Table 5 1 Cooling System Capacity Rev 0304 All information subject to change without notice 5 4 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL To avoid injury from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots a Open the cap on the surge tank slowly to allow excess pressure to escape b Place a receptacle underneath the coolant drain plug Choose one that is large enough to hold the expected quantity of coolant NOTE Make sure the coolant can flow unobstructed into the receptacle c Open the coolant drain plug on the bottom of the radiator 2 Disconnect the electrical connector from the coolant pre heater See Figure 5 2 1 Coolant Pre heater 3 Electrical Connector 2 O ring Figure 5 2 Coolant Pre Heater All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 5 5 1 3 COOLANT PRE HEATER Remove the coolant pre heater from the e
4. 303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 19 5 5 FRONT CONNECTOR HOUSING EGR ENGINE 5 5 FRONT CONNECTOR HOUSING EGR ENGINE 5 5 1 Thermostat Housing Removal EGR Engine Remove the thermostat housing as follows see Figure 5 8 for component location Lo 1 Upper Thermostat Housing 5 Banjo Bolt 2 Lower Thermostat Housing 6 Coolant Pump 3 Connector Tube 7 Oil Filter 4 Air Compressor Coolant Line 8 Cab Heater Tube Figure 5 8 Coolant Pump EGR Engine 1 Drain engine coolant 2 Remove the fan and fan shroud from the vehicle 3 Release the tension on the poly V belt and remove belt Rev 0304 All information subject to change without notice 5 20 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION 080 ER ED AE 2 10 12 13 14 15 16 17 5 5 2 MBE 900 SERVICE MANUAL Remove the pulley mounting bolts and pulley Remove EGR delivery pipe Refer to section 3 9 1 Remove EGR coolant inlet tube Refer to section 3 7 1 Remove EGR coolant return tube Refer to section 3 8 1 Remove charge air intake housing Refer to section 3 3 1 Remove engine trim panel Remove engine valve cover Refer to section 1 1 1 Remove three bolts securing heater supply tube 1 Rem
5. 4 Remove three bolts securing thermostat housing 2 and remove housing and gasket Discard gasket See Figure 5 6 15 Remove water connector tube 3 from thermostat housing 2 and discard tube See Figure 5 6 16 Remove banjo bolt and washers from air compressor coolant line on pump 5 Discard washers 17 Remove hexagon socket head bolt from belt tensioner 7 and remove tensioner See Figure 5 6 18 Remove banjo bolt and two washers from rear of oil filter housing going to turbocharger Discard washers See Figure 5 6 19 Remove bolts securing coolant pump 5 and seal ring to rear housing of coolant pump and remove Discard seal ring See Figure 5 6 NOTE The oil filter is part of the rear coolant pump housing and must be removed as an assembly NOTE Only five bolts can be removed during the removal of the rear coolant pump housing and oil filter assembly due to interference with damper Loosening the bolt near the damper completely will allow remove of assembly 20 21 5 14 Unscrew the oil filter to allow oil in the canister to drain back into the engine prior to removing Remove six bolts securing coolant pump 5 and oil filter assembly to the cylinder block Discard two seals on rear of housing See Figure 5 6 Rev 0304 All information subject to change without notice From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 5 3 2 Coolant Pump Installation
6. 5 COOLING SYSTEM Section 5 1 5 2 5 3 5 4 5 5 5 6 5 A COOLANT PRE HEATER osesesseeeseeeeeeeeserinretrtresetinnrsernrtettnnreennrserenee COOLANT PUMP NON EGR ENGINE sseeseeseessereerrrrerrrerererresereeeee COOLANT PUMP EGR ENGINE vecivicdisiusivwediviatcacuusvaoiedsieeadedveturacsaciales FRONT CONNECTOR HOUSING NON EGR ENGINE oee FRONT CONNECTOR HOUSING EGR ENGINE neeese THERMOSTAT rriena eee A E A E arae ADDITIONAL INFORMATION vuuuessen sn uakgeeiededadeibinibiitevien Rev 0304 All information subject to change without notice 5 2 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 5 1 COOLANT PRE HEATER 5 1 1 Coolant Pre Heater Removal Remove the coolant pre heater as follows All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 3 5 1 COOLANT PRE HEATER To avoid injury from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots 1 Drain the coolant from the radiator See Figure 5 1 Cooling system capacity is listed in Table 5 1 Figure 5 1 Coolant Drain Plug 4
7. AL 5 2 COOLANT PUMP NON EGR ENGINE The coolant pump is driven by a belt with automatic belt tensioner 5 2 1 Coolant Pump Removal Remove the coolant pump as follows To avoid injury from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots 1 Drain the coolant from the engine 2 Remove the six bolts attaching the fan shroud to the radiator See Figure 5 3 NOTE Remove the bolts indicated by the arrows See Figure 5 3 1 Fan Shroud 3 Radiator 2 Fan Blade Figure 5 3 Fan Shroud Mounting Bolts All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 7 52 COOLANT PUMP NON EGR ENGINE 3 Remove the fan and fan shroud from the vehicle a Remove the fan blade b Remove the fan shroud c Remove the fan hub To avoid injury from flying parts when working with components under spring tension wear adequate eye protection face shield or safety goggles 4 Release the tension on the poly V belt and set the belt aside NOTE On 6 cylinder engines there are two thermostats On 4 cylinder engines there is only one thermostat 5 Loosen the fan pulley Keep the pulley fr
8. Disconnect the electrical connector from the coolant temperature sensor Rev 0304 All information subject to change without notice 5 10 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 10 Remove the front connector housing front connector gasket and coolant pump connector fitting Discard the gasket and fitting 11 Disconnect the lower coolant hose and the coolant line from the coolant pump Discard the seal rings on the coolant line banjo fitting NOTE Collect any coolant that runs out of the lower coolant hose or coolant pump 12 Remove the coolant pump from the engine Discard the gasket 13 On both the coolant pump and the engine block clean the sealing surfaces where the gasket was attached of any adhering gasket material 14 Remove the upper coolant hose inlet thermostat housing thermostat s and O ring s from the coolant pump 5 2 2 Coolant Pump Installation Install the coolant pump as follows 1 Install the upper coolant hose inlet thermostat s and O ring s onto the coolant pump 2 Install the coolant pump on the engine block using a new gasket Tighten the mounting bolts 25 N m 18 lb ft NOTE On 4 cylinder engines secure the coolant pump with six bolts The seventh bolt will be added when the mounting bracket is installed 3 Connect the lower coolant hose and the coolant line to the coolant pump Install new seal rings on the coolan
9. Pull the front connector housing upward until it comes free of the coolant pump connector fitting 7 Discard the connector housing gasket and the coolant pump connector fitting Rev 0304 All information subject to change without notice 5 18 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION 5 4 2 MBE 900 SERVICE MANUAL Front Connector Housing Installation Install the front connector housing as follows 1 2 3 4 Install a new connector housing gasket on the front connector housing Install a new coolant pump connector fitting on the coolant pump Install the front connector housing on the coolant pump connector fitting Install the front connector housing on the cylinder head Tighten the mounting to bolt 25 N m 18 lb ft Connect the wiring harness that runs to the coolant temperature sensor a Connect the electrical connector to the coolant temperature sensor b Install the clip that attaches the harness to mounting bracket for the crankcase breather hose Install the mounting bolt attaching the crankcase breather hose to the front connector housing and the oil separator Tighten the mounting bolt 25 N m 18 lb ft Install the hose clamp attaching the surge tank coolant delivery hose to the front connector housing Fill the engine with the removed coolant and check for leaks and proper operation All information subject to change without notice Rev 0304 6SE414 0
10. asket and secure the thermostat housing 2 to the coolant pump 6 with two bolts See Figure 5 4 Tighten bolts to 31 35 N m 23 26 lb ft Connect temperature sensor electrical connector at thermostat housing Install engine valve cover Refer to section 1 1 2 All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 21 55 FRONT CONNECTOR HOUSING EGR ENGINE 11 Install engine trim panel 12 Install charge air intake housing Refer to section 3 3 2 13 Install EGR coolant return tube Refer to section 3 8 2 14 Install the EGR coolant inlet tube Refer to section 3 7 2 15 Install EGR delivery pipe Refer to section 3 9 2 16 Install water pump pulley and secure with bolts Tighten bolts to 31 35 N m 23 26 lb ft 17 Release the belt tensioner Route the poly V belt around the fan pulley and restore belt tension 18 Install the fan blade and fan shroud on the vehicle Position the fan shroud on the radiator and tighten the fan shroud mounting bolts until firm 19 Fill the engine with removed coolant and check for leaks Refer to section 3 5 2 1 Rev 0304 All information subject to change without notice 5 22 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 5 6 THERMOSTAT The vehicle is cooled by a closed system using recirculated coolant temperature is regu
11. erating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots 1 Drain the coolant from the engine All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 17 54 FRONT CONNECTOR HOUSING NON EGR ENGINE 2 Remove the hose clamp attaching the surge tank coolant delivery hose to the front connector housing See Figure 5 7 NOTE Collect any coolant that runs out of the hose 42459 1 Coolant Delivery Hose from surge tank 6 Electrical Connector 2 Crankcase Breather Hose 7 Engine Coolant Temperature Sensor 3 Front Connector Housing 8 Coolant Pump Connector Fitting 4 Connector Housing Gasket 9 Mounting Bolt 5 Oil Separator Figure 5 7 Front Connector Housing 3 Disconnect the wiring harness that runs to the coolant temperature sensor a Disconnect the electrical connector from the coolant temperature sensor located on the left hand side of the front connector housing just below the front lifting eye b Remove the clip that attaches the harness to mounting bracket for the crankcase breather hose 4 Remove the mounting bolt attaching the crankcase breather hose to the front connector housing and the oil separator Remove the mounting bolt attaching the front connector housing to the cylinder head 6
12. ing Refer to section 2 14 2 5 Fill the engine with the removed coolant and check for leaks and proper operation All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 33 5 6 THERMOSTAT Rev 0304 All information subject to change without notice 5 34 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 5 A Additional Information Description Page SPECIFICATIONS susnrdadttt dte a OE EEE EENE a 5 35 SPECIFICATIONS The cooling system capacity is listed in Table 5 3 Description 4 Cylinder 6 Cylinder L qt L qt 20 24 Total capacity 19 20 23 24 Antifreeze quantity at 50 9 5 10 0 11 5 12 0 Antifreeze quantity at 55 10 5 11 1 12 7 13 4 Table 5 3 Cooling System Capacity Listed in Table 5 4 are the thermostat test values besenpton O Temperawe Diane Main Valve Starts To Open 81 to 85 C 178 to 185 F Short Circuit Valve Fully Closed 92 C 198 F per O O Main Valve Minimum Lift Po 8 mm 0 3 in Table 5 4 Thermostat Test Values All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 35 Rev 0304 All information subject to change without notice 5 36 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION
13. l the original or replacement thermostat s See Figure 5 14 NOTE Mount each thermostat with the breather orifice pointing upward for non EGR engines and pointing forward for EGR engines 42598 Figure 5 14 Breather Orifice 3 Install the upper coolant hose inlet See Figure 5 15 for the 6 cylinder non EGR engines and see Figure 5 16 for the 4 cylinder non EGR engines All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 31 56 THERMOSTAT 1 Coolant Pump 4 Coolant Hose Inlet 2 Thermostat 5 Mounting Bolts 3 qty 3 O ring Figure 5 15 Thermostat Installation 6 cylinder Rev 0304 All information subject to change without notice 5 32 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 1 Coolant Pump 4 Coolant Hose Inlet 2 Thermostat 5 Mounting Bolts 2 qty 3 O ring Figure 5 16 Thermostat Installation 4 cylinder a For non EGR engines install the mounting bolts attaching the coolant hose inlet to the coolant pump Tighten each mounting bolts 25 N m 18 lb ft b For EGR engines install the mounting bolts attaching the upper thermostat housing to lower thermostat housing Tighten bolts to 31 35 N m 23 26 lb ft c Install the hose clamp attaching the upper coolant hose to the inlet 4 For non EGR engines only install the fuel filter hous
14. lated automatically by a thermostat 5 6 1 Thermostat Removal Remove the thermostat as follows To avoid injury from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots Check the thermostat as follows NOTE On 6 cylinder engines there are two thermostats On 4 cylinder engines there is only one thermostat 1 Drain the coolant from the engine 2 For non EGR engines remove the fuel filter housing Refer to section 2 14 1 3 Remove the upper coolant hose inlet thermostat housing See Figure 5 9 for the 6 cylinder non EGR engine and Figure 5 10 for the 4 cylinder non EGR engine and see Figure 5 11 for EGR engines All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 23 56 THERMOSTAT 1 Coolant Pump 4 Coolant Hose Inlet 2 Thermostat 5 Mounting Bolt 3 qty 3 O ring Figure 5 9 Thermostat Removal 6 cylinder Non EGR Engine Rev 0304 All information subject to change without notice 5 24 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 1 Coolant Pump 4 Coolant Hose Inlet 2 Thermostat 5 Mounting Bolts 2 qty 3 O ring Figu
15. linder engines there are two thermostats On 4 cylinder engines there is only one thermostat 1 Hang the thermostat by a wire inside a container filled with water See Figure 5 12 1 Thermostat 2 Container Figure 5 12 Heat the Thermostat NOTE To allow the thermostat to heat evenly make sure it is not touching the sides of the container NOTICE To prevent damage to the thermostat or heating container do not ever use a welding torch or soldering gun as a source of heat 2 Heat the water with a suitable heating element Stir the water occasionally to help equalize the temperature Rev 0304 All information subject to change without notice 5 28 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL A CAUTION To avoid injury from scalding use lifting tools and wear heat resistant gloves when retrieving the thermostat from boiling water a Measure the water temperature As the temperature climbs to around 75 C 165 F slow the rate of heating down to about to 2 C 2 to 3 F per minute b In about five minutes the main valve should begin to open 3 Continue to heat the water at this rate for about six to eight minutes until it reaches the opening temperature of the main valve If the main valve is not completely open replace the thermostat See Figure 5 13 A LIFT 8mm 0 3 in
16. ngine access hole Discard the O ring NOTE Collect any coolant that runs out of the access hole 5 1 2 Coolant Pre Heater Installation Install the coolant pre heater as follows 1 2 3 5 6 Install the coolant pre heater in the engine access hole Replace the O ring with a new one Connect the electrical connector to the coolant pre heater Fill the engine with the coolant a Tighten the coolant drain plug on the bottom of the radiator b Add coolant up to the maximum fill level on the surge tank Check the coolant level and check the cooling system for leaks 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 a Start the engine and run it for about one minute at varying speeds to release air pockets in the cooling system b Check all hoses at the radiator coolant pump and surge tank for leaks c Check the coolant level and add more coolant if necessary Shut down the engine Close and tighten the cap on the surge tank Rev 0304 All information subject to change without notice From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANU
17. om turning while loosening the pulley mounting bolts See Figure 5 4 for 6 cylinder engines and see Figure 5 5 for 4 cylinder engines Rev 0304 All information subject to change without notice 5 8 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 1 Coolant Delivery Hose from surge tank 7 Coolant Pump Connector Fitting 2 Crankcase Breather Hose 8 Coolant Pump 3 Front Connector Housing 9 Coolant Pump Gasket 4 Connector Housing Gasket 10 Lower Coolant Hose 5 Electrical Connector 11 Coolant Line 6 Engine Coolant Temperature Sensor 12 Fan Pulley Figure 5 4 Coolant Pump 6 cylinder Non EGR Engine All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 9 52 COOLANT PUMP NON EGR ENGINE 1 Coolant Delivery Hose from surge tank 8 Mounting Bracket 2 Crankcase Breather Hose 9 Coolant Pump 3 Front Connector Housing 10 Coolant Pump Gasket 4 Connector Housing Gasket 11 Lower Coolant Hose 5 Electrical Connector 12 Coolant Line 6 Engine Coolant Temperature Sensor 13 Fan Pulley 7 Coolant Pump Connector Fitting Figure 5 5 Coolant Pump 4 cylinder Non EGR Engine 6 Remove the fan pulley 7 Remove the belt tensioner 8 On 4 cylinder engines only remove the mounting bracket from the coolant pump and the charge air pipes 9
18. ove tube and discard seal ring See Figure 5 8 Disconnect coolant temperature sensor connector from lower thermostat housing 2 If required remove temperature sensor 6 from housing See Figure 5 8 Remove two bolts securing thermostat housing and remove housing and gasket Discard gasket Remove water connector tube 3 from lower thermostat housing 2 and discard tube See Figure 5 8 Remove three bolts securing upper thermostat housing 1 to lower thermostat housing 2 and remove cover See Figure 5 8 Remove thermostat s and O ring s from thermostat housing Discard O rings Check thermostat s Refer to section 5 6 1 1 Thermostat Housing Installation EGR Engine Install the thermostat housing as follows 1 2 9 10 Install a new O ring on each thermostat and install thermostats in lower housing Secure the thermostat upper housing 1 to lower thermostat housing 2 with three bolts Tighten bolts to 31 35 N m 23 26 lb ft See Figure 5 8 Install a new water connector tube 3 with seal in coolant pump 6 See Figure 5 8 Install a new gasket and secure the thermostat housing 2 to the coolant pump 6 with two bolts Tighten bolts to 31 35 N m 23 26 lb ft Secure coolant inlet tube at clamp on thermostat with bolt Tighten bolts to 31 35 N m 23 26 lb ft If removed install temperature sensor in thermostat housing Position thermostat housing 2 over connector tube 3 Install a new g
19. p as follows see Figure 5 6 for component location Lo 1 Upper Thermostat Housing 5 Coolant Pump 2 Lower Thermostat Housing 6 Crankshaft Damper 3 Connector Tube 7 Belt Tensioner 4 Pulley 8 Cab Heater Tube Figure 5 6 Coolant Pump and Related Components EGR Engine 1 Drain engine coolant 2 Remove the fanand fan shroud from the vehicle 3 Release the tension on the poly V belt tensioner 7 and remove belt See Figure 5 6 All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 13 5 3 COOLANT PUMP EGR ENGINE 4 Remove the pulley mounting bolts and pulley 4 See Figure 5 6 5 Remove EGR delivery pipe Refer to section 3 9 1 6 Remove EGR coolant inlet tube Refer to section 3 7 1 7 Remove EGR coolant return tube Refer to section 3 8 1 8 Remove charge air intake housing Refer to section 3 3 1 9 Remove engine trim panel 10 Remove two bolts and spacers from charge air housing support bracket 11 Remove engine valve cover Refer to section 1 1 1 12 Remove three bolts securing heater supply tube 8 Remove tube and discard seal ring See Figure 5 6 13 Disconnect temperature sensor connector on thermostat housing If required remove temperature sensor from housing 1
20. re 5 10 Thermostat Removal 4 cylinder Non EGR Engine All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 25 5 6 THERMOSTAT 1 Oil Filter and Water Pump Housing 6 Connector Tube 2 Thermostats 7 Water Pump 3 Bolt 8 Pulley 4 Upper Thermostat Housing 9 Cab Heater Tube 5 Lower Thermostat Housing Figure 5 11 Thermostat Removal for EGR Engines a Remove the hose clamp attaching the upper coolant hose to the inlet b For non EGR engines remove the mounting bolts attaching the inlet to the coolant pump c For EGR engines remove three bolts securing the upper thermostat housing to lower thermostat housing NOTE Collect any coolant that runs out of the inlet or coolant pump Rev 0304 All information subject to change without notice 5 26 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 4 Remove the thermostat s and O ring s from the coolant pump Discard the O ring s 5 Check the thermostat s for proper operation Refer to section 5 6 1 1 Replace any thermostat that fails one or more tests All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 27 56 THERMOSTAT 5 6 1 1 Thermostat Checking Check the thermostat as follows NOTE On 6 cy
21. t line banjo fitting 4 Install the front connector housing onto the coolant pump Install a new gasket and coolant pump connector fitting Tighten the mounting bolt attaching the front connector housing to the cylinder head 25 N m 18 lb ft Connect the electrical connector to the coolant temperature sensor 6 On 4 cylinder engines only install the mounting bracket on the coolant pump and the fastener to the charge air pipes Tighten the mounting bolts 50 N m 37 lb ft 7 Install the belt tensioner 8 Install the fan pulley on the coolant pump Tighten the fan pulley mounting bolts 25 N m 18 lb ft 9 Install the fan hub on the fan pulley 10 Release the belt tensioner Route the poly V belt round the fan pulley and restore the belt tension 11 Install the fan blade and fan shroud on the vehicle a Position the fan shroud on the radiator All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 11 52 COOLANT PUMP NON EGR ENGINE b Tighten the fan shroud mounting bolts until firm 12 Fill the engine with the removed coolant and check for leaks Rev 0304 All information subject to change without notice 5 12 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 53 COOLANT PUMP EGR ENGINE 5 3 1 Coolant Pump Removal EGR Engine Remove the coolant pum
22. to section 1 1 2 10 Install the charge air housing bracket two bolts and spacers and secure bracket to cylinder head 11 Install the engine trim panel 12 Install charge air intake housing Refer to section 3 3 2 13 Install EGR coolant return tube Refer to section 3 8 2 14 Install EGR coolant inlet tube Refer to section 3 7 2 15 Install EGR delivery pipe Refer to section 3 9 2 16 Install pulley and secure with bolts Tighten bolts to 31 35 N m 23 26 lb ft 17 Release the belt tensioner Route the poly V belt around the fan pulley and restore belt tension All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 5 MBE900 04 5 15 5 3 COOLANT PUMP EGR ENGINE 18 Install the fan blade and fan shroud on the vehicle then position the fan shroud on the radiator Tighten the fan shroud mounting bolts until firm I 19 Fillthe engine with removed coolant and check and test for leaks Refer to section 3 5 2 1 Rev 0304 All information subject to change without notice 5 16 From Bulletin 5 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 5 4 FRONT CONNECTOR HOUSING NON EGR ENGINE 5 4 1 Front Connector Housing Removal Remove the front connector housing as follows To avoid injury from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at op
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