1 ENGINE
Contents
1. 44137 All information subject to change without notice 1 d From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL This page intentionally left blank All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 l e 1 4 ENGINE BRAKE 1 4 ENGINE BRAKE Engine braking is controlled by a pneumatically operated exhaust brake on the turbocharger in conjunction with constant throttle valves on the cylinder head The exhaust back pressure is used by the exhaust brake to increase braking performance The constant throttle valves use the air that escapes through them on the compression stroke to provide braking force The constant throttles are small valves which are built into the cylinder heads and positioned opposite the exhaust valves When open a link is created between the combustion chamber and the exhaust port When the engine brake is switched on the constant throttle valves are opened by pneumatic pressure NOTE When in emergency running mode constant rpm the engine brake can be activated only when the engine is in overrun When constant rom has been attained the engine brake is automatically turned off For greater braking power an optional turbo brake is available 1 4 1 Constant Throttle Valve Removal Remove the constant throttle valve as follows 1 Remove the cylinder head Refer to2. 6 Follow remaining steps for piston installation in a non EGR engine Refer to section 1 15 2 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 1 168 1 1ISA EGR PISTON PISTON RING AND CONNECTING ROD This page intentionally left blank All information subject to change without notice 1 169 From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 2 Remove the collets spring retainer valve spring and spring base See Figure 1 116 J 46184 or 403 589 00 61 00 Se Se 42074 1 Valve Stem Seal 3 Valve Guide 2 Valve Stem Figure 1 116 Valve Stem Seal Replacement 3 Remove the valve stem seal Do not remove the valve 4 Lubricate the valve stem and valve stem seal installer J 46184 or 403 589 00 61 00 with a light coating of clean engine oil NOTE The installer prevents the groove on the valve stem from damaging the seal 5 Push the valve stem seal installer J 46184 or 403 589 00 61 00 over the valve stem until it makes contact with the valve 6 Slide the seal over the installer and the valve stem Using fingers press the seal into place until the seal seats on the valve guide NOTE Check the seal to make sure it is correctly seated on the valve guide 7 Remove the installer from the valve stem seal and the valve 8 Install the collets spring retainer
3. valve spring and spring base as removed 9 Repeat the procedure for the other valves 10 Install the cylinder head Refer to section 1 2 2 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 1 151 1 16A EGR VALVES 1 16A EGR VALVES The exhaust valves and valve specifications in the EGR engine have changed due to the addition of valve stem sealing rings under the valve stem seals in the engine Perform the following steps in removing the valves from the EGR engine Follow the procedures for valve removal in a non EGR engine until reaching the valve stem seals removal step Refer to section 1 16 5 1 2 With the cylinder head in an upright position remove and discard the valve stem seals and valve stem sealing rings See Figure 1 116a 1 16a 1 Valve Removal in the EGR Engine 44181 1 Valve Stem Seal 3 Valve Guide 2 Valve Stem Sealing Ring 4 Cylinder Head Figure 1 116a Removing Valve Stem Seals and Valve Stem Sealing Rings NOTE The valve guide with valve stem sealing ring are used only in the EGR engines 3 Check the following critical valve dimensions and repair as necessary See Figure 1 116b to determine the dimensions Listed in Table 1 43a are the dimensions for the intake valve and the differences between the exhaust non EGR and exhaust EGR valves C Valve stem diamet
4. See Figure 1 28 The acceptance rejection criteria is listed in Table 1 11 Measuremeni A is specified in Measuring Cylinder Liner Protrusion table 41907 1 Cylinder Block 2 Cylinder Liner Figure 1 28 Measuring Protrusion Description Value mm in Cylinder Liner Protrusion From Block 0 230 0 330 0 0090 0 0130 Difference Between the Four Measuring Points Max 0 02 0 0007 Table 1 11 Specifications for Measuring Cylinder Liner Protrusion a Set the scale on the dial gauge to zero b Move the dial gauge until the feeler touches the cylinder liner collar Record the reading on the dial gauge c Move the dial gauge and support to the next slot and repeat the measurement process until four measurements have been made one at each slot Record each measurement d Check each measurement If any one measurement records protrusion of less than 0 230 mm 0 0090 inch or more than 0 330 mm 0 0130 inch remove the cylinder liner and check it according to the procedures that refer to section 1 3 1 e Compare the four measurements If any measurement differs from any one of the others by more than 0 02 mm 0 0007 inch replace the cylinder liner 7 Remove the bolts spacers and measuring plate J 46071 or 402 589 00 21 00 as installed 8 Install the cylinder head Refer to section 1 2 2 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL C
5. section 1 2 1 2 Remove the injector nozzle Refer to section 2 3 1 All information subject to change without notice 1 f From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 1 15A EGR PISTON PISTON RING AND CONNECTING ROD The difference from the non EGR engine cylinder liner to the EGR engine is a groove on the top part of the cylinder liner which houses the carbon scraper ring The EGR engine uses a new tool for piston installation however all other procedures are the same for the EGR and non EGR engine 1 15a 1 Piston Removal for EGR Engine Perform the following steps to remove the piston from an EGR engine NOTICE The carbon scraper ring has a smaller internal diameter than the piston skirt diameter therefore the piston installation and removal must be carried out with the carbon scraper ring removed NOTE Piston removal in the EGR engine is performed with the engine facing upright not turned on it s side 1 Remove the carbon scraper ring from the cylinder liner groove See Figure 1 98a 44178 1 Cylinder Liner 3 Installed Piston 2 Carbon Scraper Ring 4 Installed Carbon Scraper Ring Figure 1 98a Removing Carbon Scraper Ring All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 1 166 115A EGR PISTON PISTON RING AND CONNECTING ROD 2
6. valve stem seal on the guide NOTE Check the seal to make sure it is correctly seated on the valve guide 13 Remove the installer from the valve stem seal and the valve 14 Install the keeper spring retainer valve spring and spring seat as removed 15 Repeat the procedure for the other valves All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 1 155 oe hr mmm ee 1 16A EGR VALVES 16 Install the cylinder head on the EGR engine Refer to section 1 3a 1 1 16a 4 Valve Seats See Figure 1 116d and listed in Table 1 43b are the specifications for valve seats SAID ME E EE EN De Nee 44186 1 Exhaust Valve Seat 2 Intake Valve Seat Figure 1 116d Valve Seats on EGR Engine Description Intake Valve mm in Exhaust Valve EPA Exhaust Valve EPA 98 mm in 04 mm in Valve seat angle E 30 Degree 45 Degree Valve seat surface 41 99 42 01 1 65 1 654 38 99 39 0 1 535 1 535 38 99 39 01 1 535 1 536 diameter G Relative position H to 4 00 4 15 0 157 0 163 3 80 3 95 0 15 0 16 4 00 4 15 0 157 0 163 diameter G Table 1 43b Valve Seat Specifications for EGR Engine All information subject to change without notice 1 156 From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL This page intentionally left blank All information subje
7. 1 ENGINE Section Page 1 1 CYLINDER HEAD COV ER o cticctisiwesstiaceixchedeSosbactcctiieenWobecd vitae 1 3 de CYLINDER HEAD ee 1 5 t3 CYLINDER BLOCK acta sci as ota aah ss Aa ree be a a 1 24 1 3A EGR CYLINDER HEAD AND BLOCK cccccccccccsssteeeeeeesssneteeeeeeeeeeeeeas 1 40 1 3B EGR FRONT AND REAR LIFTER BRACKETS cccccccsessessteeeeeeeeeees 1 40c 1A ENGINE BRAKE icsesscaxeivics tv etl obsesanteaitx drat GodesetlndlaGerrnees Aout 1 40f 1 5 FRONTRADIAL SEAL eeh EEN 1 46 167 OREARIRADIAISS EE 1 49 1 7 CRANKSHAFT ASSEMBLY EE 1 52 1 8 FRONT COVER EHNEN 1 77 1 9 CRANKSHAFT VIBRATION DAMDER 1 79 1310 GE e TEE 1 81 teft RING GEAR EE 1 90 Tole CET BEARING manse a e a eee ee 1 94 1 13 ENGINE CRANKING EE 1 96 1 14 FLYWHEEL HOUSING E 1 98 1 15 PISTON PISTON RING AND CONNECTING ROD cccceeeeeeeeeeeeeees 1 100 1 15A EGR PISTON PISTON RING AND CONNECTING POD 1 166 WT Gs VALVES beetebuerg 1 129 eG EE V A LV ES cee oye 2 er aa e EE 1 152 Wed FROG KER CARVE e Er E a e a a 1 157f 1 18 CAMSHAFT AND CAMSHAFT SENSOR cccceeesseceeeeeeeesessteeeeeeeeees 1 157 i REI e E a paar a re ne 1 169 A ADDITIONAL INFORMATION f a an 1 171 All information subject to change without notice 1 2 From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 6 Measure the cylinder liner protrusion from the block in four places once at each slot in the measuring plate
8. 3a 3 Cylinder Liner Changes One difference between the non EGR cylinder liner to the EGR model is a groove on the top part of the cylinder liner which houses the carbon scraper ring See Figure 1 28a The carbon scraper ring for the EGR engine is in the area previously hardened in the non EGR cylinder liner Its purpose is to inhibit coke formation All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 l a 1 3A EGR CYLINDER HEAD AND BLOCK 1 3a 4 Cylinder Block Changes The cylinder block has two additional openings machined in the block There is now an opening near the air compressor housing and an opening flange for attaching the coolant inlet pipe going to the EGR cooler See Figure 1 28c 44012 1 Opening near the air compressor housing 2 Flange for attaching coolant inlet pipe Figure 1 28c EGR Cylinder Block Changes All information subject to change without notice 1 b From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 1 3B EGR FRONT AND REAR LIFTER BRACKETS The front lifter bracket on the non EGR engine was moulded into the coolant pump The EGR engine has separate front and rear lifter brackets NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to l
9. ORPORATION From Bulletin 2 MBE4000 04 1 39 1 3A EGR CYLINDER HEAD AND BLOCK 1 3A EGR CYLINDER HEAD AND BLOCK There are several minor changes in the cylinder liner block and engine lifter brackets between the MBE 4000 EGR engine and the non EGR engine 1 3a 1 EGR Cylinder Head Installation Be aware of the following notice when installing the cylinder head on an EGR engine NOTICE Be sure the carbon scraper ring is seated in the groove on the top part of the cylinder liner before installing a new cylinder head gasket and the cylinder head otherwise component damage can result See Figure 1 28a liner Figure 1 28a Installed Carbon Scraper Ring NOTE All remaining installation procedures for the cylinder head are identical to a non EGR engine 44178 1 Cylinder Liner 3 Installed Piston 2 Carbon Scraper Ring 4 Carbon Scraper Ring located in groove in cylinder All information subject to change without notice 1 40 From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 1 3a 2 Cylinder Head Changes There is also drilling in the head to attach the new EGR cooler support bracket There is hardening at block division face of cylinder head also See Figure 1 28b 44013 1 Drilling to attach the EGR Cooler Support Bracket 2 Hardening at Block Division Face Figure 1 28b EGR Cylinder Head Changes 1
10. Push the piston and connecting rod assembly out of the cylinder liner 3 Follow remaining steps for non EGR engine piston removal Refer to section 1 15 1 1 15a 2 Piston Installation for EGR Engine Perform the following steps to install the piston in an EGR engine NOTICE The carbon scraper ring has a smaller internal diameter than the piston skirt diameter therefore the piston installation and removal must be carried out with the carbon scraper ring uninstalled or removed NOTE Piston installation in the EGR engine is performed with the engine facing upright not turned on it s side 1 Install J tool J 47110 to the cylinder block See Figure 1 98b d d 1 J 47110 W J 45983 e oS a 44113 1 Piston Figure 1 98b Installation of Piston NOTE There are NO arrows on the top of the EGR piston to direct the installation The piston can be installed in any direction and it will be correct All information subject to change without notice 1 167 From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 2 Push the piston into cylinder liner using ring compressor J tool J 45983 to compress the piston rings Clean the carbon scraper ring seat in the cylinder liner 4 After piston is installed install carbon scraper ring in the cylinder liner groove See Figure 1 98a 5 Check carbon scraper ring for correct fit after installation
11. ct to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 1 157 1 17 ROCKER ARM 1 17 ROCKER ARM Perform the following procedures for removal and installation of the rocker arm 1 17 1 Rocker Arm Removal Remove the rocker arm assembly as follows 1 Remove the cylinder head cover on each cylinder head Refer to section 1 1 1 2 Remove the rocker arm assembly See Figure 1 117 42077 1 Cylinder Head Cover 4 Intake Valve Bridge 2 Rocker Arm Mounting Bolt 5 Exhaust Valve Bridge 3 Rocker Arm Assembly 6 Pushrod Figure 1 117 Rocker Assembly a Loosen the each valve lash adjusting screw b Remove each rocker arm mounting bolt c If removing more than one rocker arm assembly mark the assembly with a paint pen to identify it on installation d Remove the rocker arm assembly from the cylinder head 3 Inspect the rocker arm assembly for wear If necessary disassemble the rocker arm assembly and replace any worn parts Refer to section 1 17 2 All information subject to change without notice 1 f From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 1 18AEGR CAMSHAFT The removal installation and inspection of the EGR camshaft is the same as in the non EGR engine except for the following
12. er A Valve seat diameter at the contact surface of the cylinder head B _ Valve head diameter C All information subject to change without notice 1 152 From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL Valve seat height D Valve seat width at the valve head E Valve seat angle F Valve length G A VALVE STEM DIAMETER B VALVE SEAT DIAMETER AT HEAD CONTACT SURFACE C VALVE HEAD DIAMETER D VALVE SEAT HEIGHT E VALVE SEAT WIDTH AT VALVE HEAD F VALVE SEAT ANGLE G VALVE LENGTH Figure 1 116b Critical Dimensions Valve Stem and Head for EGR Engines Description Intake mm in Exhaust EPA 98 Exhaust EPA 04 mm in mm in Valve stem diameter A 8 935 8 950 0 3518 8 925 8 940 0 3514 8 925 8 940 0 3514 0 3524 0 3520 0 3520 Valve seat diameter a 42 0 1 65 39 0 1 54 39 0 1 54 head contact surface B Valve head diameter C 45 4 45 6 1 79 1 80 40 9 41 3 1 61 1 63 41 9 42 3 1 65 1 67 Valve seat height new D 3 1 3 3 0 12 0 13 2 8 3 1 0 11 0 12 3 0 3 3 0 12 0 13 Minimum valve seat 2 9 0 11 2 3 0 09 2 9 0 11 height after grinding D Valve seat width at valve 3 5 4 5 0 14 0 18 3 5 4 5 0 14 0 18 min 3 5 0 14 head E Valve seat angle F 30 degrees 45 degrees 36 degrees Valve length G 145 0 5 71 145 0 5 71 145 0 5 71 Table 1 43a Valve Removal installati
13. guides and valve stems 2 Remove the keeper spring retainer valve spring and spring seat 3 Remove the valve stem seal and discard 4 Remove the valve 5 Remove the valve stem sealing ring and discard Repeat procedure for all remaining valves ER Clean all parts before reinstalling components 7 Install the valve stem sealing ring in the valve guide and then install the valve in the head Repeat procedure for all remaining valves All information subject to change without notice 1 154 From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 8 Lubricate the valve stem and valve stem seal installer protector J 46174 with a light coating of clean engine oil M 46184 1 re J 46174 s 44185 1 Valve Stem Seal 3 Valve Guide 2 Valve Stem 4 Valve Stem Sealing Ring installed Figure 1 116c Valve Stem Seal and Sealing Ring Replacement NOTE The installer protector prevents the groove on the valve stem from damaging the valve stem seal 9 Push the valve stem seal installer protector J 46174 over the valve stem until it makes contact with the valve 10 Slide the valve stem seal over the installer protector and the valve stem Using fingers press valve stem seal into place until the seal seats on the valve guide 11 Remove J tool J 46174 12 Using valve guide seal installer J 46184 and the appropriate hammer drive the
14. ift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 1 3b 1 Removal of Front and Rear Lifter Brackets Perform the following steps to remove the front and rear lifter brackets 1 Remove the four M10 x 25 mm mounting bolts from the front lifter bracket and remove the bracket See Figure 1 28d 2 pt a F po P h 7 1 44138 1 Front Lifter Bracket Mounting Bolts 2 Front Lifter Bracket Figure 1 28d Removal Installation of Front Lifter Bracket All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 l c 1 3B EGR FRONT AND REAR LIFTER BRACKETS 2 Remove the two bolts from the rear lifter bracket See Figure 1 28e 4 Gx SC a ay formar i a i Ge ppc fy 1 Rear Lifter Bracket Mounting Bolts 3 Rear Lifter Bracket 2 Vent Line Bracket Figure 1 28e Removal Installation of Rear Lifter Bracket 3 Remove the vent line bracket 4 Remove the rear lifter bracket 1 3b 2 Installation of Front and Rear Lifter Brackets Perform the following steps to install the front and rear lifter brackets 1 Install the front lifter bracket using the four M10 x 25 mm mounting bolts See Figure 1 28d 2 Torque the four bolts to 60 N m 44 lb ft 3 Install the rear lifter bracket using two mounting bolts See Figure 1 28e 4 Torque the two bolts to 200 N m 147 5 lb ft
15. minor changes 1 18a 1 EGR Camshaft Changes In the EGR engine there is a possibility of installing the camshaft bushings in an inverted wrong position NOTICE If the EGR camshaft bushings are installed in an inverted wrong channel position there is potential for engine damage due to lack of lubrication The holes in the camshaft journal must be lined up with the holes in the camshaft bushing O 44236 1 Bushing Groove Figure 1 127 Camshaft Bushing Installation All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 1 169 1 18A EGR CAMSHAFT This page intentionally left blank All information subject to change without notice 1 170 From Bulletin 2 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION
16. on Specifications in mm in All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 2 MBE4000 04 1 153 116A EGR VALVES 1 16a 2 Valve Installation in the EGR Engine Perform the following steps in installing the valves in the EGR engine 1 Install the valve stem sealing ring in the valve guide in the cylinder head 2 Lubricate each valve with a light coating of engine oil 3 Install the valves in order as marked on removal NOTE In the EGR engine always replace the valve stem seal and valve stem sealing ring if the valve has been removed Check the valve stem seal to make sure it is correctly seated on the valve guide 4 Using tool J 46174 install new valve stem seals and seat the valve stem seal with J tool J 46184 Refer to section 1 16a 3 5 Using the adaptor J 46173 install the spring seats springs spring retainers and collets keepers Check the keepers to be sure they are locked in place 6 Remove the adaptor J 46173 from the cylinder head 7 Install the cylinder head 1 16a 3 Valve Stem Seal and Valve Stem Sealing Ring Replacement in the EGR Engine Replace the valve stem seal and valve stem sealing ring as follows NOTE In the EGR engine always replace the valve stem seal and valve stem sealing ring if the valve has been removed 1 Remove the cylinder head from the engine NOTE Use care during removal to not damage the valve
Download Pdf Manuals
Related Search