MBE 4000 Block-to-Cylinder H
Contents
1. while a flat cylinder head requires a flat grommet style head gasket cat Mar LS aa 2 Figure 15 Open vent head CYLINDER HEAD AND BLOCK REPAIR RECOMMENDATIONS Units with cylinder head to cylinder block leakage concerns are now repairable In most cases there is no longer any reason to replace engine assemblies The sealing areas are 1 the compression seal around the liner 2 the two coolant holes that are sealed with grommets and 3 the two oil holes that are sealed with grommets See Figure 18 ost gt Figure 18 Critical head sealing areas These five areas are the most important to maintain and qualify to ensure a quality repair The liner height is set by the counterbore cut and sets the proper crush for sealing the combustion chamber as well as the other grommets For high mileage units the recommendation is to set the liner heights to the lower half of the specification this will allow for minor surface imperfection while applying maximum crush on the grommets Reference 08 5 8 If the block surface has become eroded a quality repair can still be achieved The recommendation 15 to remove the liners and the dowel pins before attempting to clean the block deck Using a collet dowel puller will make the job easier See Figure 19 Figure 19 Collet type dowel puller The next step is to stuff shop towels into the push rod holes such that the2. 900 Fluorescent Leak Detection Dye Lite TP 3400 Fluorescent Leak Detection www devcon com Devcon Titanium Putty 10760 www belzona com Belzona 11311 Ceramic R Metal 12 2 2009 Section 1 3 Cylinder Head Section 1 4 Cylinder Block 08 MBE 4000 1 REV EPA04 08 MBE 4000 1 REV EPA07 07 04 MBE 4000 6 01 5 38 05 5 38 08 TS 8Rev 09 75 411 Surface Conditioning Coolant Oil Epoxy Surface Repair Epoxy Surface Repair
3. DETROIT DIESEL DEMAND PERFORMANCE No 09 TS 9Rev December 2 2009 TO Service Locations FROM Technical Support Development SUBJECT MBE 4000 Block to Cylinder Head Joint Repair Information ISSUE Unnecessary replacement of MBE 4000 cylinder blocks REQUIRED ACTION The attached service information has been developed and released to provide the appropriate information for diagnosing and repairing MBE 4000 cylinder blocks at the cylinder head to block joint Critical areas of the MBE 4000 block can now be repaired instead of replacing the entire block cylinder blocks should be repaired using the defined procedures and listed products whenever possible Refer to this guide when doing block to cylinder head joint repairs Note In addition to the steps outlined in this document it is necessary to inspect and verify other components before during and after the repair to ensure the root cause has been corrected Refer to the service manual or TS Letter publications for any operations not covered in this document Refer to the guidelines for reusable parts in the service manual and e Parts Catalog for other part number criteria not covered in this document CONTACT INFORMATION Please contact the Detroit Diesel Customer Support Center at 313 592 5800 or email csc daimler com if you have any questions Detroit Diesel 13400 Outer Drive West Detroit Michigan 48239 4001 DAIMLER MBE 4000 Cylinder Head to Block Joint Re
4. RITERIA Small indications around the induction hardened areas are normal and ARE ACCEPTABLE Small indications in a circular pattern around the combustion chamber are normal and ARE ACCEPTABLE Indications that are NOT ACCEPTABLE include crack that radiates outward from bolt hole valve or passage crack that radiates towards the edge of the head Any crank that radiates from the edge of the head e Any crack between valves bolt holes or passages 09 TS 9Rev 12 12 2 2009 APPENDIX LINER HEIGHT MEASUREMENT SHEET ny 25 P ES T AS 2 z T mi Ps D a T 4 o 4 T 5 5 z 09 TS 9Rev 143 APPENDIX REFERENCE MATERIAL Dated Material as of 11 25 09 www ddcsn com MBE 4000 Service Manual MBE 4000 Service Information Cylinder Block Liner Service Procedure Cylinder Block Liner Service Procedure Cylinder Head Bolts Tightening Stages Technical Service Letter MBE does not recommend the use of Scotch Brite Pads or Sandpaper during engine repairs MBE 4000 Cylinder Head and Gasket Sealing Area Inspection MBE 4000 Coolant Leaks MBE 4000 Cylinder Head and Head Gasket Information www 3m com Roloc Bristle Discs www tracerline com Dye Lite TP 3
5. aining on top of engine Cylinder head cracks and cup plug leaks will also show up as coolant leak witness marks on the sides of the engine block Follow the service manual procedure for pressure checking cylinder heads to validate the heads if suspect leaking is found See Figure 4 Figure 4 Leaking cylinder head cup plug Typically the rear of the cylinder head and the rear cup plug have been more prone to cracks and leaks due to being on the exhaust side and exposed to higher temperatures Cylinder Liner Inspection Units with considerable miles or severe duty cycles may have liners that have loosened in the bore This condition may be evident by erosion and fretting around and under the liner flange With the release of a new liner o ring seal and counterbore cutting tool this concern is completely repairable reference 08 TS 8Rev for complete details on performing this repair See Figure 5 Figure 5 Fretting around cylinder liner from high mileage Oil Leaks Oil leaks that occur above the head to block joint may appear to be problems at this joint but are really not Tracerline offers Dye Lite TP 3400 to assist in finding the origin of oil leakage This product is similar to the product used for coolant but is specially formulated for oil Follow the manufacturers instruction when using any of these products Information and local source of this product can be found at www tracerline com Rocker cover ga
6. etter to use these products sparingly to minimize the removal of excess material These epoxies can also be used fill in pitting found on the seat of the counterbore The sides of the counterbore have minimal effect and should not be a concern if pitting is found there See Figure 22 Contact information for the epoxy can be found at www devcon com and www belzona com gt 7 p pee a zir 7 s Figure 22 Sidewall pitting is not critical After making epoxy repairs to the block surface lightly finish the top deck by using a stone a block AA the side wall area is 8 notan ig 5 and fine emery cloth or by draw filing See Figure 23 Minimum to no metal removal is the goal Figure 23 Draw filing the block deck to obtain a perfect sealing surface After prepping the block deck and during the liner height measurements you can use the same tools to qualify the surfaces at the grommet areas See Figure 24 The areas around the grommets should be within 0 012 mm 0 0005 of the block deck Appendix B is a Liner Height Data Sheet Figure 24 Measuring cylinder liner protrusion Remember to check the alignment of the cylinder heads to each other to avoid exhaust manifold gasket failure Use the proper alignment tool to set the cylinder heads apply a light torque and recheck to ensure the heads have not moved APPENDIX REMAN CYLINDER HEAD ACCEPTANCE C
7. h flat scotch brite pads and oil or diesel fuel to avoid altering the heat treated or machined surface around the combustion seal area Power tool scotch brite pads are not recommended as they may remove metal which could distort these details Reference 01 5 38 Letter See Appendix A for Reman cylinder head acceptance criteria Cylinder Head Gaskets Four different head gaskets have been used over the last several years 1 flat grommet without vent 2 flat grommet with vent 3 raised grommet without vent and 4 raised grommet with vent The last design that Figure 16 Gasket with flat grommet is recommended to be used is the closed vent gasket that matches the flat or recessed grommet hole in the cylinder head Figure 14 shows the closed vent gasket Figure 15 shows the open vent head gasket while Figure 16 shows the flat grommet and Figure 17 shows the raised grommet Figure 17 Gasket with raised grommet Figure 14 Closed vent head gasket Interchangeability Inspection of these parts must happen just prior to the time of assembly to ensure the proper gasket is used with the cylinder head It is possible to have different heads on the same engine for example if a remanufactured service head was used to replace a single head on a prior repair Note head gasket must match the grommet area of the cylinder head Cylinder heads machined with recessed sealing areas require raised grommet style head gasket
8. king around counterbore circumference REPLACEMENT PARTS Cylinder Heads Part numbers for the different cylinder heads can be found in technical service letter 09 TS 11 There are three types of fire decks 1 a very old flat fire deck with no heat treat in the combustion seal area and no recess in the coolant and oil grommet area see Figure 9 2 a heat treated original equipment fire deck cylinder head with flat grommet sealing areas and 3 a heat treated original equipment fire deck cylinder head with recessed grommet sealing areas see Figure 10 This style has four crescent shaped raised sections around the combustion seal These raised areas are done by design and should not be confused or misunderstood for deck warping Figure 9 Cylinder head with recess around oil and coolant grommet areas Figure 10 Head with heat treated combustion area and recessed grommet area The remanufactured cylinder head has a raised bead ring around the combustion seal surface area There will be a gap if a straight edge is placed over this deck as well See Figure 11 F Figure 11 Raised section of combustion sealing area There are also heads with two cup plugs and heads with one cup plug and one solid plug See Figure 12 and Figure 13 Figure 12 Cylinder head with cup plug 2 3 Figure 13 Cylinder head with solid plug Cleaning of the cylinder head fire deck should only be done by hand wit
9. pair Information f x all 2 Ee ins me 8 1 re ay 2 a fr gt Y 4 fe i 4 P 7 a 4 E A j X 2 1 7 4 ye i Ty Leak Diagnosis Cylinder Head and Block Repair CONTENTS DIAGNOS eee re Oe ee 4 Golo Fe ah al eee eee 4 5 5 OUIMCTIOOREGFACKS 6 a 7 19 216 Ne ACS ane 7 Cylinder Mead GASKETS 8 CYLINDER HEAD AND BLOCK REPAIR 9 APPENDIX A REMAN CYLINDER HEAD ACCEPTANCE 10 APPENDIX LINER HEIGHT MEASUREMENT 12 APPENDIX C REFERENGE MATERIAL 13 DIAGNOSIS Coolant Leaks lt is vital that practice methods like pressurizing the coolan
10. r adding the dye Another area that is misdiagnosed for a leaking head gasket is water not coolant seeping from the head gasket vent hole Any water over the top of the engine drains along the block edge towards the back of the block As the water passes by the vent hole a capillary action sucks the water in and drains the water out with the change in engine temperature This is evident by the rust found near the vent hole side during teardown inspections See Figure 2 Figure 2 Head gasket vent hole witness marks Engines built after Serial Number 0460896913 have head gaskets without a vent hole to address this concern Note Water draining from the truck s windshield rain tray may also contribute to this situation Rain tray leaks will generally leave a rusty streak since it Is plain water Head gasket leaks are less rusty in appearance and will generally appear just wet Rain tray leaks are usually location specific on the engine Columbia Century etc will have rusty streaks between cylinders 5 6 because the rain tray hole is directly above that joint between the cylinders In Sterling car haulers the rusty streaks will be up around either cylinders 1 2 or 2 3 because the engine is set farther under the cab in that application Reference Freightliner bulletin 60 140 and Sterling bulletin 60 21 for more info on plugging the rain tray hole See Figure 3 Figure 3 Plugging the rain tray drain hole may reduce water dr
11. sket leaks are the predominate source of oil leaks See Figure 6 This leak will typically be heavy staining of the sides of the block and allow dirt to stick Normal inspection is made difficult by most of the sealing surfaces being hidden behind other components Rocker cover gaskets are reusable therefore tightening of the rocker cover hold down bolts may be the only service required slight Rocker Cover Oil Leak SE 5 Figure 6 Rocker cover oil leak The Constant Throttle Valve line is another possible source of oil leaks to consider The CTV line is hidden behind the EGR cooler and EGR cooler brackets there is a connection on the exhaust face of each head and will leave oil traces down the side of the block See Figure 7 EOE ee es wal a lt 2 ELES AE a a a lt ee os gt i Figure 7 Oil traces from leaking CTV line Counterbore Cracks Counterbore cracking is primarily caused from thermal and stress relief of the cylinder block however these circumferential cracks have no influence on the sealing area and are acceptable for engine overhaul See Figure 8 Any erosion of the counterbore can usually be cleaned up with a light cutting Liner heights are the most important dimension to be maintained for proper sealing Shim thickness must match the cut depth to ensure the appropriate liner height Figure 8 Crac
12. t are used first to assist in determining the root origin of coolant leaks Consider the length of time in service and prior repair history as a guideline for where to look for coolant loss Typically the less time a unit has been in service the more minor the correction will be while the factors for coolant leaks from high mileage units may be corrosion deterioration or lack of cooling system maintenance The coolant vent line is often misdiagnosed as a head gasket leak The coolant vent line is attached to the center top of each cylinder head and is very difficult to see behind the EGR cooler and EGR cooler bracket However any leakage from this coolant vent line will show near the head to block joint and down the side of the block See Figure 1 Figure 1 Typically any leaks from a properly maintained coolant system will show up as the coolant color or white ash if dry A product that has been very successful in assisting to find the origin of a coolant leak is tracer dye Tracerline offers Dye Lite TP 3900 Fluorescent Leak Detection Dye for Coolant Systems Kits are available with dye and a black light Information and local source of this product can be found at www iracerline com Follow the manufacturer s instructions when using this product 1 oz to 6 gal of coolant bring the engine to operating temperature shutdown the engine look for dye traces with a black light It is not necessary to change the coolant afte
13. towel is below the surface but can later be removed with needle nose pliers This will keep any debris from contamination the cam and cam followers Note Remove towels from cylinder block after surface refinishing is complete 3M Roloc Bristle Discs are recommended to remove carbon and surface rust These discs come in three levels of abrasiveness green 50 grit yellow 80 grit and white 120 grit for different purposes See Figure 20 Figure 20 3M Roloc Bristle Disc 2 used for cleaning mating surfaces Severe areas may require tapping or chipping but you must stay away from the grommet sealing areas These areas will typically be the cleanest because they were protected by the grommets and as long as there is no area higher than the grommet sealing areas everything should seal properly Pitted surfaces that are not in a sealing or grommet area should not be a problem but they do look bad and if in question or they are in a sealing area there are epoxy products recommended to repair these areas See Figure 21 Sake Ti Len ert 7 07709 I Figure 21 Repairable block surface using Devcon Titanium Putty 10760 Devcon Titanium Putty 10760 with cleaner is a recommended epoxy for filling in pitting Also Belzona 11311 Ceramic R Metal is considered an industry standard Follow the manufacturer s instruction when using these products It is always b
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