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1. 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 3 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine Rev 0311 All information subject to change without notice 14 130 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL b If lack of power occurred during the test drive shut down the engine Check for high fuel pressure refer to section 14 13 3 14 13 3 Troubleshooting Procedure for High Fuel Pressure To determine if high fuel pressure is causing a lack of power perform the following steps 1 Remove the fuel temperature sensor See Figure 14 19 1 Fuel Temperature Sensor 2 Engine Wiring Harness Figure 14 19 Disconnecting the Sensor All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 131 14 13 LACK OF POWER 2 Install the adaptor KM 541 589 00 91 00 banjo fitting and high pressure line KM 123 589 04 21 18 See Figure 14 20 PO say GE KM 541 589 00 91 00 is AF a gt PINE AN aes 1 Banjo Fitting 2 Solenoid Unit Pump Figure 14 20 Connecting the Adaptor
2. Perform the following steps to replace inoperative thermo modulated fan 1 Replace inoperative thermo modulated fan refer to OEM guidelines 2 Verify thermo modulated fan replacement refer to section 14 15 13 1 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 165 14 15 HIGH ENGINE COOLANT TEMPERATURE 14 15 13 1 Test Engine with Replaced Thermo modulated Fan Perform the following steps to determine if thermo modulated fan replacement resolved high engine coolant temperature To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F0 no further troubleshooting is required Shut down the engine b If
3. 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 1 Start and vary engine speed between 1800 2100 rpm 2 Stop the engine and measure oil pressure a If the oil pressure is correct no further troubleshooting is required Shut down the engine b If the oil pressure at rated speed is less than 250 kPa 36 psi shut down the engine Check lubricating oil viscosity refer to section 14 14 3 14 14 3 Troubleshooting Procedure for Improper Lubricating Oil Viscosity To determine if improper lubricating oil viscosity is causing low oil pressure perform the following steps 1 Acquire a lubricating oil sample from the engine oil pan 2 Submit oil sample for an ASTM test analysis a Ifengine oil sample meets ASTM specifications check to determine if lubricating oil is diluted with fuel or coolant refer to section 14 14 5 b If engine oil sample did not meet ASTM specifications refer to section 14 14 4 14 14 4 Lubricating Oil Replacement Perform the following steps to replace engine oil Rev 0311 All information subject to change without notice 14 146 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 1 Drain and refill engine with new lubricating oil listed in Table 14 36 2 Verify lubricating oil replacement refer
4. tests have shown that during the first hour after full load operation the engine actually cools down at a faster rate when idling than when turned off Therefore perform the following step to increase fuel economy 1 Minimize engine idling 14 17 3 Troubleshooting Guidelines for Fuel Economy in Cold Weather It is not uncommon to experience a loss in fuel economy during the winter Cold ambient conditions bring on more engine idling increased resistance in moving parts such as engine transmission and axle due to fluid viscosity increase There is also the issue of winter blended fuel Blended fuel typically does not contain as much energy as summer fuel Therefore it takes more fuel to move the equipment Tests have shown that there can be as much as a 7 penalty in fuel economy due to blended fuels Therefore perform the following step to save on fuel economy 1 Fuel economy comparisons must be made for the same yearly time frame Rev 0311 All information subject to change without notice 14 178 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION
5. CORPORATION From Bulletin 11 MBE900 03 14 141 14 13 LACK OF POWER To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check for high inlet air temperature refer to section 14 13 14 14 13 14 Troubleshooting Procedure for High Inlet Air Temperature To determine if high inlet air temperature is causing lack of power perform the following steps 1 Test check the radiator fan fan drive or fan shroud for proper operation or configuration refer to OEM guidelines a If the radiator fan fan drive or fan shroud pass the OEM test check camshaft timing refer to section 14 13 16 b If the radiator fan drive or shroud did not operate correctly refer
6. If coolant or fuel are not present check for a faulty oil pressure gauge refer to section 14 14 7 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 147 14 14 LOW OIL PRESSURE b If coolant or fuel are present refer to section 14 14 6 14 146 Contaminated Lubricating Oil Resolution Perform the following steps to resolve contaminated lubricating oil 1 If coolant is present consider head gasket replacement and repair as required 2 If fuel is present consider fuel nozzle replacement and repair as required 3 Drain engine oil pan 4 Refill engine crankcase with new oil 5 Verify lubricating oil replacement refer to section 14 14 6 1 14 14 6 1 Test Replaced Lubricating Oil Perform the following steps to determine if replaced lubricating oil resolved low oil pressure To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start a
7. for Abnormal Radiator Coolant Flow To determine if abnormal radiator coolant flow is causing high engine coolant temperature perform the following All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 169 14 15 HIGH ENGINE COOLANT TEMPERATURE 1 Install a sight glass with string both ends to the radiator outlet hose near radiator and before fill and heater return lines see Figure 14 23 STRING SIGHT GLASS Figure 14 23 Radiator Flow Check Rev 0311 All information subject to change without notice 14 170 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION 2 3 MBE 900 SERVICE MANUAL To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 Start and run the engine at full load Observe the string for flow and direction as well as the fill and bleed lines Continue observation while varying the en
8. of all clogging debris or excessive dirt refer to OEM guidelines 2 Verify exterior radiator repair refer to section 14 16 5 1 14 16 5 Radiator Shroud Repair Perform the following steps for radiator shroud repair 1 Repair or replace damaged radiator shrouding refer to OEM guidelines 2 Verify exterior radiator repair refer to section 14 16 5 1 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 175 14 16 LOW COOLANT TEMPERATURE 14 16 5 1 Test Engine with Repaired Exterior Radiator and Shrouding To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Run the engine through its operating range with no load condition for approximately five minutes allowing the engine coolant to reach normal operating range a Ifthe engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is req
9. 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 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If lack of power did not occur during the test drive no further troubleshooting is required Shut down the engine b If lack of occurred during the test drive shut down the engine Check for a restricted air cleaner element refer to section 14 13 7 14 13 7 Troubleshooting Procedure for Restricted Air Cleaner Element To determine if a restricted air cleaner element is causing lack of power perform the following steps 1 Remove the air filter element from the air cleaner container refer to OEM guidelines 2 Visually inspect the air cleaner element for damage or clogging a Ifno damage or clogging is found check the charge air cooler refer to section 14 13 9 b If damage or clogging is found refer to section 14 13 8 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 137 14 13 LACK OF POWER 14 13 8 Air Filter Element Replacement Perform the following st
10. the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check thermostats refer to section 14 15 14 14 15 14 Troubleshooting Procedures for Faulty Thermostats To determine if faulty thermostats are causing high engine coolant temperature perform the following 1 Remove thermostat from the thermostat housing refer to section 5 4 1 2 Inspect thermostat for correct operation refer to section 5 4 1 1 a If thermostat is fully open at 95 C 203 F check water pump refer to section 14 15 16 b If thermostat is not fully open at 95 C 203 F refer to section 14 15 15 Rev 0311 All information subject to change without notice 14 166 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 14 15 15 Thermostat Replacement Perform the following steps to replace thermostats 1 Install new thermostat refer to section 5 4 2 2 Verify replaced thermostat refer to section 14 15 15 1 14 15 15 1 Test Engine with New Thermostat Perform the following steps to determine if thermostat replacement resolved high engine coolant temperature To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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
11. to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 129 14 13 LACK OF POWER a If air bubbles are not present shut down the engine check for high fuel pressure refer to section 14 13 3 b If air bubbles are present shut down the engine refer to section 14 13 2 14 13 2 Aerated Fuel Resolution Perform the following steps to resolve aerated fuel condition 1 Tighten all fuel line connections between fuel tank and fuel pump refer to OEM guidelines 2 Visually inspect all fuel lines between fuel tank and fuel pump for leaks 3 Repair damaged components as required refer to OEM guidelines 4 Verify aerated fuel resolution refer to section 14 13 2 1 14 13 2 1 Test the Engine with Aerated Fuel Resolution Perform the following steps to determine if aerated fuel resolution has resolved lack of power condition To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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
12. 14 TROUBLESHOOTING Section 14 1 14 2 14 3 14 4 14 5 14 6 14 7 14 8 14 9 14 10 14 11 14 12 14 13 14 14 14 15 14 16 14 17 Page TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM reke Nesen 14 3 GENERAL TROUBLESHOOTING a 226e secu chs eee eis 14 10 FUEL INJECTION TROUBLESHOOTING c cccccceeeesteeeeeeeeessteeeeeeees 14 23 MISFIRING CYLINDER suv re an 14 47 STARTING DIFFICULTY ENGINE ROTATES c cccccceesssseteeeeeeeeeees 14 57 NO START ENGINE WILL NOT ROTATE cccccccssssteeeeeeeseeeseeenees 14 78 EXCESSIVE OIL CONSUMPTION senda dasadcbedecest eae etade 14 86 EXCESSIVE CRANKCASE PRESSURE cccccccsssseeeeeeeeeeseteeeeeees 14 95 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY rrrrrrrrrnrrnnvvvnvrrrennn 14 103 EXCESSIVE BLUE SMOKE sisictiecricetsstancnnct aura Sonicuntsnisen retecura ibccnpieoneet 14 112 EXCESSIVE WHITE SMOKE ba sic ncoss ea cnc cece SuceSestsbieel game 14 116 ROUGH RUNNING OR STALLING orrrrrrnnnnnrvvnnerrrrnnnnrrnnnnnsssnrrsnnvvvnnessennn 14 123 LAGK OE POWER svare 14 129 LOW OIL PRESSURE ass 14 145 HIGH ENGINE COOLANT TEMPERATURE ccccccccesseeeeeeesseesseenees 14 158 LOW COOLANT TEMPERATURE saadan see 14 173 POOR FUEL ECONOMY Laser hist 14 177 Rev 0311 All information subject to change without notice 14 2 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 14 13 LACK OF POWER The
13. 5 18 Cylinder Head Gasket Replacement Perform the following steps to replace cylinder head gasket 1 Remove and replace cylinder head gasket refer to section 1 2 2 2 Verify new cylinder head gasket replacement refer to section 14 15 18 1 14 15 18 1 Test Engine with Replaced Cylinder Head Gasket Perform the following to determine if cylinder head gasket replacement resolved high engine coolant temperature To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a Ifthe engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check radiator coolant flow refer to section 14 15 19 14 15 19 Troubleshooting Procedure
14. 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a Ifthe engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check water pump refer to section 14 15 16 14 15 16 Troubleshooting Procedure for Faulty Water Pump To determine if a faulty water pump is causing high engine coolant temperature perform the following 1 Remove the water pump and inspect pump for failed shaft or rotor All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 167 14 15 HIGH ENGINE COOLANT TEMPERATURE 2 Replace water pump if damaged 14 15 16 1 Test Engine with Replaced Water Pump Perform the following steps to determine if thermo modulated fan replacement resolved high engine coolant temperature To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the w
15. Overflow Valve 2 Bypass to Fuel Return Port 5 Metering Valve 3 Nozzle Holder Figure 14 22 Metering Valve Location 3 Verify metering valve replacement refer to section 14 13 4 1 14 13 4 1 Test the Engine with Replaced Metering Valve Perform the following steps to determine if the replaced metering valve has resolved lack of power condition All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 135 14 13 LACK OF POWER To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 3 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lac
16. Rev 0311 All information subject to change without notice 14 132 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION KM 123 589 04 21 18 42904 MBE 900 SERVICE MANUAL 3 Attach a calibrated gauge KM 541 589 02 21 00 capable of reading 0 100 Ib in to the high pressure fuel line KM 123 589 04 21 18 leading to the tee fitting See Figure 14 21 KM 541 589 02 21 00 42902 ee KM 123 589 04 21 18 1 Engine Trim Panel 3 Fuel Temperature Sensor 2 Engine Wiring Harness Figure 14 21 Attaching the Calibrated Gauge All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 133 14 13 LACK OF POWER A CAUTION To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked A CAUTION 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 4 Start and run the engine to the speeds listed in Table 14 35 and record the
17. aced coolant system hoses refer to section 14 15 9 1 14 15 9 1 Test Engine with Replaced Coolant Hoses Perform the following to determine if the new coolant hoses resolved high engine coolant temperature To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range and visually examine replaced hoses for any leaks a If the engine coolant temperature is 82 105 C 180 221 F and no leaks are found no further troubleshooting is required b If the engine coolant temperature is 82 105 C 180 221 F and leaks are found repair the leaks refer to section 14 15 9 Shut down the engine c If the engine coolant temperature is not 82 105 C 180 221 F and no leaks are found shut down the engine Check fan belt refer to section 14 15 10 14 15 10 Troubleshooting Proce
18. ate 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 4 Start and run the engine 5 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 6 Run the engine speed to full load a If the exhaust back pressure at full load is less than 12 kPa 3 5 in Hg check for high inlet air temperature refer to section 14 13 14 b If the exhaust back pressure at full load is 12 kPa 3 5 in Hg or greater refer to section 14 13 13 14 13 13 Engine Exhaust System Resolution Perform the following steps to resolve the engine exhaust system concern 1 Visually inspect the engine exhaust system refer to OEM guidelines 2 Repair or replace defective exhaust system components refer to OEM guidelines 3 Verify exhaust system resolution refer to section 14 13 13 1 14 13 13 1 Test the Engine with Replaced Exhaust System Perform the following steps to determine if replaced engine exhaust system components have resolved the lack of power condition All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL
19. avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Check the engine oil level Listed in Table 14 36 4 Cylinder Engines 6 Cylinder Engines Oil Pan Capacity 16 L 17 qt 29 L 31 qt In standard pan including oil filter Table 14 36 Lubricating Oil Capacity a Ifthe engine oil level is correct check lubricating oil viscosity refer to section 14 14 3 b If the engine oil level is incorrect refer to section 14 14 2 14 142 Low Engine Oil Level Resolution Perform the following steps for low engine oil level 1 Fill engine oil pan to correct level listed in Table 14 36 2 Verify low engine oil resolution refer to section 14 14 2 1 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 145 14 14 LOW OIL PRESSURE 14 14 2 1 Test for Proper Engine Oil Level Perform the following steps to determine if properly filled oil pan has resolved low oil pressure To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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
20. circulation refer to section 14 16 3 b If the thermostat is not fully open at 95 C 203 F refer to section 14 16 2 14 16 2 Thermostat Replacement Perform the following steps to replace thermostats 1 Install new thermostat refer to section 5 4 2 2 Verify replaced thermostat refer to section 14 16 2 1 14 16 2 1 Test Engine with New Thermostat Perform the following steps to determine if thermostat replacement resolved low engine coolant temperature All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 173 14 16 LOW COOLANT TEMPERATURE To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 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 b
21. d with the oil filter housing bypass valve components check for defective pressure relief valve refer to section 14 14 14 b If damage is found with the oil filter housing bypass valve bore replace housing 14 14 14 Troubleshooting Procedure for Defective Pressure Relief Valve To determine if a defective pressure relief valve is causing low oil pressure perform the following steps 1 Remove the pressure relief valve 2 Inspect the oil pressure relief valve a Ifthe relief valve moves freely in the valve body reinstall the oil pressure relief valve Check the pickup tube and screen assembly for defects b If the relief valve will not move freely in the valve body refer to section 14 14 15 14 14 15 Pressure Relief Valve Repair Perform the following steps to repair the pressure relief valve 1 Disassemble the pressure relief valve and replace damaged components 2 Assemble and install the pressure relief valve 3 Verify repair of the relief valve refer to section 14 14 15 1 14 14 15 1 Test Engine with Repaired Relief Valve Perform the following steps to determine if repaired relief valve resolved low oil pressure 1 Install the Diagnostic Data Reader All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 153 14 14 LOW OIL PRESSURE To avoid injury before starting and running the engine ensure the vehicle is par
22. dure for Fan Belt is Incorrectly Adjusted To determine is a misadjusted fan belt is causing high engine coolant temperature perform the following 1 Check the auto tensioner for spring loading All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 163 14 15 HIGH ENGINE COOLANT TEMPERATURE 2 Compare tension to belt specifications a Ifthe belt tension is normal check the thermo modulated fan refer to section 14 15 12 b If the belt tension is not normal refer to section 14 15 11 14 15 11 Belt Tension Resolution Perform the following steps to resolve incorrect belt tension To avoid injury from flying parts when working with components under spring tension wear adequate eye protection face shield or safety goggles To avoid injury to hands and fingers from the spring loaded auto belt tensioner violently snapping back do not cut the belt to remove it 1 Replace the auto tensioner as required 2 Verify belt tension resolution refer to section 14 15 11 1 14 15 11 1 Test Engine with Correct Belt Tension Perform the following to determine if belt tension resolved high engine coolant temperature Rev 0311 All information subject to change without notice 14 164 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL To avoid injury before starting and
23. eaked check the exhaust system refer to section 14 13 12 14 13 10 Charge Air Cooler Replacement Perform the following steps to replace the charge air cooler 1 Remove and replace the charge air cooler refer to OEM guidelines 2 If the intake manifold doesn t leak verify replacement of the charge air cooler refer to section 14 13 11 1 3 Ifthe intake manifold leaks repair intake manifold refer to section 14 13 11 14 13 11 Air Intake Manifold Repair Perform the following steps to repair the air intake manifold 1 Remove the air intake manifold refer to section 7 2 1 2 Inspect the air intake manifold and gaskets 3 Install the air intake manifold with new gaskets refer to section 7 2 2 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 139 14 13 LACK OF POWER 4 Verify repair of the intake manifold refer to section 14 13 11 1 14 13 11 1 Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold To determine if the repairs resolved the lack of power condition perform the following steps To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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
24. ed is less than 250 kPa 36 Ib in check for defective crankshaft main bearing shells refer to section 14 14 18 14 14 18 Troubleshooting Procedure for Defective Crankshaft Main Bearing Shells To determine if defective crankshaft main bearing shells are causing low oil pressure perform the following steps 1 Check main bearing to crankshaft journal clearances a If main bearing shell to journal clearance is within 0 051 0 127 mm 0 002 0 005 in check for defective oil pump assembly refer to section 14 14 20 b If main bearing shell to journal clearance is not within 0 051 0 127 mm 0 002 0 005 in refer to section 14 14 19 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 155 14 14 LOW OIL PRESSURE 14 14 19 Crankshaft Main Bearing Shell Repair Perform the following steps to repair crankshaft main bearing shells 1 Remove and replace defective crankshaft main bearing shells 2 Verify crankshaft main bearing shells repair refer to section 14 14 19 1 14 14 19 1 Test Engine with New Crankshaft Main Bearing Shells Perform the following steps to determine if new crankshaft main bearing shells have resolved low oil pressure To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Diesel engine exhaust and some
25. eps to replace the air filter element 1 Remove and replace the damaged or clogged air filter element refer to OEM guidelines 2 Verify air filter element replacement refer to section 14 13 8 1 14 13 8 1 Test the Engine with Replaced Air Filter Element Perform the following steps to determine if the new air filter element has resolved lack of power To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If lack of power did not occur during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check the charge air cooler refer to section 14 13 9 14 13 9 Troubleshooting Procedure for Restricted or Cracked Charge Air Cooler or Leaking Intake Manifold To determine if a restricted or cracked charge air cooler or leaking manifold is causing lack
26. flange gaskets are found refer to section 14 14 17 14 14 17 Pickup Screen Tube and Screen Assembly Repair Perform the following steps to repair the pickup screen tube and screen assembly Rev 0311 All information subject to change without notice 14 154 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 1 Replace all damaged components identified during inspection and install 2 Verify repairs to pickup screen tube and screen assembly refer to section 14 14 17 1 14 14 17 1 Test Engine with Repaired Pickup Screen Tube and Screen Assembly Perform the following steps to determine if repaired relief valve resolved low oil pressure To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine speed at 1800 rpm 2 Visually examine oil pressure reading a If the oil pressure is correct no further troubleshooting is required b If the oil pressure at rated spe
27. fuel pressure Engine Speed rpm Fuel Pressure kPa psi 600 650 430 62 2500 400 650 58 94 Table 14 35 Fuel Pressure at Various Speeds X 6 7 8 Shut down the engine Remove the adaptor banjo fitting high pressure line and high pressure gauge Reinstall the fuel temperature sensor Analyze the measure fuel pressure readings a If the fuel pressure is within specifications listed in Table 14 35 check for high fuel temperature return refer to section 14 13 5 b If the fuel pressure is greater than specifications listed in Table 14 35 refer to section 14 13 4 14 13 4 Metering Valve Replacement Perform the following steps to replace the metering valve 1 Remove the metering valve from the fuel return line Rev 0311 All information subject to change without notice 14 134 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 2 Install a new metering valve See Figure 14 22 FLOW TEST AT FUEL FILTER 6 FLOW TEST AT NOZZLE HOLDER FUEL DELIVERY SUB SYSTEM LOW PRESS SIDE DOWNSTREAM OF FUEL PUMP amp FILTER lt m B FUEL DELIVERY SUB SYSTEM HIGH PRESS SIDE DOWNSTREAM OF UNIT PUMPS wa C FUEL RETURN SUB SYSTEM FROM LEAK LINE 44018 1 Unit Pump 4 Check
28. gine speed between 1800 2400 rpm a Ifa balanced coolant flow is observed in the sight glass call Detroit Diesel Technical Service Group Shut down the engine b Ifa balanced coolant flow is not observed in the sight glass refer to section 14 15 20 Shut down the engine 14 15 20 Abnormal Radiator Coolant Flow Resolution Perform the following steps as necessary to resolve abnormal radiator coolant flow L 2 3 4 5 Correct bleed line size refer to OEM guidelines Correct fill line size or connector fitting size refer to OEM guidelines Correct restrictive top tank opening refer to OEM guidelines Correct location of standpipe refer to OEM guidelines Verify repairs made to correct abnormal radiator coolant flow refer to section 14 15 20 1 14 15 20 1 Test Engine with Resolved Radiator Coolant Flow Perform the following to determine if thermo modulated fan replacement resolved high engine coolant temperature All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 171 14 15 HIGH ENGINE COOLANT TEMPERATURE To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 Alway
29. go excessive idling Vehicle Maintenance Plugged air filter low tire pressure poor wheel alignment brakes dragging Vehicle Cruise Speed Driver Habits Weather Conditions NOTE If any of these variables is not optimized a serious penalty in fuel economy will result Many of these items are out of the operator s control However there are factors that can be controlled and have a major impact on fuel economy 14 17 1 Troubleshooting Guidelines for Vehicle Cruise Speed One of the most common factors that reduces fuel economy is vehicle cruise speed Perform the following step to help increase fuel economy All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 177 14 17 POOR FUEL ECONOMY 1 Maintain cruising speed as low as possible Listed in Table 14 37 are the approximate percentages of fuel economy reduction based on vehicle cruising speed Table 14 37 Fuel Economy Reduction based on Cruising Speed 14 17 2 Troubleshooting Guidelines for Excessive Engine Idling Another factor to consider is excessive engine idling Aside from the fact that the operator is getting 0 mpg during idling combustion is less than ideal This can compromise the efficiency of the turbocharger Regarding the notion that idling maintains cab heat in the winter some
30. heels 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check combustion gases in coolant refer to section 14 15 17 14 15 17 Troubleshooting Procedure for Combustion Gases in Coolant To determine if combustion gases in coolant is causing high engine coolant temperature perform the following 1 Perform a cylinder compression test a If test results are to specifications check radiator coolant flow refer to section 14 15 19 b If test results are not to specifications refer to section 14 15 18 Rev 0311 All information subject to change without notice 14 168 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 14 1
31. k of power occurred during the test drive shut down the engine Check for high fuel temperature return refer to section 14 13 5 14 13 5 Troubleshooting Procedure for High Fuel Temperature Return To determine if high fuel temperature return is causing lack of power perform the following steps 1 Test for high fuel temperature return 2 Analyze the high fuel temperature test results a If the return fuel temperature is less than or equal to 60 C 140 F check for air cleaner restriction refer to section 14 13 7 b If the return fuel temperature is greater than 60 C 140 F resolve the high fuel temperature return condition refer to section 14 13 6 14 13 6 High Fuel Temperature Resolution Perform the following steps to resolve high fuel temperature return Rev 0311 All information subject to change without notice 14 136 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 1 Remove and replace fuel filter s refer to section 2 14 1 2 Verify high fuel temperature repair refer to section 14 13 6 1 14 13 6 1 Test the Engine with Resolved High Fuel Temperature Perform the following steps to determine if high fuel temperature repairs have resolved lack of power condition To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Diesel engine exhaust and
32. ked on a level surface parking 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 and run engine speed at 1800 rpm 3 Visually examine the DDR for oil pressure reading a If the DDR indicates 241 kPa 35 lb in or more at 1800 rpm shut down the engine and disconnect the DDR No further troubleshooting is required b If the DDR indicates less than 241 kPa 35 Ib in at 1800 rpm shut down the engine and disconnect the DDR Check for defective pickup tube and screen assembly refer to section 14 14 16 14 14 16 Troubleshooting Procedure for Defective Pickup Screen Tube and Screen Assembly To determine if a defective pickup screen tube or screen assembly is causing low oil pressure perform the following steps 1 Remove pickup screen tube and screen assembly 2 Visually inspect pickup screen tube and screen assembly a If no tube stress cracks twisted screen tube or cracked flange gaskets are found check for defective crankshaft main bearing shells refer to section 14 14 18 b If stress cracks twisted screen tube or cracked
33. lack of power occurred during the test drive shut down the engine Check camshaft timing refer to section 14 13 16 14 13 16 Troubleshooting Procedure for Incorrect Camshaft Timing To determine if incorrect camshaft timing is causing lack of power perform the following steps 1 Check the camshaft timing refer to section 1 20 1 1 a If the dial indicator reading on the unit pump lobe is 13 8 mm 0 54 in or above no further troubleshooting in required b If the dial indicator reading is not above 13 8 mm 0 54 in check engine timing refer to section 14 13 17 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 143 14 13 LACK OF POWER 14 13 17 Engine Timing Resolution Perform the following steps to resolve incorrect engine timing 1 Perform an engine gear train timing check 2 Verify engine timing resolution refer to section 14 13 17 1 14 13 17 1 Test Engine with Correct Timing Perform the following steps to determine if corrected engine timing has resolved lack of power condition To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 e
34. logging debris and dirt check the pressure control cap refer to section 14 15 6 b If the radiator has excessive clogging debris or dirt refer to section 14 15 4 c Ifthe radiator shrouding is not damaged incorrectly positioned or inadequate check the pressure control cap refer to section 14 15 6 d If the radiator shrouding is damaged incorrectly positioned or inadequate refer to section 14 15 5 All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 159 14 15 HIGH ENGINE COOLANT TEMPERATURE 14 15 4 Exterior Radiator Repair Perform the following for exterior radiator repair 1 Clean the exterior radiator of all clogging debris or excessive dirt refer to OEM guidelines 2 Verify exterior radiator repair refer to section 14 15 5 1 14 15 5 Radiator Shroud Repair Perform the following for radiator shroud repair 1 Repair or replace damaged radiator shrouding refer to OEM guidelines 2 Verify exterior radiator repair refer to section 14 15 5 1 14 15 5 1 Test Engine with Repaired Exterior Radiator and Shrouding Perform the following to determine if exterior radiator and shrouding repair resolved high engine coolant temperature To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Diesel engine exhau
35. mo Modulated Fan Faulty Thermostats Faulty Water Pump Combustion Gases in Coolant Abnormal Radiator Coolant Flow 14 15 1 Troubleshooting Procedure for Improper Engine Coolant Level To determine if improper engine coolant level is causing high engine coolant temperature perform the following 1 Visually inspect the radiator coolant level refer to OEM guidelines a Ifthe radiator coolant level is within approximately 50 mm 2 0 in of the radiator filler neck check for insufficient radiator air circulation refer to section 14 15 3 b If the radiator coolant level is not within approximately 50 mm 2 0 in of the radiator filler neck refer to section 14 15 2 14 15 2 Improper Coolant Level Resolution Perform the following steps to resolve improper coolant level 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 Fill coolant system to correct level refer to section 5 1 1 2 Verify coolant level resolution refer to section 14 15 2 1 14 15 2 1 Test Engine with Proper Coolant Level Perform the following to determine if proper coolant level resolved high engine coolant temperature Rev 0311 All information subject
36. nd run the engine speed at 1800 rpm a If the oil pressure is correct no further troubleshooting is required b If the oil pressure at rated speed is less than 250 kPa 36 psi shut down the engine Check for faulty oil pressure gauge refer to section 14 14 7 Rev 0311 All information subject to change without notice 14 148 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 14 14 7 Troubleshooting Procedure for Faulty Oil Pressure Gauge Sensor To determine if a faulty oil pressure gauge sensor is causing low oil pressure perform the following steps 1 Install the Diagnostic Data Reader To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 and vary the engine speed between 1800 2100 rpm 3 Visually examine the DDR for oil pressure reading a Ifthe oil pressure is greater than or equal to 250 kPa 36 psi at 1800 rpm shut down the engine b If the oil press
37. ngine 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 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Call Detroit Diesel Technical Service Group Rev 0311 All information subject to change without notice 14 144 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 14 14 LOW OIL PRESSURE There are several causes for low oil pressure These probable causes are Improper Engine Oil Level Improper Lubricating Oil Viscosity Lubricating Oil Diluted with Fuel or Engine Coolant Faulty Oil Pressure Gauge Sensor Oil Pressure Gauge Line Obstructed Restricted Oil Cooler Defective Bypass Valve Defective Pressure Relief Valve Defective Pickup Screen Tube and Screen Assembly Defective Crankshaft Main Bearing Shells Defective Oil Pump Assembly 14 14 1 Troubleshooting Procedure for Improper Engine Oil Level To determine if improper engine oil level is causing low oil pressure perform the following steps To
38. of power perform the following steps Rev 0311 All information subject to change without notice 14 138 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL NOTICE To avoid engine damage follow the installation instructions provided with the air to air charge air cooler test kit 1 Attach a WK93 air to air charge air cooler test kit refer to OEM guidelines 2 Disconnect the air inlet hose from the outlet side of the turbocharger compressor housing refer to section 7 4 1 3 Attach the air to air cooler test kit adaptor plug to fit into the hose at the compressor connector refer to OEM guidelines 4 Attach an air pressure hose to the air chuck at the regulator and gradually pressurize the air inlet system to a pressure of 177 kPa 26 Ib in 5 Apply a water and soap solution to each hose connection across the face of the charge air cooler 6 Apply a water and soap solution to the air intake manifold and cylinder head mating surface area 7 Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress leaks a If air leaks are present around the joints replace the charge air cooler refer to section 14 13 10 b If any leaks are present around the air intake manifold replace gaskets and or repair the air intake manifold accordingly refer to section 14 13 11 c If neither charge air cooler nor intake manifold l
39. 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 1 Start and run engine speed to 1800 rpm 2 Visually examine the oil pressure reading a If the oil pressure is correct no further troubleshooting is required Shut down the engine b If the oil pressure at rated speed is less than 250 kPa 36 lb in shut down the engine Check the oil pump assembly refer to section 14 14 20 14 14 20 Troubleshooting Procedure for Defective Oil Pump Assembly To determine if a defective oil pump is causing low oil pressure perform the following steps 1 Remove the oil pump assembly refer to section 4 3 1 2 Manually rotate the oil pump drive gear Rev 0311 All information subject to change without notice 14 156 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL a If the drive gear rotates freely in the pump housing call Detroit Diesel Technical Service Group b If the drive gear did not rotate freely replace the oil pump assembly and verify repair refer to section 14 14 20 1 14 14 20 1 Test Engine with Replaced Oil Pump Assembly Perform the following s
40. on 14 15 7 14 15 7 Pressure Control Cap Resolution Perform the following steps to resolve faulty pressure control cap 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 Remove and replace pressure control cap refer to OEM guidelines 2 Install a new pressure control cap refer to OEM guidelines 3 Verify pressure control cap repair refer to section 14 15 7 1 14 15 7 1 Test Engine with Replaced Pressure Control Cap Perform the following to determine if exterior radiator repair resolved high engine coolant temperature All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 161 14 15 HIGH ENGINE COOLANT TEMPERATURE To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 s
41. ontamination with compressed air 4 Install cleaned oil gauge line refer to OEM guidelines 5 Verify oil gauge line repair refer to section 14 14 10 1 14 14 10 1 Test the Engine with Repaired Oil Gauge Line Perform the following steps to determine if replaced oil pressure gauge resolved low oil pressure Rev 0311 All information subject to change without notice 14 150 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run engine speed at 1800 rpm a If the oil pressure is correct no further troubleshooting in required Shut down the engine b If the oil pressure at rated speed is less than 250 kPa 36 psi shut down the engine Check for restricted oil cooler refer to section 14 14 11 14 14 11 Troubleshooting Procedure for Restricted Oil Cooler To determine if a restricted oil cooler is causing low oil p
42. oots 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check insufficient radiator air circulation refer to section 14 16 3 14 16 3 Troubleshooting Procedure for Insufficient Radiator Air Circulation To determine if insufficient radiator air circulation is causing low engine coolant temperature perform the following 1 Visually examine the radiator and radiator shrouding a If the radiator has excessive clogging debris or dirt refer to section 14 16 4 Rev 0311 All information subject to change without notice 14 174 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL b If the radiator shrouding is not damaged incorrectly positioned or inadequate and if the radiator is absent of clogging debris and dirt then call Detroit Diesel Technical Service Group c If the radiator shrouding is damaged incorrectly positioned or inadequate refer to section 14 16 5 14 16 4 Exterior Radiator Repair Perform the following steps for exterior radiator repair 1 Clean the exterior radiator
43. re are several causes for lack of power These probable causes are Aerated Fuel High Fuel Pressure High Fuel Temperature Return Restricted Air Cleaner Element Restricted or Cracked Charge Air Cooler or Leaking Intake Manifold Faulty Exhaust System High Inlet Air Temperature Incorrect Camshaft Timing 14 13 1 Troubleshooting Procedure for Aerated Fuel To determine if aerated fuel is causing lack of power perform the following steps To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Test for aerated fuel 2 Disconnect the fuel line return hose from the fitting located at the fuel tank refer to OEM guidelines 3 Place the open end of the fuel line into a suitable container 4 Start and run the engine 5 Operate the engine at 1000 rpm 6 Visually check to see if air bubbles are rising to the surface of the fuel that collects within the container All information subject
44. ressure perform the following steps Refer to section 14 14 10 1 for the two emission cautions 1 Start and run the engine at 1800 rpm 2 Run the engine at 1800 rpm with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 88 96 C 190 205 F a Ifthe oil temp sensor is indicating a lubricating oil temperature less than or equal to 110 C 230 F shut down the engine and check for a defective bypass valve refer to section 14 14 13 b If the oil temp sensor is indicating a lubricating oil temperature greater than 110 C 230 F shut down the engine and repair oil cooler refer to section 14 14 12 14 14 12 Oil Cooler Repair Perform the following steps to repair the oil cooler 1 Remove the oil cooler All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 151 14 14 LOW OIL PRESSURE 2 Clean the oil cooler before sludge hardens Flush oil passages with clean hot water 3 Inspect the oil cooler for damage 4 Install repaired oil cooler 5 Verify repair of oil cooler refer to section 14 14 12 1 14 14 12 1 Test Engine with Repaired Oil Cooler Perform the following steps to determine if oil cooler repair resolved low oil pressure To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake i
45. running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a Ifthe engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check thermo modulated fan refer to section 14 15 12 14 15 12 Troubleshooting Procedure for Inoperative Thermo Modulated Fan To determine if an inoperative thermo modulated fan is causing high engine coolant temperature perform the following 1 Test the thermo modulated fan refer to OEM guidelines a If the thermo modulated fan is functioning correctly check thermostats refer to section 14 15 14 b If the thermo modulated fan is not functioning correctly refer to section 14 15 13 14 15 13 Thermo moduluated Fan Replacement
46. s 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 1 Start and run the engine 1800 rpm 2 Run the engine through its operating range with no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 88 96 C 190 205 F a Ifthe DDR indicates 241 kPa 35 Ib in or more at 1800 rpm shut down the engine and disconnect the DDR No further troubleshooting is required b Ifthe DDR indicates less than 241 kPa 35 1b in or more at 1800 rpm shut down the engine and disconnect the DDR Check for defective bypass valve refer to section 14 14 13 14 14 13 Troubleshooting Procedure for Defective Bypass Valve To determine if a defective bypass valve is causing low oil pressure perform the following steps 1 Remove the oil pressure temperature sensor Rev 0311 All information subject to change without notice 14 152 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 2 Inspect the oil filter bypass valve components a Ifno damage is foun
47. s 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Call the Detroit Diesel Technical Service Group Rev 0311 All information subject to change without notice 14 172 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 14 16 LOW COOLANT TEMPERATURE There are several causes for low coolant temperature These probable causes are Faulty Thermostats Insufficient Radiator Air Circulation 14 16 1 Troubleshooting Procedure for Faulty Thermostats To determine if faulty thermostats are causing low engine coolant temperature perform the following steps 1 Remove thermostat from the thermostat housing refer to section 5 4 1 2 Inspect thermostat for correct operation refer to section 5 4 1 1 a If the thermostat is fully open at 95 C 203 F check insufficient radiator air
48. st 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a Ifthe engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine Rev 0311 All information subject to change without notice 14 160 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check the pressure control cap refer to section 14 15 6 14 15 6 Troubleshooting Procedure for Faulty Pressure Control Cap To determine if a faulty pressure control cap is causing high engine coolant temperature perform the following 1 Perform coolant pressure control cap tests a If the cooling system pressure is less than or equal to 62 kPa 9 Ib in check the coolant hoses refer to section 14 15 8 b If the cooling system pressure is greater than 62 kPa 9 lb in refer to secti
49. 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 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check the exhaust system refer to section 14 13 12 14 13 12 Troubleshooting Procedure for a Faulty Exhaust System To determine if a faulty exhaust system is causing lack of power perform the following steps 1 Drill an 11 32 in hole in the exhaust pipe 125 305 mm 5 12 in from the turbocharger exhaust outlet NOTE The tapped hole must be in a comparatively straight area of the turbocharger exhaust outlet 2 Tap the hole to accommodate a 1 8 in pipe plug Rev 0311 All information subject to change without notice 14 140 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 3 Connect a manometer to the tapped hole To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Diesel engine exhaust and some of its constituents are known to the St
50. teps to determine if oil pump replacement resolved low oil pressure To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine speed at 1800 rpm 2 Visually examine the oil pressure reading a If the oil pressure is correct no further troubleshooting is required Shut down the engine b If the oil pressure at rated speed is less than 250 kPa 36 Ib in shut down the engine and call Detroit Diesel Technical Service Group All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 157 14 15 HIGH ENGINE COOLANT TEMPERATURE 14 15 HIGH ENGINE COOLANT TEMPERATURE There are several causes for high engine coolant temperature These probable causes are Improper Engine Coolant Level Insufficient Radiator Air Circulation Faulty Pressure Control Cap Defective Coolant Hoses Fan Belt is Incorrectly Adjusted Inoperative Ther
51. to change without notice 14 158 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a Ifthe engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check for insufficient radiator air circulation refer to section 14 15 3 14 15 3 Troubleshooting Procedure for Insufficient Radiator Air Circulation To determine if insufficient radiator air circulation is causing high engine coolant temperature perform the following 1 Visually examine the radiator and radiator shrouding a Ifthe radiator is absent of c
52. to section 14 13 15 14 13 15 Radiator Fan Drive and Shroud Replacement Perform the following steps to replace the radiator fan drive and or shroud 1 Remove and replace the radiator fan drive and or shroud refer to OEM guidelines 2 Verify replacement refer to section 14 13 15 1 Rev 0311 All information subject to change without notice 14 142 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 14 13 15 1 Test the Engine with Radiator Fan Fan Drive or Fan Shroud Replacement Perform the following steps to determine if replaced radiator fan fan drive or fan shroud resolved lack of power condition To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If
53. to section 14 14 4 1 14 14 4 1 Test Engine with Replaced Lubricating Oil Perform the following steps to determine if replaced lubricating oil resolved low oil pressure To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking 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 1 Start and run engine speed at 1800 rpm 2 Stop the engine and measure oil pressure a If the oil pressure is correct no further troubleshooting is required Shut down the engine b If the oil pressure at rated speed is less than 250 kPa 36 psi shut down the engine Check the lubricating oil for fuel and engine coolant dilution refer to section 14 14 5 14 14 5 Troubleshooting Procedure for Lubricating Oil Diluted with Fuel or Engine Coolant To determine if lubricating oil diluted with fuel or engine coolant is causing low oil pressure perform the following steps 1 Acquire a lubricating oil sample from the engine oil pan 2 Visually examine lubricating oil sample for presence of engine coolant or fuel a
54. uired Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Call Detroit Diesel Technical Service Group Rev 0311 All information subject to change without notice 14 176 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 14 17 POOR FUEL ECONOMY Customer expectations of fuel economy are usually based on past experiences recommendations from colleagues or sales staff and wishful thinking It is paramount that the end user attain reasonable expectations based on sound predictions This can be accomplished with the aid of Detroit Diesel s Spec Manager computer program The program takes into consideration a number of factors such as vehicle design duty cycle and route profile as it predicts real world fuel economy Contact the local Detroit Diesel distributor for Spec Manager support prior to contacting the factory Make sure that there is sound basis for the poor fuel economy complaint This applies to both new and in service vehicles There are many variables which may affect fuel economy Included are Vehicle Frontal Area Vehicle Weight Rolling Resistance Static and rolling Air Resistance Excessive add ons increase air resistance trailer gap too large Engine Speed Tire Size Revs mile Axle Ratio Transmission Gear Ratios Road Surface Cement blacktop gravel Duty Schedule Highway stop and
55. ure is less than 250 kPa 36 psi at 1800 rpm shut down the engine refer to section 14 14 8 14 14 8 Oil Pressure Gauge Sensor Replacement Perform the following steps to replace the oil pressure gauge sensor 1 Remove and replace the oil pressure gauge sensor refer to OEM guidelines 14 14 9 Troubleshooting Procedure for Oil Pressure Gauge Line Obstructed To determine if an oil pressure gauge line obstruction is causing low oil pressure perform the following steps 1 Disconnect oil gauge line from oil pressure gauge refer to OEM guidelines All information subject to change without notice Rev 0311 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 11 MBE900 03 14 149 14 14 LOW OIL PRESSURE 2 Visually inspect oil gauge line for obstructions a If no obstructions are found check to determine if rocker arm shaft plugs are missing new or rebuilt engines only b If obstructions are found refer to section 14 14 10 14 14 10 Obstructed Oil Pressure Gauge Line Repair Perform the following steps to resolve oil pressure gauge line obstructions 1 Remove oil pressure gauge line refer to OEM guidelines 2 Clean oil gauge line by soaking in cleaning solution for five minutes To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure 3 Blow out oil gauge line of residue c
56. ystem or emission control system 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is normal no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not normal shut down the engine Check coolant hoses refer to section 14 15 8 14 15 8 Troubleshooting Procedure for Defective Coolant Hoses To determine if defective coolant hoses are causing high engine coolant temperature perform the following 1 Visually examine cooling system hoses refer to OEM guidelines a If cooling system hoses are not soft deteriorated collapsed or have leaking connections check the fan belts refer to section 14 15 10 b If cooling system hoses are soft deteriorated collapsed or have leaking connections refer to section 14 15 9 14 15 9 Coolant System Hoses Replacement Perform the following steps to resolve worn or damaged coolant system hoses 1 Remove and replace damaged or worn coolant hoses as necessary refer to OEM guidelines Rev 0311 All information subject to change without notice 14 162 From Bulletin 11 MBE900 03 6SE414 0303 Copyright 2003 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 2 Install new coolant hoses as necessary refer to OEM guidelines 3 Verify repl
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