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1. Rev 0304 All information subject to change without notice 3 26 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 4 Remove the coolant inlet tube 3 from the coolant hose 2 and the water pump 6 3 7 2 Install t Remove and discard seal 7 from tube EGR Coolant Inlet Tube Installation he EGR coolant inlet tube as follows See Figure 3 14 for component locations 1 Lubricate new coolant inlet tube seal 7 with lubricant order number 000 989 11 60 and install on inlet tube 2 Inspect the coolant hose 2 for damage and replace if required 3 Install inlet tube in hose 2 and at water pump 6 and secure with bolts 4 and 5 at clamps Tighten bolts to 31 35 N m 23 26 lb ft and tighten hose clamps 4 Install EGR delivery pipe Refer to section 3 8 2 Fill engine with fresh coolant to required level 6 Test engine for leaks refer to section 3 5 2 1 and perform the required steps All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 27 3 8 EGR COOLANT RETURN TUBE 3 8 EGR COOLANT RETURN TUBE 3 8 1 EGR Coolant Return Tube Removal Remove the EGR coolant return tube as follows see Figure 3 15 for component locations 1 Coolant Return Tube 4 Hose 2 Thermostat Housing 5 Bolts 3 Clamp 6 Gasket Figure 32. See Figure 3 10 Rev 0304 All information subject to change without notice From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION 15 16 17 MBE 900 SERVICE MANUAL Install the EGR delivery pipe 3 using a new gasket 2 and two bolts 1 Tighten bolts to 31 35 N m 23 26 lb ft See Figure 3 10 Tighten EGR delivery pipe bolts 4 at lower flange Tighten bolts to 31 35 N m 23 26 lb ft See Figure 3 10 Fill engine with fresh coolant to required levels 3 5 2 1 Testing Engine for Leaks Perform the following steps to test the engine for coolant leaks li 2 3 Check the coolant level and top off if required Check for leaks with the engine running If any leaks are observed shut engine down and make necessary repairs All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 23 3 6 EGR ROTARY VALVE 3 6 EGR ROTARY VALVE 3 6 1 EGR Rotary Valve Removal Remove the EGR rotary valve as follows see Figure 3 13 for component locations 1 Nuts 3 EGR Rotary Valve 2 Gasket 4 EGR Cooler Figure 3 13 Exploded view of Rotary EGR Valve i 1 Drain engine coolant i 2 Remove EGR cooler Refer to section 3 5 1 3 Remove five nuts 1 from EGR rotary valve 3 and remove from EGR cooler 4 Discard gasket 2 See Figure 3 13 NOTE The EGR rotary valve is not servi
3. 15 EGR Coolant Return Tube and Related Components 1 Drain the engine coolant 2 Remove EGR delivery pipe Refer to section 3 9 1 j 3 Remove the two bolts 5 attaching the coolant return tube 1 to the thermostat housing 2 Rev 0304 All information subject to change without notice 3 28 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 4 Loosen the hose clamp 3 on the coolant hose 4 5 Remove coolant return tube 1 from the coolant hose 4 and thermostat housing 2 Discard gasket 6 3 8 2 EGR Coolant Return Tube Installation Install the EGR coolant return tube as follows see Figure 3 15 for component locations 1 Replace gasket 6 and inspect the coolant hose 4 for any damage Replace hose if required Install the coolant return tube 1 to the coolant hose 4 and at the thermostat housing 2 2 Tighten the hose clamps 3 on the coolant hose 4 3 Install and tighten the two bolts 5 attaching the coolant return tube 1 to the thermostat housing 2 Tighten bolts to 31 35 N m 23 26 lb ft 4 Install EGR delivery pipe Refer to section 3 9 2 5 Fill engine with fresh coolant to required level 6 Test engine for leaks refer to section 3 5 2 1 and perform the required steps All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 29
4. 17 4 Remove EGR delivery pipe refer to section 3 9 1 3 10 2 EGR Exhaust Elbow Installation Install the EGR exhaust elbow as follows see Figure 3 17 for component locations i NOTE The EGR cooler end gasket is a one piece gasket Whenever the EGR delivery tube is removed the EGR exhaust elbow must also be removed to replace the gasket If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order to replace the gasket I I 1 Install exhaust elbow 6 in housing 4 2 Install a new gasket on the EGR exhaust housing 4 and secure to the EGR cooler with four bolts 5 Tighten bolts to 31 35 N m 23 26 lb ft 3 Install EGR delivery pipe refer to section 3 9 2 All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 33 3 10 EGR EXHAUST ELBOW Rev 0304 All information subject to change without notice 3 34 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 3 A ADDITIONAL INFORMATION Description Page SPECIFICATIONS EE 3 35 leese EE 3 35 PAP GOVEDO deet hc ue EEN ER 3 36 SPECIFICATIONS Any specifications for special equipment are listed below Air Compressor The specifications for the air compressor torque values are listed in Table 3 1 Air Compressor Mounting Bolts 40 30 Discharge Line Fitting 100 74 Coolant Line Banjo Bo
5. line fitting with pipe thread sealant at the air governor port NOTE Coat the surface between the fitting and port on the air governor Do not put sealant on the surfaces between the fitting and the air line 4 Install the three air line fittings as removed Make sure all fittings receive the proper torque as listed in Table 3 1 All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 11 3 3 1 3 3 3 3 EGR CHARGE AIR INTAKE HOUSING EGR CHARGE AIR INTAKE HOUSING EGR Charge Air Intake Housing Removal i Remove the charge air intake housing as follows see Figure 3 8 for component location 1 2 3 4 3 12 Disconnect the electrical plug connector 5 of the temperature sensor 6 Remove bolt securing the charge air intake housing to support bracket Remove two bolts 3 from the EGR delivery pipe 4 Remove marmon clamp 1 from charge air intake housing 2 Rev 0304 All information subject to change without notice From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 5 Remove the charge air intake housing 2 and seal ring Discard seal ring 1 Marmon Clamp 4 EGR Delivery Pipe 2 Charge Air Intake Housing 5 Electrical Plug Connector 3 EGR Delivery Pipe Bolts 6 Temperature Sensor Figure 3 8 Charge Air Intake Hou
6. to replace the gasket 1 Install a new gasket on the EGR delivery pipe 3 and loosely secure pipe to the EGR cooler 4 with four bolts 6 2 Install a new gasket 2 between EGR delivery pipe 3 and charge air intake 5 and secure with two bolts 1 Tighten bolts to 31 35 N m 23 26 lb ft 3 Tighten the four EGR delivery pipe bolts 6 at EGR cooler 4 to 31 35 N m 23 26 lb ft All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 31 3 10 EGR EXHAUST ELBOW 3 10 EGR EXHAUST ELBOW 3 10 1 EGR Exhaust Elbow Removal Remove the EGR exhaust elbow as follows see Figure 3 17 for component locations 1 EGR Delivery Pipe 4 EGR Exhaust Housing 2 Heat Shield 5 Bolts 3 Bolts 6 EGR Exhaust Elbow Figure 3 17 EGR Exhaust Elbow and Related Components i 1 Remove three bolts 3 from heat shield 2 and remove shield See Figure 3 17 2 Remove four bolts 5 from the lower EGR cooler flange Remove housing 4 and elbow 6 See Figure 3 17 Rev 0304 All information subject to change without notice 3 32 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 3 Remove elbow 6 from housing 4 and inspect seal rings If damaged replace seal rings See Figure 3
7. 1 EGR CA Mixer Housing Removal Remove the EGR CA mixer housing as follows see Figure 3 9 for component locations 1 Remove the charge air intake housing 1 Refer to section 3 3 1 2 Remove the EGR CA mixer housing cover bolts 2 and remove the gasket and cover 3 Discard gasket All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 15 3 4 EGR CA MIXER HOUSING 3 Remove two hexagon socket head head screws 7 securing the EGR CA mixer tube 6 inside the charge air intake housing 1 1 Charge Air Intake Housing 5 Delivery Pipe 2 EGR CA Mixer Housing Cover Bolts 6 EGR CA Mixer Tube 3 EGR CA Mixer Housing Cover 7 Hexagon Socket head Screw 4 Delivery Pipe Gasket I Figure 3 9 EGR CA Mixer Housing Removal and Installation 3 4 2 EGR CA Mixer Housing Installation Install the EGR CA mixer housing as follows see Figure 3 9 for component locations 1 Install EGR CA mixer tube 6 in charge air intake housing 1 with two hexagon socket head screws 7 Tighten screws to 12 14 N m 9 10 lb ft 2 Install charge air housing Refer to section 3 3 2 Rev 0304 All information subject to change without notice 3 16 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 3 5 EG
8. 3 9 EGR DELIVERY PIPE 3 9 EGR DELIVERY PIPE 3 9 1 EGR Delivery Pipe Removal Remove the EGR delivery pipe as follows see Figure 3 16 for component locations 1 Bolts 4 EGR Cooler 2 EGR Delivery Pipe Gasket 5 Charge Air Intake 3 EGR Delivery Pipe 6 Bolts Figure 3 16 EGR Delivery Pipe and Related Components Rev 0304 All information subject to change without notice 3 30 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 1 Remove two bolts 1 and gasket 2 securing EGR delivery pipe 3 to charge air intake 5 Discard gasket NOTE The EGR cooler end gasket is a one piece gasket Whenever the EGR delivery tube is removed the EGR exhaust elbow must also be removed to replace the gasket If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order to replace the gasket 2 Remove EGR delivery pipe 3 and gasket from EGR cooler 4 by removing four bolts 6 Discard gasket 3 9 2 EGR Delivery Pipe Installation Install the EGR delivery pipe as follows see Figure 3 16 for component locations NOTE The EGR cooler end gasket is a one piece gasket Whenever the EGR delivery tube is removed the EGR exhaust elbow must also be removed to replace the gasket If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order
9. 3 SPECIAL EQUIPMENT Section Page 3 1 AIR COMPRESSOR iciise suietincccxtatecaiviasedlatinacsadoniedetussissunbnacsabeuuducroaiens 3 3 Se AIR GOVERNORS srinarendra aie aae gedeelt 3 10 3 3 EGR CHARGE AIR INTAKE HOUSING 3 12 3 4 EGR CA MIXER HOUSING 2 0 ccccccceeeeeesneeeeeeeeesseeeeeeeeeeessseaaeeeeees 3 15 Jo SEG RC OO WE Re ee 3 17 3 0 EGR ROTARY VALVE Aere 3 24 3 7 EGR COOLANT INLET TUBE tee 3 26 3 8 EGR COOLANT RETURN DEIER eegene EE 3 28 3 9 EGR DELIVERY EE 3 30 3 10 EGR EXHAUST ELBOW ee 3 32 3 A ADDITIONAL INFORMATION AAA 3 35 Rev 0304 All information subject to change without notice 3 2 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 3 1 AIR COMPRESSOR The air compressor with a power steering pump attached is driven by a gear on the camshaft Perform the following procedures for removal and installation of the air compressor 3 1 1 Air Compressor Removal Remove the air compressor as follows To avoid injury from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots 1 Drain the coolant 2 Remove the two bolts attaching the power steering pump to the air compressor See Figure 3 1 Figure 3 1 Power Steering Pump NOTE Do n
10. R COOLER 3 5 1 EGR Cooler Removal Remove the EGR cooler as follows 1 Drain the coolant All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 17 3 5 EGR COOLER NOTICE No coolant must escape during disassembly of the coolant inlet line 1 EGR Delivery Pipe Bolts 6 Heat Shield 2 EGR Delivery Pipe Gasket 7 Heat Shield Mounting bolts 3 EGR Delivery Pipe 8 EGR Exhaust Elbow 4 Bolts 9 EGR Exhaust Housing 5 Bolts Figure 3 10 EGR Cooler Removal and Installation i 2 Remove the two bolts 1 from the EGR delivery pipe 3 See Figure 3 10 i 3 Remove four bolts 4 from the EGR cooler upper flange See Figure 3 10 Rev 0304 All information subject to change without notice 3 18 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 4 Remove EGR delivery pipe 3 See Figure 3 10 i NOTE The EGR cooler end gasket is a one piece gasket Whenever the EGR delivery tube is removed the EGR exhaust elbow must also be removed to replace the gasket If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order to replace the gasket I 5 Remove three bolts 7 from heat shield 6 and remove shield See Figure 3 10 6 Remove four bolts 5 fro
11. ary valve 2 See Figure 3 12 14 Remove two bolts 3 securing the EGR cooler 4 See Figure 3 12 NOTE On MBE 904 906 924 and 926 engines the EGR cooler is secured with two brackets with two hose clamps 1 EGR Rotary Valve Electrical Connector 4 EGR Cooler 2 EGR Rotary Valve 5 Clamps 3 Bolts Figure 3 12 EGR Rotary Valve and Related Components All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 21 3 5 EGR COOLER 15 16 17 18 oo ol N 1 zl Sr Oe e a S o 12 LA EE 3 22 Remove the hose clamps 5 on the EGR cooler 4 See Figure 3 12 Remove the EGR cooler 4 with the EGR rotary valve 2 still attached See Figure 3 12 If required remove two EGR cooler lower support brackets by removing two bolts per bracket Remove the EGR rotary valve 2 from the EGR cooler 4 by removing five nuts and gasket Discard gasket See Figure 3 12 EGR Cooler Installation Install the EGR cooler as follows see Figure 3 12 for component location Install the EGR rotary valve 2 and new gasket on the EGR cooler 4 with five nuts Tighten nuts to 31 35 N m 23 26 lb ft If removed install two lower EGR cooler support brackets and secure with two bolts per bracket Tighten bolts to 60 66 N m 44 49 lb ft Install the EGR cooler 4 on lower support bracke
12. ced and must be replaced as an assembly Install the EGR rotary valve as follows See Figure 3 13 for component locations 1 Using a new gasket 2 install the EGR valve 3 to the cooler using the five nuts 1 Tighten nuts to 31 35 N m 23 26 lb ft 3 6 2 EGR Rotary Valve Installation i 2 Install EGR cooler Refer to section 3 5 2 Rev 0304 All information subject to change without notice 3 24 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 3 Fill engine with fresh coolant to required level 4 Test engine for leaks Refer to section 3 5 2 1 All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 25 3 7 EGR COOLANT INLET TUBE 3 7 EGR COOLANT INLET TUBE 3 7 1 EGR Coolant Inlet Tube Removal Remove the EGR coolant inlet tube as follows see Figure 3 14 for componet locations N S d A V Cie Yan a Ne 1 Clamp 5 Bracket Bolt 2 Hose 6 Water Pump 3 Coolant Inlet Tube 7 Seal 4 Bracket Bolt Figure 3 14 EGR Coolant Inlet Tube and Related Components i 1 Remove EGR delivery pipe Refer to section 3 9 1 i 2 Loosen the hose clamps 1 on the coolant hose 2 See Figure 3 14 i 3 Remove the two bolts 4 5 from the brackets securing the coolant inlet tube 3
13. compressor as follows 1 Install the air compressor 2 Install the four air compressor mounting bolts Tighten each bolt 40 N m 30 lb ft 3 Install the three air lines See Figure 3 3 Rev 0304 All information subject to change without notice 3 8 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL a Install the discharge line Make sure the O ring is properly installed on the fitting Tighten the fitting 100 N m 74 lb ft b Install the unloader line Make sure the O ring is properly installed on the fitting c Install the intake air line and tighten the hose clamp 4 Install the two coolant lines a Pay particular attention to the coolant delivery line at the rear of the air compressor It is difficult to line up the bolt and fitting correctly NOTE If necessary to line up the banjo bolt loosen the coolant line that attaches to the rear of the engine NOTE Attach the coolant delivery line to the crank angle position sensor wire with a tie strap b Tighten the banjo bolts on the coolant delivery and return lines 40 N m 30 lb ft 5 Install the cross plate Use grease to hold it in place while installing the power steering pump 6 Install the two bolts attaching the power steering pump to the air compressor Tighten the bolts 40 N m 30 lb ft See Figure 3 1 7 Fill the radiator with coolant All information subject to change without notice Re
14. l information subject to change without notice 3 6 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 4 Install the two locking bolts on the locking device KM 904 589 03 63 00 and tighten them until the air compressor drive is locked and incapable of movement See Figure 3 5 904 589 03 63 00 1 Air Compressor 2 End of Drive Shaft Figure 3 5 Locking the Air Compressor Drive All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 7 3 1 AIR COMPRESSOR 5 Remove the drive gear from the air compressor See Figure 3 6 1 Vise 3 Drive Gear 2 Air Compressor 4 Impact Wrench Figure 3 6 Pulling the Drive Gear a Place the air compressor in a vise Make sure it is tightly secured and cannot slip or slide out of the vise b Place an impact wrench on the drive gear nut and remove the drive nut c Remove the drive gear from the air compressor with a gear puller if necessary 6 Inspect the drive gear for worn or broken teeth spalling and corrosion Replace the drive gear if necessary 7 Install the drive gear and drive nut on the drive shaft of the air compressor Tighten the drive nut 270 N m 200 lb ft 8 Remove the locking device from the air compressor and release the air compressor from the vise 3 1 2 Air Compressor Installation Install the air
15. lts 40 30 270 200 Power Steering Pump Mounting Bolts 40 30 Table 3 1 Air Compressor Torque Values All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 35 Air Governor The specifications for the air governor torque values are listed in Table 3 2 The list of approved pipe thread sealants are listed in Table 3 3 Air Governor Mounting Bolt M8 16 12 Table 3 2 Air Governor Torque Values Protectant Material Approved Brand Pipe Thread Sealant 49 00094 108 Henkel 790 Pipegrip Perma Lok LH 150 Table 3 3 Approved Pipe Thread Sealants Rev 0304 All information subject to change without notice 3 36 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION
16. m the lower EGR cooler flange Remove housing 9 and elbow 8 See Figure 3 10 All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 19 3 5 EGR COOLER 7 Remove elbow 8 from housing and inspect seal rings If damaged replace seal rings See Figure 3 10 Wee di B wk GC KE TE V g x Ak SAY Lat th i A dai R d 5 sD Os E 0 coe SI 5 o alt g e Jk La S ai Ei Ti ff P f Sp ke CS A AW IF 1 Coolant Inlet Tube 5 Hose Clamps 2 Coolant Return Tube 6 Bolts 3 Clamps 7 Coolant Return Tube Clamp 4 EGR Delivery Pipe 8 EGR Cooler Figure 3 11 Coolant Inlet Line and Related Components Remove bolts from clamps 3 securing coolant inlet tube 1 to thermostat housing and air intake manifold See Figure 3 11 9 Loosen two hose clamps 5 from hose on coolant inlet tube 1 m WO oO 10 Remove coolant inlet tube and O ring Discard O ring Rev 0304 All information subject to change without notice 3 20 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 11 Remove two bolts hose and clamps securing EGR coolant return tube 2 to thermostat housing and EGR cooler 8 See Figure 3 11 12 Remove EGR coolant return tube 2 and gasket Discard gasket 13 Remove electrical plug connector 1 from the EGR rot
17. ot remove the power steering lines Tie up the lines and the pump out of the way All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 3 3 1 AIR COMPRESSOR 3 Remove the cross plate between the compressor and the power steering pump See Figure 3 2 1 Air Compressor 8 Copper Washer 2 2 Coolant Return Line 9 Drive Nut 3 Discharge Line air 10 Drive Gear 4 Intake Air Line 11 O ring 5 Unloader Air Line 12 Mounting Bolt 4 qty 6 Coolant Delivery Line 13 Cross Plate 7 Banjo Fitting 14 Power Steering Pump Figure 3 2 Air Compressor Mounting and or Removal 4 Remove the coolant delivery line and coolant return line NOTE The coolant delivery line is attached to the crank angle position sensor wire with a tie strap Cut the tie strap and remove the coolant delivery line Rev 0304 All information subject to change without notice 3 4 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL To avoid injury from the sudden release of a high pressure hose connection wear a face shield or goggles 5 Remove the three air lines See Figure 3 3 A TO AIR GOVERNOR B FROM INTAKE SIDE OF TURBOCHARGER C TO WET TANK OR AIR DRYER IF INSTALLED 1 Discharge Port 4 Unloader Port 2 Unloader Air Line 5 Di
18. scharge Air Line 3 Intake Air Line 6 Air Compressor Figure 3 3 Air Line Attachments a Remove the discharge compressed air line Check the fittings for damage and replace if necessary Check inside the discharge line for carbon deposits If deposits are found replace the discharge line b Remove the unloader line Check the fittings for damage and replace if necessary c Loosen the hose clamp and remove the intake suction air line 6 Remove the four mounting bolts attaching the air compressor to the cylinder block See Figure 3 2 7 Slide the drive gear away from the flywheel Collect any oil that runs out and dispose of it properly All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 5 3 1 AIR COMPRESSOR 3 1 1 1 Air Compressor Inspection Inspect the air compressor as follows 1 Inspect the O rings on the fittings at the air system ports and replace if necessary If the O rings are damaged also replace the fittings 2 Replace the O ring between the power steering pump and the air compressor 3 Install the locking device KM 904 589 03 63 00 on the air compressor at the end of the drive shaft where it connects to the power steering pump This locks the drive shaft to allow removal of the drive nut See Figure 3 4 SS SS 42474J Figure 3 4 Air Compressor Locking Device KM 904 589 03 63 00 Rev 0304 Al
19. sing Removal and Installation 3 3 1 1 EGR Charge Air Intake Housing Cleaning Clean the EGR charge air intake housing as follows 1 Clean sealing surface of the EGR CA mixer housing and discard gasket 2 Clean the sealing surface where the charge air intake housing meets with the air intake housing All information subject to change without notice Rev 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 13 3 3 EGR CHARGE AIR INTAKE HOUSING 3 3 2 EGR Charge Air Intake Housing Installation Install the EGR charge air intake housing as follows see Figure 3 8 for component locations Lubricate new seal with lubricant order number 000 989 11 60 and install on charge air intake housing 2 manifold and secure with bolt Tighten bolt to 31 35 N m 23 26 lb ft 3 Secure charge air intake housing 2 to support bracket with bolt Tighten bolt to 31 35 N m 23 26 lb ft 4 Using a new gasket secure EGR delivery pipe 4 to charge air intake housing 2 with kb 2 Install marmon clamp 1 around charge air intake housing 2 and mount to air intake I two bolts Tighten bolts to 31 35 N m 23 26 lb ft 5 Connect the electrical plug connector 5 to the temperature sensor 6 Rev 0304 All information subject to change without notice 3 14 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 3 4 EGR CA MIXER HOUSING 3 4
20. ts Secure EGR cooler 4 with two bolts 3 Tighten bolts to 31 35 N m 23 26 lb ft Install and tighten clamps 5 on the EGR cooler 4 Install electrical plug connector 1 to the rotary valve 2 See Figure 3 12 Inspect the coolant return hose for any damage Replace hose if required Install the coolant return tube 2 in hose Using a new gasket and two bolts secure to the thermostat housing Tighten bolts to 31 35 N m 23 26 lb ft See Figure 3 11 Tighten hose clamps on coolant hose Install new seal ring on coolant inlet tube 1 See Figure 3 11 Install coolant inlet tube 1 into hose 5 and secure coolant inlet tube with two bolts at clamps 3 Tighten bolts to 31 35 N m 23 26 lb ft See Figure 3 11 Install EGR exhaust elbow 8 with seal rings in EGR exhaust housing 9 and into end of exhaust manifold See Figure 3 10 NOTE The EGR cooler end gasket is a one piece gasket Whenever the EGR delivery tube is removed the EGR exhaust elbow must also be removed to replace the gasket If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order to replace the gasket Using a new gasket install the EGR exhaust housing 9 using four bolts 5 Tighten bolts to 31 35 N m 23 26 lb ft See Figure 3 10 Install heat shield 6 using three mounting bolts 7 Tighten bolts to 12 14 N m 9 10 lb ft See Figure 3 10 Loosely install EGR delivery pipe 3 at upper cooler flange with four bolts 1
21. v 0304 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 4 MBE900 04 3 9 3 2 AIR GOVERNOR 3 2 AIR GOVERNOR The following sections describe the removal and installation of the air governor 3 2 1 Air Governor Removal Remove the air governor as follows 1 Release system air pressure 2 Remove and mark the three air line fittings See Figure 3 7 Inspect all fittings for damage and replace if necessary A FROM AIR COMPRESSOR UNLOADER PORT B TO AIR DRYER IF INSTALLED C TO WET TANK 1 Air Governor 6 Unloader Port Air Compressor 2 Unloader Port Air Dryer 7 Mounting Bracket 3 Reservoir Port 8 Mounting Bolt M8 4 Supply Air Line 9 Unloader Air Line 5 Air Dryer Control Line Figure 3 7 Air Governor Removal and Installation 3 Remove the mounting bolt and remove the mounting bracket from the vehicle with the air governor attached 4 Remove the two bolts holding the air governor to the mounting bracket Rev 0304 All information subject to change without notice 3 10 From Bulletin 4 MBE900 04 6SE414 0303 Copyright 2004 DETROIT DIESEL CORPORATION MBE 900 SERVICE MANUAL 3 2 2 Air Governor Installation Install the air governor as follows 1 Install the air governor on the mounting bracket using the two bolts as removed 2 Install the mounting bracket with the air governor attached on the engine Tighten the M8 mounting bolt 16 N m 12 lb ft 3 Coat each air
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