Mbe4000 service manual

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Using the injector line torque wrench adaptor J , loosen the injector line nuts at the transfer tube and at the injector unit pump.

Using the injector line torque wrench adaptor, J , tighten the injector line nuts at the transfer tube and at the unit pump. Run the engine and check for leaks. Tighten the connections as needed. Shut down the engine and install the engine trim cover.

Page Fuel Injector Nozzle 1. To remove the injector nozzle for one cylinder, do these procedures step by step. To remove all the injector nozzles, repeat each step in these instructions, as applicable, for all six cylinders. Page Fuel Injection System exploded view 5. Remove the thrust bolt and the transfer tube. Discard the old O-ring. Remove the tensioning arm. Cap off or cover the openings in the fuel lines to prevent contamination of the fuel.

Install a new seal ring on the nozzle. NOTE: Take care that the nozzle is installed correctly and is aligned properly with respect to the transfer tube.

Install the retaining bolt in the tensioning arm. NOTE: The tensioning arm insures the correct positioning of the nozzle. Install the charge-air manifold. Install the cylinder head cover s , as removed. Verify correct nozzle before insertion into engine. Page Protective Sleeve 1. Drain the engine coolant into a clean container. If the coolant is clean, save it for later use.

Using the claw-foot wrench 00 07 00 , remove the protective sleeve from the cylinder head. Protective Sleeve 2. Fill the cooling system with clean coolant. Page Ddec Electronic Control Unit 2. Disconnect the batteries. Open the hood. Engine Wiring Harness Heat Exchanger Case Bolt 7.

Fuel Feed Line Vehicle Electrical Connector 2. Pull down on the locking unit to lock it in place. Page Do not modify or tamper with the exhaust system or emission control system.

Close the hood. Then check for normal operation. Page Fuel Heat Exchanger Do not smoke when refueling. Then remove the fuel heat exchanger. NOTE: Do not disassemble the fuel heat exchanger. It cannot be serviced. Connect the batteries. Prime the fuel system. Page Fuel Filter 1. Open the fuel fill cap to release pressure in the fuel system. Replace and tighten the cap. Fuel Return Line 4. O-ring 5. Fuel Filter Cap Fuel Drain Line 6.

Page Tighten the high-pressure lines and repeat the priming procedure. With the engine running, check the fuel filter for leaks. Page Egr Fuel Filter 1. Bracket Mounting Bolts 2. Attach fuel inlet, fuel outlet, and fuel drain connection hoses to the fuel filter. Page Fuel Pump Do not smoke when refueling. Slowly remove the fuel pump from the engine, taking care not to damage the splined shaft on the fuel pump.

Discharge the fuel pump gasket. Page [c] Install and tighten the three socket-head bolts that attach the fuel pump to the cylinder block. With the engine running, check the fuel pump and the rest of the fuel system for leaks. Perform a fuel pressure test. Fuel Outlet Line 2. Fuel Filter Housing 5. Unit Pump 3. This fitting is a component and it can be ordered from Canton PDC under part number Page 29 psi. Check to see if the fuel system is drawing air.

Page Check the fuel pressure valve for a blocked or restricted regulator orifice. Page This test measures the percentage of fuel delivery for each cylinder in order to maintain a smooth operation at idle. Page Refer to section 2. If the condition follows the unit pump, replace the unit pump.

Remove the fuel pump drive gear cover. Apply Loctite sealant and install the cover. Install new gasket and the fuel pump. Page Fuel System Inspection Maximum difference between fuel filter housing 0. Page Additional Information www. Page Oil Pan 3. Loosen all front suspension shackle bolts. Remove the front spring bolts and shock absorber bolts. Using the floor jack, lower the axle to the ground.

Fill Tube Flatwasher 9. Oil Fill Tube Retainer Fill Tube Bolt Remove and discard the oil pan gasket. Save the bolts. Thoroughly clean the pan. Remove all traces of gasket material from the pan and from the block. Install the standoff bracket, as removed. Tighten the locknuts until firm. Page Oil Dipstick NOTE: Do not fill beyond the maximum fill level on the dipstick, since overfilling may result in high oil consumption.

Page Oil Spray Nozzle J or 00 63 Rotate the crankshaft to gain access to the nozzles. Page Remove the oil spray nozzle from the engine. Page [c] Set the nozzle so that the tip of the nozzle fits, without tension, into the cup of the setting rod. If necessary, bend the nozzle gently until it fits easily. Fill the crankcase to the specified oil level. Do not overfill the crankcase. Page Egr Camshaft Lubrication Sprayer 1. Install the lubrication sprayer to block with injector unit pump lubricator bolt.

Page Oil Pump [b] Remove the two bolts attaching the sump pipe to the oil pump. Discard the gasket. Remove the bolt attaching the oil pump to the cylinder block. Remove the oil pump from the oil pan. Thoroughly clean the contact surfaces of the oil pump and cylinder block. Page Replace any worn or damaged parts.

NOTE: If either the idler gear or pump drive gear needs replacing, replace both gears as a set. Heat the drive wheel to approximately F 80 C in a hot water tank. Seat the idler gear in the pump housing. Install the face plate on the pump housing. Page [g] Repeat this procedure for the idler gear. Install the oil pump in the cylinder block. Check the engine oil level and add oil if necessary. Page EGR engine. Page Oil Filter 1. Clean the outside of the oil filter housing, then unscrew the oil filter cap from the housing.

Insert a new filter element into the housing. Install the oil heat exchanger and new gaskets on the heat exchanger housing. Page [a] Clean the mating surfaces of the heat exchanger housing and the cylinder block. Remove any bits of adhering gasket material.

Connect the coolant pump shunt line to the coolant pump inlet pipe. Fill the cooling system. Connect the wiring harness at the oil temperature sensor. Using a new O-ring if necessary , install the oil filter cap.

Start the engine. Check the gauge for the correct oil pressure; check the lubrication system for leaks. Check and add engine oil as needed. Page Aadditional Information 3. Page inch Projection of Pump Drive Gear 0. Page www. Page Cooling System 1. Cap 3. Low-Coolant- Level Probe 2. Surge Tank Figure Surge Tank 2.

Open the water regulating valve for the heating system. Drain the coolant from the radiator. Cooling system capacity is listed in Table Figure Coolant Drain Plug All information subject to change without notice. Page Make sure the coolant can flow unobstructed into the receptacle. Page [b] Add coolant up to the maximum fill level on the surge tank.

Check the coolant level and check the cooling system for leaks. Page [c] Check the coolant level and add more coolant if necessary. Close and tighten the cap on the surge tank. Page Coolant Pump 2. Remove the fan. Release the tension on the main drive belt and the fan belt and set the belts aside All information subject to change without notice. Remove the upper alternator mounting bolt, loosening the alternator enough to tilt it out of the way.

On both the coolant pump and the cylinder block, clean the sealing surfaces where the gasket was attached of any adhering bits of gasket material. Using a puller, pull the coolant pump hub away from the bearing. Puller 3. Coolant Pump Housing 2.

Hub Figure Pulling the Hub All information subject to change without notice. Snap Ring 5. Sleeve Seal 3. Drive Shaft and Bearing Assembly 6. Impeller Figure Coolant Pump Assembly exploded view All information subject to change without notice.

Page Inspect the coolant pump unit as follows: 1. Check all coolant pump components for signs of damage. Replace any damaged components.

Press the drive shaft and bearing assembly into the coolant pump housing. Drive Shaft 2. Page [b] Press the hub onto the drive shaft, while holding the bearing and drive shaft assembly to prevent it from turning. Make sure the hub is flush with the end of the drive shaft. Page Pressing in the Impeller NOTE: Secure both the drive shaft and hub to prevent them from turning while the impeller is being installed.

Install the fan. Fill the engine with coolant, as removed, and check for leaks. EGR Coolant Pump 2. Remove the belt tensioner from the front idler and tensioner support. Install the front idler and tensioner support on the cylinder block. Install the belt tensioner on the support.

Release the tension on the main belt tensioner and install the main drive belt. Release the tension on the fan belt tensioner and install the fan belt. Page Thermostat 4. O-ring 2. Thermostat Housing 5.

Thermostat 3. Upper Coolant Tube 6. Page Refer to section 4. Remove the thermostat from the coolant pump. Heat the water with a suitable heating element. Stir the water occasionally to help equalize the temperature. Page If the main valve is not completely open, replace the thermostat. Short Circuit Valve 2. Page O-ring s on the coolant pump, as removed.

Fill the engine with coolant, as removed, and check for leaks and proper operation. Page Egr Thermostat Housing 4. Remove any other hose or fitting connections. Install EGR modulated valve to thermostat housing cover using four bolts.

Attach reed valve housing bracket to thermostat cover. Install any other hose or fitting connections. Page Coolant Temperature Sensor 2. Remove the engine trim panel. Connect the electrical connector to the sensor. Make sure the connection is secure.

Install the engine trim panel. Fill the engine with coolant, and check for leaks and proper operation. Page Gap between the Impeller and the 0. Page The sensor torque value is listed in Table Page Fuel In most cases, winter-grade fuel can be used without problems at cold outside temperatures.

Page Do not add anything to cold-resistant winter-grade diesel fuels. The fuel's low-temperature flow characteristics could actually deteriorate with additives.

Synthetic oil offers improved low-temperature flow properties and high-temperature resistance to oxidation. Page SAE viscosity class which corresponds to the outside temperatures anticipated during this period of operation. Page Coolant 5. Antifreeze containing glycol compounds and corrosion inhibitors is known as fully-formulated antifreeze. Page The concentrations of some inhibitors will gradually deplete during normal engine operation. SCAs replenish the protection for cooling system components.

The coolant must be maintained with the proper concentration of SCA. The antifreeze must be recycled by distillation, reverse osmosis, or ion exchange. Other recycled antifreeze, especially any antifreeze recycled by means of filtration processes, is not approved. Page This can cause deposits or dropout in the cooling system. All corrosion inhibitors protect against corrosion caused by acid, and cavitation of wet cylinder liners. Automotive coolants offer no protection against liner pitting, and generally contain high levels of phosphate and silicate.

Page Intake Manifold 3. Remove the bolts from the engine trim cover. Move the side panels down and out of the way to expose the manifold mounting bolts. Install the charge air inlet pipe, with a new gasket, on the charge air manifold. Lower the hood and remove the chocks from the rear tires. Install the 2 cylinder head cover. Page Turbocharger Do not modify or tamper with the exhaust system or emission control system.

Place the transmission in neutral and start the engine. Check the exhaust system for leaks. To find leaks, check for color changes to the pipe caused by heating around the leak area. Check both wheels for damage to the blade caused by dirt, debris, and other foreign matter in the turbocharging air system. See Figure for the turbocharger wheel and see Figure for the compressor wheel. Turbocharger Housing 3. Blade 2.

Rotor Shaft Figure Turbocharger Wheel 1. Page Neither turbo wheel nor compressor wheel should rub against the housing. Page Remove the turbocharger as follows: 1. Apply the parking brakes, shut down the engine, and chock the rear tires. Return Line Mounting Bolt 3. Oil Supply Line 7. Oil Return Line 4. Page [a] Remove the two bolts attaching the oil return line to the turbocharger.

Discard the two seal rings. Using new nuts, install the exhaust brake valve housing on the turbocharger if removed. Refill the oil inlet port and connect the oil supply line. Check for oil leaks. Correct any if found. Page Exhaust System www. Page Exhaust Manifold Remove the exhaust manifold as follows: 1. Disconnect the batteries and tilt the hood. Remove the turbocharger from the exhaust manifold. Page [a] Remove each mounting bolt and spacer from the exhaust manifold and each cylinder head.

Start the engine and make sure there is oil pressure. Shut down the engine and check for leaks. Page To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles. Remove the exhaust brake compressed-air line from the exhaust brake cylinder. Remove the locknuts that attach the brake valve housing to the studs on the turbocharger. Remove the housing from the engine. Adjusting-Lever Hexnut Shaft 9. Adjusting Lever Front Bushing integral to shaft Page Exhaust Brake Assembly 8.

Using a suitable drift, press the rear bushing out of the brake valve housing. Page [a] Choose a feeler gauge equal to dimension B, 2. Install the exhaust brake cylinder on the bracket. Install the exhaust brake assembly on the engine. Slide the exhaust pipe and clamp over the end of the housing. Tighten the clamp.

Install the air cleaner. Connect the batteries, lower the hood, and remove the chocks from the rear tires. Page Egr Exhaust Manifold Upper or main heat shield must remain on the exhaust manifold assembly until the assembly is removed due to inaccessibility of some of the heat shield mounting bolts. Page NOTE: Stud and stud bracket should be loose enough to allow removal of the exhaust manifold inlet pipe.

Loosen and remove bolt from positioning clamp which holds the gas inlet pipe to the throttle valve. Page not shown in graphic. Page Removing Upper Heat Shield 8. Remove the stud and M8 nut and collar still attached to the center exhaust manifold piece.

Remove the two side pieces of the exhaust manifold from the center piece. Refer to section 7. Install the exhaust manifold guide studs to the cylinder head and mount the two exhaust manifold gaskets.

The rear gasket will overlap the front in the center of block. Stud 3. Exhaust Manifold Center Piece 2. Torque remaining five mounting bolts captured bolt and washer type of the upper heat shield to the exhaust manifold.

See Step Five in see Figure Remove the bolt attaching the coolant outlet pipe bracket to the pipe. Remove the bracket. Remove the two bolts attaching the coolant outlet pipe flange to the coolant pump. Remove the three bolts from the front bracket that holds and stabilizes the reed valve housing to the thermostat housing. Page Also, do not remove the two EGR cooler-to-sheet metal support bolts at this time. They will all be removed once the EGR cooler as an assembly is taken off of the engine.

Remove the air line mounting bolts. Loosen and remove the air supply line from the EGR shut off valve. Page The oil filter and oil filter cover should be removed for good clearance when removing and installing the EGR cooler assembly. Page Before removing the eight bolts from the EGR cooler support, insert the four guide studs into the exhaust manifold gasket holes to support the gaskets once the cooler support is removed. M10 x 65 mm bolts 2. Remove the two EGR cooler-to-sheet metal support bolts.

Page Exhaust manifold gaskets will have to be installed before EGR cooler support or cooler can be installed. Page Assemble and attach the EGR reed valve housing to the cooler before mounting the cooler to the cooler support. Insert the reed valves into the EGR reed valve housing flange. Attach the EGR cooler to the front sheet metal support with two bolts. Install the EGR air temperature sensor into reed valve housing flange. Using plastic ties, attach remainder of sensor to reed valve-housing bracket.

Sensor and Housing Bracket All information subject to change without notice. EGR Cooler 3. Clamps 4 Qty. Tightening Tool for Clamps 4. Tighten EGR shutoff valve using two bolts. Install and attach air supply line using two mounting bolts.

Loosen the wiring harness terminal from the back cover mounting bracket by punching the push-mount cable tie out of the drilled hole in the mounting bracket. Remove the two All information subject to change without notice. Page Remove back bracket. Remove the three bolts that attach the gas outlet pipe mounting bracket to the intake manifold and to the outlet pipe. Remove membrane from the EGR control valve. New emissions standards require engine makers to reduce nitrogen oxide emissions by more than 50 percent and particulate matter emissions by 90 percent for all on-highway diesel engines.

These changes prompted the use of specially formulated engine oil and lower-sulfur diesel fuel. They also feature an electrostatic breather to address crankcase emissions requirements.