Detroit Diesel MBE 4000 Engine Service & Repair Manual
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MBE 4000 SERVICE MANUAL
ABSTRACT
This manual provides instruction for servicing the MBE 4000 Diesel Engine. Specifically, a basic
overview of each major component and the system, along with the recommendations for removal,
cleaning, inspection, criteria for replacement, repair, installation, and mechanical troubleshooting
are contained in this manual.
TRADEMARK INFORMATION
Loctite® is a registered trademark of Henkel Corporation. Wabco® is a registered trademark
of American Standard, Inc. Hengst® is a registered trademark of Walter Hengst GMBH & Co.
Perma-Lok® is a registered trademark of National Starch and Chemical Investment Holding
Corporation. Henkel® is a registered trademark of Henkel Corporation.
ENGINE EXHAUST
Consider the following before servicing engines:
PERSONAL INJURY
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.
All information subject to change without notice.
DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION i
MBE 4000 SERVICE MANUAL
All information subject to change without notice.
ii DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION
MBE 4000 SERVICE MANUAL
TABLE OF CONTENTS
GENERAL INFORMATION ...................................................................... 1
SCOPE AND USE OF THIS MANUAL .................................................... 3
GENERAL DESCRIPTION ...................................................................... 3
ELECTRONIC ENGINE CONTROL SYSTEM ......................................... 4
ENGINE BRAKING POWER .................................................................... 7
GENERAL SPECIFICATIONS AND ENGINE VIEWS ............................. 7
ENGINE MODEL AND SERIAL NUMBER ............................................... 13
EXHAUST GAS RECIRCULATION (EGR) SYSTEM ............................... 15
SAFETY INSTRUCTIONS AND PRECAUTIONS .................................... 19
ENGLISH TO METRIC CONVERSION .................................................... 28
DECIMAL AND METRIC EQUIVALENTS ................................................ 29
TORQUE SPECIFICATIONS ................................................................... 31
1 ENGINE
1.1 CYLINDER HEAD COVER ...................................................................... 1-3
1.2 CYLINDER HEAD .................................................................................... 1-4
1.3 CYLINDER BLOCK .................................................................................. 1-22
1.4 EGR CYLINDER HEAD AND BLOCK ..................................................... 1-44
1.5 EGR FRONT AND REAR LIFTER BRACKETS ....................................... 1-47
1.6 ENGINE BRAKE ...................................................................................... 1-49
1.7 FRONT RADIAL SEAL ............................................................................. 1-56
1.8 REAR RADIAL SEAL ............................................................................... 1-60
1.9 CRANKSHAFT SEAL WEAR SLEEVE .................................................... 1-63
1.10 CRANKSHAFT ASSEMBLY ..................................................................... 1-68
1.11 FRONT COVER HOUSING ..................................................................... 1-91
1.12 CRANKSHAFT VIBRATION DAMPER .................................................... 1-93
1.13 FLYWHEEL .............................................................................................. 1-95
1.14 RING GEAR ............................................................................................. 1-104
1.15 PILOT BEARING ...................................................................................... 1-108
1.16 ENGINE BARRING TOOL ....................................................................... 1-112
1.17 FLYWHEEL HOUSING ............................................................................ 1-114
1.18 PISTON, PISTON RING, AND CONNECTING ROD ............................... 1-116
1.19 EGR PISTON, PISTON RING, AND CONNECTING ROD ...................... 1-140
1.20 VALVES .................................................................................................... 1-143
1.21 EGR VALVES ........................................................................................... 1-162
1.22 ROCKER ARM ......................................................................................... 1-167
1.23 CAMSHAFT AND CAMSHAFT POSITION SENSOR .............................. 1-171
1.24 EGR CAMSHAFT ..................................................................................... 1-181
1.A ADDITIONAL INFORMATION .................................................................. 1-183
2 FUEL SYSTEM
2.1 INJECTOR UNIT PUMP ........................................................................... 2-3
2.2 EGR INJECTOR UNIT PUMP .................................................................. 2-15
All information subject to change without notice.
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MBE 4000 SERVICE MANUAL
2.3 HIGH PRESSURE FUEL LINE AND TRANSFER TUBE ......................... 2-16
2.4 FUEL INJECTOR NOZZLE ...................................................................... 2-26
2.5 EGR FUEL INJECTOR NOZZLE ............................................................. 2-34
2.6 PROTECTIVE SLEEVE ........................................................................... 2-35
2.7 DDEC-ELECTRONIC CONTROL UNIT ................................................... 2-39
2.8 FUEL HEAT EXCHANGER ...................................................................... 2-44
2.9 FUEL FILTER ........................................................................................... 2-47
2.10 FUEL FILTER HOUSING ......................................................................... 2-50
2.11 FUEL FILTER BRACKET ......................................................................... 2-54
2.12 FUEL PUMP ............................................................................................. 2-57
2.13 FUEL PUMP DRIVE ................................................................................. 2-61
2.14 FUEL SYSTEM INSPECTION ................................................................. 2-65
2.A ADDITIONAL INFORMATION .................................................................. 2-73
3 LUBRICATION SYSTEM
3.1 LUBRICATION SYSTEM DESCRIPTION ................................................ 3-3
3.2 OIL PAN ................................................................................................... 3-5
3.3 PISTON OIL SPRAY NOZZLE(S) ............................................................ 3-11
3.4 CAMSHAFT LUBRICATION SPRAYER ................................................... 3-17
3.5 OIL PUMP AND SUMP PIPE ................................................................... 3-19
3.6 OIL FILTER .............................................................................................. 3-27
3.7 OIL HEAT EXCHANGER/FILTER HOUSING .......................................... 3-29
3.8 OIL PRESSURE/TEMPERATURE SENSOR ........................................... 3-34
3.A ADDITIONAL INFORMATION .................................................................. 3-37
4 COOLING SYSTEM
4.1 COOLING SYSTEM ................................................................................. 4-3
4.2 COOLANT PUMP .................................................................................... 4-7
4.3 EGR COOLANT PUMP ............................................................................ 4-18
4.4 FRONT IDLER AND TENSIONER SUPPORT ........................................ 4-19
4.5 THERMOSTAT ......................................................................................... 4-22
4.6 EGR THERMOSTAT HOUSING .............................................................. 4-27
4.7 COOLANT TEMPERATURE SENSOR .................................................... 4-29
4.A ADDITIONAL INFORMATION .................................................................. 4-31
5 FUEL, LUBRICATING OIL, AND COOLANT
5.1 FUEL ........................................................................................................ 5-3
5.2 LUBRICATING OIL .................................................................................. 5-5
5.3 COOLANT ................................................................................................ 5-7
5.A ADDITIONAL INFORMATION .................................................................. 5-13
6 AIR INTAKE SYSTEM
6.1 INTAKE MANIFOLD ................................................................................. 6-3
6.2 CHARGE PRESSURE/TEMPERATURE SENSOR ................................. 6-5
6.3 TURBOCHARGER ................................................................................... 6-6
6.A ADDITIONAL INFORMATION .................................................................. 6-17
7 EXHAUST SYSTEM
7.1 EXHAUST MANIFOLD ............................................................................. 7-3
7.2 EXHAUST BRAKE ASSEMBLY ............................................................... 7-6
All information subject to change without notice.
iv DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION
MBE 4000 SERVICE MANUAL
7.3 EGR EXHAUST MANIFOLD .................................................................... 7-14
7.4 EGR COOLER AND COOLER SUPPORT BRACKET ............................ 7-26
7.5 EGR CONTROL VALVE, GAS OUTLET PIPE, AND GAS MIXER .......... 7-47
7.6 EPV (ELECTRONIC PROPORTIONAL VALVE) AND WABCO® AIR
SOLENOID VALVE ................................................................................... 7-54
7.7 HENGST BREATHER FILTER ................................................................. 7-58
7.A ADDITIONAL INFORMATION .................................................................. 7-67
8 ELECTRICAL EQUIPMENT
8.1 DRIVE BELTS .......................................................................................... 8-3
8.A ADDITIONAL INFORMATION .................................................................. 8-15
9 POWER TAKE-OFF
9.1 FRONT ENGINE POWER TAKE-OFF (FEPTO) ...................................... 9-3
9.2 REAR ENGINE POWER TAKE-OFF (REPTO) ........................................ 9-7
10 SPECIAL EQUIPMENT
10.1 AIR COMPRESSOR FLANGE ................................................................. 10-3
10.2 AIR COMPRESSOR ................................................................................ 10-5
10.A ADDITIONAL INFORMATION .................................................................. 10-11
11 OPERATION AND VERIFICATION
11.1 PREPARATION FOR A FIRST TIME START ........................................... 11-3
11.2 STARTING THE ENGINE ........................................................................ 11-8
11.3 RUNNING THE ENGINE ......................................................................... 11-11
11.4 STOPPING THE ENGINE ........................................................................ 11-13
12 ENGINE TUNE-UP
12.1 VALVE LASH CHECKING ........................................................................ 12-3
12.2 ADJUSTING VALVE LASH ...................................................................... 12-9
13 PREVENTIVE MAINTENANCE
13.1 SCHEDULED INTERVALS ...................................................................... 13-3
14 ENGINE STORAGE
14.1 PREPARING ENGINE FOR STORAGE .................................................. 14-3
15 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL
SYSTEM
15.1 ELECTRONIC ENGINE CONTROL SYSTEM ......................................... 15-3
16 GENERAL MECHANICAL TROUBLESHOOTING
16.1 MECHANICAL TROUBLESHOOTING .................................................... 16-3
17 LOW POWER CONCERN
17.1 FACTORS THAT AFFECT WHEEL HORSEPOWER .............................. 17-3
17.2 LOW HORSEPOWER INTERVIEW ......................................................... 17-6
17.3 AERATED FUEL ..................................................................................... 17-13
17.4 RESTRICTED AIR CLEANER ELEMENT ............................................... 17-15
17.5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING
INTAKE MANIFOLD ................................................................................. 17-16
17.6 FAULTY EXHAUST SYSTEM .................................................................. 17-18
All information subject to change without notice.
DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION v
MBE 4000 SERVICE MANUAL
17.7 HIGH INLET AIR TEMPERATURE .......................................................... 17-20
17.8 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER ........... 17-22
INDEX ................................................................................................. Index-1
All information subject to change without notice.
vi DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION
GENERAL INFORMATION
Section Page
SCOPE AND USE OF THIS MANUAL ....................................................... 3
GENERAL DESCRIPTION ......................................................................... 3
ELECTRONIC ENGINE CONTROL SYSTEM ............................................ 4
ENGINE BRAKING POWER ...................................................................... 7
GENERAL SPECIFICATIONS AND ENGINE VIEWS ................................ 7
ENGINE MODEL AND SERIAL NUMBER ................................................. 13
EXHAUST GAS RECIRCULATION (EGR) SYSTEM ................................. 15
SAFETY INSTRUCTIONS AND PRECAUTIONS ...................................... 19
ENGLISH TO METRIC CONVERSION ...................................................... 28
DECIMAL AND METRIC EQUIVALENTS ................................................... 29
TORQUE SPECIFICATIONS ...................................................................... 31
MBE 4000 SERVICE MANUAL
All information subject to change without notice.
2 DDC-SVC-MAN-0023 Copyright © 2009 DETROIT DIESEL CORPORATION
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$40.99
The Detroit Diesel MBE 4000 Engine Service & Repair Manual is a comprehensive resource for professionals and DIY enthusiasts. It details the 12.8L 6-cylinder, liquid circuit turbocharger & charge-air cooler, 4-stroke direct-injection diesel engine used in Detroit Diesel applications. This manual provides in-depth information on:
- General engine maintenance
- Fuel system
- Lubrication system
- Cooling system
- Air intake system
- Exhaust system
- Electrical equipment
- Power take-off
- Special equipment
- Operation & verification
- Engine tune-up
- Preventive maintenance
- Engine storage
- Engine control system
- Mechanical troubleshooting
- Low power concern
- Technical specifications
- Operator's manual
This electronic manual is compatible with all Windows and Mac platforms. To view the document, Adobe Acrobat Reader is required, which can be downloaded for free from the Adobe website. For the .OVA file format, free extraction software is available from the respective provider.
Featuring detailed illustrations, step-by-step instructions, and necessary diagrams, the manual is an essential guide for repairing and servicing vehicles, ensuring cost-effective solutions to maintain optimal engine performance.
