Detroit Diesel MBE4000 Service Manual

2 FUEL SYSTEMSection Page2.1 INJECTOR UNIT PUMP ... 2- 32.2 EGR INJECTOR UNIT

2.1 INJECTOR UNIT PUMP1. Identify the failed unit pump and failure mode (fuel leak at the solenoid). Remove thefailed unit pump. Refer to section 2.1.

MBE4000 SERVICE M ANU AL4. Markthepositionoftheintermediateplateinrelationtotheunitpumpbody(SeearrowA of Figure 2-8) and rest the unit pump on the sto

2.1 INJECTOR UNIT PUMP8. Mark the cross piece and anchor plate in relation to the unit pump. (See arrow C of Figure2-9). Use a marker; do not use a sc

MBE4000 SERVICE M ANU AL2-10) at the opening in the intermediate plate must face towards the cross piece. Thepainted surface is a reference mark to th

2.1 INJECTOR UNIT PUMP2. Install the two new O-rings on the unit pump shaft using the Unit Pump O-ring installer(J-45373). See Figure 2-11.1. Inner (l

MBE4000 SERVICE M ANU ALPERSONAL INJUR YTo avoid injury from the sudden release of a high-pressurehose connection, wear a face shield or goggles.7. Co

2.2 EGR INJECTOR UNIT PUMP2.2 EGR INJECTOR UNIT PUMPThe removal and installation of the EGR injector unit pump is the same as the non-EGR engine;howev

MBE4000 SERVICE M ANU AL6. Turn off key and unplug minidiag2.7. Install the unit pump. Refer to section 2.1.3.All information subject to change withou

2.3 FUEL INJECTOR LINE2.3 FUEL INJECTOR LINEPerform the following procedures for removal and installation of the fuel i njector line. Thefollowing pro

MBE4000 SERVICE M ANU AL3. From the topside of the engine use the injector line torque wrench adaptor (J-45062) andloosen the injector line nut at the

(Rev. 3/04) All information subject to change without notice.2-2 From Bulletin 2– MBE 4000– 06 6SE412 0403 Copyright © 2006 DETROIT DIESEL CORPORATION

2.3 FUEL INJECTOR LINE2.3.2 Fuel Injector Line InstallationInstall the fuel high pressure fuel line and a new transfer tube as follows:NOTICE:New inje

MBE4000 SERVICE M ANU ALPERSONAL INJUR YDiesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birthd

2.4 FUEL INJEC TOR NOZZLE2.4 FUEL INJECTOR NOZZLEPerform the following procedures for removal and installation of the fuel injector nozzle.2.4.1 Fuel

MBE4000 SERVICE M ANU AL4. Remove the injector line. See Figure 2-14. Refer to section 2.3.1.1. Retaining Bolt 6. Constant-Throttle End Cover2. Tensio

2.4 FUEL INJEC TOR NOZZLE7. Attach the injector unit pump puller (J-46375) and adaptor (J-46384). Thread the narrowend of the adaptor onto the interna

MBE4000 SERVICE M ANU AL2.4.2 Fuel Injector Nozzle InstallationInstall the fuel injector nozzle as follows:1. Using a dial caliper, measure t he lengt

2.4 FUEL INJEC TOR NOZZLE[b] Place the receptacle from the heat isolator installer over the head of the nozzle holderand the pressure-fitcapovertheheat

MBE4000 SERVICE M ANU AL[c] Place this entire assembly in a vise and close the vise enough to pressure-fit the heatisolator around the nozzle. See Figu

2.4 FUEL INJEC TOR NOZZLE4. Install the nozzle in the cylinder head. Align the notch in the tensioning arm with the pinonthetopofthenozzle.SeearrowinF

MBE4000 SERVICE M ANU AL6. Lubricate a new transfer-tube O-ring with a light coating of engine oil and install it on thetransfer tube.NOTE:Do not t ig

MBE4000 SERVICE MANUAL2.1 INJECTOR UNIT PUMPA special tool is required for this procedure.2.1.1 Injector Unit Pump RemovalRemove the injector unit pum

2.5 EGR FUEL INJEC TOR NOZZLE2.5 EGR FUEL INJECTOR NOZZLEThe removal and installation procedures remain the same for the non-EGR and EGR fuel injector

MBE4000 SERVICE M ANU AL2.6 PROTECTIVE SLEEVEPerform the following procedures for removal and installation of the protective sleeve.2.6.1 Protective S

2.6 PROTECTIVE SLEEV E[a] Insert the 4-toothed socket (J-46186) into the protective sleeve. Make sure the teethof the socket engage the four openings

MBE4000 SERVICE M ANU AL4. Remove the O-ring from the c ylinder head. See Figure 2-23.1. Nozzle 3. Protective Sleeve2. Heat Isolator 4. O-ringFigure 2

2.6 PROTECTIVE SLEEV E[b] Immediately compare the end pad to the color chart on the container to determinethe glycol concentration.[c] Sixty-seconds (

MBE4000 SERVICE M ANU AL4. Connect the electrical connector.NOTE:Be sure that the correct elec trical connector is connected to the sensor.All informa

2.7 DDEC-ELECTRONIC CONTROL UNIT2.7 DDEC-ELECTRONIC CONTROL UNITPerform the following procedures for removal and installation of the DDEC-ECU.2.7.1 DD

MBE4000 SERVICE M ANU AL3. Remove the heat exchanger mounting bolts, but do not disconnect the fuel lines to theheat exchanger. See Figure 2-25.1. D D

2.7 DDEC-ELECTRONIC CONTROL UNIT4. Lift up the slide on the locking unit to release the vehicle wiring harness connector anddisconnect it from the DDE

MBE4000 SERVICE M ANU AL5. Rotate the safety latch down to release the engine wiring harness connector and disconnectit from the DDEC-ECU unit. See Fi

2.1 INJECTOR UNIT PUMP3. Disconnect the engine wiring harness from the injector unit pump. See Figure 2-2.1. Engine Wiring Harness 3. Terminal Screw2.

2.7 DDEC-ELECTRONIC CONTROL UNIT5. Connect the engine wiring harness to the DDEC-ECU. Rotate the safety latch upwardto lock it in place.6. If a new DD

MBE4000 SERVICE M ANU AL2.8 FUEL HEAT EXCHANGERPerform the following procedures for removal and installation of the fuel heat e xchanger.2.8.1 Fuel He

2.8 FUEL HEAT EXCHA NGERPERSONAL INJURYTo avoid injury from the sudden release of a high-pressurehose connection, wear a face shield or goggles.3. Dis

MBE4000 SERVICE M ANU AL2.8.2 Fuel Heat Exchanger InstallationInstall the fuel heat exchanger as follows:1. Attach the fuel heat exchanger to the DDEC

2.9 FUEL FILTER2.9 FUEL FILTERThe removal and installation procedures are the same for the non-EGR and EGR fuel filterelement.2.9.1 Fuel Filter Removal

MBE4000 SERVICE M ANU AL4. Using a 36-mm socket, unscrew the cap on the main fuel filter housing. Remove the capand lift the filter element a short dist

2.9 FUEL FILTER4. If equipped with a hand pump on the fuel/water separator, work the hand pump untilresistance is felt.NOTE:There should be a strong r

MBE4000 SERVICE M ANU AL2.10 FUEL FILTER HOUSINGPerform the following procedures for removal and installation of the fuel fi lter housing.2.10.1 Fuel F

2.10 FUEL FILTER HOUSINGor Figure 2-31 for EGR engines. Allow the fuel to drain off the filter into the housingbefore removing.1. Fuel Filter Housing M

MBE4000 SERVICE M ANU AL4. Remove the priming valve assembly or banjo bolt and seal rings from the delivery line onthe filter housing. Mark both sides

MBE4000 SERVICE M ANU AL6. Drain fuel from the engine through the fuel gallery outlet on the return lines. See Figure2-3.1. H igh-Pressure Fuel Inject

2.10 FUEL FILTER HOUSINGNOTE:MBE4000 engines built in March 2005 will be equipped with a fuel priming valve which islocated in secondary filter. Engine

MBE4000 SERVICE M ANU AL2.11 FUEL FILTER BRACKETThe removal and installation procedures remain the same for the non-EGR and EGR fuel filterassembly; ho

2.11 FUEL FILTER BRAC KET2.11.2 Non-EGR Fuel Filter Bracket InstallationInstall the non-EGR fuel filter bracket as follows:1. Install the fuel filter br

MBE4000 SERVICE M ANU AL2. Install the fuel filter housing to the mounting bracket. Refer to section 2.10.2.All information subject to change without n

2.12 FUEL PU M P2.12 FUEL PUMPPerform the following procedures for removal and installation of the fuel pump.2.12.1 Fuel Pump RemovalRemove the fuel p

MBE4000 SERVICE M ANU ALPERSONAL INJUR YTo avoid injury from the sudden release of a high-pressurehose connection, wear a face shield or goggles.3. Re

2.12 FUEL PU M P2.12.2 Fuel Pump InstallationInstall the fuel pump as follows:NOTICE:When inserting the fuel pump into the opening in thecylinder bloc

MBE4000 SERVICE M ANU ALPERSONAL INJUR YTo avoid injury from the sudden release of a high-pressurehose connection, wear a face shield or goggles.2. In

2.13 FUEL PUMP DRIVE2.13 FUEL PUMP DRIVEPerform the following procedures for removal and installation of the fuel pump drive.2.13.1 Fuel Pump Drive Re

MBE4000 SERVICE M ANU AL7. Remove the bolt from the fuel pump driven gear and use a puller to remove the gear.SeeFigure2-37.1. Drive Gear Mounting Bol

2.1 INJECTOR UNIT PUMPEYE INJUR YTo avoid injury fro m flying parts when working withcomponents under spring tension, wear adequate eyeprotection (face

2.13 FUEL PUMP DRIVE9. Using fuel pump bearing driver (J-47073), drive the bearing out from the rear to the frontof engine. see Figure 2-38. If bearin

MBE4000 SERVICE M ANU AL2. From the front of the engine and using fuel pump bearing driver (J–47073), drive the fuelpump drive assembly into the housi

2.14 FUEL SYSTEM INSPECTION2.14 FUEL SYSTEM INSPECTIONPerform the following steps to inspect the fuel system for damage:PERSONAL INJURYTo avoid injury

MBE4000 SERVICE M ANU AL2.14.1 Performing a Fuel Pressure TestPerform the following steps to conduct a fuel pressure test:1. Install the pressure gaug

2.14 FUEL SYSTEM INSPECTION1. Fitting 4. Fuel Outlet Line2. Fuel Filter Housing 5. Unit Pump3. Mechanical GaugeFigure 2-40 Gauge Installation – After

MBE4000 SERVICE M ANU ALPERSONAL INJUR YTo avoid injury before starting and running the eng ine,ensure the vehicle is parked on a level surface, parki

2.14 FUEL SYSTEM INSPECTION2. At rated rpm, for fuel pressure lower than 5.5 bar (80 psi), check the following:□ Check the water separator filter condi

MBE4000 SERVICE M ANU AL2. Afterestablishingtheconnectionwiththetruck,chooseoption4–Routines.3. UnderRoutinessection,selectoption4–IdleSmoothlyBalance

2.14 FUEL SYSTEM INSPECTION2.14.2.2 Impact Delay Time TroubleshootingThis test measures the reaction time of the unit pumps. The operation range is fr

MBE4000 SERVICE M ANU ALNOTICE:Do not apply a torque over 30 N·m (22 lb·ft). Excessive torquecan cause the bolt/gear failure.3. T urn the torque wrenc

MBE4000 SERVICE M ANU ALNOTICE:If the injector unit pump doesn 't come out easily, do not tryto pry up on the body of the pump. This will damage

2.14 FUEL SYSTEM INSPECTION8. Remove the bolt and use a puller to remove the gear. See Figure 2-43.1. Camshaft Gear Cover 4. Fuel Pump Drive Gear2. Dr

MBE4000 SERVICE M ANU AL2.A ADDITIONAL INFORMATIONDescription PageSPECIFICATIONS ...

Engine Brake HarnessThe former 8-pin Engine Harness Connector is identified with part number A460 150 00 33, andit is used in the engines that have one

MBE4000 SERVICE M ANU ALFuel and Fuel ControlThe fuel control torque values are listed in Table 2-8. Listed in Table 2-9 and listed in Table2-10 are t

Figure 2-44 55-Pin Connector Wiring Diagram for EPA98 Engine(Rev. 3/04) All information subject to change without notice.2-74 From Bulle tin 2–MBE 400

MBE4000 SERVICE M ANU ALFigure 2-45 55-Pin Connector Wiring Diagram for EPA04 (EGR) EngineAll information subject to change without notice. (Rev. 3/04

Fuel System InspectionThetorquespecifications for fuel line nuts are listed in Table 2-11. The fuel system specificationsfor pressure are listed in Tabl

2.1 INJECTOR UNIT PUMP11. Remove both mounting bolts completely. Carefully pull the unit pump out of the cylinderblock. See Figure 2-6.1. Mounting Bol

MBE4000 SERVICE M ANU AL2.1.2 Repairing the Unit Pump SolenoidA Unit Pump Solenoid repair kit (P/N: 0120740001) is now available for repair of the uni