NOTICE: If the injector unit pump doesn`t come out easily
Contents
1. 7 Connect the fuel line at the fuel gallery inlet Tighten the fitting to 50 N m 37 lb ft 8 Install the fuel lines and pressure limiting valve on the fuel gallery outlet Tighten all fasteners to 50 N m 37 lb ft a Install the inner banjo fitting and two new seal rings on the pressure limiting valve as marked on removal b Install the threaded end of the pressure limiting valve in the fuel gallery outlet When the valve is firmly seated tighten it to 50 N m 37 lb ft c Install the outer banjo fitting again with two new seal rings on the banjo bolt as marked on removal d Install the banjo bolt on the pressure limiting valve and tighten to 40 50 N m 30 37 Ib ft 9 Install the fuel filter cap Inspect the O ring in the fuel filter and replace it if worn Tighten the cap nut to 25 N m 18 lb ft 10 Install the high pressure fuel injector line Refer to section 2 3 2 A WARNING 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 11 Start the engine and check for leaks Tighten connections as needed 12 Install the engine trim cover All information subject2. MBE 4000 SERVICE MANUAL NOTICE If the injector unit pump doesn t come out easily do not try to pry up on the body of the pump This will damage it 10 If the injector unit pump is locked up or frozen in its seat release it using the blade of a small screwdriver on the flange where the mounting bolt attaches See arrow in Figure 2 5 42101 Figure 2 5 Releasing a Locked up Pump All information subject to change without notice 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 MBE4000 05 2 7 2 1 INJECTOR UNIT PUMP 11 Remove both mounting bolts completely Carefully pull the unit pump out of the cylinder block See Figure 2 6 42102 1 Mounting Bolt 3 Cylinder Block 2 Unit Pump Figure 2 6 Removing the Unit Pump 12 Check the injector unit pump for wear or damage If any is found refer to section 2 1 1 1 13 Remove and discard the two O rings on the unit pump shaft All information subject to change without notice 2 8 From Bulletin 3 MBE4000 05 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 2 1 1 1 Repairing the Unit Pump Solenoid A Unit Pump Solenoid repair kit P N 0120740001 is now available for repair of the unit pump This service kit is used to repair fuel leakage at the solenoid For this type of complaint total replacement of the unit pump is no longer necessary Perform the following steps to inst
3. all the unit pump repair kit AWwarninc PERSONAL INJURY To avoid injury from penetrating fluids do not put your hands in front of fluid under pressure Fluids under pressure can penetrate skin and clothing WARNING FIRE To avoid injury from fire keep all potential ignition sources away from diesel fuel including open flames sparks and electrical resistance heating elements Do not smoke when refueling All information subject to change without notice 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 MBE4000 05 2 9 2 1 INJECTOR UNIT PUMP Identify the failed unit pump and failure mode fuel leak at the solenoid Remove the failed unit pump Refer to section 2 1 1 for unit pump removal procedure See Figure 2 6a O oa A WO PD 2 Wipe the pump clean removing excess fuel 3 Remove the O rings from the unit pump Push the unit pump O ring installer J 45373 1 Stop Plate 7 Screw Unit Pump 8 Model Plate Anchor Plate 9 Cross Piece Seal 10 O ring Intermediate Plate 11 O ring Magnet Figure 2 6a Unit Pump Components onto the unit pump This will prevent dirt from entering the unit pump holes All information subject to change without notice 2 10 From Bulletin 3 MBE4000 05 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 4 Mark the position of the intermediate plate in relation to the unit pump body See arrow A of Figure 2 6
4. b and rest the unit pump on the stop plate Use a pencil or scriber for marking Do not use any stamping tools 1 Intermediate Plate 3 Torx Bit 2 Screw Figure 2 6b Removing the Magnet and Intermediate Plate 5 Remove all traces of paint from screw heads Remove screws using the torx bit P N 9045890210 00 and lift off the magnet together with the intermediate plate and model plate See arrow B of Figure 2 6b 6 Remove the intermediate plate and the model plate from the magnet Wipe clean the sealing surface on the magnet removing any excess fuel Clean the model plate and remove paint from the screw heads contact area 7 Remove the two spacer seals and clean the intermediate plate Do not damage sealing surfaces All information subject to change without notice 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 MBE4000 05 2 10a 2 1 INJECTOR UNIT PUMP 8 Mark the cross piece and anchor plate in relation to the unit pump See arrow C of Figure 2 6c Use a marker do not use a scriber or stamping tool The cross piece should not be moved or twisted 1 Unit Pump 3 Cross Piece 2 Anchor Plate Figure 2 6c Marking the Cross Piece and Anchor Plate 9 Wipe clean the sealing surfaces on the unit pump cross piece and anchor plate removing any excess fuel Clean the parts thoroughly Do not remove the paint on the unit pump it is used as a reference point for the intermediate plate ass
5. embly 10 Remove the stop plate 11 Place a new stop plate under the unit pump body 12 Install the new seals in the intermediate plate Protect the seals with a thin layer of high temperature grease 13 Place the intermediate plate on the unit pump body Observe the identification mark on the cross piece and anchor plate for the unit pump body The cutouts see arrows D of All information subject to change without notice 2 10b From Bulletin 3 MBE4000 05 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL Figure 2 6d at the opening in the intermediate plate must face towards the cross piece The painted surface is a reference mark to the intermediate plate assembly on the unit pump 1 Anchor Plate 3 Intermediate Plate 2 Cross Piece Figure 2 6d Installing the Intermediate Plate 14 Place the magnet on the intermediate plate and place the model plate on the magnet 15 Secure the model plate magnet intermediate plate unit pump and stop plate together using new screws Hand tighten 16 Tighten the screws in a crosswise pattern to 5 N m 4 lb ft using torx bit P N 9045890210 00 17 Push the unit pump O ring installer J 45373 onto the unit pump 18 Install new O rings on the unit pump and install the unit pump in the engine Refer to section 2 1 2 for installation procedures 2 1 2 Injector Unit Pump Installation Install the injector unit pump as follows 1 Lubricate t
6. to change without notice 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 MBE4000 05 2 10e 2 1 INJECTOR UNIT PUMP This page intentionally left blank All information subject to change without notice 2 10f From Bulletin 3 MBE4000 05 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION
7. wo new O rings with a light coating of engine oil All information subject to change without notice 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 MBE4000 05 2 10c ma E e a _ ee 2 1 INJECTOR UNIT PUMP 2 Install the two new O rings on the unit pump shaft using the Unit Pump O ring installer J 45373 See Figure 2 7 42103 1 Inner larger O ring 2 Outer smaller O ring Figure 2 7 O ring Installation 3 Install the injector unit pump into the cylinder block a Insert the injector unit pump into the mounting hole in the cylinder block b Use light hand pressure to push in the unit pump until it seats about 4 mm 0 16 inch If it won t seat easily rotate the crankshaft until the unit pump seats NOTE Use the bolt mounting holes on the engine as a guide for positioning the injector pump 4 Install the mounting bolts and tighten to 65 N m 48 lb ft 5 Connect the engine wiring harness to the injector unit pump 6 Remove the engine cranking tool and replace the inspection cover on the flywheel housing Tighten the inspection cover mounting bolts to 25 N m 18 Ib ft All information subject to change without notice 2 10d From Bulletin 3 MBE4000 05 6SE412 0403 Copyright 2005 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL A WARNING PERSONAL INJURY To avoid injury from the sudden release of a high pressure hose connection wear a face shield or goggles
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