1.9 CRANKSHAFT ASSEMBLY
Contents
1. WARNING FALLING ENGINE To avoid injury from a falling engine ensure the engine is securely attached to the engine overhaul stand before releasing the lifting sling Mount the engine on an engine stand Remove the cylinder heads Refer to section 1 2 1 Remove the oil pan and oil pump Refer to section 3 1 1 Refer to section 3 4 1 Remove the flywheel and flywheel housing Refer to section 1 12 1 Remove the front cover housing Refer to section 1 10 1 Remove the pistons Refer to section 1 17 1 Rev 3 04 All information subject to change without notice From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 16 Install the cylinder heads Refer to section 1 2 2 A DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 17 Remove the engine from the stand 18 Install the engine in the vehicle 1 9 2 1 Crankshaft Measuring and Inspecti2. 1 Piston and Rings 5 Bearing Cap 2 Wrist Pin 6 Connecting Rod Stretch Bolt 3 Snap Ring 7 Bearing Shell 4 Connecting Rod Figure 1 79 Piston Assembly exploded view 1 17 1 Piston Removal Remove the piston assembly as follows All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 107 1 17 PISTON PISTON RING AND CONNECTING ROD A DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 1 Remove the engine from the vehicle NOTE The MBE4000 engine has individual heads for each cylinder To remove one piston do these procedures step by step To remove all the pistons repeat each step in these instructions as applicable for all six pistons 2 Remove each cylinder head as required Refer to section 1 2 1 3 Remove the oil pan Refer to section 3 1 1 NOTICE Do not damage the piston travel surfa
3. All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 171 1 22 CAMSHAFT AND CAMSHAFT SENSOR 8 Remove the fuel pump drive gear from the front of the camshaft See Figure 1 131 3 42080 1 Drive Gear Mounting Bolt 4 Fuel Pump Drive Gear 2 Front Camshaft Cover 5 Front of Camshaft 3 Cover Mounting Bolt 6 Fuel Pump Driven Gear Figure 1 131 Camshaft Assembly 9 Remove the rocker arm assembly and pushrods Refer to section 1 21 1 10 Turn the engine on the stand until it is upside down 11 Remove the oil pan Refer to section 1 16 1 Rev 3 04 All information subject to change without notice 1 172 From Bulletin 1 MBE4000 06 6SE412 0403 Copyiiaht 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 12 Remove the flywheel housing Refer to section 1 16 1 NOTICE Do not damage the camshaft bearings in the crankcase If the camshaft bearings are damaged the crankcase will have to be replaced 13 Attach the camshaft guide tool J 46183 to the front of the camshaft See Figure 1 132 1 Front of Camshaft Figure 1 132 Attaching the Camshaft Guide Tool 14 From the gear end rear of the engine carefully remove the camshaft from the block See Figure 1 132 All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DI
4. assembly Refer to section 1 21 4 DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 13 Remove the engine from the stand and install it on the vehicle 14 Fill the engine with oil 1 22 2 1 Camshaft Inspection Inspect the camshaft as follows NOTE To get a correct hardness reading it is critical to place a hard base below the cam or bearing journal Rev 3 04 All information subject to change without notice 1 176 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION
5. 0 322 mm 0 0127 inch as listed in Table 1 19 then replace the crankshaft End Play Axial Play Measured at Center Bearing 0 190 0 322 0 0074 0 0127 Journal Table 1 19 Crankshaft End Play a For the center main bearing journal note the width thickness of the bearing journal Example W 1 8120 inches b For the center main bearing shell note the width thickness of the bearing shell Example W 1 8030 inches All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 78a 1 9 CRANKSHAFT ASSEMBLY This page intentionally left blank Rev 3 04 All information subject to change without notice 1 78b From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL c From the value for the journal width subtract the value for the bearing shell width This result is the end play Example W W 0 0090 inch NOTE In the above example both measurements belonged to repair stage Standard If necessary listed in Table 1 20are the correct repair stages for each measurement Size mm in Center Bearing Shell Width Center Bearing Journal mm eee Width mm eer aa Standard o 45 74 45 81 45 74 45 81 1 801 1 804 801 1 804 46 000 46 062 46 000 46 062 1 8110 1 8135 8110 1 8135 Undersize 0 020 0 50 46 24 46 31 1 820 1 823 46 500 46 562 1 8307 1 8331 U
6. 2 4 3701 4 3709 shell housing Permissible Imbalance of Crankshaft at 400 rpm 0 6 N cm 0 05 Ib in Except as otherwise noted tMeasure with the crankshaft mounted on the outer main bearing journals With the pin for the flywheel installed but without the flywheel and with the crankshaft mounted on the outer bearings Table 1 13 Crankshaft Specifications 5 Measure the deviation from true of the crankshaft If the deviation from true is greater than 0 09 mm 0 004 inch regrind the crankshaft a Support the crankshaft on a stand held by the two external journals b Set up a dial gauge and holder on the center journal with some preload on the gauge c Set the dial gauge to 0 zero d Turn the crankshaft through one full revolution and check the dial gauge If the dial gauge deviates by more than 0 09 mm 0 004 inch regrind the crankshaft Check the crankshaft for dynamic balance Permissible imbalance is listed in Table 1 13 7 Using a micrometer measure the diameters of the main journals and the connecting rod journals Measure in both the vertical and horizontal directions on each journal Refer to section 1 9 2 2 for detailed procedures 8 Comparing the two measurements taken above check each crankshaft main and connecting rod journal for out of round If for any one journal the two measurements differ by more than 0 01 mm 0 0004 inch regrind the crankshaft If for any one journal the two m
7. 6 Valve Installation Install the intake and exhaust valves as follows 1 Lubricate each valve with a light coating of engine oil 2 Install the valves in order as marked on removal NOTE Always replace the valve stem seal if the valve has been removed Check the seal to make sure it is correctly seated on the valve guide Refer to section 1 19 7 Install new valve stem seals Refer to section 1 19 7 4 Using the adaptor remover J 46173 install the spring bases springs spring retainers and collets Check the collets to be sure they are locked in place 5 Remove the adaptor remover J 46173 from the cylinder head 6 Install the cylinder head Refer to section 1 2 2 1 19 7 Valve Stem Seal Replacement Replace the valve stem seal as follows NOTE Always replace the valve stem seal if the valve has been removed 1 Remove the cylinder head from the engine Refer to section 1 2 1 NOTE Use care during removal to not damage the valve guides and valve stems All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 159 1 19 VALVES 2 Remove the collets spring retainer valve spring and spring base See Figure 1 123 J 46174 1 Valve Stem Seal 3 Valve Guide 2 Valve Stem Figure 1 123 Valve Stem Seal Replacement 3 Remove the valve stem seal Do not remove the valve 4 Lubricate the valve stem a
8. ESEL CORPORATION From Bulletin 1 MBE4000 06 1 173 1 22 CAMSHAFT AND CAMSHAFT SENSOR 15 Pull the tappets valve lifters out of the block Mark the tappets in order as removed See Figure 1 133 1 Cylinder Block 3 Tappet valve lifter 2 Camshaft Entry Hole 4 Fuel Pump Driven Gear Figure 1 133 Removing the Tappets 16 Clean and inspect the tappets Replace the tappets if there are signs of damage or wear or if any of the measurements do not meet the specifications listed in Table 1 49 Repair Stage Specifications mm in Tappet Outside Diameter Standard 29 931 29 952 1 1784 1 1792 Tappet Outside Diameter Repair Stage 30 444 30 465 1 1986 1 1994 Tappet Housing Diameter in cylinder Standard 30 000 30 021 1 1811 1 1819 block Tappet Housing Diameter in cylinder Repair Stage 30 500 30 525 1 2008 1 2018 block Table 1 49 Valve Tappet Specifications a Measure the outside diameter of each tappet b Measure the diameter of the tappet housing in the cylinder block 17 Inspect the camshaft Refer to section 1 22 2 1 Rev 3 04 All information subject to change without notice 1 174 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 1 22 2 Camshaft Installation Install the camshaft as follows 1 Lubricate the tappets with a light coating of clean engine oil 2 Install the tappets in the block in order as removed NOT
9. ICE Do not damage the camshaft bearings in the crankcase If the camshaft bearings are damaged the crankcase will have to be replaced 3 Install the camshaft a Lubricate the cams and camshaft journals with a light coating of clean engine oil b Attach the camshaft guide tool J 46183 to the camshaft c Rotate the camshaft until the marked gear teeth on the camshaft gear are aligned with the marked tooth on the crankshaft gear See Figure 1 134 42083 1 Camshaft Gear 2 Crankshaft Gear Figure 1 134 Aligning the Marked Gear Teeth d Carefully insert the camshaft into the block 4 Install the flywheel housing Refer to section 1 16 2 5 Install the oil pan Refer to section 3 1 2 All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 175 1 22 CAMSHAFT AND CAMSHAFT SENSOR 6 Install the fuel pump drive gear on the front of the camshaft as removed Torque the bolts to 60 N m 44 lb ft 7 Turn the engine on the stand until it is right side up Install the unit pumps Refer to section 2 1 2 9 Install the camshaft front cover on the cylinder block as removed Torque the mounting bolts to 50 N m 37 lb ft 10 Install the fan support 11 Install the vibration damper Refer to section 1 11 2 12 Lubricate the pushrods with a light coating of clean engine oil Install the pushrods and the rocker arm
10. MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 1 16 1 Flywheel Housing Removal Remove the flywheel housing as follows 1 With the engine removed from the vehicle remove the flywheel Refer to section 1 12 1 Remove the crank angle position sensor Refer to section 2 6 3 Remove the camshaft TDC sensor Refer to section 1 22 3 2 3 4 Remove the starter from the block 5 Remove the crankcase breather from the flywheel housing 6 Remove the flywheel housing mounting bolts Then remove the flywheel housing from the cylinder block See Figure 1 78 7 Remove and discard the flywheel housing gasket 1 16 2 Flywheel Housing Installation Install the flywheel housing as follows 1 Check the flywheel housing for damage 2 Install a new rear radial seal Refer to section 1 8 2 3 Using a suitable scraper such as a putty knife clean the mating surfaces of the cylinder block and the flywheel housing Remove any dirt or grease and all traces of old sealant 4 Coat the mating surfaces of the flywheel housing and the cylinder block with Loctite 574 sealant Install a new flywheel housing gasket 6 Put the flywheel housing onto the cylinder block making sure that it clears the oil pan and that the bolt holes line up 7 Install the flywheel housing mounting bolts and tighten them 70 N m 52 lb ft 8 Install the starter 9 Install the crankcase breather on the flywheel hous
11. MBE4000 SERVICE MANUAL 1 9 CRANKSHAFT ASSEMBLY The crankshaft is precision forged with seven main bearings and eight custom forged counter weights and a vibration damper at the front end For an exploded view of the crankshaft main bearings and main bearing caps see Figure 1 42 41937 1 Crankshaft 5 Lower Bearing Shell center 2 Upper Bearing Shell s 6 Main Bearing Cap s 3 Upper Bearing Shell center 7 Main Bearing Cap center 4 Lower Bearing Shell s 8 Main Bearing Cap Bolt Figure 1 42 Crankshaft Main Bearings and Main Bearing Caps All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 57 1 9 1 9 1 CRANKSHAFT ASSEMBLY Crankshaft Removal Remove the crankshaft as follows DA ON oe gt ES A DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically Remove the engine from the vehicle
12. ce of the cylinder 4 Using a plastic scraping tool carefully scrape off any combustion residues from the combustion area in the cylinder in order to avoid damage to the piston rings when the piston is removed 5 Install the engine cranking tool J 46167 Refer to section 1 15 1 Rev 3 04 All information subject to change without notice 1 108 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION for installation See Figure 1 80 MBE4000 SERVICE MANUAL 6 Be sure the connecting rods and the bearing caps are marked so that they can be matched ee 2 l 41981 1 Bearing Cap 2 Connecting Rod Figure 1 80 Checking Rod and Bearing Cap Markings All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 108a 1 17 PISTON PISTON RING AND CONNECTING ROD 7 Remove and inspect the oil spray nozzles See Figure 1 81 Refer to section 3 2 1 Replace them if damaged 1 Oil Spray Nozzle 2 Cylinder Liner Figure 1 81 Location of Oil Spray Nozzle Rev 3 04 All information subject to change without notice 1 108b From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 15 Using a dial gauge and holder measure the piston projection relative to c
13. ckets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 21 Install the engine in the vehicle 1 17 3 Piston Ring Replacement Replace the piston ring as follows 1 Remove the piston Refer to section 1 17 1 2 Remove the rings using suitable ring pliers Remove the rings in order starting from the top of the piston down See Figure 1 89 See Figure 1 90 Rev 3 04 All information subject to change without notice 1 116 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL m EN J i co aN eae 41990 1 Keystone Piston Ring Groove l 3 Double Chamfered Oil Control Ring with Garter Spring Groove III 2 Taper Face Ring with Internal Angle Groove II 4 Piston Figure 1 89 Piston Rings 41991 1 Piston 2 Ring Pliers Removing the Piston Rings Figure 1 90 All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 117 1 17 PISTON PISTON RING AND CONNECTING ROD 3 Clean all the carbon from the ring grooves Be sure the grooves are not damaged and that there are n
14. de 4 Using valve stem seal installer protector J 46174 install new valve stem seals and seat the valve stem seal with valve stem seal installer JI 46184 Refer to section 1 20 3 5 Using the adaptor J 46173 install the spring seats springs spring retainers and collets keepers Check the keepers to be sure they are locked in place 6 Remove the adaptor J 46173 from the cylinder head 7 Install the cylinder head 1 20 3 Valve Stem Seal and Valve Stem Sealing Ring Replacement in the EGR Engine Replace the valve stem seal and valve stem sealing ring as follows NOTE In the EGR engine always replace the valve stem seal and valve stem sealing ring if the valve has been removed 1 Remove the cylinder head from the engine NOTE Use care during removal to not damage the valve guides and valve stems Remove the keeper spring retainer valve spring and spring seat 2 3 Remove the valve stem seal and discard 4 Remove the valve 5 Remove the valve stem sealing ring and discard Repeat procedure for all remaining valves D Clean all parts before reinstalling components 7 Install the valve stem sealing ring in the valve guide and then install the valve in the head Repeat procedure for all remaining valves All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 163 1 20 EGR VALVES 8 Lubricate the
15. easurements differ by more than 0 02 mm 0 0008 inch replace the crankshaft Refer to section 1 9 1 Rev 3 04 All information subject to change without notice 1 66 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL b For the main bearing journal note the outside diameter of the journal Example D 4 0850 inches c From the value for the bearing shell diameter subtract the value for the journal diameter This result is the radial play Example D D 0 0025 inch NOTE In the above example both measurements belonged to repair stage Undersize 0 010 inch Listed in Table 1 17 is the correct repair stage for each measurement 11 Install the crankshaft into the crankcase Refer to section 1 9 2 A DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 12 Install the engine in the vehicle 1 9 2 3 Crankshaft End Play Checking Check t
16. ent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 7 Install the engine in the vehicle 1 9 3 Crankshaft Gear Replacement _ Replace the crankshaft gear as follows Rev 3 04 All information subject to change without notice 1 80 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 1 Remove the engine from the vehicle and install on an engine stand 2 Remove the flywheel housing Refer to section 1 16 1 Rotate the crankshaft until the marked gear tooth on the crankshaft gear is aligned between the two similarl
17. er 5 Cover Housing Gasket 2 Oil Deflector 6 Oil Pan 3 Front Radial Seal 7 Housing Mounting Bolt 4 Front Cover Housing Figure 1 61 Front Cover Housing 1 10 1 Front Cover Housing Removal Remove the front cover housing as follows 1 Park the vehicle on a level spot set the parking brakes and chock the tires To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Tilt the hood 3 Remove the front engine mounting bolts attaching the front cover housing to the front crossmember Rev 3 04 All information subject to change without notice 1 82 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION A DANGER FALLING COMPONENT To avoid injury from a falling component ensure a proper lifting device is used 2 Install the flywheel over the guide pins J 46172 Align the dowel on the crankshaft with the guide hole in the flywheel arrow See Figure 1 67 3 Install the engine cranking tool J 46167 in the flywheel housing and secure with two bolts Insert the pin and make sure the tool is blocked Refer to section 1 15 2 41966 Figure 1 67 Flywheel Alignment Mark NOTE Verify the alignment of the crankshaft dowel with the guide hole in the flywheel 4 With a light coating of engine oil lubricate the threads of the ten multipoint socket head flywheel bo
18. he crankshaft end play as follows 1 Remove the crankshaft Refer to section 1 9 1 All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 77 1 9 CRANKSHAFT ASSEMBLY 2 Check the width of the center main bearing journal If damage or cracks are present replace the crankshaft See Figure 1 57 E WIDTH OF MAIN CENTER JOURNAL Figure 1 57 Measuring the Width of the Center Journal Rev 3 04 All information subject to change without notice 1 78 F rom Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 3 Check the width of the center main bearing shell If damage or cracks are present replace the crankshaft See Figure 1 58 TO Cc Z eenen eee J WIDTH OF CENTER MAIN BEARING SHELL Ji Figure 1 58 Measuring the Width of the Center Main Bearing Shell NOTE To obtain a correct value for crankshaft end play the width of each bearing shell and its corresponding journal must belong to the same repair stage both must be Standard Undersize 0 020 inch etc 4 Calculate the end play or axial play fore to aft movement of the crankshaft If the end play is less than 0 190 mm 0 0074 inch or more than
19. ing 10 Install the flywheel Refer to section 1 12 2 11 Install the camshaft TDC sensor Refer to section 1 22 3 12 Install the crank angle position sensor Refer to section 2 6 3 All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 105 1 16 FLYWHEEL HOUSING DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 13 Install the engine in the vehicle 3 Rev 3 04 All information subject to change without notice 1 106 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 1 17 PISTON PISTON RING AND CONNECTING ROD The pistons are made of aluminum alloy with ring carriers and a shallow combustion chamber recess The pistons are cooled by oil spray nozzles See Figure 1 79 for an exploded view of the piston and connecting rod assembly
20. lts All information subject to change without notice Copyright DETROIT DIESEL CORPORATION 1 91 1 12 FLYWHEEL 5 Tighten the eight bolts in two stages In each stage use an alternate sequence to tighten the bolts as listed in Table 1 21 Max Shaft Length mm in Tightening Stage Torque Value N m Ib ft 77 0 3 03 Stage 1 200 147 5 77 0 3 03 Stage 2 90 degrees Table 1 21 Tightening Stages Flywheel Mounting Bolts a Install eight bolts to hold the flywheel in position b Remove the two guide pins J 46172 and install the two remaining bolts in their place c Tighten the bolts in an alternate tightening sequence 200 N m 147 5 lb ft d Using the same tightening sequence turn the flywheel bolts 90 degrees 6 Remove the engine cranking tool J 46167 Install the inspection cover on the flywheel housing with two bolts Tighten the bolts 25 N m 18 lb ft 7 Install the crank angle position sensor into the flywheel housing Refer to section 2 6 3 8 Install the clutch on the flywheel 9 Install the transmission 1 12 3 Flywheel Inspection Perform the following procedures for inspecting the flywheel 1 12 3 1 Flywheel Inspection Inspect the flywheel as follows 1 Remove the flywheel Refer to section 1 12 1 2 Thoroughly clean the flywheel and check it for cracks scoring burned areas or rough spots Rev 3 04 All information subject to change without notice 1 92 From Bulletin 1
21. nd valve stem seal installer protector J 46174 with a light coating of clean engine oil NOTE The installer prevents the groove on the valve stem from damaging the seal 5 Push the valve stem seal installer protector J 46174 over the valve stem until it makes contact with the valve 6 Slide the seal over the installer protector and the valve stem Using fingers press the seal into place until the seal seats on the valve guide NOTE Check the seal to make sure it is correctly seated on the valve guide 7 Remove the installer from the valve stem seal and the valve 8 Install the collets spring retainer valve spring and spring base as removed 9 Repeat the procedure for the other valves 10 Install the cylinder head Refer to section 1 2 2 Rev 3 04 All information subject to change without notice 1 160 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 1 20 2 Valve Installation in the EGR Engine Perform the following steps in installing the valves in the EGR engine 1 Install the valve stem sealing ring in the valve guide in the cylinder head 2 Lubricate each valve with a light coating of engine oil 3 Install the valves in order as marked on removal NOTE In the EGR engine always replace the valve stem seal and valve stem sealing ring if the valve has been removed Check the valve stem seal to make sure it is correctly seated on the valve gui
22. ndersize 1 00 0 040 46 74 46 81 1 840 1 843 47 000 47 062 1 8504 1 8528 Table 1 20 Bearing Shell and Bearing Journal Width 5 Install the crankshaft Refer to section 1 9 2 6 Using a dial gauge and holder measure the end play of the crankshaft Measure at the front end of the crankshaft with the crankshaft fully installed and all the bearing caps tightened to the correct torque See Figure 1 59 41955 1 Dial Gauge 3 Crankshaft 2 Dial Gauge Holder 4 Screwdriver Figure 1 59 Measuring the End Play of the Crankshaft a Setup a dial gauge and a dial gauge holder on the front end of the crankshaft Set the dial gauge to 5 mm 0 2 inch preload All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 79 1 9 CRANKSHAFT ASSEMBLY b Move the crankshaft all the way forward by prying on one of the bearing caps then reset the dial gauge to 0 zero c Move the crankshaft all the way aft Note the end play on the dial gauge d Ifthe end play does not correspond to the calculated amount in the example above 0 0090 inch replace the crankshaft DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prev
23. ngth as listed in Table 1 48 Outside Diameter of Valve Tappets Normal 29 931 29 952 1 1784 1 1792 Outside Diameter of Valve Tappets Repair Stage 30 444 30 465 1 1986 1 1994 Diameter of Tappet Seats in cylinder Normal 30 000 30 021 block 1 1811 1 1819 Diameter of Tappet Seats in cylinder Repair Stage 30 500 30 525 block 1 2008 1 2018 Total Length of Pushrods 345 0 346 5 mm 13 58 13 64 Maximum Pushrod Warpage 0 5 mm 0 02 Maximum Length of Rocker Arm Mounting Bolts 91 mm 3 6 Table 1 48 Rocker Arm Specifications 4 Install the rocker arm assembly a Position the rocker arm assembly on the cylinder head as removed b Install the mounting bolts in the holes in the cylinder head c Tighten each mounting bolt 60 N m 44 lb ft Final angular tightening 90 degrees 5 Adjust the valve lash Refer to section 1 19 3 6 Install the cylinder head cover on each cylinder head Refer to section 1 1 2 All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 169 1 22 CAMSHAFT AND CAMSHAFT SENSOR 1 22 CAMSHAFT AND CAMSHAFT SENSOR The camshaft is made of induction hardened steel and has seven main bearings Each cylinder has cams for intake and exhaust valves and a unit pump 1 22 1 Camshaft Removal Remove the camshaft as follows NOTE Before removing the camshaft clean the engine to prevent road dirt g
24. o burrs or combustion residue in the grooves 4 Before installing the new rings check the end gap The correct end gap measurements are listed in Table 1 26 Ring Designation Groove Gap When New Maximum End Gap mm in mm in Keystone 0 45 to 0 60 1 0 039 0 018 to 0 024 Taper Faced with Internal 0 40 to 0 55 1 0 039 Angle 0 016 to 0 022 Double Chamfered Oil 0 40 to 0 55 1 0 039 Control with Garter Spring 0 016 to 0 022 Table 1 26 Piston Ring End Gap Dimensions NOTE Check the end gap of the upper two piston rings first The garter spring must be removed from the third lowest piston ring before you can measure its end gap a Place each ring squarely into the combustion area of a cylinder liner or cylinder then measure the end gap using a feeler gauge See Figure 1 91 Figure 1 91 Checking the Ring End Gap b Remove the spring garter from the third lowest ring then measure its gap in the same way as the other two rings Rev 3 04 All information subject to change without notice 1 118 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 14 Inspect the valve springs Check the springs for correct pressure using the values listed in Table 1 43 If damaged replace the springs Length Without Load 69 7 2 74 Length Under Load of 382 418 N 86 94 Ibf 49 1 9 Table 1 43 Spring Specifications Intake and Exhaust Valves 1 19
25. on Inspect the crankshaft as follows 1 Remove the crankshaft Refer to section 1 9 1 2 Clean the crankshaft with a chamois 3 Check the crankshaft for condition If cracks or fissures are found replace the crankshaft 4 Using the hardness tester 000 589 53 21 00 test the hardness of the journals Each journal must pass the hardness test at two thirds of its circumference If it doesn t either replace the crankshaft or have it re hardened a Place a hard base underneath the bearing journal to be tested All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 65 1 9 CRANKSHAFT ASSEMBLY b Test hardness all the way around the journal circumference Hardness must be 53 to 59 HRC as listed in Table 1 13 Main Bearing and Connecting Rod Journal Hardness 53 to 59 HRC Rockwell hardness Permissible Deviation From True of Crankshaftt 0 09 0 004 Permissible Out Of Round for Main and Connecting Rod 0 01 0 0004 Bearing Journals When New reground Permissible Out Of Round for Main and Connecting Rod 0 02 0 0008 Bearing Journals Wear Limit Fillet Radii of Main Bearing Journals 4 2 4 5 0 165 0 177 Fillet Radii of Connecting Rod Bearing Journals 3 7 4 0 0 146 0 157 Crown of Main Bearing Journals and Connecting Rod 0 000 0 004 0 0000 0 0002 Journals Main Bearing Outside Diameter diameter of bearing 111 000 111 02
26. rankcase top dead center at all the pistons See Figure 1 88 Axt g y Z ef hho a A PROJECTION 0 244 TO 0 715 mm 0 0096 to 0 0281 in 41989 1 Piston 2 Cylinder Liner Figure 1 88 Piston Projection at Top Dead Center TDC 16 Ifthe piston projection dimensions are not between 0 244 and 0 715 mm 0 0096 and 0 0281 inch replace the piston Listed in Table 1 25 Piston Projection from TDC 0 244 to 0 715 0 0096 to 0 0281 Table 1 25 Piston Projection Specifications 17 Remove the engine cranking tool J 46167 NOTICE Be careful not to damage the oil spray nozzles Damaged oil spray nozzles could result in a loss of oil pressure and cause engine damage 18 Install the oil spray nozzles as removed Be sure they are seated and aligned correctly Refer to section 3 2 2 19 Install the oil pan Refer to section 3 1 2 20 Install each cylinder head as removed Refer to section 1 2 2 All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 115 1 17 PISTON PISTON RING AND CONNECTING ROD A DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter bra
27. rease or other foreign matter from contaminating the exposed gears and other engine parts 1 Drain the engine oil A DANGER FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution all provided lifter brackets must be used NOTICE A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result The brackets are designed to lift vertically 2 Remove the engine from the vehicle A WARNING FALLING ENGINE To avoid injury from a falling engine ensure the engine is securely attached to the engine overhaul stand before releasing the lifting sling Install the engine on an engine stand 4 Remove the unit pumps Refer to section 2 1 1 5 Remove the vibration damper Refer to section 1 11 1 Rev 3 04 All information subject to change without notice 1 170 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 6 Remove the fan support 7 Remove the eight mounting bolts attaching the camshaft front cover to the cylinder block See Figure 1 130 42079 Figure 1 130 Removing the Camshaft Front Cover
28. valve stem and valve stem seal installer protector J 46174 with a light coating of clean engine oil J 46184 1 Valve Stem Seal 3 Valve Guide 2 Valve Stem 4 Valve Stem Sealing Ring installed Figure 1 126 Valve Stem Seal and Sealing Ring Replacement NOTE The installer protector prevents the groove on the valve stem from damaging the valve stem seal 9 Push the valve stem seal installer protector J 46174 over the valve stem until it makes contact with the valve 10 Slide the valve stem seal over the installer protector and the valve stem Using fingers press valve stem seal into place until the seal seats on the valve guide 11 Remove the valve stem seal installer protector J 46174 12 Using valve stem seal installer J 46184 and the appropriate hammer drive the valve stem seal on the guide NOTE Check the seal to make sure it is correctly seated on the valve guide 13 Remove the installer from the valve stem seal and the valve 14 Install the keeper spring retainer valve spring and spring seat as removed 15 Repeat the procedure for the other valves Rev 3 04 All information subject to change without notice 1 164 From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL 3 Inspect each pushrod to be sure it is correctly seated in its tappet Replace any pushrods that are warped are not correctly seated or are not the correct le
29. y marked teeth on the camshaft gear All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 WMBE4000 06 1 80a 1 9 CRANKSHAFT ASSEMBLY 4 Pull the crankshaft gear off the end of the crankshaft If necessary use a plastic hammer to loosen the gear See Figure 1 60 A MAIN JOURNAL DIAMETER OTHER THAN CENTER B CONNECTING ROD JOURNAL DIAMETER E WIDTH OF CENTER MAIN JOURNAL 1 Crankshaft 3 Crankshaft Gear 2 Guide Pin Figure 1 60 Removing the Crankshaft Gear 5 Remove the crankshaft from the engine Refer to section 1 9 1 6 Clean the crankcase cylinder block and oil pan Remove all burrs and sharp edges from the oil passage holes 7 Press the gear onto the end of the crankshaft Make sure the chamfer on the gear is facing outward See Figure 1 60 8 Install the crankshaft Refer to section 1 9 2 9 Install the engine Rev 3 04 All information subject to change without notice 1 80b From Bulletin 1 MBE4000 06 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION MBE4000 SERVICE MANUAL This page intentionally left blank All information subject to change without notice Rev 3 04 6SE412 0403 Copyright 2006 DETROIT DIESEL CORPORATION From Bulletin 1 MBE4000 06 1 81 1 10 FRONT COVER HOUSING 1 10 FRONT COVER HOUSING For an exploded view of the front cover housing see Figure 1 61 1 Vibration Damp
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