7 EXHAUST SYSTEM
Contents
1. 44141 1 Lower Coolant Inlet Pipe 4 Shut off Valve Housing Bolt 2 qty 2 Membrane 4 Air Supply Line 3 Air Line Mounting Bolts Figure 7 34 Installing Coolant Inlet Pipe 16 Tighten EGR shutoff valve using two bolts Torque to 35 N m 26 Ib ft 17 Install and attach air supply line using two mounting bolts Torque to All information subject to change without notice 7 42 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 7 5 EGR CONTROL VALVE GAS OUTLET PIPE AND GAS MIXER The EGR control valve controls the quantity of exhaust gas returning back to the intake manifold 7 5 1 Removal of EGR Control Valve Gas Outlet Pipe and Gas Mixer Remove the EGR control valve gas outlet pipe and gas mixer as follows 1 Remove the EGR control valve cover mounting bolts attached to the front lifter bracket and to the rear of the EGR valve See Figure 7 35 2 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 44159 1 EGR Control Valve Cover Mounting Bolts Figure 7 35 Removal of EGR Control Valve Cover All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 43 EGR CONTROL VALVE GAS OUTLET PIPE AND GAS M2. EGR Cooler to Sheet Metal Support bolts of the engine All information subject to change without notice 7 28 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 8 Remove the two bolts mounting the lower coolant inlet pipe to the block and remove the bracket bolt just below the membrane which attaches the lower coolant inlet pipe to the block Remove gasket See Figure 7 21 44141 1 Lower Coolant Inlet Pipe 4 Shut off Valve Housing Bolt 2 qty 2 Membrane 4 Air Supply Line 3 Air Line Mounting Bolts Figure 7 21 Removing Coolant Inlet Pipe 9 Pull down on the lower coolant inlet pipe to loosen it from the upper pipe Remove the membrane also NOTE Have a container nearby to drain any unused coolant from the inlet pipes 10 Remove the two shut off valve housing bolts that hold the valve housing to the EGR cooler support See Figure 7 21 11 Remove the air line mounting bolts Loosen and remove the air supply line from the EGR shut off valve See Figure 7 21 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 29 74 EGR COOLER AND COOLER SUPPORT BRACKET 12 Loosen and remove the four bolts from the four tighteni
3. MBE 4000 SERVICE MANUAL 4 Pull the coolant outlet pipe away from the cooler leaving the connecting membrane in the EGR cooler boss 5 Remove the EGR temperature sensor from the reed valve housing and disconnect the sensor wiring harness where it is attached with cable ties to the reed valve housing mounting bracket See Figure 7 19 2 fmi beso 44143 1 EGR Air Temperature Sensor 2 Reed Valve Housing Bracket Figure 7 19 Removing EGR Air Temperature Sensor 6 Remove the three bolts from the front bracket that holds and stabilizes the reed valve housing to the thermostat housing See Figure 7 19 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 27 74 EGR COOLER AND COOLER SUPPORT BRACKET Remove the two front sheet metal support to cooler support bolts See number 1 in graphic See Figure 7 20 2 Front Sheet Metal Support Figure 7 20 Removing Front Sheet Metal Support NOTE Do not remove the eight mounting bolts attaching the reed valve housing to the cooler at this time 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 44139 1 Front Sheet Metal Support to Cooler Support Bolts 3
4. Remove the two M8 x 50 mm bolts that hold the EPV valve on the left side of bracket DOO GUAE L o9 Remove the two M8 x 50 mm bolts that hold the Wabco solenoid valve on the right side of bracket 8 Remove the two M14 x 25 mm bolts that hold the EPV solenoid valve bracket to the block All information subject to change without notice 7 52 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 7 6 2 Installation of EPV Valve and Wabco Air Solenoid Valve Perform the following steps to install the EPV valve Wabco air solenoid valve and all corresponding connections 1 Install the EPV solenoid valve bracket to the block with two M14 x 25 mm bolts Torque to 100 N m 74 lb ft 2 Mount the Wabco solenoid valve on right side of bracket using two M8 x 50 mm bolts Apply 25 N m 19 lb ft tightening torque See Figure 7 43 L 7 4 9 b L GTI NU FA ETUR Im ap J 1 EPV Electronic Proportional Valve 6 Hollow Screw 2 Turbo Brake Actuator 7 Small Hollow Screw 3 Electric Wiring Harness Terminals 8 EPV Valve Inlet 4 5 Wabco Valve 9 EPV Valve Outlet hidden Solenoid Valve Mounting Bolts 10 EPV Valve Mounting Bolts Figure 7 43 Installing the EPV Valve Wabco Solenoid Valve 3 Mount the EPV valve on left side of bracket using two M8 x 50 mm bolts Torque to 25 N m 19 lb ft tightening torque 4 Install large hollow screw in threaded con
5. 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 39 74 EGR COOLER AND COOLER SUPPORT BRACKET H NOTICE There is a possibility of installing the air temperature sensor wrong sided Take care to install it properly NT JHI m W 0 basi 44143 1 EGR Air Temperature Sensor Figure 7 32 71 40 From Bulletin 6 MBE4000 04 2 Reed Valve Housing Bracket Installing the EGR Air Temperature Sensor and Housing Bracket All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 14 Install the four tightening tools with four tightening clamps that hold the EGR cooler to the cooler support bracket Apply 10 N m 8 lb ft clamping force to clamps See Figure 7 33 NX bs J 44140 1 EGR Cooler 3 Clamps 4 Qty 2 Tightening Tool for Clamps 4 Clamp Bolts Figure 7 33 Installing Tightening Clamps on the Cooler All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 41 74 EGR COOLER AND COOLER SUPPORT BRACKET 15 Fit lower coolant inlet pipe into the symmetric membrane Install the two bolts in the metal gasket and engine block Also install bolt in pipe support bracket Torque both bolts to 35 N m 26 lb ft
6. 8 Install the four gas mixer mounting studs into the intake manifold 9 Install metal gasket over studs m gt Fit gas mixer over mounting studs and push on as far as possible _ Install the gas mixing pipe into the air inlet pipe of mixer using a new metal gasket See Figure 7 40 NOTICE To avoid any engine damage ensure that the gas passage of the mixing pipe is turned towards the intake manifold NOTE Due to its ackward shape gas outlet pipe must be mounted to gas mixer before the gas mixer can be firmly attached to intake manifold 12 Mount gas outlet pipe to gas mixer using a new metal gasket and two M8 x 16 mm bolts Adjust gas mixer if necessary to accommodate the gas outlet pipe Torque to 25 N m 19 lb ft 13 Position support bracket in place for gas outlet pipe Install bracket using three M8 x 16 mm bolts Torque to 25 N m 19 lb ft 14 Install the air inlet pipe to the gas mixer using four nuts Torque to 50 N m 37 Ib ft See Figure 7 4 15 Install the turbo boost air intake temperature sensor to the gas mixer All information subject to change without notice 7 50 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 7 6 EPV ELECTRONIC PROPORTIONAL VALVE AND WABCO AIR SOLENOID VALVE Listed in Table 7 4 is each proportional valve listed and the component it activates Exhaust flap enable EGR shutoff valve or boost con
7. I I O amp I l All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 25 74 EGR COOLER AND COOLER SUPPORT BRACKET 7 4 EGR COOLER AND COOLER SUPPORT BRACKET The EGR system is equipped with a single pass cooler Exhaust gasses coming from the first three cylinders are directed through the EGR shut off valve through the cooler and reed valves past the EGR control valve and the mixer then back to the cylinder 7 4 1 EGR Cooler and Support Bracket Removal Remove the EGR cooler and its support bracket as follows NOTE The exhaust manifold and the gas inlet pipe have already been removed at this point It is then possible to remove the cooler and support bracket without removing the throttle valve first 1 Disconnect the coolant vent line located on top of the EGR cooler See Figure 7 18 2 4 5 44133 1 Coolant Outlet Pipe Bolts 4 EGR Coolant Outlet Pipe 2 Coolant Vent Line 5 Coolant Outlet Pipe Bracket 3 Membrane Figure 7 18 Removal of Coolant Vent Line and Coolant Outlet Pipe 2 Remove the bolt attaching the coolant outlet pipe bracket to the pipe Remove the bracket 3 Remove the two bolts attaching the coolant outlet pipe flange to the coolant pump Discard the gasket All information subject to change without notice 7 26 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION
8. time push the cooler flange into the membrane See Figure 7 30 NOTE The oil filter and oil filter cover should be removed for good clearance when removing and installing the EGR cooler assembly All information subject to change without notice 7 38 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 8 Insert the connecting membrane in the EGR cooler boss using industrial petroleum grease and push the EGR coolant outlet pipe onto the cooler See Figure 7 31 E UI j l 3 lw EL 2 Ea j 1 44133 1 Coolant Outlet Pipe Bolts 4 EGR Coolant Outlet Pipe 2 Coolant Vent Line 5 Coolant Outlet Pipe Bracket 3 Membrane Figure 7 31 Installation of Coolant Vent Line and Coolant Outlet Pipe 9 Attach front sheet metal support to cooler support using two M8 x 12 mm bolts Torque to 25 N m 19 lb ft 10 Install the bolt to the coolant outlet pipe bracket Torque to 35 N m 26 lb ft See Figure 7 31 11 Install coolant vent line Torque to 25 N m 19 lb ft 12 Install the reed valve housing bracket to the thermostat housing with the three mounting bolts Torque to 25 N m 19 lb ft See Figure 7 32 13 Install the EGR air temperature sensor into reed valve housing flange Torque to 25 N m 19 lb ft Using plastic ties attach remainder of sensor to reed valve housing bracket See Figure 7 32 All information subject to change without notice 6SE412
9. 04 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 13 73 EGR EXHAUST MANIFOLD 7 3 EGR EXHAUST MANIFOLD The EGR exhaust manifold is a three piece manifold The manifold assembly is assembled apart from the cylinder heads then the entire assembly is installed to the heads 7 3 1 EGR Exhaust Manifold Removal Remove the EGR exhaust manifold as follows NOTE Although not shown in the below graphic the heat exchanger and heat exchanger bracket are still installed on the engine before the exhaust manifold is removed Remove the bolt that attaches the smaller front heat shield to the main heat shield then remove the three bolts attaching the shield to the bottom of the exhaust manifold Now remove the heat shield See Figure 7 6 NOTE 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 44109 1 Upper or Main Heat Shield 2 Lower or Front Heat Shield Figure 7 6 Removal or Installation of the Exhaust Manifold Front Heat Shield All information subject to change without notice 7 14 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION 2 Loosen and remove outside nut that is resting on outside face of stud bracket See Figure 7 7 MBE 4000 SERVICE MANUAL 44121 1 Stud Bracket 2 Stud Nut 3 Stud 2 Exhaust Gas Inle
10. 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 10 Remove the fey rings 2 in each groove from the two grooves of each exhaust manifold end piece See Figure 7 13 44111 1 Fey Ring 2 Exhaust Manifold Grooves Figure 7 13 Installing or Removing Rings in Exhaust Manifold Grooves NOTE EGR cooler and cooler bracket will need to be removed before removing the exhaust manifold gaskets Refer to section 7 4 1 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 21 73 EGR EXHAUST MANIFOLD 11 Remove exhaust manifold two piece gasket from cylinder heads See Figure 7 14 7 3 2 EGR Exhaust Manifold Installation Install the EGR exhaust manifold as follows NOTE The three piece exhaust manifold and its related parts are first put together as an assembly it is then mounted to the cylinder heads as one unit 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 3 44110 1 Two Piece Gasket 3 Gasket Overlap Rear overlaps the Front 2 Guide Studs Figure 7 14 Removal or Installation of Exhaust Manifold Gaskets See Figure 7 14 All information subject to change without notice 7 22 From Bulletin 6 MBE4000 04
11. 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL NOTICE There is a front and rear exhaust manifold gasket and the rear gasket is marked with a deep notch on top The front gasket must be installed before the rear gasket can be installed NOTE At this point the heat exchanger and heat exchanger mounting bracket should be installed on the block but the remaining exhaust manifold installation graphics will not show these two parts installed NOTE The exhaust manifold gasket studs are to be removed after installing the EGR cooler support bracket 2 Install stud with M8 nut with collar onto exhaust manifold center piece Do not tighten nut at this point NOTE Stud must be installed on exhaust manifold center piece before fitting the two end pieces of manifold into center piece 1 Stud 3 Exhaust Manifold Center Piece 2 M8 Nut with Collar Figure 7 15 Installing Stud in Exhaust Manifold Center Piece All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 23 n EGR EXHAUST MANIFOLD Install the fey rings 2 in each groove in the two grooves of each exhaust manifold end piece See Figure 7 16 44111 4 Fit fey ring ends of exhaust manifold pieces into center part of exhaust manifold Do not use lubricant See Figure 7 12 Bolt upper heat shield to exhaust manifold using th
12. 7 EXHAUST SYSTEM Section 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 A EXHAUST MANIFOLD a eaZ irona Oea boat yR aa EZ 70 vac EXHAUST BRAKE ASSEMBLY EGR EXHAUST MANIFOLD occas ene aia ia eae EGR COOLER AND COOLER SUPPORT BRACKET EGR CONTROL VALVE GAS OUTLET PIPE AND GAS MIXER EPV ELECTRONIC PROPORTIONAL VALVE AND WABCO AIR SOLENOID VALV TTT HENGST BREATHER FILTER ADDITIONAL INFORMATION All information subject to change without notice 7 2 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION 7 2 4 MBE 4000 SERVICE MANUAL Exhaust Brake Assembly Installation Install the exhaust brake assembly as follows 1 2 So ie M es Clean the mating surfaces on the brake valve housing and the turbocharger Install the brake valve housing on the turbocharger by slipping the housing over the turbocharger studs Tighten the locknuts 50 N m 37 Ib ft To avoid injury from the sudden release of a high pressure hose connection wear a face shield or goggles Install the compressed air line on the exhaust brake cylinder Clean the sealing surfaces on the exhaust pipe and brake valve housing 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 All information subject to change without notice 6SE412 0206 Copyright 20
13. IXER mounting bolts attaching the back cover bracket to the control valve See Figure 7 36 Remove back bracket 1 EGR Control Valve Back Mounting Bracket 2 Push Mount Cable Tie Figure 7 36 Removing the Back Control Valve Cover Bracket All information subject to change without notice 7 44 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION 3 Remove the two bolts from gas outlet pipe attaching the pipe to the gas mixer See Figure 7 37 MBE 4000 SERVICE MANUAL 2 44160 1 Gas Outlet Pipe Flange 2 Gas Outlet Pipe Mounting Bracket Figure 7 37 Removal of EGR Gas Outlet Pipe 4 Remove the metal gasket 5 Remove the three bolts that attach the gas outlet pipe mounting bracket to the intake manifold and to the outlet pipe See Figure 7 37 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 45 75 EGR CONTROL VALVE GAS OUTLET PIPE AND GAS MIXER 6 Pulloutlet pipe away from mixer and from the EGR control valve exposing the membrane in the control valve See Figure 7 38 7 Remove membrane from the EGR control valve 44136 1 Membrane 2 EGR Temperature Sensor Figure 7 38 Removing the Symmetric Membrane on Gas Outlet Pipe Side 8 Disconnect wiring harness terminal from valve connector See Figure 7 39 All information subject to change withou
14. Related Parts All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 55 77 HENGST BREATHER FILTER 2 Unsnap the filter cap and remove the spring and diaphragm insert from centrifugal filter Remove the two assembly bolts from the breather filter assembly and pull the breather assembly out See Figure 7 45 44176 3 Remove the three plastic clamps holding the breather piping to the bracket Remove the piping See Figure 7 44 4 Remove the two bolts from the air compressor and the block that are holding the piping bracket on Remove the piping bracket 5 Remove the three M8 x 35 mm bolts holding the breather filter to the timing case Remove the two M8 x 25 mm bolts holding the breather filter to the block Remove the breather filter 7 7 2 Installation of Hengst Filter Filter Cap 4 Breather 2 Spring and Diaphragm 5 Assembly Bolt 3 Centrifugal Filter Figure 7 45 Hengst Filter Assembly Perform the following steps to install the Hengst filter All information subject to change without notice 7 56 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 1 Assemble the centrifugal filter spring and diaphragm insert and the cap into the breather housing Bolt down with two hex head bolts See Figure 7 46 44176 1 Filter Cap 2 Spring and Diaph
15. e six mounting bolts M8 x 12mm Finger tighten all of the bolts but torque the first bolt nearest the front part of the manifold to 25 N m 19 Ib ft NOTE Upper heat shield bolt that is closest to front of engine is torqued before assembly is attached to engine due to impossible access after attachment to engine 6 7 24 1 Fey Rings 2 per groove 2 Exhaust Manifold Grooves Figure 7 16 Installing or Removing Rings in Exhaust Manifold Grooves Bolt the lower heat shield to the upper heat shield with one captured bolt and washer M8 x 12mm Torque to 25 N m 19 Ib ft Install the entire exhaust manifold assembly onto the cylinder heads by lifting the right side or front into place first followed by the left or rear Install all exhaust manifold bolts and then torque all 12 mounting bolts to 50 N m 38 lb ft using a crisscross sequence Torque remaining three mounting bolts captured bolt and washer type of the lower heat shield to the exhaust manifold Torque to 25 N m 19 lb ft Torque remaining five mounting bolts captured bolt and washer type of the upper heat shield to the exhaust manifold Torque to 25 N m 19 Ib ft All information subject to change without notice From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 10 Install the fey rings 4 per groove on the gas inlet pipe leading to exhaust manifold center piece Do not use lubricant 11 G
16. eJASSemblyc ose ases ee eben ins t ot EE EE e 7 60 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 59 SPECIFICATIONS This section contains the specifications for servicing the engine Exhaust Manifold The torque values for the turbocharger and the exhaust manifold are listed in Table 7 5 Turbocharger to Exhaust Manifold Nuts 50 37 Exhaust Manifold Mounting Bolts 50 37 Table 7 5 Turbocharger and Exhaust Manifold Torque Values Exhaust Brake Assembly The exhaust brake assembly specifications are listed in Table 7 6 Listed in Table 7 7 are the exhaust brake assembly torque values End Play axial play of Exhaust Brake Shaft 0 4 0 7 0 016 0 028 0 200 0 263 0 00787 0 01035 I Projection of the Rear Bushing into the Brake Valve 2 6 0 10 Housing Table 7 6 Exhaust Brake Assembly Specifications Adjusting Lever Bolt 15 11 Exhaust Brake Cylinder Locknut Valve Mounting Bolts Bracket Mounting Bolt Table 7 7 Exhaust Brake Assembly Torque Values All information subject to change without notice 7 60 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION
17. ently push gas inlet pipe into center exhaust manifold piece Do not use lubricant 12 Push gas inlet pipe of heat exchanger into throttle valve Tighten screw at bottom of positioning clamp on throttle valve assembly Clamp must be tightened to 10 N m 7 Ib ft after stud adjustment Refer to step 14 13 Screw the nut onto stud installed in exhaust manifold Fit stud in the bracket that is attached to the gas inlet pipe Attach a nut to the outer edge of bracket also 14 Adjust 219 mm dimension on stud by doing the following a Apply 25 N m 19 lb ft tightening torque to the nut on exhaust manifold Position stud to avoid any friction between the exhaust manifold and the gas inlet pipe See Step One in see Figure 7 17 L 7 25 OR Ib R MC 2 219 mm z 25 N m 19 Ib ft L 25 N m 119 IR ONE Figure 7 17 Stud Adjustment b c d e Adjust dimension to 219 mm 8 62 in This measurement is from the machined face of manifold to the resting face on the pipe See Step Two in see Figure 7 17 Bring nut against the resting face on pipe internal See Step Three in see Figure 7 17 Apply 25 N m 19 lb ft tightening torque to nut on resting face on pipe external See Step Four in see Figure 7 17 Apply 25 N m 19 lb ft tightening torque to nut on resting face on pipe internal See Step Five in see Figure 7 17
18. ight mounting bolts from the EGR cooler support and remove the support from cylinder heads See Figure 7 24 44131 1 M10 x 65 mm bolts 2 M10 x 45 mm bolts Figure 7 24 Removing the EGR Cooler Support All information subject to change without notice 7 32 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 15 Remove the eight mounting bolts from the EGR cooler flange which houses the reed valves See Figure 7 25 44144 1 EGR Cooler to Sheet Metal Support Bolts 2 EGR Cooler Flange Bolts Figure 7 25 Removing the EGR Cooler Flange 16 Remove the two EGR cooler to sheet metal support bolts See Figure 7 25 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 33 74 EGR COOLER AND COOLER SUPPORT BRACKET 17 Remove the reed valves from housing See Figure 7 26 44146 1 EGR Cooler Housing 4 EGR Reed Valve Flange 2 EGR Cooler Gasket 5 Reed Valves 3 EGR Cooler Intermediate Flange Figure 7 26 Removing the EGR Cooler Flange and Components 18 Remove the intermediate flange and gasket from cooler flange assembly See Figure 7 26 7 4 2 EGR Cooler and Support Bracket Installation Install the EGR cooler and the EGR cooler support bracket as follows NOTE Exhaust manifold gaskets will have to be i
19. ld See Figure 7 41 Pull gas mixer off of four long studs away from intake manifold 16 Unscrew the four studs from intake manifold 17 Remove the metal gasket 7 5 2 Installation of EGR Control Valve Gas Outlet Pipe and Gas Mixer Install the EGR control valve and gas outlet pipe as follows 1 Insert a symmetric membrane into the reed valve housing flange using industrial petroleum jelly See Figure 7 38 2 Insert the EGR control valve onto this membrane using petroleum jelly 3 Install the back two bolts of the EGR control valve M8 x 90 mm Install the front two bolts those closest to the front lifter bracket of the EGR control valve M8 x 40 mm Torque all bolts to 25 N m 19 Ib ft 4 Using two bolts install the back control valve bracket that holds the wiring harness terminal in place Torque to 25 N m 19 Ib ft 3 44163 1 Air Inlet Mixer Mounting Bolts 2 qty 3 Air Inlet Pipe 2 EGR Gas Mixer Figure 7 41 Removal of EGR Gas Mixer All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 49 75 EGR CONTROL VALVE GAS OUTLET PIPE AND GAS MIXER Connect wiring harness terminal to valve connector 6 Insert a second membrane into the right side of the EGR control valve housing using industrial petroleum jelly 7 Taking the EGR gas outlet pipe in hand fit component manually onto symmetric membrane using petroleum jelly
20. nection Torque to 50 N m 37 lb ft See Figure 7 43 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 53 7 6 EPV ELECTRONIC PROPORTIONAL VALVE AND WABCO AIR SOLENOID VALVE To avoid injury from the sudden release of a high pressure hose connection wear a face shield or goggles Install inlet and outlet connections at EPV pressure regulating valve Torque to 15 N m 11 lb ft NOTICE Avoid friction on compressed air pipe traveling under the EPV valve or potential damage to engine could result 6 Install smaller hollow screw below larger hollow screw securing connection Torque to 15 N m 11 lb ft 7 Fit the pipe between inlet connection installed at EPV valve and turbo brake actuator NE END 9 NENNEN 9 E 69 EENNNSSSSSSSSSSSSSSENN A 8 Connect wiring harness to EPV valve and Wabco valve All information subject to change without notice 7 54 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION 7 7 HENGST BREATHER FILTER MBE 4000 SERVICE MANUAL 7 7 1 Removal of Hengst Filter and Bracket Perform the following steps to remove the Hengst filter 1 Disconnect the breather piping from the Hengst filter See Figure 7 44 ae Nes e 2 44175 1 Filter Piping 3 Hengst Filter 2 Filter Piping Bracket 4 Plastic Clamps Figure 7 44 Removal of Hengst Filter and
21. ng clamps that are holding the EGR cooler to the cooler support bracket Remove the four tightening tools for clamps also See Figure 7 22 3 4 44140 1 EGR Cooler 3 Clamps 4 Qty 2 Tightening Tool for Clamps 4 Clamp Bolts Figure 7 22 Removing Tightening Clamps on the Cooler NOTE The oil filter and oil filter cover should be removed for good clearance when removing and installing the EGR cooler assembly All information subject to change without notice 7 30 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 13 With the cooler completely loosened at this point pull the cooler housing flange away from the EGR control valve As the cooler is lifted slide the cooler inlet pipe up through the opening in the cooler support bracket See Figure 7 23 5 4 1 44128 1 Oylinder Heads 4 EGR Cooler 2 EGR OoolerTightening Clamps 5 EGR Cooler Support 3 Tightening Tool for Clamps Figure 7 23 Removing EGR Cooler NOTE 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 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 31 74 EGR COOLER AND COOLER SUPPORT BRACKET 14 Remove the e
22. nstalled before EGR cooler support or cooler can be installed Refer to section 7 3 2 All information subject to change without notice 7 34 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 1 Install coolant outlet pipe Install the two M8 x 25 mm bolts through the coolant pipe flange metal gasket and into the coolant pump Leave loose until the cooler assemly is installed then torque bolts to 35 N m 26 lb ft See Figure 7 27 1 44133 1 Coolant Outlet Pipe Bolts 4 EGR Coolant Outlet Pipe 2 Coolant Vent Line 5 Coolant Outlet Pipe Bracket 3 Membrane Figure 7 27 Installation of Coolant Outlet Pipe NOTE Coolant outlet pipe must be installed to coolant pump before the EGR cooler support and cooler are installed All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 35 74 EGR COOLER AND COOLER SUPPORT BRACKET 2 Install the cooler support to the cylinder heads using the eight mounting bolts Torque all bolts to 25 N m 19 lb ft See Figure 7 28 44131 1 M10 x 65 mm bolts 2 M10 x 45 mm bolts Figure 7 28 Installing EGR Cooler Support NOTE If at this point the exhaust manifold gasket studs are still in place they will need to be removed NOTE Assemble and attach the EGR reed valve housing to the cooler before moun
23. oval All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 17 73 EGR EXHAUST MANIFOLD 6 Remove the twelve bolts connecting the three piece exhaust manifold to the block remove the exhaust manifold assembly by first lowering the left side then the right side out from under the heat exchanger bracket not shown in graphic See Figure 7 10 44124 Figure 7 10 Removing or Installing Three piece Exhaust Manifold Assembly All information subject to change without notice 7 18 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 7 Remove the six mounting bolts from the main or upper heat shield at this point Remove the heat shield See Figure 7 11 44109 1 Upper or Main Heat Shield 2 Lower or Front Heat Shield Figure 7 11 Removing Upper Heat Shield 8 Remove the stud and M8 nut and collar still attached to the center exhaust manifold piece All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 19 73 EGR EXHAUST MANIFOLD 9 Remove the two side pieces of the exhaust manifold from the center piece See Figure 7 12 44112 Figure 7 12 Three Piece Exhaust Manifold Assembly All information subject to change without notice 7 20 From Bulletin
24. ragm 3 Centrifugal Filter Figure 7 46 Hengst Filter Assembly All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION 4 Breather 5 Assembly Bolt From Bulletin 6 MBE4000 04 7 57 77 HENGST BREATHER FILTER 2 Install the filter assembly onto the timing case using three M8 x 35 mm bolts Torque to 25 N m 19 Ib ft ry C A M l is Shor h kK 3 44175 1 Filter Piping 3 Hengst Filter 2 Filter Piping Bracket 4 Plastic Clamps Figure 7 47 Installation of Hengst Filter and Related Parts 3 Install the assembly to the block using two M8 x 25 mm bolts Torque to 25 N m 19 Ib ft 4 Attach the temporary filter piping bracket to the air compressor and block as follows a Install a M14 x 60 mm bolt with a spacer at the engine block b Install MIO x 35 mm bolt at the air compressor c Torque to 60 N m 44 lb ft at the air compressor and 100 N m 74 lb ft torque at the block 5 Install pipe connecting it at the Hengst filter mouth 6 Install three plastic clamps at pipe bracket See Figure 7 47 All information subject to change without notice 7 58 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 7 A ADDITIONAL INFORMATION Description Page SPECIFICATIONS s eiit p opes ERE take Zag ies DH DU eb aaa caged 7 60 Exhaust Manifold morresse eom aet e vius 7 60 Exhaust Brak
25. t Pipe Hot Pipe Figure 7 7 Removing Stud from Exhaust Manifold and Inlet Pipe 3 Loosen center nut on stud that is resting on the inside against the intake manifold center piece See Figure 7 7 NOTE If the inside nut that rests against the stud bracket is NOT loosened or moved at this point it is possible that the stud dimension adjustment will remain the same without needing further adjustment when reinstalled NOTE Stud and stud bracket should be loose enough to allow removal of the exhaust manifold inlet pipe All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 15 73 EGR EXHAUST MANIFOLD 4 Loosen and remove bolt from positioning clamp which holds the gas inlet pipe to the throttle valve See Figure 44120 Figure 7 8 Removing or Installing Positioning Clamp to Throttle Inlet Pipe All information subject to change without notice 7 16 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 5 Gently pull exhaust manifold gas inlet pipe from center piece of exhaust manifold and from throttle valve see arrows in graphic Remove the fey rings four per groove on the gas inlet pipe leading to the exhaust manifold center piece See Figure 7 9 44123 Figure 7 9 Exhaust Manifold Gas Inlet Pipe Rem
26. t notice 7 46 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 9 Remove the four bolts attaching the EGR control valve to the thermostat housing See Figure 7 39 44161 1 EGR Control Valve Mounting Bolts 3 EGR Control Valve 2 Wiring Harness Terminal 4 EGR Temperature Sensor Figure 7 39 Removal or Installation of EGR Control Valve 10 Pull the EGR control valve out of the reed valve housing flange 11 Remove symmetric membrane from the housing flange See Figure 7 38 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 47 7 5 EGR CONTROL VALVE GAS OUTLET PIPE AND GAS MIXER 12 Pull the gas mixing pipe and metal gasket out of the air inlet pipe of mixer See Figure 7 40 44162 1 Intake Manifold 3 Gas Mixing Pipe 2 Alr Inlet Mixer 4 Metal Gasket Figure 7 40 Removal of Gas Mixing Pipe 13 Remove the turbo boost air temperature sensor attached to the gas mixer All information subject to change without notice 7 48 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 14 Remove the four bolts that attach the air intake pipe to the gas mixer Remove the metal gasket as well See Figure 7 41 15 Remove the two bolts that attach the EGR gas mixer to the intake manifo
27. ting the cooler to the cooler support I 3 Insert the reed valves into the EGR reed valve housing flange All information subject to change without notice 7 36 From Bulletin 6 MBE4000 04 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION MBE 4000 SERVICE MANUAL 4 Assemble the EGR reed valve housing flange cooler intermediate flange gasket and front sheet metal support together Attach all to the cooler housing using the eight mounting bolts Torque the bolts to 10 N m 8 lb ft See Figure 7 29 44144 1 EGR Cooler to Sheet Metal Support Bolts 2 EGR Cooler Flange Bolts Figure 7 29 Installing the EGR Cooler Flange 5 Attach the EGR cooler to the front sheet metal support with two bolts Torque to 25 N m 19 lb ft See Figure 7 29 All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 37 74 EGR COOLER AND COOLER SUPPORT BRACKET 6 Using industrial petroleum grease insert a membrane into the side of the EGR control valve that is closest to the EGR cooler See Figure 7 30 44136 1 Symmetric membrane 2 EGR Temperature Sensor Figure 7 30 Installing Symmetric Membrane into EGR Valve 7 Lift entire EGR cooler with attached cooler flange and sit this on top of cooler support taking care to insert the upper half of the coolant inlet pipe down through the appropriate hole in the cooler support At the same
28. trol wastegate valve Turbobrake EGR control valve CTV Constant Throttle Valve Turbobrake sliding sleeve EGR shutoff valve Table 7 4 Proportional Valve Chart 7 6 1 Removal of EPV Valve and Wabco Air Solenoid Valve Perform the following steps to remove the EPV valve Wabco air solenoid valve and all the corresponding connections 1 Disconnect wiring harness from the EPV valve and the Wabco solenoid valve All information subject to change without notice 6SE412 0206 Copyright 2004 DETROIT DIESEL CORPORATION From Bulletin 6 MBE4000 04 7 51 7 6 EPV ELECTRONIC PROPORTIONAL VALVE AND WABCO AIR SOLENOID VALVE To avoid injury from the sudden release of a high pressure hose connection wear a face shield or goggles 2 Disconnect the compressed air pipe between inlet connection installed at EPV valve and turbo brake actuator See Figure 7 42 Ns WM 5 1 S d i e 1 EPV Electronic Proportional Valve Large Hollow Screw Wastegate Small Hollow Screw Wabco Valve 6 2 7 3 Electric Wiring Harness Terminals 8 EPV Valve Inlet 4 9 EPV Valve Outlet hidden 5 10 Solenoid Valve Mounting Bolts EPV Valve Mounting Bolts Figure 7 42 Installing the EPV Valve Wabco Solenoid Valve Remove the smaller hollow screw below the larger hollow screw Disconnect the inlet and outlet connections at EPV pressure regulating valve Remove the large hollow screw in threaded connection
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