NUMBER: 8 5 09 S.M. REF.: Listed in Table ENGINE: EPA07 MBE 4000 DATE: August 2009 SUBJECT: CYLINDERHEADCOOLANTVENTLINE ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0026 EPA07 MBE 4000 4.6 Cylinder Head Coolant Vent Line New Section Insert after 4.5 NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
REMOVAL OF CYLINDER HEAD COOLANT VENT LINE Remove as follows: 1. Drain the cooling system. 2. Remove air cleaner assembly. 3. Remove the radiator support bracket from the top of the EGR cooler bracket and radiator. 4. Disconnect the coolant vent line located on top of the EGR cooler by removing the banjo bolt and seal rings. Discard the seal rings. 5. Remove the bolt securing the air compressor suction supply bracket to the EGR cooler bracket. See Figure 1. Figure 1 Air Compressor Suction Supply Bracket 6. Remove the two bolts securing the turbocharger inlet elbow to the EGR cooler bracket. Rotate the turbocharger inlet elbow away from the engine. NOTE: Do not remove the turbocharger air inlet elbow. 7. Remove the clamp halves securing the exhaust gas inlet pipe to the EGR cooler and to the center pipe of the exhaust manifold. Remove the exhaust gas inlet pipe. 8. Remove the EGR cooler gas outlet pipe. Refer to section 8.2.1 "Removal of EGR Cooler Gas Outlet Pipe." 9. Remove the EGR control valve. Refer to section 8.7.1 "Removal of EGR Control Valve." 10. Remove the EGR cooler straps. See Figure 2.
11. Disconnect the upper coolant inlet pipe from the lower coolant inlet pipe. See Figure 2. 1. Clamp 6. EGR Cooler Straps 2. Exhaust Gas Inlet Pipe 7. Coolant Vent Line Connection 3. Exhaust Heat Shield Bracket 8. EGR Cooler Bracket 4. Exhaust Heat Shield 9. Lower Coolant Pipe 5. EGR Cooler 10. Upper Coolant Pipe Figure 2 EGR Cooler 12. Pull the EGR cooler straight up from the EGR cooler support bracket. See Figure 2. EYE INJURY To avoid injury from flying debris, wear a face shield or goggles. NOTE: Remove only enough material to allow a socket to fit on the banjo bolts.
13. Using a die grinder or other suitable device, remove material from the EGR cooler support bracket as shown in Figure 3. Do not remove cylinder head covers before this modification. Figure 3 EGR Cooler Support Bracket 14. Remove shavings and clean cylinder head area, taking care not to allow metal shavings into any part of the engine. 15. Remove the cylinder head covers from cylinders 1-4. Refer to section 1.2.1 "Removal of Cylinder Head Cover." 16. Remove the injector harness adaptor frames from cylinders 1-4. Refer to section 2.5.1 "Removal of Fuel Injector HarnessAdaptorFrame."
17. Remove exhaust heat shield. See Figure 4. 1. Exhaust Manifold Heat Shield 4. Injector Harness Adaptor Frame/Cylinder Head cover Mounting Studs 2. Heat Shield Mounting Bolts 5. Cylinder Head Cover Cap Nuts 3. Injector Harness Adaptor Frame 6. Cylinder Head Cover Figure 4 Exhaust Manifold Heat Shield
NOTE: The lower exhaust mounting bolt cannot be fully removed with the exhaust manifold installed. Loosen the bolt enough to provide clearance for the coolant vent line to be removed. See Figure 5. Figure 5 Lower Heat Shield Bracket and Mounting Bolt 18. Remove the doser injector coolant line banjo bolt and seal rings from the #6 cylinder head connection. Discard seal rings. 19. Remove the six banjo bolts retaining the cylinder head coolant vent line.
20. Remove the cylinder head coolant vent line. Discard seal rings. See Figure 6. 1. Doser Injector Coolant Line 5. Coolant Vent Line Banjo Bolt (6 qty.) 2. Doser Injector Coolant Line Seal Rings 6. Coolant Vent Line 3. Doser Injector Coolant Line Banjo Bolt 7. Coolant Vent Line Banjo Bolt 4. Coolant Vent Line Seal Rings (15 qty.) 8. Banjo Union Figure 6 Coolant Vent Line
INSTALLATION OF CYLINDER HEAD COOLANT VENT LINE Install as follows: 1. Install the cylinder head coolant vent line using new seal rings. Torque the six banjo bolts to 35 N m (26 lb ft). 2. Install the doser injector coolant line to the #6 cylinder head connection using new seal rings. Torque the banjo bolt to 16-20 N m (12-15 lb ft). 3. Install the exhaust heat shield. Torque heat shield bolts to 25 N m (18 lb ft). See Figure 7. 1. Exhaust Manifold Heat Shield 4. Injector Harness Adaptor Frame/Cylinder Head cover Mounting Studs 2. Heat Shield Mounting Bolts 5. Cylinder Head Cover Cap Nuts 3. Injector Harness Adaptor Frame 6. Cylinder Head Cover Figure 7 Exhaust Manifold Heat Shield 4. Install the injector harness adaptor frames for cylinders 1-4. Refer to section 2.5.2 "Installation of Fuel Injector Harness Adaptor Frame." 5. Install the cylinder head covers for cylinders 1-4. Refer to section 1.2.2 "Installation of Cylinder Head Cover." 6. Coat the EGR cooler coolant inlet and outlet connector pipes with International Product Corporation Rubber Lubricant Emulsion (P-80). See Figure 8.
NOTICE: During installation, ensure that the EGR cooler coolant pipes are seated correctly with the connector pipes. Improperly seated pipes will leak causing engine damage. 7. Install the EGR cooler. Secure the EGR cooler to the bracket with clamps. Torque the clamps to 10 N m (7 lb ft). See Figure 8. 1. Clamp 6. EGR Cooler Straps 2. Exhaust Gas Inlet Pipe 7. Coolant Vent Line Connection 3. Exhaust Heat Shield Bracket 8. EGR Cooler Bracket 4. Exhaust Heat Shield 9. Lower Coolant Pipe 5. EGR Cooler 10. Upper Coolant Pipe Figure 8 EGR Cooler 8. Rotate the turbocharger inlet elbow back into the correct position and secure the support bracket with two bolts. Torque the bolts to 35 N m (26 lb ft). 9. Properly align the coolant pipe and small support bracket to the water pump. Torque the bolts to 35 N m (26 lb ft). 10. Install the inlet gas pipe to EGR cooler and center pipe of exhaust manifold and secure with clamp halves. Torque clamp bolts to 25 N m (18 lb ft). 11. Install the EGR control valve. Refer to section 8.7.2 "Installation of Installation of EGR Control Valve."
12. Install the EGR cooler gas outlet pipe. Refer to section 8.2.2 "Installation of EGR Cooler Gas Outlet Pipe." 13. Install the coolant vent line to the top of the EGR cooler and secure with banjo bolts and washers. Torque banjo bolt to 25 N m (18 lb ft). 14. Install the air compressor suction pipe to the mounting bracket and secure with one M10 bolt. Torque the bolt to 35 N m (26 lb ft). See Figure 9. Figure 9 Air Compressor Suction Supply Bracket 15. Install the radiator support bracket from the top of the EGR cooler bracket and radiator. 16. Refill engine with coolant.
ADDITIONAL SERVICE INFORMATION Additional service information is available in Power Service Literature. Detroit Diesel, DDC, Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. Copyright 2009 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.