Deciding to replace a $3,000.00 turbocharger on a Mercedes MBE 900 isn’t an easy decision. This particular bus has been a thorn in our side for years mainly because of this one engine code that keeps popping up over and over again regardless of what we do to try and eliminate it. This time we… Continue reading Mercedes MBE 900 Turbo Replacement
The cylinder sleeves are the next step on this rebuild project. They have a rubber seal that goes around the outside to separate the coolant from the crankcase. Once lubricated each sleeve is forced into the block and counterbores. We purchased all of the necessary tools to carry out this job and cylinder sleeve hold… Continue reading DT MaxxForce Diesel Engine Cylinder Sleeve Protrusion
Mechanics have a serious need for the right tools and equipment to get their jobs done. It takes serious power to work on cars and that’s why the shop must be outfitted properly. When designing a shop for yourself make sure you have taken steps to have an experienced contractor helping you get exactly what… Continue reading Building the Ideal Mechanics Shop
This EGR Valve fault code popped up and it caused a slight hesitation on acceleration which would make sense if the valve is open at the wrong time. The EGR funnels cooled exhaust coming from the EGR cooler into the intake system to cut down on emission levels. The code was 1896 EGR Valve Controller… Continue reading Cummins ISB Engine Code EGR Valve
This step involves replacing and torquing down the main bearings on a DT MaxxForce diesel engine. The main reason for replacing the bearings is to bring the crankshaft end play back to specs and replace the washed out original bearings. Some of them showed discoloration so we didn’t want to take a chance. The coolant… Continue reading Main Bearings DT Diesel Engine in a School Bus
Our In Frame has begun and #6 piston and liner has shown the damage caused by coolant contamination in the oil. If left too long the coolant will wash away the oil lubrication between the piston and piston liner. The terms for the piston cylinder for diesel engines that are able to be rebuilt in… Continue reading MaxxForce DT Removing Pistons and Liners
This is an important step with any rebuild. Cleaning and inspection must be carried out with care so nothing gets missed. The cylinder head was sent out to a local machine shop for testing and inspection. They needed the injectors to block the fuel galleries to allow for a pressure test. Everything including injector sleeves,… Continue reading DT Diesel Engine InFrame Parts Inspection
If you told me we would be rebuilding one of our MaxxForce engines in six years I would have laughed and then went into total denial. There’s no way a school bus carrying 60 or so children operating 4 to 5 hours a day would be enough to wear out a diesel engine. I could… Continue reading Diesel Engine In Frame MaxxForce DT
This was my first experience getting a tour through a tire retread plant. Kal Tire supplies our recaps for our bus fleet and they asked us to come down and see where it all happens. It’s a long process from start to finish and I can see why they do not want to find a… Continue reading Touring a Tire Retread Plant
As you can see the EGR cooler from this Navistar DT MaxxForce engine is massive and it weighs I’m guessing around 50 pounds. Why is it so large? Well the main reason was to circulate more cooled exhaust gases to the air intake system and reduce emissions to meet the demanding emission standards set by… Continue reading MaxxForce DT Diesel Engine EGR Cooler Failure
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